Method for reducing concrete spraying rebound rate and concrete wet spraying equipment

Abstract

The invention relates to the technical field of concrete construction, and discloses a method for reducing the concrete spraying rebound rate and a concrete wet spraying device.The method comprises the following steps that a fluid control model based on historical guniting data is established, the model is used for performing parameter matching on the concrete guniting volume and the spraying speed, the spraying pressure and the spraying temperature of the high-speed fluid; the real-time guniting volume of the concrete wet spraying equipment is collected; and according to the guniting volume and the control model, generating fluid jet control parameters matched with the guniting volume and the control model. And through an accurate fluid control model and a real-time feedback mechanism, the concrete spraying rebound rate is effectively reduced. And an automatic spraying parameter adjusting mechanism is adopted, so that the pressure, the angle and the spraying amount of the sprayed fluid are accurately adjusted according to real-time monitoring data, and the construction efficiency and the spraying consistency are improved. And through a high-precision rebound rate monitoring system, rebound data are automatically calculated and fed back, the spraying process is optimized, concrete waste is reduced, and the resource utilization rate is increased.

Description

Technical Field

[0001] The present invention relates to the technical field of concrete construction, and specifically to a method for reducing the rebound rate of concrete spraying and a wet concrete spraying device. Background Art

[0002] With the gradual improvement of tunnel mechanized construction in China, construction machinery products such as concrete spraying vehicles have now been widely used in tunnel construction scenarios.

[0003] In recent years, shotcrete has been widely used in construction, and the technology has been gradually improved. However, there are still problems such as a high rebound volume, poor surface quality of spraying, and the spraying thickness not meeting the design requirements during the use process, and these problems have not been effectively controlled. In order to ensure and improve the quality of tunnel construction, control construction costs, and reduce the harm to the health of workers, it is of great practical significance to take effective measures to reduce the rebound volume of shotcrete.

[0004] The existing publicly known technical methods have the following problems: Actively controlling the quality of raw materials, the mix ratio of shotcrete, the length of the conveying pipeline, the working air pressure, the spraying distance, and the angle, etc., all ignore the fundamental mechanism of rebound generation, can only treat the symptoms but not the root cause, can only assist in reducing the rebound rate, have high requirements for the skills of operators, and the interference of human factors is too large, resulting in low construction economic benefits. Summary of the Invention

[0005] In view of the deficiencies of the prior art, the present invention provides a method for reducing the rebound rate of concrete spraying and a wet concrete spraying device, which solves the problems of high rebound rate and unstable spraying effect of concrete spraying in the prior art.

[0006] To achieve the above objectives, the present invention is realized through the following technical solutions: A method for reducing the rebound rate of concrete spraying includes the following steps:

[0007] Establish a fluid control model based on historical spraying data, and the model is used to match the parameters of the concrete spraying volume with the spraying speed, spraying pressure, and spraying temperature of the high-speed fluid;

[0008] Collect the real-time spraying volume of the wet concrete spraying device;

[0009] Generate fluid spraying control parameters matching the spraying volume and the control model;

[0010] Send the control parameters to the fluid supply system to adjust the spraying speed, spraying pressure, and spraying temperature of the high-speed fluid;

[0011] The high-speed fluid is ejected through a plurality of high-speed fluid nozzles arranged around the main nozzle, forming an air field surrounding the concrete spraying path, which is used to suppress the rebound generated when the concrete impacts the sprayed surface.

[0012] Monitor the rebound amount after concrete spraying, and calculate the rebound rate by comparing the adhesion amounts before and after spraying.

[0013] Feed back the rebound rate to the control model, optimize the parameters of the model, and generate updated control parameters for the next cycle of spraying control.

[0014] Preferably, the high-speed fluid includes compressed air, water, or liquid accelerator, or a combination of two or more of them.

[0015] Preferably, the fluid control model is a multivariable fitting model or a data rule matching model constructed based on the spraying volume, spraying distance, concrete mix ratio, and environmental parameters.

[0016] Preferably, the high-speed fluid nozzles are a plurality of adjustable-diameter spray holes arranged around the main nozzle, and the structure of the spray holes is circular, conical, square, or flared.

[0017] Preferably, the fluid supply system includes a pressure regulating unit, a flow control unit, and a temperature control unit, which respectively adjust the ejection state of the high-speed fluid according to the control parameters.

[0018] Preferably, the optimization of the control model adopts a feedback mechanism based on the rebound rate deviation, and the control parameters are iteratively updated through a PID regulation or neural network training algorithm.

[0019] Preferably, the spraying volume is collected in real time by a flow sensor connected to the concrete pump, and the rebound rate is obtained by measuring the image or weight of the concrete adhered to the sprayed surface after spraying.

[0020] Preferably, the control parameters include the set value of the spraying speed, the target value of the pressure, and the set value of the temperature, which are respectively used to drive the corresponding control units to realize the adjustment of the spraying state.

[0021] A wet concrete spraying device includes

[0022] A combined nozzle for simultaneously performing concrete spraying and high-speed fluid controlled spraying, the combined nozzle includes a concrete spraying nozzle and a plurality of surrounding high-pressure fluid spraying nozzles;

[0023] A spraying area, which is the construction surface area where the concrete and the fluid act together; the spraying area includes a central area, a peripheral area, and a spraying overlapping area between the two;

[0024] A wet spraying machine for preparing and transporting concrete;

[0025] A storage tank is provided on the wet shotcreting machine for storing concrete raw materials;

[0026] A fluid booster pump is connected between the storage tank and the combined nozzle for increasing the injection pressure of the high-pressure fluid;

[0027] Pipes are respectively connected to the concrete conveying path and the fluid supply path;

[0028] A control system includes a control unit for running a control model, generating control parameters and driving the injection components;

[0029] The control system is communicatively connected to the wet shotcreting machine, the combined nozzle and the fluid booster pump for realizing closed-loop regulation of fluid control.

