A node pile intelligent pouring system and a pouring method

Abstract

The application discloses a node pile intelligent pouring system and a pouring method.The application provides a kind of intelligent pouring for deep stratum node pile, including perception layer, transmission layer, decision layer, execution layer, including respectively for parsing and executing edge computing hub sending instruction servo driver and execution mechanism, the execution mechanism includes the vibration providing unit for cleaning, pulse providing unit, obstacle removing unit;For adjusting the fixed unit of reinforcement cage, and for pouring concrete pouring unit.The intelligent pouring system and method provided by the application realize precise decision-making driven by data, risk pre-processing and significant progress in resource efficiency, realize the technological innovation from "experience construction" to "digital construction", reduce the traditional technical problems that may occur in the pouring process, and improve the pouring construction safety and efficiency.

Description

Technical Field

[0001] This invention relates to the field of geological construction technology, and more particularly to the field of deep foundation pile construction systems and methods, specifically to an intelligent pouring system and method for node piles. Background Technology

[0002] Nodal piles are one of the most critical construction steps in the construction of anti-seepage curtain walls. They are also core components in the construction of geological anti-seepage curtain walls. Nodal piles are vertical piles formed by pouring concrete into regularly shaped holes created in the strata through methods such as rotary drilling or impact drilling. Their functions include reinforcing weak strata and forming an anti-seepage barrier. During construction, steel casings are often used as temporary molds to fix the hole walls and constrain the concrete forming. After demolding, they interlock with the concrete structure of adjacent trench sections to form a continuous and integrated anti-seepage wall or support system, serving both structural load-bearing and water interception functions.

[0003] Current node pile casting technology has revealed numerous systemic defects in complex geological formations and high-standard projects, severely restricting construction quality and efficiency. Traditional methods rely on manual experience to control the tremie pipe embedment depth and casting speed, resulting in an initial grouting and sealing failure rate as high as 18% (statistics from a cross-sea bridge construction project), mainly manifested as follows:

[0004] Inadequate bottom sealing and mud contamination: During the initial grouting stage, the lack of precise monitoring of the thickness of sediment at the bottom of the hole and the fluidity of the concrete often leads to incomplete jet cleaning or insufficient sealing concrete, resulting in sediment or mud contamination at the pile bottom. Core sampling in a subway project revealed that 27% of the pile foundations had a weak interlayer >10cm at the bottom, directly reducing the pile tip bearing capacity by more than 30%. Uncontrolled rebar cage floating: Traditional counterweight fixing methods cannot dynamically balance the upward force of the concrete. When the pouring speed >1.2m³ / min, UWB monitoring showed a maximum rebar cage displacement of 15mm (exceeding the standard 10mm limit), resulting in insufficient concrete cover thickness and structural eccentricity. Frequent pipe blockage accidents: Due to the lack of real-time feedback on concrete rheological properties (such as viscosity and slump), the adjustment of the tremie pipe burial depth lags behind changes in working conditions. In a deep foundation pit project, the applicant experienced a sudden increase in burial depth to 7m without timely handling, triggering a chain of pipe blockages. The single pile treatment took over 8 hours, resulting in a direct loss of 120,000 yuan. Resource waste and inefficiency: Conservative construction strategies (such as low-flow-rate pouring throughout) lead to excessive material consumption (average over-pouring amount reaches 135% of the design value) and extend the construction period by 20%-30%. More seriously, the randomness of human judgment has caused the proportion of Class I piles to hover around 80% for a long time, and rework costs account for 3%-5% of the total project cost.

