Concrete stirring system and concrete production method applying same

Abstract

The invention relates to a concrete mixing system and a concrete production method applying the same, and belongs to the technical field of concrete production, the concrete mixing system comprises an aggregate screening unit, a concrete mixing unit and a concrete mixing unit, the aggregate screening unit is provided with multiple stages of screening holes and is used for screening aggregate and obtaining aggregate data and screening data; the storage unit comprises a plurality of silos for storing aggregates, powder, additives and water; the stirring unit comprises a stirrer for stirring and producing concrete; the transportation unit is used for transporting the screened aggregate to the storage unit and transporting the raw materials to the stirring unit; the control unit is used for calculating optimal gradation by applying a fullerene curve according to aggregate data and screening data of the aggregate screening unit; and the control unit is also used for controlling and monitoring the work of the concrete stirring unit and the transportation unit, and generating a carbon footprint report according to the consumption and output of each unit. The concrete mixing system can be directly based on actually available aggregate, and the problem that theoretical gradation is disjointed with on-site materials in a traditional method is solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of concrete production, and particularly relates to a concrete mixing system and a concrete production method using the same. Background Art

[0002] The grading optimization of concrete (i.e., the reasonable distribution of aggregate particles) is one of the core links in the design of concrete mix proportion, which directly affects the performance of concrete and the economy of concrete production. Optimizing the grading can significantly improve the performance of concrete and reduce the material cost at the same time. The Fuller Curve is an idealized curve used in soil mechanics and geotechnical engineering to describe the particle grading (grain size distribution) of soil, mainly used to evaluate the optimal grading of soil or aggregates (such as sand and gravel in concrete) to achieve the best compaction degree and mechanical properties.

[0003] In the prior art, the optimization calculation of grading is often carried out separately without matching with the aggregates at the actual construction site; for example, after calculating the optimal grading, when selecting aggregates according to the grading ratio, there may be a lack of aggregates of a certain particle size at the construction site. If the particle size of one of the aggregates is changed, the ratios and particle sizes of other aggregates should be recalculated; this results in the calculation of the optimal grading being likely to deviate from the actual construction situation.

[0004] Therefore, how to provide a concrete mixing system and a concrete production method using the same that are combined with the actual situation of the construction site is a technical problem that needs to be solved urgently at present. Summary of the Invention

[0005] In view of the deficiencies in the prior art, the present invention provides a concrete mixing system and a concrete production method using the same, which can directly be based on the actually available aggregates, avoiding the problem of the disconnection between the theoretical grading and the on-site materials in the traditional method.

[0006] The present invention provides a concrete mixing system, comprising:

[0007] An aggregate screening unit, which is provided with multiple sieve holes for screening aggregates and obtaining aggregate data and screening data;

[0008] A storage unit, which is connected to the aggregate screening unit and comprises several silos for storing aggregates, powders, admixtures and water;

[0009] A mixing unit, which is connected to the storage unit and comprises a mixer for mixing and producing concrete;

[0010] A transportation unit, which is used to transport the aggregates screened by the aggregate screening unit to the storage unit and transport the raw materials stored in the storage unit to the mixing unit;

[0011] A control unit, which is communicatively connected to the aggregate screening unit, the storage unit, the mixing unit, and the transportation unit respectively; the control unit is configured to calculate the optimal gradation by applying the Fuller curve according to the aggregate data and screening data of the aggregate screening unit, and transmit the optimal gradation to the aggregate screening unit and the storage unit; the control unit is further configured to control and monitor the operation of the concrete mixing unit and the transportation unit, and generate a carbon footprint report based on the consumption and output of each unit.

[0012] This technical solution can directly be based on the actually available aggregates, avoiding the problem of the disconnection between the theoretical gradation and the on-site materials in the traditional method.

[0013] In some embodiments, the aggregate screening unit is further provided with a laser particle size analyzer, which is used to assist in obtaining the aggregate data and screening data. This technical solution can obtain the particle size distribution data of the aggregates more quickly and accurately.

[0014] In some embodiments, the concrete mixing system further includes a waste heat recovery unit, which is respectively connected to the powder silo and the mixer, and is used to recover the waste heat generated by the powder silo and the mixer. This technical solution can conduct the waste heat of the powder silo through the waste heat recovery unit, avoiding the over-high temperature of the powder silo.

[0015] In some embodiments, the waste heat recovery unit is further communicatively connected to the control unit, and is used to transmit the recovered waste heat data to the control unit, and the control unit perfects the carbon footprint report according to the waste heat recovery data.

[0016] In some embodiments, the concrete mixing system further includes a waste residue recovery unit, which is used to recover the waste residue generated by the mixer and the waste residue adhered to the tires of the engineering vehicles, and press the waste residue into bricks. This technical solution reduces the environmental pollution caused by the stacking of waste residues, and also reduces the raw material procurement cost, especially applicable to temporary roads or subgrade projects with low strength requirements.