[0030] Preferably, the control system includes:

[0031] A data acquisition module for obtaining the concrete output volume of the wet shotcreting machine and obtaining the image or morphological data of the shotcrete surface after spraying through an image acquisition unit or a laser measurement unit installed in front of the equipment, so as to calculate the concrete adhesion amount;

[0032] A control calculation unit for generating injection control parameters based on the fluid control model and combining the morphological analysis results of the central area, the peripheral area and the injection overlapping area formed in the injection area;

[0033] An execution unit for driving the concrete injection nozzle and the high-pressure fluid injection nozzle to execute the injection parameters output by the control calculation unit;

[0034] A communication interface module for establishing real-time data transmission and feedback control connections with the wet shotcreting machine, the fluid booster pump, the pipes and the combined nozzle to form a closed-loop regulation system.

[0035] The present invention provides a method for reducing the rebound rate of concrete spraying and a wet concrete spraying device. It has the following beneficial effects:

[0036] 1. The present invention adopts an accurate fluid control model and a real-time feedback mechanism, achieving the technical effect of significantly reducing the rebound rate of concrete spraying. Compared with the existing solutions that simply rely on injection pressure control, the present invention solves the problem that the rebound caused by air flow or pressure fluctuation during spraying cannot be effectively suppressed through fluid collaborative spraying and rebound rate monitoring, realizes the dynamic adjustment of the rebound rate, and improves the quality and efficiency of spraying.

[0037] 2. The present invention introduces an automated injection parameter adjustment mechanism. By real-time monitoring of key data such as the spraying volume, rebound rate, and ambient temperature, it automatically adjusts the pressure and spraying angle of the injection fluid. Compared with the prior art solutions that rely on manual intervention and empirical adjustment, the adaptive control of the present invention can precisely adjust the parameters according to the real-time changes in the construction environment, significantly improving the construction efficiency and spraying consistency, and reducing the unstable factors caused by human errors.

[0038] 3. The high-precision rebound rate monitoring system adopted by the present invention can accurately calculate the rebound rate during the spraying process and provide real-time feedback to the control system. Compared with the prior art solutions that rely on manual observation and rough estimation, the present invention realizes automated and efficient rebound rate monitoring, and optimizes the injection parameters through a closed-loop control mechanism, thereby effectively reducing the amount of wasted concrete during the spraying process and improving the resource utilization rate.

[0039] 4. The present invention optimizes the concrete mix ratio and spraying strategy through an intelligent feedback control system. Compared with the prior art solutions with fixed spraying processes and mix ratios, the system of the present invention can flexibly adjust the concrete formula according to the real-time collected spraying volume and rebound rate data, ensuring the best spraying effect under different environmental conditions, and solving the problems of unstable spraying effect and insufficient adhesion caused by improper mix ratio. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 is the overall view of the wet concrete spraying equipment of the present invention;

[0041] Figure 2 is the structural schematic diagram of the combined nozzle in the wet concrete spraying equipment of the present invention;

[0042] Figure 3 is the structural schematic diagram of the spraying area in the wet concrete spraying equipment of the present invention;

[0043] Figure 4 is the layout process schematic diagram of the method for reducing the rebound rate of concrete spraying in the present invention.

[0044] Among them, 1. Combined nozzle; 11. Concrete spraying nozzle; 12. High-pressure fluid spraying nozzle; 2. Spraying area; 21. Central area; 22. Peripheral area; 23. Spraying overlapping area; 3. Wet spraying machine; 31. Storage tank; 32. Fluid booster pump; 33. Pipeline. DETAILED DESCRIPTION OF THE INVENTION

[0045] Next, in combination with the accompanying drawings in the specification of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described. 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.

[0046] Embodiment:

[0047] Please refer to the attached Figure 1 - attached Figure 3 , the embodiment of the present invention provides a wet concrete spraying device, including

[0048] The combined nozzle 1 is used for simultaneous concrete spraying and high-speed fluid controlled spraying. The combined nozzle 1 includes a concrete spraying nozzle 11 and a plurality of surrounding high-pressure fluid spraying nozzles 12;

[0049] The combined nozzle 1 is arranged at the front-end output port of the wet spraying system, and its structure is designed in a multi-axis surrounding layout.

[0050] Specifically, the combined nozzle 1 includes:

[0051] A concrete spraying nozzle 11 is provided at the central position, and its internal channel is connected to the conveying pipeline of the wet spraying machine for outputting wet concrete. This nozzle is designed to be streamlined and evenly sprays concrete through a built-in stirring device. This nozzle usually has a diameter of 25 - 40 mm to control the flow rate of concrete. The concrete is sent from the storage tank 31 through the main pump, and after mixing and stirring, it is directly sprayed by the nozzle.

[0052] A number of high-pressure fluid spraying nozzles 12 are symmetrically distributed around the concrete nozzle, usually 4 - 12 in number. These nozzles spray compressed air or water through a fluid booster pump 32 to control the fluid spraying pressure to generate a turbulent gas field. By adjusting the angle and jet direction of the nozzles, a specific gas field coverage layer is formed on the spraying surface to reduce concrete rebound. The nozzle angle is generally set at 15°, and the spraying pressure can be adjusted between 1.0 MPa.

[0053] The overall nozzle adopts a split and detachable structure, which is convenient for on-site maintenance and replacement of multiple models. The nozzle material is selected as wear-resistant stainless steel or composite ceramic liner to cope with high-frequency spraying conditions.

[0054] The wet spraying machine 3 serves as the material processing unit of the system, responsible for the storage, mixing and conveying of concrete;

[0055] The storage tank 31 is arranged on the wet spraying machine 3 for storing concrete raw materials, and is equipped with a stirring device to ensure the uniformity of concrete. During operation, the concrete is conveyed through the conveying pipeline 33 to the concrete spraying nozzle 11 for spraying;

[0056] The wet shotcreting machine is equipped with a flow sensor to measure the flow rate of the sprayed concrete in real time. The working principle of this flow sensor is that of a mass flowmeter, which can accurately measure the volume Q of the sprayed concrete per minute. By monitoring the shotcreting volume in real time, the control system can adjust the parameters of the spraying fluid as needed.

[0057] A fluid booster pump 32. The high-pressure fluid spraying nozzle 12 is supplied with compressed air or water flow through the fluid booster pump 32. The pressure of the booster pump is adjustable, and the pressure range is 0.4 - 1.0 MPa. It can be adjusted according to the changes in the construction environment and the shotcreting volume to maintain the stability of fluid spraying.

[0058] A pipeline 33, which connects the concrete conveying path and the fluid supply path respectively.