[0005] In summary, the existing node pile casting process is still relatively traditional, with many steps still relying on manual intervention and experience-based judgment. There is an urgent need for a system that can make autonomous judgments and intelligently cast piles to replace the current system, which mainly relies on manual experience-based judgment and operation, resulting in high dependence, low efficiency, and high risk of pipe blockage. Summary of the Invention

[0006] To address the problems of inadequate bottom sealing, mud contamination, uncontrolled floating of the reinforcing cage, and pipe blockage accidents caused by the inability to adjust the buried pipe depth in a timely manner in traditional manual pouring, this application provides an intelligent pouring system and method for node piles. Through multimodal sensors, edge computing, and dynamic execution closed-loop control, it can achieve intelligent pouring. In particular, it is significantly superior to existing technologies in terms of data-driven timely decision-making and early prediction and avoidance of pipe blockage risks. In addition, the split cross-shaped mold mechanism adopted in this invention is more conducive to demolding than existing barrel molds. By reducing the contact area between a single mold and the concrete, the difficulty of demolding is significantly reduced, and the problem of mold scrapping due to mold demolding failure is reduced.

[0007] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0008] This invention provides an intelligent casting system for node piles in deep strata, including a sensing layer for data acquisition and monitoring in the system, comprising a pile hole scanning module, a flow perception module, a displacement suppression module, a pipe blockage prediction module, and a visualization monitoring module.

[0009] The transport layer is used to enable real-time data interaction between the perception layer and the decision layer, including TSN switches for time synchronization and real-time data transmission.

[0010] The decision layer is an edge computing hub that receives and processes data sent from the TSN switch. The edge computing hub is communicatively connected to the cloud digital twin platform and the execution layer.

[0011] The execution layer includes servo drivers and execution mechanisms for parsing and executing commands sent from the edge computing hub, respectively. The execution mechanisms include a vibration supply unit, a pulse supply unit, and a clearing unit for cleaning pipes; a fixing unit for adjusting the reinforcing cage; and a pouring unit for grouting concrete.

[0012] Preferably, the pile hole scanning module includes a guide rail pre-embedded on the side wall of the pile hole or a multi-beam sonar array that can be detachably fixed near the bottom of the reinforcing cage; the flow sensing module includes a microwave slump meter installed at the outlet of the concrete conveying duct to detect the state of the concrete entering the pile hole and vibrating wire pressure sensors installed at the bottom and middle of the duct to detect the concrete pressure; the displacement suppression module includes UWB positioning tags and distributed strain gauges set at the four corners of the top of the reinforcing cage to detect the displacement of the reinforcing cage.

[0013] More preferably, the pipe blockage prediction module includes an LSTM neural network analysis unit for analyzing pressure time-series characteristics, and the LSTM neural network analysis unit is communicatively connected to the edge computing hub.

[0014] To facilitate demolding, improve the efficiency of continuous pouring, and reduce the probability of the concrete being unable to be pulled out due to excessive adhesion between the concrete and the mold after initial setting, thus preventing the mold from being removed, preferably, this system also includes a mold mechanism for limiting the skewness of the reinforcing cage and the cross-sectional shape of the node pile. The mold mechanism includes four hollow molds arranged in a circumferential array around the center of the pile hole. Each hollow mold includes a mold body with radial reinforcing ribs and a mold joint for connecting two adjacent mold bodies. The cross-section of the mold body consists of an arc adapted to the inner diameter of the pile hole, two symmetrical inclined sides distributed at both ends of the arc and extending radially along the direction of the pile hole radius, and a bottom edge connecting the two inclined sides.

[0015] To improve pouring efficiency and reduce the probability of problems such as pipe blockage, rebar cage floating, and inadequate bottom sealing during the pouring process, this invention also provides an intelligent pouring method for node piles, transforming the existing "experience-based construction" to a "digital construction" mode. This method utilizes the aforementioned intelligent pouring system and specifically includes the following pouring steps:

[0016] Step STP100: Lower the rebar cage and mold. Temporarily fix the rebar cage of equal length and the mold mechanism to form the first unit segment. Install a multi-beam sonar array at the lower end of the first unit segment. Hoist and lower it into the pile hole. When the upper end of the first unit segment is 1-1.5m from the ground, fix it with a pipe pulling machine. Then hoist the second unit segment above the first unit segment and align it. Weld the rebar cages respectively and connect the mold mechanism. Repeat the unit segment docking until the entire rebar cage touches the bottom.