[0017] In some embodiments, the waste residue recovery unit is further communicatively connected to the control unit, and is used to transmit the waste residue brick-making data to the control unit, and the control unit perfects the carbon footprint report according to the waste residue brick-making data.

[0018] In addition, the present invention also provides a concrete production method, which is applied to the above-mentioned concrete mixing system, and includes the following steps:

[0019] Aggregate screening: using the aggregate screening unit to screen the aggregates to obtain the aggregate data and screening data, where the aggregate data includes the aggregate type and the particle size distribution data of different aggregates, and the screening data includes the aggregate type, particle size and quality screened out by each sieve hole.

[0020] Optimal gradation calculation: The control unit calculates the optimal gradation of the required concrete by applying the Fuller curve according to the aggregate data and screening data in combination with the performance requirements of the concrete;

[0021] Raw material storage: Transport the aggregates, powders, admixtures, and water with the particle sizes required for the optimal gradation to the storage unit for storage;

[0022] Concrete mixing: The transport unit transports the aggregates, powders, admixtures, and water stored in the storage unit to the mixing unit, and the mixing unit mixes and produces concrete according to the optimal gradation.

[0023] This technical solution obtains accurate data such as aggregate type and particle size distribution in real time through the aggregate screening unit, and combines the Fuller curve theory to calculate the optimal gradation to ensure that the concrete reaches the best density and mechanical properties; the system can dynamically adjust the gradation plan according to the actual particle size distribution of the aggregates obtained by screening, perfectly solving the problem of incomplete aggregate specifications at the construction site; even if a certain aggregate is temporarily in short supply, the mixing ratio can be quickly re-optimized through the algorithm to ensure that production is not interrupted.

[0024] In some of these embodiments, in the aggregate screening step, a laser particle size analyzer is used to scan the aggregates to obtain the aggregate data and screening data. This technical solution can quickly and accurately obtain the particle size distribution data of the aggregates, making the gradation data more complete and accurate.

[0025] In some of these embodiments, the optimal gradation calculation method includes the following sub-steps:

[0026] Establish an aggregate database: According to the aggregate type, the particle size distribution of different aggregates, and the maximum aggregate particle size;

[0027] Calculate the actual sieve residue percentage: Calculate the actual sieve residue percentage of each sieve hole according to the screening data and the mass of the aggregates before screening;

[0028] Calculate the ideal sieve residue percentage: Calculate the ideal sieve residue percentage of each sieve hole according to the Fuller curve;

[0029] Determine the optimal gradation: According to the performance requirements of the concrete, calculate the error between the actual sieve residue percentage and the ideal sieve residue percentage of each sieve hole, obtain the actual sieve residue percentage and the corresponding sieve hole size when the error is the smallest, use this sieve hole size as the particle size required for the optimal gradation, and then obtain the optimal gradation. This technology dynamically combines the Fuller curve theory with the actual aggregate characteristics, making the calculation results not only meet the theoretical optimum but also adapt to the on-site material conditions.

[0030] In some of these embodiments, in the step of determining the optimal gradation, the formula for calculating the error between the actual sieve residue percentage and the ideal sieve residue percentage is:

[0031]

[0032] In formula (1), e is the error between the actual sieve residue percentage and the ideal sieve residue percentage, n is the total number of sieve pore gradings of the aggregate screening unit, ω i is the weight coefficient of the i-th sieve pore set according to the concrete performance requirements, P 实际(di) is the actual sieve residue percentage of the i-th sieve pore, P Fuller(di) is the ideal sieve residue percentage of the i-th sieve pore.

[0033] Based on the above solution, the concrete mixing system in the embodiments of the present invention obtains the particle size distribution data (aggregate data and screening data) of the aggregates at the construction site in real time through the aggregate screening unit. When the control unit dynamically calculates the optimal gradation based on the Fuller curve, it directly uses the actually available aggregates as the basis, avoiding the problem of the disconnection between the theoretical gradation and the on-site materials in the traditional method; the control unit realizes data intercommunication and instruction linkage by connecting all links through communication, improving the coordination of the entire system, reducing the lag of manual intervention, enhancing production efficiency, and at the same time reducing the risk of rework caused by inconsistent gradation; moreover, by generating a carbon footprint report through the control unit, the carbon emissions of the entire production process can be accurately calculated, and the logistics path or equipment scheduling can be optimized specifically to reduce ineffective energy consumption and achieve a win-win situation for economy and environmental protection. The concrete production method in the embodiments of the present invention obtains accurate data such as aggregate type and particle size distribution in real time through the aggregate screening unit, combines the Fuller curve theory to calculate the optimal gradation, and ensures that the concrete reaches the best density and mechanical properties; the system can dynamically adjust the gradation plan according to the actually screened aggregate particle size distribution, perfectly solving the problem of incomplete aggregate specifications at the construction site; even if a certain aggregate is temporarily in short supply, the mixing ratio can be quickly re-optimized through the algorithm to ensure the uninterrupted production. In this embodiment, from aggregate screening, data collection to gradation calculation, raw material transportation and mixing production, the whole process realizes automated closed-loop control, which can not only avoid manual operation errors, but also improve production efficiency, and is especially suitable for large-scale continuous operations. In summary, the concrete production method in this embodiment upgrades the concrete production from the traditional "experience-driven" to "data-driven", and realizes multi-dimensional optimization of material cost, production efficiency, resource utilization and environmental protection performance on the premise of ensuring project quality, providing reliable technical support for modern intelligent construction. Description of the Drawings