[0059] The wet shotcreting machine 3, as the core material processing unit of the system, is mainly responsible for the storage, mixing and conveying of concrete raw materials.

[0060] The spraying area 2 is the construction surface area where the concrete and the fluid act together. The spraying area 2 includes a central area 21, a peripheral area 22 and a spraying overlap area 23 between the two.

[0061] The spraying area 2 is the actual receiving surface of the concrete, which can be divided into:

[0062] The central spraying area 21, corresponding to the direction of the nozzle axis. The concrete directly impacts this area at the highest speed, and the adhesion rate is relatively high. This is the main receiving surface for concrete spraying. The spraying flow of the nozzle directly acts on this area, and the rebound rate is relatively low. Usually, the spraying angle in the central area is relatively concentrated.

[0063] The peripheral area 22, within a certain angular range around the nozzle axis, is prone to rebound accumulation and is the key area for intervention. In order to reduce the rebound in this area, the fluid spraying nozzle 12 will spray the auxiliary fluid at a higher pressure and a larger angle to form an interfering air flow, reducing the concrete splash and splash rebound.

[0064] The spraying overlap area 23, located at the junction between the central area and the peripheral area, is formed by the alternating coverage of multiple spray flows. This area is often the concentrated area of rebound. By finely adjusting the fluid spraying pressure and the concrete spraying volume, the spraying stability and adhesion effect in this area are optimized.

[0065] The control system is responsible for monitoring and adjusting the parameters in the concrete spraying process in real time. Based on the information such as the shotcreting volume, air flow velocity, and ambient temperature collected by the sensors, the control system dynamically adjusts the spraying pressure and the fluid state.

[0066] The control system is communicatively connected to the wet shotcreting machine 3, the combined spray head 1, and the fluid booster pump 32, and is used to achieve closed-loop regulation of fluid control.

[0067] The control system includes:

[0068] A data acquisition module, which is used to obtain the concrete output volume of the wet shotcreting machine 3, and to obtain the image or morphological data of the shotcrete surface after spraying through an image acquisition unit or a laser measurement unit installed in front of the equipment, so as to calculate the concrete adhesion amount;

[0069] A control calculation unit, which is used to generate spray control parameters based on a fluid control model and in combination with the morphological analysis results of the central area 21, the peripheral area 22, and the spray overlap area 23 formed in the spray area 2;

[0070] An execution unit, which is used to drive the concrete spray head 11 and the high-pressure fluid spray nozzle 12 to execute the spray parameters output by the control calculation unit;

[0071] A communication interface module, which is used to establish real-time data transmission and feedback control connections with the wet shotcreting machine 3, the fluid booster pump 32, the pipeline 33, and the combined spray head 1 to form a closed-loop regulation system.

[0072] In the control system, the control algorithm performs spray optimization through data input, including the following steps:

[0073] Data acquisition and parameter initialization: The system collects the key parameters such as the concrete volume Q sprayed per minute, the fluid pressure P, and the temperature T through a flow sensor. When the system is initialized, all devices start working according to the preset spray parameters.

[0074] Rebound rate detection and dynamic feedback: Through an image recognition device or a laser ranging module, the adhesion effect after concrete spraying is monitored, and the rebound rate R is calculated in real time. The calculation formula for the rebound rate is:

[0075]

[0076] Where: V rebound is the concrete volume in the rebound area; V total is the total spray volume.

[0077] In some embodiments, when the rebound rate exceeds the set threshold, the control system will trigger a feedback mechanism to automatically adjust the spray pressure and spray flow.

[0078] Control algorithm and model update: The system adopts a dynamic adjustment strategy to predict the spray effect and optimize parameters through a model. Control algorithms such as PID control, genetic algorithm, or deep learning model will adjust the spray parameters at each stage to achieve the best spray quality.

[0079] The formula is defined as follows:

[0080] P = αQ m e -βT +γ

[0081] Where: P represents the injection pressure, with the unit of MPa; Q represents the volume of sprayed mortar, with the unit of m 3 / min; T represents the ambient temperature, with the unit of °C; α, β, γ are fitting parameters regressed based on on-site experimental data; m is an exponent adjusted according to the concrete properties and construction environment.

[0082] Closed-loop feedback control: According to the real-time feedback of the rebound rate, the control system transmits the adjustment parameters to the booster pump and the nozzle to adjust the injection pressure and the air flow angle. This closed-loop control mechanism can ensure that the injection state remains optimal, thereby minimizing the rebound loss to the greatest extent.

[0083] Please refer to the appendix Figure 4 , a method for reducing the rebound rate of concrete spraying, comprising the following steps:

[0084] S1. Establish a fluid control model based on historical spraying data, which is used to match the parameters of the concrete spraying volume with the spraying speed, injection pressure, and injection temperature of the high-speed fluid;

[0085] In this embodiment, the establishment of the fluid control model is one of the crucial links in the entire spraying system. By establishing an accurate fluid control model, the system can dynamically adjust the fluid spraying state according to the changes in various parameters during the concrete spraying process, thereby effectively reducing the spraying rebound rate and improving the adhesion effect of the concrete. With the help of this model, the system can respond in real time to the changes in different construction environments and automatically adjust the spraying parameters, such as injection pressure, flow rate, temperature, etc., to ensure the stability of the construction quality and spraying effect.

[0086] The establishment of the fluid control model is mainly based on the collection and analysis of multi-dimensional data, and the parameters involved include but are not limited to the spraying volume, spraying air flow rate, air pressure, fluidity of the concrete formula, etc. By modeling and deriving the interrelationships of these parameters, the control system can generate an accurate spraying optimization plan and dynamically adjust the spraying parameters according to the actual feedback data. In some embodiments, the establishment of this model combines a variety of mathematical tools and calculation methods, such as regression analysis, fitting algorithms, optimal control theory, etc.

[0087] Specifically, the establishment of the fluid control model involves the following steps:

[0088] First, the concrete volume Q output by the wet spraying machine 3 is measured in real time through a flow sensor, and the volume of concrete sprayed per minute is recorded. To ensure the accuracy of the model, this data is considered one of the basic parameters input to the control model.