[0017] Step STP200: Information collection before pouring. Install the pile hole scanning module, flow perception module, and displacement suppression module according to the structure and position of the node pile intelligent pouring system. After initialization and debugging, collect the thickness distribution information of sediment at the bottom of the pile hole through the pile hole scanning module.

[0018] Step STP300, initial grouting and sealing condition judgment: In step STP200, the pile hole scanning module uses a multi-beam sonar array to scan the thickness of the sediment at the bottom of the pile hole. If the actual sediment thickness... ≤Preset sediment thickness If the actual sediment thickness is... >Preset sediment thickness Then proceed to step STP400.

[0019] Step STP400: Jet cleaning. Increase the pressure of the mud conduit to 20MPa to the bottom of the pile hole to disturb the sediment. At the same time, use the return mud pump to extract and clean the sediment-containing mud at the bottom of the pile hole, and replace the sediment at the bottom of the pile hole. The replacement time is maintained for 5 minutes. Then repeat step STP300.

[0020] Step STP500: High-pressure jet-assisted bottom sealing. Adjust the outlet pressure of the concrete delivery duct to 25MPa for bottom grouting. Simultaneously, monitor the return grout density in real time. When the actual return grout density... ∈[ , Stop jet grouting when [the time is right].

[0021] Step STP600: Pressure thixotropic determination. If the pressure at the bottom of the concrete delivery duct exceeds the system's preset bottom sealing pressure for 15 seconds, then proceed to step STP800; otherwise, proceed to step STP700.

[0022] Step STP700, incremental grouting, increases the concrete grouting volume by 20% and continues grouting until the pressure holding requirements of step STP600 are met;

[0023] Step STP800 involves continuous pouring, with the concrete delivery duct depth intelligently adjusted based on the slump. burial depth The intelligent adjustment constraints are: ;in, Represents the real-time catheter burial depth, in meters (m). Represents the pouring speed, in meters (m). 3 / min; Represents the cross-sectional area of ​​the pile hole, in meters. 2 ; This represents the catheter lifting speed, measured in m / min. This represents the pouring time, in minutes.

[0024] In step STP900, after initial setting and pipe removal, when the pouring depth reaches 1.5 unit section length, reduce the pouring speed to 10%-15%. Hold for 60 minutes, then continue pouring until the pouring is complete; when the pouring time reaches the initial setting time of the concrete... When the length is an integer multiple of the given length, the tube pulling machine is used to pull out the length of the unit segment of the mold mechanism separately or simultaneously until the pulling is completed.

[0025] Furthermore, in order to achieve dynamic adjustment, the pouring speed is matched in real time according to the state of concrete pouring. To ensure that the concrete delivery duct is always buried at the optimal depth, and to match the pouring volume and efficiency to the best possible level, thereby achieving a leap in resource efficiency, step STP800 preferably also includes adjusting the pouring speed. The multi-objective optimization steps specifically include optimizing pouring efficiency, displacement suppression, and pipe blockage risk.

[0026] The function for optimizing pouring efficiency is: ;

[0027] The displacement suppression optimization function is: ;

[0028] The pipe blockage risk optimization function is: ;

[0029] The constraints are: ;in, Represents the pouring speed, in meters (m). 3 / min; Represents the cross-sectional area of ​​the net space for casting, in meters. 2 ; Represents the effective casting density, unit: kg / m³ 3 ; This represents the displacement of the reinforcing cage, in mm. This represents the probability of pipe blockage risk; This represents the maximum permissible grouting pressure, in MPa.

[0030] More preferably, it also includes the pouring speed. The steps for comprehensive optimization of multi-objective functions are as follows, and the comprehensive optimization is achieved using the following weighted comprehensive objective function: ;in, It is the temperature influence coefficient. It is the construction progress pressure coefficient. It is a risk sensitivity coefficient, and In the above formula, Preset verification coefficients for the system. For the sensor to collect temperature, To predict the probability of pipe blockage risk.