[0034] The drawings described herein are used to provide a further understanding of the present invention, form a part of this application, and the schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings:

[0035] Figure 1 is the process flow chart of the storage unit, transportation unit and mixing unit of the concrete mixing system in the embodiments of the present invention;

[0036] Figure 2 It is the process flow diagram of the waste heat recovery unit and waste residue recovery unit of the concrete mixing system in the embodiment of the present invention;

[0037] Figure 3 It is the process flow diagram of the transportation unit of the concrete mixing system in the embodiment of the present invention;

[0038] Figure 4 It is the flow chart of the concrete production method in the embodiment of the present invention;

[0039] Figure 5 It is the flow chart of the optimal gradation calculation method of the concrete production method in the embodiment of the present invention.

[0040] In the figure:

[0041] 1. Storage unit; 2. Mixing unit; 3. Transportation unit; 4. Waste heat recovery unit; 5. Waste residue recovery unit;

[0042] 101. Stone storage hopper; 102. Sand storage hopper; 103. Cement cylinder; 104. Powder material cylinder; 105. Water pool; 106. Admixture cylinder; 107. Weighing scale;

[0043] 201. Mixer; 202. Dust collector; 203. Material gathering hopper;

[0044] 301. Belt conveyor; 302. Aggregate temporary storage hopper; 303. Hoist;

[0045] 401. Heat pipe device; 402. Temperature scanner; 403. Heat distribution device;

[0046] 501. Sand and stone separator; 502. Engineering vehicle; 503. Wheel washer; 504. Hydrocyclone; 505. Filter membrane; 506. Brick making machine. Detailed implementation manners

[0047] Next, the technical solutions in the embodiments will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0048] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "center", "lateral", "longitudinal", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the drawings. These are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation on the present invention.

[0049] In the description of the present invention, it should be noted that unless otherwise clearly specified and limited, the terms "installed", "connected", and "coupled" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0050] The terms "system", "unit", and "module" used herein are a method for distinguishing different components, elements, parts, portions, or assemblies at different levels, and these terms can be replaced by other expressions that can achieve the same purpose.

[0051] As Figures 1 - 3 shown, in an embodiment of the concrete mixing system and the concrete production method using the same in the present invention, the concrete mixing system includes an aggregate screening unit, a storage unit 1, a mixing unit 2, a transportation unit 3, and a control unit; wherein, the aggregate screening unit is provided with multiple levels of sieve holes for screening aggregates and obtaining aggregate data and screening data; the storage unit 1 is connected to the aggregate screening unit and includes a plurality of silos for storing aggregates, powders, admixtures, and water; the mixing unit 2 is connected to the storage unit 1 and includes a mixer 201 for mixing and producing concrete; the transportation unit 3 is used to transport the aggregates screened by the aggregate screening unit to the storage unit 1 and transport the raw materials stored in the storage unit 1 to the mixing unit 2; the control unit is respectively communicatively connected to the aggregate screening unit, the storage unit 1, the mixing unit 2, and the transportation unit 3; the control unit is used to calculate the optimal gradation according to the aggregate data and screening data of the aggregate screening unit and transmit the optimal gradation to the aggregate screening unit and the storage unit 1; the control unit is also used to control and monitor the operation of the concrete mixing unit 2 and the transportation unit 3 and generate a carbon footprint report according to the consumption and output of each unit.

[0052] In the above-described exemplary embodiment, the concrete mixing system obtains the particle size distribution data (aggregate data and screening data) of the aggregate at the construction site in real time through the aggregate screening unit. When the control unit dynamically calculates the optimal gradation based on the Fuller curve, it directly uses the actually available aggregate as the basis, avoiding the problem of the disconnection between the theoretical gradation and the on-site materials in the traditional method. Even if a certain aggregate is in short supply, the system can quickly adjust the proportion of other aggregates to ensure that the gradation always adheres to the actual conditions, taking into account both the compactness and mechanical properties; the control unit connects all links through communication to achieve data interconnection and instruction linkage, improving the coordination of the entire system, reducing the lag of manual intervention, enhancing production efficiency, and at the same time reducing the risk of rework caused by inconsistent gradation; moreover, by generating a carbon footprint report through the control unit, the carbon emissions of the entire production process can be accurately calculated, and the logistics path or equipment scheduling can be optimized specifically to reduce ineffective energy consumption and achieve a win-win situation for economy and environmental protection.