[0089] Then, by establishing the mathematical relationships between the injection pressure P, injection temperature T, and the concrete spraying volume Q, their mutual influences are determined. In this embodiment, the relationship between the injection pressure P and the concrete spraying volume Q is considered to exhibit a certain power function relationship, and its mathematical expression is as follows:

[0090] P = αQ m e -βT +γ

[0091] Wherein, the definitions of the parameters are as follows: P: injection pressure, unit is MPa. Q: spraying volume, unit is m 3 / min. T: ambient temperature, unit is °C. α: coefficient, representing the proportional relationship between the injection pressure and the concrete spraying volume. β: coefficient, representing the influence degree of temperature on the injection pressure. γ: constant term, correcting other unmodeled influencing factors. m: exponent, representing the non-linear relationship between the spraying volume and the injection pressure.

[0092] In this formula, Q m describes the power function relationship between the concrete spraying volume and the injection pressure, indicating that an increase in the spraying volume will significantly increase the injection pressure. By adjusting parameters such as α and m, the change of the injection pressure can be flexibly controlled according to the requirements of the construction scenario. In addition, the influence of the temperature T on the injection pressure is represented by the exponential decay term e -βT in this model, and this relationship reflects that when the temperature rises, the fluidity of gas or liquid increases, thereby possibly reducing the injection resistance.

[0093] Furthermore, the system also considers the influence of the fluidity of the concrete formulation on the spraying process. Concrete with better fluidity has stronger adhesion during spraying and can reduce rebound. In the model, the fluidity parameter can be fitted through experimental data to optimize the spraying parameters.

[0094] During the process of establishing the model, a feedback mechanism is also introduced, that is, the system can adjust the spraying parameters by real-time monitoring of the rebound rate R after spraying. This feedback control logic ensures the best adhesion effect of the concrete during the spraying process and reduces the waste of concrete caused by rebound.

[0095] Specifically, the rebound rate R is calculated by the following formula:

[0096]

[0097] Where: V rebound is the volume of concrete in the rebound area, unit is m 3 ; V total is the total spraying volume, unit is m 3 .

[0098] During system operation, the adhesion thickness of the surface after spraying is obtained through a real-time image acquisition device or a laser ranging module, and the spraying rebound rate is calculated. If the rebound rate exceeds the set threshold, the control system will readjust the spraying parameters according to the feedback data to ensure that the spraying effect meets the requirements. Generally, when the rebound rate is high, the system will automatically increase the high-pressure air flow spraying volume, thereby changing the distribution of the spraying flow field and reducing the occurrence of rebound.

[0099] In some embodiments, the fluid control model also incorporates other dynamic adjustment mechanisms, such as variables like spraying angle, fluid velocity, and fluid type. These factors all have an impact on the rebound rate during the concrete spraying process. Therefore, the control system needs to adjust each control variable according to the parameters measured in real time to optimize the spraying effect.

[0100] By establishing this fluid control model, the present invention can provide more precise spraying control, achieve adaptive adjustment during the spraying process, reduce the rebound rate, and improve construction efficiency.

[0101] This fluid control model can not only provide real-time feedback and adjust parameters during the concrete spraying process, but also has strong adaptability and expandability, and can be optimized according to different construction environments, different concrete mixes, and different spraying machine models. Through this control model, the system can operate stably in various actual construction scenarios, ensuring the construction quality and the efficiency of the spraying effect.

[0102] S2. Collect the real-time spraying volume of the wet concrete spraying equipment;

[0103] In this embodiment, the real-time collection of the spraying volume is one of the important steps in the control of the entire spraying process. By accurately monitoring and recording the spraying volume of concrete per minute (i.e., the spraying volume, Q), the control system can obtain the change in the spraying volume in real time and use this data as input for subsequent fluid control models and spraying parameter adjustments. The real-time collection of the spraying volume can not only ensure the stability of the spraying volume, but also provide key data for the control system to achieve real-time adjustment and optimization of the spraying rebound.

[0104] Specifically, the step of real-time collection of the spraying volume is crucial for the dynamic adjustment of the entire system because the spraying volume of concrete directly affects the spraying uniformity, rebound rate, and concrete adhesion effect. By correlating with parameters such as spraying pressure, spraying angle, and ambient temperature, the control system can adjust the working state of the spraying equipment according to the actual construction situation, thereby achieving a better construction effect.

[0105] In this embodiment, the specific implementation of the step of real-time collection of the spraying volume is as follows:

[0106] First, install a flow sensor inside the wet shotcreting machine 3 to monitor the flow rate of the shotcrete in real time. The main function of the flow sensor is to detect the volume of concrete passing through the pipeline of the wet shotcreting machine. Usually, a mass flowmeter or a volumetric flowmeter is used for monitoring. The mass flowmeter can accurately calculate the spraying volume Q per unit time according to the density and fluidity of the concrete. This flow data will be continuously recorded and regularly transmitted to the control system for use as a reference for subsequent adjustment of the spraying parameters.

[0107] In some embodiments, the adopted flow sensor can automatically adjust its acquisition accuracy during the flow process of the concrete to adapt to concretes with different viscosities and fluidities. This flexibility ensures that the flow sensor can maintain a high measurement accuracy in different construction environments.

[0108] The spraying volume data Q collected in real time by the flow sensor is transmitted to the central control system. The control system takes these data as inputs and combines other environmental parameters, such as temperature, humidity, spraying pressure, etc., to generate a spraying optimization plan. In a possible implementation, the control system will compare the spraying volume data collected in real time with a preset spraying volume range. If the spraying volume Q deviates from the predetermined value, the control system will issue an adjustment instruction to automatically adjust the working state of the spraying equipment, such as increasing the spraying pressure or adjusting the spraying angle, etc.

[0109] Specifically, the spraying volume data Q collected in real time is also combined with the monitoring result of the rebound rate R. By establishing a feedback relationship between the two, closed-loop control is achieved. When the rebound rate is too high, the system can suppress the occurrence of rebound by adjusting the spraying volume or the flow rate of the spraying fluid. For example, if the spraying volume Q increases, the spraying pressure P will increase accordingly to ensure the uniformity and adhesion of the concrete spraying; conversely, if the spraying volume decreases, the system will reduce the flow rate of the spraying fluid to prevent unstable spraying caused by too high a flow rate.