[0031] Beneficial effects:

[0032] 1. This invention significantly improves the success rate of initial grouting and bottom sealing by using sonar scanning and pressure thixotropic interlocking. It can effectively control the displacement of the reinforcing cage within 3mm and effectively solve the problems in the existing technology that lead to slag inclusion or mud mixing at the bottom of the pile due to factors such as lack of accurate monitoring of the thickness of sediment at the bottom of the hole and the fluidity of concrete, incomplete jet cleaning, or insufficient amount of sealing concrete in the initial grouting stage.

[0033] 2. This invention establishes an intelligent dynamic adjustment mechanism for the burial depth of the concrete delivery conduit by real-time detection of parameters such as concrete slump, temperature, and pouring flow rate. This enables intelligent adjustment throughout the entire pouring process, ensuring that the burial depth of the concrete pouring conduit is always controlled between 2 and 6 meters, fundamentally solving the problem of pipe blockage.

[0034] 3. The intelligent pouring system and method provided by this invention achieves significant progress in data-driven precise decision-making, risk pre-processing, and resource efficiency through multimodal sensing, edge computing, and dynamic execution closed-loop control. It realizes the technological innovation from "experience-based construction" to "digital construction", reduces traditional technical problems that may occur during the pouring process, and improves the safety and efficiency of pouring construction. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the system architecture of the present invention.

[0037] Figure 2 This is a schematic block diagram illustrating the flow of data and instructions during the pouring process of this invention.

[0038] Figure 3 This is a schematic diagram of the data acquisition location during pile hole pouring.

[0039] Figure 4 This is a schematic diagram of the pouring process.

[0040] Figure 5 This is a flowchart of the pouring process when the reinforcing cage shifts.

[0041] Figure 6 This is a schematic diagram of the mold mechanism.

[0042] Figure 7 yes Figure 6 A sectional view with the section symbol AA along the center line.

[0043] In the diagram: 1-Pressure sensor; 2-UWB positioning tag; 3-Microwave slump meter; 4-Multibeam sonar array; 5-Temperature sensing unit; 6-Mold body; 61-Reinforcing rib; 7-Mold joint; 8-Pipe pulling machine; 9-Concrete. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0046] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0047] In the description of this application, it should be noted that the use of terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" to indicate orientation or positional relationships is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationships commonly used when the product is in use. These terms are used solely for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the use of terms such as "first" and "second" in the description of this application is only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0048] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this application does not imply that the component is required to be absolutely horizontal or suspended, but rather that it may be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but rather that it may be slightly tilted.

[0049] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0050] Example 1:

[0051] This invention provides an intelligent casting system for node piles, used for intelligent casting of node piles in deep strata. See the appendix to the specification. Figure 1 As shown, it includes a perception layer for data acquisition and monitoring in the system, including a pile hole scanning module, a flow perception module, a displacement suppression module, a pipe blockage prediction module, and a visualization monitoring module;

[0052] The transport layer is used to enable real-time data interaction between the perception layer and the decision layer, including TSN switches for time synchronization and real-time data transmission.

[0053] The decision layer is an edge computing hub that receives and processes data sent from the TSN switch. The edge computing hub is communicatively connected to the cloud digital twin platform and the execution layer.

[0054] The execution layer includes servo drivers and execution mechanisms for parsing and executing commands sent from the edge computing hub, respectively. The execution mechanisms include a vibration supply unit, a pulse supply unit, and a clearing unit for cleaning pipes; a fixing unit for adjusting the reinforcing cage; and a pouring unit for grouting concrete.