[0053] In some embodiments, the aggregate screening unit is further provided with a laser particle size analyzer, which is used to assist in obtaining aggregate data and screening data. By adding a laser particle size analyzer to the aggregate screening unit, the particle size distribution data of the aggregate (especially fine particles) can be obtained more quickly and accurately, making up for the deficiency of the traditional screening method in measuring fine aggregates. Combined with the Fuller curve calculation of the control unit, the accuracy of gradation optimization can be further improved, ensuring the compactness and strength of the concrete, and at the same time reducing the proportion deviation caused by manual sampling errors.

[0054] In some embodiments, as Figure 2 shown, the concrete mixing system further includes a waste heat recovery unit 4, which is respectively connected to the powder silo 104 bin and the mixer 201 to recover the waste heat generated by the powder silo 104 bin and the mixer 201. At the construction site, after the powder in the powder silo 104 bin is stored for a period of time, the temperature of the powder silo 104 bin will become higher and higher, and the waste heat generated by the powder silo 104 bin will even exceed the waste heat generated by the mixer 201. The main sources of waste heat in the powder silo 104 bin include: the hydration heat release when powders such as cement or lime are damp, the heat generated by friction when the powder flows in the tank, the heat generated by the underlying particles being compressed when the powder accumulates in the pipe, and the heat conduction from the external high-temperature environment to the internal powder. The heat generated by the above ways accumulates in the tank, all of which will cause the temperature of the powder silo 104 bin to become higher and higher, and directly using high-temperature powder may accelerate the setting of the concrete and affect the concrete performance. By conducting the waste heat of the powder silo 104 bin through the waste heat recovery unit 4, the temperature of the powder silo 104 bin can be prevented from being too high, and the recovered waste heat can be used for preheating concrete raw materials, heating the living area or generating electricity in winter, avoiding the waste of heat, thereby improving the environmental protection of the entire concrete mixing system.

[0055] In some embodiments, the waste heat recovery unit 4 is also communicatively connected to the control unit, and is configured to transmit the recovered waste heat data to the control unit. The control unit improves the carbon footprint report according to the waste heat recovery data.

[0056] In some embodiments, as Figure 2 shown, the waste heat recovery unit 4 includes a heat pipe device 401, a temperature scanner 402, and a heat distribution device 403. The heat pipe device 401 is respectively connected to the powder tank and the mixer 201, and is configured to transfer and store the waste heat of the powder tank and the mixer 201. The temperature scanner 402 is installed on the heat pipe device 401 and is configured to measure the temperature inside the heat pipe device 401. The heat distribution device 403 is respectively connected to the heat pipe device 401 and the temperature scanner 402, and is configured to allocate the heat use according to the temperature inside the heat pipe device 401. By efficiently recovering the waste heat generated by the powder tank and the mixer 201 through the heat pipe device 401, combining with the real-time monitoring of the heat parameters by the temperature scanner 402, and intelligently allocating the waste heat use by the heat distribution device 403, the waste of thermal energy in the production process can be significantly reduced, the external energy consumption can be reduced, and at the same time, the powder drying efficiency can be improved, indirectly shortening the mixing cycle, realizing the dual optimization of energy conservation and production efficiency.

[0057] In some embodiments, as Figure 2 shown, the concrete mixing system further includes a waste residue recovery unit 5. The waste residue recovery unit 5 is configured to recover the waste residue generated by the mixer 201 and the waste residue adhered to the tires of the engineering vehicle 502, and press the waste residue into bricks. The waste residue recovery unit 5 realizes the resource utilization of construction waste by recovering the waste residue generated by the mixer 201 and the waste residue adhered to the tires of the engineering vehicle 502 and pressing it into bricks. This not only reduces the environmental pollution caused by the stacking of waste residue, but also reduces the raw material procurement cost, and is especially suitable for temporary roads or subgrade projects with low strength requirements, reflecting the concept of circular economy.

[0058] In some embodiments, the waste residue recovery unit 5 is also communicatively connected to the control unit, and is configured to transmit the waste residue brick-making data to the control unit. The control unit improves the carbon footprint report according to the waste residue brick-making data.