[0110] To further ensure the accuracy of the spraying volume data, in some embodiments, the flow sensor is also equipped with a temperature and pressure compensation module. This module can automatically correct the flow data according to the temperature change of the concrete and the environmental pressure change, so as to maintain the measurement accuracy. For example, as the temperature rises, the fluidity of the concrete increases, and the flow sensor corrects it through a compensation algorithm to ensure the accuracy of the data.

[0111] In this way, the data of the spraying volume Q will be continuously updated for the system to perform real-time optimization and adjustment. In this way, the control system can dynamically adjust parameters such as the pressure, flow rate, and spraying angle of the spraying fluid according to the actual needs of the construction site, ensure that the rebound rate is effectively controlled during the spraying process, and at the same time improve the adhesion effect of the concrete.

[0112] In this embodiment, real-time collection of the shotcrete volume data can not only help adjust the spraying parameters, but also provide important data support for other technical problems arising during the construction process. For example, by analyzing the relationship between the shotcrete volume and the rebound rate, construction personnel can better predict the spraying effect under different environmental conditions and make preparations in advance and adjustments in the later stage to ensure the construction quality.

[0113] In summary, real-time collection of the shotcrete volume is not only a key link in controlling the concrete spraying process, but also closely cooperates with other control measures to ensure the optimization of the spraying effect and the improvement of construction efficiency. This process helps achieve precise adjustment during the spraying process through intelligent and automated data collection and feedback control, reduces human intervention, and improves construction quality.

[0114] S3. Generate fluid spraying control parameters that match the shotcrete volume and the control model;

[0115] S4. Send the control parameters to the fluid supply system to adjust the spraying speed, spraying pressure, and spraying temperature of the high-speed fluid;

[0116] In this embodiment, the step of calculating and generating the control parameters is one of the core links in the spraying control system. By comprehensively analyzing the data such as the real-time collected shotcrete volume Q, spraying pressure P, and ambient temperature T, the system can automatically calculate the optimal spraying parameters according to the established fluid control model. These control parameters will be transmitted to the spraying equipment to ensure that the concrete adhesion effect during the spraying process reaches the expected goal, thereby minimizing the rebound rate to the greatest extent.

[0117] This step involves the collaborative work of multiple calculation modules. By processing and analyzing the input data, control parameters suitable for the current construction environment and spraying requirements are generated. These control parameters include not only the spraying pressure, but also factors such as the speed of the spraying fluid, spraying angle, and temperature. Through the adjustment of these parameters, the control system can achieve dynamic control of the rebound rate during the actual spraying process, thereby improving the spraying quality of the concrete.

[0118] In this embodiment, the specific steps of calculating and generating the control parameters are as follows:

[0119] First, the real-time collected shotcrete volume Q data will be input into the control system as the basic data for calculating the control parameters. The control system will calculate the required spraying pressure P and fluid spraying volume according to the collected shotcrete volume and other environmental parameters, combined with the established fluid control model. This calculation process uses the previously mentioned formula and is dynamically adjusted according to different situations at the construction site.

[0120] In some embodiments, the control system will use the established fluid control model to predict the injection pressure P and the injection fluid flow rate according to the change in the spraying volume Q. Specifically, the control system will refer to the output of the following control model:

[0121] P = αQ m e -βT +γ

[0122] In this formula, P represents the injection pressure, Q represents the spraying volume per unit time, T represents the ambient temperature, and α, β, γ, m are respectively the model fitting parameters. Through this formula, the control system can calculate the appropriate injection pressure P according to the current spraying volume, temperature, and environmental conditions. The setting of these parameters ensures that the non-linear relationship between pressure and spraying volume during the concrete spraying process is optimized, thereby improving the spraying quality.

[0123] In some embodiments, the calculation of the injection pressure P is also affected by the type of injection equipment. Different types of wet spraying equipment have different injection pressure requirements. The control system can adjust the coefficients (such as α, β, etc.) in the calculation process according to the specifications and parameters of the equipment to ensure that the calculation results match the equipment performance. Generally, the control system will set the upper and lower limits of the injection pressure according to the rated working pressure range of the equipment, so as to avoid the adverse effects of too high or too low pressure on the spraying quality.

[0124] Furthermore, the control system will also combine the calculated injection pressure with the velocity V of the injection fluid to adjust the injection angle θ and the flow rate to ensure that the concrete can be evenly sprayed onto the target area and reduce the occurrence of rebound. During this process, the injection angle θ and the velocity V of the injection fluid will be optimized through a control algorithm and dynamically adjusted according to the different requirements of the spraying area 2.

[0125] Specifically, the control system will be optimized and designed according to the characteristics of the spraying area. For example, the central spraying area 21 usually requires a higher injection pressure and a smaller injection angle to ensure that the concrete can directly and evenly adhere to the target surface. While the peripheral spraying area 22 requires a relatively lower injection pressure and a larger injection angle to avoid the rebound of concrete in the edge area. By dynamically adjusting the injection pressure, flow rate, and injection angle, the control system can effectively control the rebound rate and improve the spraying quality.

[0126] In addition, in this embodiment, the control system also includes a feedback control mechanism. During the spraying process, the system will real-time monitor the rebound rate R after spraying and feed this data back to the control system. If the rebound rate exceeds the preset threshold, the control system will adjust the spraying parameters according to the feedback information. Specifically, the control system will automatically adjust parameters such as the spraying flow rate Q, the injection pressure P, and the fluid injection volume to ensure that the rebound rate during the spraying process is effectively controlled and the best spraying effect is achieved.

[0127] Generally speaking, the steps of calculating and generating control parameters provide the entire system with the ability of dynamic adjustment. By continuously collecting, calculating, and adjusting parameters, the system can cope with different environmental conditions and construction requirements, ensuring the maximization of the concrete adhesion effect and the minimization of the rebound rate during the spraying process, thereby improving the spraying quality and construction efficiency.

[0128] S5. Jet high-speed fluid through multiple high-speed fluid nozzles arranged around the main nozzle to form an air field surrounding the concrete spraying path, which is used to suppress the rebound generated when the concrete impacts the sprayed surface.