[0055] Participating in the instruction manual Figure 3 As shown, in this embodiment, the pile hole scanning module includes a multi-beam sonar array 4 installed on a pre-embedded guide rail on the side wall of the pile hole or detachably fixed near the bottom of the reinforcing cage; the flow perception module includes a microwave slump meter 3 installed at the outlet of the concrete conveying duct to detect the state of the concrete entering the pile hole, vibrating wire pressure sensors installed at the bottom and middle of the duct to detect the concrete pressure, and an infrared thermal imaging unit or multiple temperature sensing units 5 located at different positions installed on the outer wall of the duct to collect the concrete temperature field distribution; the displacement suppression module includes UWB positioning tags 2 and distributed strain gauges installed at the four corners of the top of the reinforcing cage to detect the displacement of the reinforcing cage. The pipe blockage prediction module includes an LSTM neural network analysis unit for analyzing the pressure time series characteristics, and the LSTM neural network analysis unit is communicatively connected to the edge computing hub.

[0056] Working principle explanation: The pouring system provided in this embodiment is composed of the above modules, combined with multimodal sensing technology, Internet of Things communication and intelligent algorithms built into the edge computing hub to form a closed-loop control system architecture; In this embodiment, the connection / communication relationship between system structures is emphasized. The detailed content of the algorithm mainly affects the dynamic adjustment during construction, and will be described in detail in subsequent method embodiments, and will not be described in this embodiment.

[0057] The pile hole scanning module uses multi-beam sonar to scan the geometry of the pile hole and sends three-dimensional point cloud data to the edge center after scanning, triggering the calculation of the initial grouting volume. The initial grouting volume is used for sealing the bottom of the pile hole to avoid geological defects such as leakage or collapse at the bottom of the pile hole, which would lead to incomplete sealing and defects in the nodal pile structure.

[0058] The flow perception module uses a microwave slump meter and a pressure gradient sensor to monitor the concrete state. After data fusion, the data is input to a PID controller to adjust the lifting speed of the duct. Of course, other controllers, such as a PLC-based logic controller, can be used in the actual device used to lift the concrete conveying duct. The displacement suppression module uses a UWB positioning system and distributed strain gauges to monitor the displacement of the reinforcing cage. The real-time displacement information can be used to dynamically balance the buoyancy of the counterweight robotic arm or to apply different stresses / clamping forces to limit and fix the reinforcing cage using fixed units. It also serves as a basis for adjusting the pouring rate. The blockage prediction module uses an LSTM neural network to analyze the pressure time-series characteristics, receives edge layer data, and overlays a BIM model to assist human decision-making. For example, the degree of pressure change in the concrete conveying duct is used to determine the possibility of blockage. If, under the premise of constant pouring rate, the pressure gradually and slowly increases with pouring time, or the cumulative increase reaches a preset value, such as 0.2 MPa, then it is determined to be a minor blockage. At this time, a high-frequency vibration, such as 30 Hz, with an amplitude of 1-2 mm, is provided to the concrete conveying duct through a vibration supply unit. If the pressure characteristics analyzed by the LSTM neural network continue to increase, reaching the preset moderate range and slight vibrations are no longer effective in alleviating the trend of pipe blockage, then a reverse pulse is provided by the pulse supply unit to clear the blockage, with the pulse interval set to 0.5-1s. If there is still no positive improvement, and the pressure continues to increase to 2MPa for more than 30 seconds, then the system determines that pipe blockage is imminent, and a self-expanding cleaning ball is deployed for cleaning. If the blockage is not relieved in a short time, manual intervention is required for cleaning.

[0059] The transport layer is the node for data interaction. Its installation location is not specifically required, as long as it can send data from the perception layer to the decision layer for processing and subsequent decision-making, command issuance, and visualization data updates. The decision layer is the information processing center of this system, responsible for processing all information collected by all front-end multimodal sensors. It is also the source of drive signals for all actuators in the execution layer. The overall process involves the front-end perception layer collecting different types of data from different locations, transmitting it through the transport layer to the decision layer, where the edge computing hub identifies the data and, based on a pre-defined data classification mechanism, logically outputs corresponding commands to drive the execution layer to perform the pouring construction. See details... Figure 2 The data and command streams are transmitted in a manner shown. Information is continuously or intermittently collected during construction to provide feedback on the current pouring status, thus achieving closed-loop control. The entire system relies on objective data collected by the system itself, not on the operator's experience; therefore, reliability is significantly improved, response time is significantly faster, and resource utilization efficiency is significantly enhanced.