[0059] In some embodiments, as Figure 2As shown, the waste residue recycling unit 5 includes a sand and gravel separator 501, a wheel washer 503, a hydrocyclone 504, and a filter membrane 505. Among them, the sand and gravel separator 501 is used to clean and separate the waste residue generated by the mixer 201. The wheel washer 503 is used to clean the waste residue adhered to the tires of the engineering vehicle 502. The hydrocyclone 504 is connected to the wheel washer 503 and is used to separate the waste residue adhered to the tires of the engineering vehicle 502 after cleaning. The filter membrane 505 is respectively connected to the sand and gravel separator 501 and the hydrocyclone 504 and is used to filter the waste residue to obtain reusable brick-making raw materials. Through the multi-stage treatment of the sand and gravel separator 501, the wheel washer 503, the hydrocyclone 504, and the filter membrane 505, components such as sand and gravel and slurry in the waste residue are efficiently separated and purified, ensuring the purity and stability of the brick-making raw materials. The hydrocyclone 504 can recover fine particles in the car wash wastewater, and the filter membrane 505 further removes impurities, converting the waste residue into a high-cost-effective recycled building material raw material, while reducing sewage discharge, meeting the requirements of environmental protection construction.

[0060] In some embodiments, as Figure 2 shown, the waste residue recycling unit 5 further includes a brick-making machine 506, and the brick-making machine 506 uses the brick-making raw materials obtained after filtration by the filter membrane 505 to make bricks. It can be understood that the construction requirements for some construction roads at the construction site are not high, and the brick-making raw materials after waste residue recycling can be used to make subgrade bricks. The brick-making machine 506 directly uses the filtered waste residue raw materials to produce subgrade bricks, "localizing the resource of the waste residue". Such bricks can be used for temporary roads at the construction site or the base layer with low strength requirements, which not only saves the cost of purchasing building materials externally, but also reduces the carbon emissions and disposal costs of transporting the waste residue out, realizing the closed-loop management of "zero waste" construction.

[0061] In some embodiments, the mixer 201 is a double-power mixer 201 with an electric motor and a hydraulic motor. It operates purely electrically under light load and hybridly with electricity and oil under heavy load to save the energy consumption of the mixer 201. The surfaces of the double horizontal shafts of the blades are laser-cladded with tungsten carbide layers to improve the mixing efficiency and extend the service life of the blades. In addition, the mixer 201 is installed with a rubber-spring composite shock-absorbing base to reduce the noise in the construction site.

[0062] In some embodiments, as Figure 1 shown, the mixing unit 2 is also provided with a dust collector 202, and the dust collector 202 is arranged above the mixer 201. Through the setting of the dust collector 202, the dust generated during the mixing process can be effectively collected, significantly improving the working environment, reducing air pollution, protecting the health of workers, and avoiding waste of raw materials, meeting the requirements of environmental protection production.

[0063] In some embodiments, as Figure 1 shown, a material gathering hopper 203 is provided at the outlet of the mixer 201. Through the setting of the material gathering hopper 203, the concrete is guided into the mixing truck tank to avoid spilling.

[0064] In some embodiments, the silos are steel-structured modular silos, which store raw materials such as sand, stone, cement, and fly ash in separate compartments. The height of the silos is higher than that of the mixer 201, and the materials fall by their own weight to the conveyor belt and are then conveyed to the mixer 201, reducing the energy consumption of traditional loaders for handling. Using steel-structured modular silos to store raw materials in separate compartments and taking advantage of the height difference for the materials to fall by their own weight to the conveyor belt reduces the need for loader handling, lowers energy consumption and noise, improves the conveying efficiency, and at the same time, the modular design facilitates installation and expansion.

[0065] In some embodiments, as Figure 1 shown, weighing meters 107 are provided at the output ports of the silos to output the aggregates, powders, admixtures, and water required for making concrete according to the concrete mix design. By setting weighing meters 107 at the output ports of the silos, the feeding amounts of various raw materials can be accurately controlled, ensuring the accuracy of the concrete mix design, improving the quality stability of the concrete, reducing human metering errors at the same time, and enhancing the production efficiency.

[0066] In some embodiments, as Figure 1 shown, the aggregate silo is a bucket-shaped silo, and the weighing meter 107 below the aggregate silo is a bucket-shaped scale. As a schematic embodiment, the silos include a stone storage hopper 101, a sand storage hopper 102, a cement silo 103, a powder silo 104, a water tank 105, and an admixture silo 106.

[0067] In some embodiments, sensors for monitoring the remaining amount of raw materials are provided inside the silos. Specifically, a level gauge or a liquid level sensor can be selected according to actual needs. As a schematic embodiment, radar level gauges are selected inside the aggregate silo and the powder silo 104, and a liquid level sensor is used inside the water tank 105.