[0129] In this embodiment, the fluid collaborative spraying step is one of the key links for the present invention to control the concrete spraying rebound rate. The core of this step is to form an interference air field surrounding the concrete spraying flow through the collaborative spraying of spraying fluids (such as compressed air, liquid accelerator, or water), reducing the occurrence of concrete rebound. By adjusting the spraying pressure, spraying angle, and spraying position of the fluid, the system can effectively interfere with the rebound direction during the spraying process, ensuring that the sprayed concrete can adhere to the target surface evenly and firmly.

[0130] The implementation process of fluid collaborative spraying is based on the established fluid control model. This model calculates the optimal fluid spraying parameters according to factors such as the spraying volume, environmental temperature, and concrete fluidity. By reasonably adjusting the pressure and flow rate of the spraying fluid, the air flow or liquid flow around the nozzle can play an interfering role while the concrete is being sprayed, suppressing the rebound phenomenon. This process not only enhances the uniformity of the spraying effect but also improves the adhesion of the sprayed concrete, further reducing the rebound rate.

[0131] In this embodiment, the specific implementation steps of fluid collaborative spraying are as follows:

[0132] First, the system obtains spraying parameters such as the spraying pressure P, spraying angle θ, and spraying volume Q according to the aforementioned steps of calculating and generating control parameters. At this time, the fluid spraying nozzle 12 provides compressed air or water flow through the booster pump 32, and determines the spraying pressure and fluid flow rate according to the calculation results. The spraying speed and spraying angle of the fluid will be dynamically adjusted according to different concrete spraying areas, so as to achieve the best fluid interference effect.

[0133] Generally, fluid collaborative spraying will adjust the spraying intensity differently according to different positions within the spraying area 2. The central area 21 usually requires stronger fluid spraying to stabilize the adhesion of the concrete, while the peripheral area 22 requires weaker fluid spraying to avoid unnecessary rebound caused by excessive air flow. The spraying pressure and angle of the fluid will be adjusted according to the requirements of these areas to ensure that the spraying effect of each area is uniform and stable.

[0134] Specifically, multiple fluid injection nozzles 12 on the outer ring of the nozzle can form a stable air field when spraying concrete by adjusting the injection angle and flow rate of the fluid. These airflows effectively inhibit the rebound force generated during concrete spraying. The injection of the fluid not only needs to meet the requirement of the spraying volume Q, but also needs to be matched with the injection pressure P and the temperature T to form an effective airflow interference.

[0135] In a possible implementation, the injected fluid (such as compressed air or liquid accelerator) will be adjusted as follows:

[0136] Injection pressure P: According to the working state of the fluid injection nozzles on the periphery of the nozzle, the system automatically adjusts the injection pressure to ensure that the fluid can generate sufficient flow rate and cover the concrete spraying area. In the high-rebound area, the system will automatically increase the injection pressure to enhance the airflow interference effect.

[0137] Injection angle θ: The system controls the angle of the injected fluid through the driving device of the adjustable nozzle to precisely adjust the airflow direction. Generally, the adjustment range of the injection angle θ is 15° to 45°, and it can be optimized according to different construction requirements.

[0138] Fluid injection speed V f : The change in the fluid injection speed will affect the spraying stability and the coverage range of the airflow. The system will dynamically adjust the fluid injection speed according to the changes in the spraying volume and the injection pressure.

[0139] In some embodiments, the type of the injected fluid can be selected according to the construction requirements. Compressed air is commonly used to form a strong airflow interference effect, while liquid accelerator helps to increase the early solidification speed of the sprayed concrete and further enhance its adhesion. The system can select a suitable fluid type according to the current construction environment and automatically adjust its injection parameters.

[0140] Through the implementation of fluid co-injection, the rebound phenomenon generated during the concrete spraying process is effectively inhibited. After spraying, the rebounded concrete will be blown away from the spraying area by the airflow, reducing material waste and improving construction efficiency at the same time. During this process, the interference effect of the fluid can directly affect the spraying quality. Therefore, the adjustment of the injection pressure, injection angle and flow rate is crucial.

[0141] In some embodiments, the system also models the relationship between the rebound rate R and the fluid injection parameters. The control system adjusts the fluid injection parameters in real time according to the rebound rate feedback information to ensure that the rebound rate is always within the target range. This feedback mechanism can effectively cope with the differences in different construction environments, concrete formulations and spraying equipment, ensuring the high efficiency and stability of the spraying process.

[0142] In summary, the fluid collaborative injection step ensures the uniformity and adhesion of concrete injection by precisely controlling the injection parameters of the fluid, reduces the rebound rate, and improves the construction quality and efficiency. This process is not only a crucial part of the injection control system but also closely cooperates with other control steps of the system (such as the collection of shotcrete volume and the generation of control parameters), forming an efficient and intelligent injection control mechanism.

[0143] S6. Monitor the rebound amount after concrete injection and calculate the rebound rate by comparing the adhesion amounts before and after injection;

[0144] S7. Feed back the rebound rate to the control model, optimize the parameters of the model, and generate updated control parameters for the next cycle of injection control.

[0145] In this embodiment, the step of monitoring the rebound rate and feedback control is one of the key links to achieve efficient rebound control during the concrete injection process. This step monitors the rebound phenomenon after injection in real time and automatically adjusts the injection parameters according to the change of the rebound rate R to ensure that the rebound phenomenon during the concrete injection process is minimized as much as possible. Through this closed-loop feedback mechanism, the system can automatically adjust parameters such as the injection fluid, injection pressure, and injection angle during the construction process, thereby optimizing the injection effect and improving the adhesion and stability of the concrete.

[0146] The real-time monitoring and feedback control of the rebound rate not only rely on the effective detection of the injection area but also require a detailed analysis of the injection surface through advanced sensing technologies (such as image recognition, laser ranging, etc.). Based on these real-time data, the control system can precisely adjust the injection equipment to form an effective control loop. The core of the feedback control is to adjust according to the relationship between the rebound amount (i.e., the rebound volume) after injection and the total injection volume to optimize the rebound control during the injection process.