[0060] Example 2:

[0061] See the instruction manual appendix Figures 6-7 As shown, in order to facilitate demolding, improve the efficiency of continuous pouring, and reduce the probability of the concrete 9 being unable to be pulled out due to excessive adhesion between the concrete and the mold after initial setting, thus preventing the mold from being removed, this embodiment of the system also includes a mold mechanism for limiting the deflection of the reinforcing cage and the cross-sectional shape of the node pile. The mold mechanism includes four hollow molds arranged in a circular array around the center of the pile hole. The hollow mold includes a mold body 6 with radial reinforcing ribs 61 and a mold joint 7 for connecting two adjacent mold bodies. The cross-section of the mold body 6 consists of an arc adapted to the diameter of the inner wall of the pile hole, two symmetrical inclined sides distributed at both ends of the arc and extending radially along the direction of the pile hole radius, and a bottom edge connecting the two inclined sides.

[0062] Compared to existing technologies, this embodiment uses a decentralized arrangement, which effectively solves the problem of insufficient bonding force due to excessively large concrete bonding area, leading to difficulty in demolding. The advantages of this arrangement are:

[0063] Firstly, the bonding surface between the individual mold and the poured concrete is significantly reduced, requiring less pulling force during demolding and pipe pulling, thus lowering the possibility of mold damage. The hydraulic device for demolding can also be smaller, resulting in lower overall costs and better economic efficiency. Secondly, the weight of a single mold of the same length is significantly reduced compared to existing circular steel sleeve molds, greatly reducing the probability of mold damage preventing successful pulling. Thirdly, since the mold is installed at all four positions of the pipe pulling frame, bonding positions for connecting to the cutoff wall are reserved in all four directions, enabling "+", "T", and "I" shaped point pouring, meeting the pouring requirements of various cutoff wall structures.

[0064] Example 3:

[0065] To improve pouring efficiency and reduce the probability of problems such as pipe blockage, rebar cage floating, and inadequate bottom sealing during the pouring process, this embodiment provides an intelligent pouring method for node piles, transforming the existing "experience-based construction" model into a "digital construction" model. This method is implemented using the intelligent pouring system provided in any of the above embodiments, as detailed in the appendix to the specification. Figure 2 , Figures 4-5 As shown, the specific pouring steps include the following:

[0066] Step STP100: Lower the rebar cage and mold. Temporarily fix the rebar cage of equal length and the mold mechanism to form the first unit segment. Install a multi-beam sonar array 4 at the lower end of the first unit segment. Hoist and lower it into the pile hole. When the upper end of the first unit segment is 1-1.5m from the ground, fix it with the pipe pulling machine 8. Then hoist the second unit segment above the first unit segment and align it. Weld the rebar cages respectively and connect the mold mechanism. Repeat the unit segment docking until the entire rebar cage touches the bottom.

[0067] Step STP200: Information collection before pouring. Install the pile hole scanning module, flow perception module, and displacement suppression module according to the structure and position of the node pile intelligent pouring system. After initialization and debugging, collect the thickness distribution information of sediment at the bottom of the pile hole through the pile hole scanning module.

[0068] Step STP300, initial grouting and sealing condition judgment: In step STP200, the pile hole scanning module uses a multi-beam sonar array to scan the thickness of the sediment at the bottom of the pile hole. If the actual sediment thickness... ≤Preset sediment thickness If the actual sediment thickness is... >Preset sediment thickness Then proceed to step STP400.