[0068] In some embodiments, a screw conveyor is provided at the inner bottom of the powder silo 104, and the screw conveyor is used for contactless conveying of powders. A screw conveyor is configured at the bottom of the powder silo 104. Contactless conveying is adopted to avoid powder caking or segregation, ensure the fluidity and mixing ratio accuracy of the powders, and reduce dust pollution at the same time. It is especially suitable for the enclosed conveying of easily flying materials such as cement.

[0069] In some embodiments, a laser particle size analyzer for monitoring the particle size distribution of aggregates is provided inside the aggregate silo. A laser particle size analyzer is integrated inside the aggregate silo to monitor the change in the particle size distribution of aggregates in real time, and the grading scheme is dynamically adjusted in combination with the control unit to ensure the performance stability of the concrete and solve the lag problem of traditional manual sampling inspection.

[0070] It should be noted that a microwave moisture meter, a temperature and humidity sensor, and an air conditioning system are also provided in the aggregate silo to keep the moisture content of the aggregate stable and reduce the water consumption for mixing. Through the coordinated action of the microwave moisture meter, the temperature and humidity sensor, and the air conditioning system, the moisture content of the aggregate is accurately controlled, the error of the mixing water consumption caused by moisture fluctuations is reduced, the consistency of the concrete strength is improved, and at the same time, the burden of wastewater treatment is reduced.

[0071] In some embodiments, as Figure 1 shown, a stirrer for preventing precipitation is provided in the admixture barrel 106. Through the arrangement of the stirrer, the precipitation and stratification of the admixture are prevented, the active ingredients of the chemical additive are evenly distributed, the functional stability of the concrete admixture (such as the water reduction rate) is ensured, and the performance deviation caused by precipitation is avoided.

[0072] In some embodiments, the transportation unit 3 includes a number of belt conveyors 301. Among them, a hoist 303 is provided at the end of the belt conveyor 301 for transporting the aggregate to the mixing unit 2. As a schematic embodiment, as Figure 3 shown, the engineering vehicle 502 transports sand and stones to the sand discharge hopper and the stone discharge hopper respectively. The sand and stones pass through the inclined belt and the transition inclined belt in sequence to reach the forward and reverse belt, and then enter the cloth belts at both ends through the forward and reverse belt respectively. The cloth belts drive the sand and stones to enter the sand storage hopper 102 and the stone storage hopper 101 respectively. As Figure 1 shown, the sand and stones in the sand storage hopper 102 and the stone storage hopper 101 enter the aggregate temporary storage hopper 302 through the belt conveyor 301 after weighing, and the hoist 303 is used to transport the sand and stones in the aggregate temporary storage hopper 302 to the conveyor belt leading to the mixer 201. By adopting the combined design of the belt conveyor 301 and the hoist 303, through the linkage of the sand and stone discharge hoppers, the forward and reverse belt, and the cloth belt, the classified transportation and accurate feeding of the aggregate are realized, the manual handling intensity is greatly reduced, and the design of the hoist 303 solves the energy consumption problem of high-drop transportation.

[0073] It should be noted that the belt conveyor 301 adopts a closed air-cushioned belt to reduce the frictional resistance and the belt loss.

[0074] In some embodiments, the control unit sets up a digital twin platform for the concrete mixing system. The digital twin platform collects the status of each device and environmental parameters through the Internet of Things, constructs a 3D visualization model, and gives a real-time warning when a device fails. Based on the Internet of Things, the digital twin platform constructs a 3D visualization model, maps the device status and environmental parameters in real time, and through fault warning and simulation optimization, production risks are avoided in advance, downtime losses are reduced, and a data basis is provided for remote operation and maintenance and process improvement.

[0075] Based on the above concrete mixing system, the present invention also provides a concrete production method, which is applied to the above concrete mixing system, as Figure 4As shown, it includes the following steps:

[0076] Aggregate screening: Use the aggregate screening unit to screen the aggregates to obtain aggregate data and screening data. The aggregate data includes aggregate types and particle size distribution data of different aggregates, and the screening data includes the aggregate types, particle sizes, and masses screened out by each sieve hole;

[0077] Optimal gradation calculation: The control unit calculates the optimal gradation of the required concrete by applying the Fuller curve according to the aggregate data and screening data in combination with the concrete performance requirements;

[0078] Raw material storage: Transport the aggregates with the particle sizes required for the optimal gradation, as well as powders, admixtures, and water, to storage unit 1 for storage;

[0079] Concrete mixing: Transport unit 3 transports the aggregates, powders, admixtures, and water stored in storage unit 1 to mixing unit 2, and mixing unit 2 mixes and produces concrete according to the optimal gradation.