[0147] In this embodiment, the specific implementation process of the step of monitoring the rebound rate and feedback control is as follows:

[0148] First, the system monitors the rebound situation after injection in real time through an image acquisition device or a laser ranging module. Specifically, the image acquisition device or the laser ranging module can capture the morphology of the surface after injection, analyze the adhesion thickness of the concrete, and calculate the concrete volume V of the rebound area. rebound . By comparing with the total injection volume V total , the rebound rate R can be calculated, and its calculation formula is:

[0149]

[0150] Where: V rebound is the concrete volume of the rebound area, with the unit of m 3 ; V total is the total injection volume, with the unit of m3 。

[0151] Through this formula, the control system can calculate the rebound rate during the spraying process in real time, which is an important indicator for judging whether the spraying effect meets the requirements.

[0152] When the rebound rate exceeds the preset threshold, the system will trigger a feedback control mechanism. The core of the feedback mechanism is to optimize and adjust through the relationship between the rebound rate and spraying parameters (such as spraying pressure P, spraying volume Q, etc.). Specifically, if the rebound rate is too high, the control system will increase the spraying pressure or spraying flow rate to ensure that the concrete can adhere more firmly to the target surface; on the contrary, if the rebound rate is low, the system can reduce the spraying pressure or flow rate to avoid uneven spraying or concrete waste caused by excessive air flow or water flow.

[0153] In some embodiments, the control system will comprehensively optimize parameters such as spraying pressure P and spraying volume Q in combination with a fluid control model. In some cases, the control system will also adjust the spraying angle θ to ensure the uniformity and effectiveness of spraying. The adjustment of the spraying angle, especially in areas with severe rebound phenomena, will help disperse the impact force of the spraying flow and slow down the force generated by rebound.

[0154] For example, the synergistic effect of the spraying fluid will form a reverse air flow in the rebound area, which will effectively prevent the splashing of rebound concrete, reduce waste and improve adhesion. In this case, the system adjusts the spraying angle, the speed and pressure of the spraying fluid to form an optimal interference gas field in the target area, thereby minimizing rebound to the greatest extent.

[0155] As an option, in some embodiments, sensors or laser ranging modules may also be combined to divide regions during the spraying process and perform local adjustment according to the spraying rebound conditions in different regions. By accurately calculating the rebound rate of each region, the system can flexibly adjust the spraying pressure and flow rate during the local spraying process, thereby more precisely controlling the rebound phenomenon.

[0156] Furthermore, the feedback control mechanism of the system not only involves the adjustment of the spraying flow, but also the dynamic optimization of the concrete mix ratio. In some embodiments, the system will automatically adjust the cement-to-aggregate ratio of the concrete according to the relationship between the real-time spraying volume Q and the rebound rate R. This operation helps to improve the fluidity and adhesion of the concrete and further reduce the rebound phenomenon.

[0157] Generally speaking, monitoring the rebound rate and the feedback control steps form an intelligent and automated feedback control system by accurately monitoring the rebound phenomenon and multiple parameters during the spraying process. The system can respond in real time to different construction environments and spraying requirements, ensure the best adhesion effect of the concrete during the spraying process, and ensure the stability and efficiency of the construction quality.

[0158] In summary, the monitoring and feedback control steps of the present invention achieve precise control of the shotcrete rebound phenomenon through the combination of real-time rebound rate monitoring and parameter adjustment. The system can dynamically adjust the shotcrete parameters according to the change of the rebound rate, optimize the shotcrete effect, reduce the rebound rate, and thus improve the quality and efficiency of concrete construction.

[0159] In this embodiment, the parameter adjustment logic and strategy details steps are one of the core parts of the entire concrete shotcrete control system. Through this step, the system can accurately adjust the shotcrete parameters, such as shotcrete pressure P, shotcrete volume Q, shotcrete angle θ, etc., according to various construction data collected in real time, so as to optimize the shotcrete effect, reduce the rebound rate, and enhance the concrete adhesion. The parameter adjustment logic and strategy details not only control the rebound phenomenon during the shotcrete process, but also adjust various operations during the shotcrete process through real-time feedback to ensure the optimization of construction quality and efficiency.

[0160] The key to this step is to perform dynamic adjustment according to the gap between the real-time feedback and the preset target value. Through control algorithms (such as PID control, genetic algorithm, etc.), the system can calculate the optimal adjustment strategy based on the collected shotcrete volume, rebound rate, and shotcrete parameters, and output control signals in real time. These adjustment strategies consider the fluidity of the concrete, the performance of the shotcrete equipment, and the changes in the construction environment, so as to achieve comprehensive optimization of rebound control.

[0161] In this embodiment, the specific implementation steps of the parameter adjustment logic and strategy details are as follows:

[0162] First, the system obtains key data such as shotcrete volume Q, shotcrete pressure P, ambient temperature T, and rebound rate R in real time according to the data collection steps in the foregoing process. The control system will predict and calculate the optimal shotcrete parameters under the current construction conditions through the established fluid control model (such as the foregoing formula).

[0163] In some embodiments, the control system will also dynamically adjust the shotcrete pressure based on the change of the shotcrete volume Q and the feedback of the rebound rate R. Specifically, if the rebound rate exceeds the preset threshold, the system will increase the shotcrete pressure or the flow rate of the shotcrete fluid to form a stronger fluid interference to reduce the rebound phenomenon. If the rebound rate is low, the shotcrete parameters will be adjusted accordingly to reduce the influence of air flow or water flow on the concrete shotcrete process.

[0164] As an option, the control system in this embodiment also adopts a PID control strategy to optimize the adjustment of shotcrete pressure and flow rate. The PID control algorithm continuously adjusts the proportional, integral, and differential coefficients, enabling the control system to adjust the rebound rate to the target range in the shortest time. Specifically, the PID control algorithm is calculated based on the following formula:

[0165]

[0166] Wherein: u(t) represents the adjustment amount of the control quantity (such as injection pressure, flow rate, etc.); e(t) is the error of the rebound rate R, that is, the gap between the current rebound rate and the target rebound rate; K p , K i , k d are the proportional, integral and differential gain coefficients; t is time.

[0167] According to this formula, the system automatically adjusts in real time by adjusting parameters such as the injection pressure P and the shotcrete quantity Q, so as to maintain the rebound rate within the set target range.

[0168] In some embodiments, more complex adaptive control algorithms can also be adopted, such as genetic algorithms or neural network control algorithms. Different from traditional PID control, these algorithms can continuously adjust and optimize the control parameters by learning and optimizing historical construction data, so that the system can adapt to various construction environments and spraying conditions, thereby further improving the construction quality and efficiency.

[0169] In a possible implementation manner, the control system also performs local adjustment according to different regions of the rebound rate R. For regions with a higher rebound rate, the system will increase the injection pressure or adjust the flow rate of the spraying fluid, while for regions with a lower rebound rate, it will reduce the fluid spraying quantity or adjust the spraying angle. This detailed control can not only reduce material waste, but also improve the uniformity of the spraying effect in each region during the spraying process.

[0170] Through this dynamic parameter adjustment logic, the control system can automatically adjust the working state of the spraying equipment according to the actual situation at the construction site to minimize the rebound rate. In addition, the system can also set different parameter adjustment strategies to adapt to the requirements of different types of concrete formulations, the performance of different spraying equipment, and different construction environments.

[0171] In some embodiments, the system also optimizes the concrete formulation according to the relationship between the measured shotcrete quantity Q and the rebound rate R in real time. These formulation adjustments will help improve the fluidity and adhesion of the concrete and further reduce the rebound rate. For example, the system may adjust the ratio of cement to aggregate according to the change in the environmental temperature T to cope with the impact of temperature changes on the construction quality of concrete.

[0172] Generally speaking, the parameter adjustment logic and the detailed steps of the strategy ensure dynamic control throughout the spraying process. By adjusting the spraying parameters through real-time feedback, the system can precisely control the pressure, speed, angle, etc. of the sprayed fluid, minimize the rebound phenomenon to the greatest extent, and optimize the spraying effect. This step is closely integrated with other parts of the system (such as shotcrete volume collection, fluid co-spraying, rebound rate monitoring) to form an efficient and intelligent spraying control system.

[0173] In summary, the parameter adjustment logic and the detailed steps of the strategy are not only the core control links in the concrete spraying process, but also ensure the efficiency and stability of the spraying effect by continuously optimizing the spraying parameters. By precisely adjusting parameters such as spraying pressure, flow rate, and angle, the control system can effectively reduce the rebound rate and improve the construction efficiency and spraying quality.

[0174] Although the embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for reducing the rebound rate of concrete spraying, characterized in that: The following steps are involved: Establishing a fluid control model based on historical shotcrete data, wherein the model is used to parameter-match the concrete shotcrete volume with the injection velocity, injection pressure and injection temperature of the high-speed fluid; Collect the real-time shotcrete volume of concrete wet shotcrete equipment; Generating matching fluid injection control parameters according to the shotcrete volume and the control model; Sending the control parameters to the fluid supply system to adjust the injection speed, injection pressure and injection temperature of the high-speed fluid; The high-speed fluid is sprayed through a plurality of high-speed fluid nozzles arranged at the periphery of the main nozzle to form an air field surrounding the concrete spray path, which is used to suppress the rebound generated when the concrete impacts the sprayed surface; Monitor the rebound of concrete after spraying and calculate the rebound rate by comparing the adhesion before and after spraying; The rebound rate is fed back to the control model, parameters of the model are optimized, and updated control parameters are generated for the next cycle injection control.

2. A method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The high-speed fluid includes compressed air, water or liquid accelerating agent, one of the three or a combination of two or more thereof.

3. A method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The fluid control model is a multivariable fitting model or a data rule matching model constructed based on shotcrete volume, injection distance, concrete mix ratio and environmental parameters.

4. A method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The high-speed fluid nozzle is a plurality of adjustable diameter nozzle holes arranged around the main nozzle, and the structure of the nozzle holes is circular, conical, square or flared.

5. The method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The fluid supply system includes a pressure regulating unit, a flow control unit and a temperature control unit, which respectively regulate the ejection state of the high-speed fluid according to the control parameters.

6. The method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The optimization of the control model adopts a feedback mechanism based on rebound rate deviation, and the control parameters are iteratively updated through PID regulation or neural network training algorithm.

7. The method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The shotcrete volume is collected in real time by a flow sensor connected to a concrete pump, and the rebound rate is obtained by measuring the image or weight of the amount of concrete attached to the sprayed surface after spraying.

8. The method for reducing the rebound rate of concrete spraying according to claim 1, characterized in that: The control parameters include an injection speed setting value, a pressure target value and a temperature setting value, which are respectively used to drive corresponding control units to achieve injection state adjustment.

9. A concrete wet spraying equipment, characterized in that: A method for reducing the rebound rate of concrete spraying as described in any one of claims 1 to 8, comprising: A combined nozzle (1) is used for simultaneously performing concrete spraying and high-speed fluid control spraying, the combined nozzle (1) comprising a concrete spraying nozzle (11) and a plurality of surroundingly arranged high-pressure fluid spraying nozzles (12); The spraying area (2) is a construction surface area where concrete and fluid act together; the spraying area (2) includes a central area (21), a peripheral area (22) and a spraying overlap area (23) therebetween; Wet spraying machine (3), used to prepare and deliver concrete; A storage box (31), arranged on the wet spraying machine (3), for storing concrete raw materials; A fluid booster pump (32), connected between the storage tank (31) and the combined nozzle (1), for increasing the injection pressure of the high-pressure fluid; A pipeline (33) connecting the concrete delivery path and the fluid supply path respectively; a control system including a control unit for running a control model, generating control parameters and driving an injection assembly; The control system is communicatively connected with the wet spraying machine (3), the combined spray head (1) and the fluid booster pump (32) to realize closed-loop regulation of fluid control.

10. The concrete wet spraying equipment according to claim 9, characterized in that: The control system comprises: A data acquisition module is used to obtain the concrete output volume of the wet spraying machine (3), and to obtain the image or morphological data of the sprayed surface after spraying is completed through an image acquisition unit or a laser measurement unit installed in front of the device, so as to infer the amount of concrete adhesion; A control calculation unit, for generating injection control parameters based on a fluid control model and combining morphological analysis results of a central area (21), a peripheral area (22) and an injection overlap area (23) formed in the injection area (2); An execution unit, used for driving the concrete spray nozzle (11) and the high-pressure fluid spray nozzle (12) to execute the spray parameters output by the control calculation unit; The communication interface module is used to establish real-time data transmission and feedback control connections with the wet spraying machine (3), the fluid booster pump (32), the pipeline (33) and the combined spray head (1) to form a closed-loop regulation system.

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