[0080] In the above-described exemplary embodiment, accurate data such as aggregate types and particle size distributions are obtained in real time through the aggregate screening unit. Combining with the Fuller curve theory to calculate the optimal gradation ensures that the concrete reaches the best density and mechanical properties; the system can dynamically adjust the gradation plan according to the actual particle size distribution of the screened aggregates, perfectly solving the problem of incomplete aggregate specifications at the construction site; even if a certain type of aggregate is temporarily in short supply, the ratio can be quickly re-optimized through the algorithm to ensure uninterrupted production. This embodiment realizes automatic closed-loop control throughout the process from aggregate screening, data collection to gradation calculation, raw material transportation, and mixing production, which can not only avoid manual operation errors but also improve production efficiency, and is especially suitable for large-scale continuous operations. In summary, the concrete production method in this embodiment upgrades concrete production from the traditional "experience-driven" to "data-driven", realizing multi-dimensional optimization of material cost, production efficiency, resource utilization, and environmental protection performance on the premise of ensuring project quality, providing reliable technical support for modern intelligent construction.

[0081] In some embodiments, in the aggregate screening step, a laser particle size analyzer is used to scan the aggregates to obtain aggregate data and screening data. By introducing a laser particle size analyzer in the aggregate screening step, the particle size distribution data of the aggregates can be obtained quickly and accurately, making the gradation data more complete and accurate, providing a reliable basis for subsequent optimal gradation calculation, and reducing manual sampling errors at the same time.

[0082] In some embodiments, as Figure 5 shown, the optimal gradation calculation method includes the following sub-steps:

[0083] Establish an aggregate database: According to the aggregate types, particle size distributions of different aggregates, and the maximum aggregate particle size;

[0084] Calculate the actual residue percentage: Calculate the actual residue percentage of each sieve aperture according to the screening data and the mass of the aggregate before screening;

[0085] Calculate the ideal residue percentage: Calculate the ideal residue percentage of each sieve aperture according to the Fuller curve;

[0086] Determine the optimal gradation: According to the performance requirements of the concrete, calculate the error between the actual residue percentage and the ideal residue percentage of each sieve aperture, obtain the actual residue percentage and the corresponding sieve aperture size when the error is the smallest, use this sieve aperture size as the particle size required for the optimal gradation, and then obtain the optimal gradation.

[0087] The optimal gradation calculation method in the above embodiments dynamically combines the Fuller curve theory with the actual aggregate characteristics, making the calculation results not only meet the theoretical optimum but also adapt to the on-site material conditions.

[0088] In some embodiments, in the step of determining the optimal gradation, the formula for calculating the error between the actual residue percentage and the ideal residue percentage is:

[0089]

[0090] In formula (1), e is the error between the actual residue percentage and the ideal residue percentage, n is the total number of sieve aperture gradings of the aggregate screening unit, ω i is the weight coefficient of the i-th sieve aperture set according to the performance requirements of the concrete, P 实际(di) is the actual residue percentage of the i-th sieve aperture, P Fuller(di) is the ideal residue percentage of the i-th sieve aperture.

[0091] In some embodiments, the ideal residue percentage is calculated by formula (2), and the expression of formula (2) is:

[0092]

[0093] In formula (2), d is the sieve aperture size, D is the maximum aggregate particle size, and a is the Fuller index, usually taking 0.45 - 0.5.

[0094] In some embodiments, as Figure 5 shown, in the optimal gradation calculation method, after determining the optimal gradation, it further includes the step of generating a batching list. Automatically generate a digital batching list after determining the optimal gradation, directly connect to the mixing system to execute production, realize seamless connection of "calculation - proportioning - production", avoid manual transcription errors, and at the same time support quality traceability and process optimization.

[0095] Through the description of multiple embodiments of the concrete mixing system of the present invention and the concrete production method using the same, it can be seen that the embodiments of the concrete mixing system of the present invention and the concrete production method using the same have at least one or more of the following advantages:

[0096] 1. For the concrete mixing system provided by the present invention, by the aggregate screening unit, the particle size distribution data (aggregate data and screening data) of the aggregates at the construction site are obtained in real time. When the control unit dynamically calculates the optimal gradation based on the Fuller curve, it directly uses the actually available aggregates as the basis, avoiding the problem of the disconnection between the theoretical gradation and the on-site materials in the traditional method;

[0097] 2. For the concrete mixing system provided by the present invention, the control unit realizes data intercommunication and instruction linkage by communicating with each link, improves the coordination of the entire system, can reduce the lag of manual intervention, improves production efficiency, and at the same time reduces the risk of rework caused by inconsistent gradation;

[0098] 3. For the concrete production method provided by the present invention, the concrete production is upgraded from the traditional "experience-driven" to "data-driven". On the premise of ensuring the project quality, multi-dimensional optimization of material cost, production efficiency, resource utilization and environmental protection performance is realized, providing a reliable technical support for modern intelligent construction.

[0099] Finally, it should be noted that: the various embodiments in this specification are described in a progressive manner, and the key point of each embodiment is to illustrate the differences from other embodiments. The same or similar parts among the various embodiments can be referred to each other.

[0100] The above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that: still modifications can be made to the specific implementation manners of the present invention or equivalent replacements can be made to some technical features; without departing from the spirit of the technical solutions of the present invention, they should all be covered within the scope of the technical solutions claimed by the present invention.

Claims

1. A concrete mixing system, characterized in that: include: An aggregate screening unit, which is provided with multi-level sieve holes for screening aggregates and obtaining aggregate data and screening data; A storage unit connected to the aggregate screening unit, comprising a number of silos for storing aggregates, powder, admixtures and water; A mixing unit, which is connected to the storage unit and includes a mixer for mixing and producing concrete; A transport unit, which is used to transport the aggregate screened by the aggregate screening unit to the storage unit, and transport the raw materials stored in the storage unit to the mixing unit; A control unit is respectively connected to the aggregate screening unit, the storage unit, the mixing unit and the transport unit in communication; the control unit is used to calculate the optimal gradation according to the aggregate data and screening data of the aggregate screening unit by applying the Fuller curve, and transmit the optimal gradation to the aggregate screening unit and the storage unit; the control unit is also used to control and monitor the operation of the concrete mixing unit and the transport unit, and generate a carbon footprint report according to the consumption and output of each unit.

2. The concrete mixing system according to claim 1, characterized in that: The aggregate screening unit is also equipped with a laser particle size analyzer, which is used to assist in obtaining aggregate data and screening data.

3. The concrete mixing system according to claim 1, characterized in that: It also includes a waste heat recovery unit, which is connected to the powder silo and the mixer respectively and is used to recover the waste heat generated by the powder silo and the mixer.

4. The concrete mixing system according to claim 3, characterized in that: The waste heat recovery unit is also connected to the control unit for communication, and is used to transmit the recovered waste heat data to the control unit, and the control unit completes the carbon footprint report based on the waste heat recovery data.

5. The concrete mixing system according to claim 1, characterized in that: It also includes a waste residue recovery unit, which is used to recover the waste residue generated by the mixer and the waste residue adhered to the tires of the engineering vehicle, and press the waste residue into bricks.

6. The concrete mixing system according to claim 5, characterized in that: The waste residue recovery unit is also connected to the control unit for communication, and is used to transmit the waste residue brick making data to the control unit, and the control unit completes the carbon footprint report based on the waste residue brick making data.

7. A method for producing concrete, characterized in that: A concrete mixing system as claimed in any one of claims 1 to 6, comprising the following steps: Aggregate screening: Aggregates are screened using the aggregate screening unit to obtain aggregate data and screening data. Aggregate data includes aggregate type and particle size distribution data of different aggregates. Screening data includes the type, particle size and mass of aggregate screened out at each level of sieve hole. Optimal gradation calculation: The control unit calculates the optimal gradation of the required concrete using the Fuller curve based on aggregate data and screening data combined with concrete performance requirements; Raw material storage: transport aggregates of the required particle size for optimal grading, powder, admixtures and water to the storage unit for storage; Concrete mixing: The transport unit transports the aggregates, powders, admixtures and water stored in the storage unit to the mixing unit, which mixes and produces concrete according to the optimal gradation.

8. The concrete production method according to claim 7, characterized in that: In the aggregate screening step, the aggregate is scanned by a laser particle size analyzer to obtain aggregate data and screening data.

9. The concrete production method according to claim 7, characterized in that: The optimal gradation calculation method includes the following steps: Establishing aggregate database: Based on aggregate type, particle size distribution of different aggregates and maximum aggregate particle size; Calculate the actual percentage of screen residue: Calculate the actual percentage of screen residue at each level of sieve hole based on the screening data and the mass of the aggregate before screening; Calculate the ideal percentage of screen residue: Calculate the ideal percentage of screen residue for each level of screen hole according to the Fuller curve; Determine the optimal gradation: According to the concrete performance requirements, calculate the error between the actual residue percentage and the ideal residue percentage of each sieve hole, obtain the actual residue percentage and the corresponding sieve hole size when the error is minimum, and use the sieve hole size as the particle size required for the optimal gradation to obtain the optimal gradation.

10. The concrete production method according to claim 9, characterized in that: In the step of determining the optimal gradation, the formula for calculating the error between the actual residual percentage and the ideal residual percentage is: In formula (1), e is the error between the actual screen residue percentage and the ideal screen residue percentage, n is the total number of screen hole classifications of the aggregate screening unit, ω i is the weight coefficient of the i-th level sieve hole set according to the concrete performance requirements, P 实际(di) is the actual percentage of residue in the sieve hole of the i-th level, P Fuller(di) is the ideal residue percentage of the i-th level sieve hole.

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