[0069] Step STP400: Jet cleaning. Increase the pressure of the mud conduit to 20MPa to the bottom of the pile hole to disturb the sediment. At the same time, use the return mud pump to extract and clean the sediment-containing mud at the bottom of the pile hole, and replace the sediment at the bottom of the pile hole. The replacement time is maintained for 5 minutes. Then repeat step STP300.

[0070] Step STP500: High-pressure jet-assisted bottom sealing. Adjust the outlet pressure of the concrete delivery duct to 25MPa for bottom grouting. Simultaneously, monitor the return grout density in real time. When the actual return grout density... ∈[ , Stop jet grouting when [the time is right].

[0071] Step STP600: Pressure thixotropic determination. If the pressure at the bottom of the concrete delivery duct exceeds the system's preset bottom sealing pressure for 15 seconds, then proceed to step STP800; otherwise, proceed to step STP700.

[0072] Step STP700, incremental grouting, increases the concrete grouting volume by 20% and continues grouting until the pressure holding requirements of step STP600 are met;

[0073] Step STP800 involves continuous pouring, with the concrete delivery duct depth intelligently adjusted based on the slump. burial depth The intelligent adjustment constraints are: ;in, Represents the real-time catheter burial depth, in meters (m). Represents the pouring speed, in meters (m). 3 / min; Represents the cross-sectional area of ​​the pile hole, in meters. 2 ; This represents the catheter lifting speed, measured in m / min. This represents the pouring time, in minutes.

[0074] In step STP900, after initial setting and pipe removal, when the pouring depth reaches 1.5 unit section length, reduce the pouring speed to 10%-15%. Hold for 60 minutes, then continue pouring until the pouring is complete; when the pouring time reaches the initial setting time of the concrete... When the length is an integer multiple of the given length, the tube pulling machine is used to pull out the length of the unit segment of the mold mechanism separately or simultaneously until the pulling is completed.

[0075] Furthermore, in order to achieve dynamic adjustment, the pouring speed is matched in real time according to the state of concrete pouring. By consistently maintaining the optimal burial depth of the concrete delivery duct and matching the pouring volume and efficiency to the best possible level, STP800 achieves a leap in resource efficiency. The process also includes adjusting the pouring speed. The multi-objective optimization steps specifically include optimizing pouring efficiency, displacement suppression, and pipe blockage risk.

[0076] The function for optimizing pouring efficiency is: ;

[0077] This represents the effective concrete mass actually poured per unit time (kg / min). Maximizing this target can shorten the construction period. The key control point lies in correction. When the temperature sensing unit 5 or the infrared thermal imager detects a temperature gradient >15℃ / m, it can automatically reduce... The coefficient is reduced to 0.92.

[0078] The displacement suppression optimization function is: ;

[0079] Displacement of the reinforcing cage With pouring speed The relationship is quadratic; to suppress displacement, it is necessary to reduce... However, this would sacrifice efficiency, and the objective can be achieved by minimizing the displacement using the reciprocal form.

[0080] The pipe blockage risk optimization function is: ; The constraints are: ;in, Represents the pouring speed, in meters (m). 3 / min; Represents the cross-sectional area of ​​the net space for casting, in meters. 2 ; Represents the effective casting density, unit: kg / m³ 3 ; This represents the displacement of the reinforcing cage, in mm. This represents the probability of pipe blockage risk; This represents the maximum permissible grouting pressure, in MPa.

[0081] Using the Sigmoid function The risk of pipe blockage is quantified as a probability value of 0-1, where: the physical meaning in application is: It is the viscosity of concrete and its flow rate. Inversely proportional, ; It is the second derivative of pressure, reacting to a sudden change in flow regime; when the burial depth... The risk index increases when it is insufficient. The weighting index in this embodiment... , , The aforementioned weighting index can be obtained through training on historical pipe blockage data; of course, different types of concrete, different concrete delivery pipes, different effective cross-sectional areas of the joint piles, and the density of the rebar cage mesh can all affect the aforementioned weighting index. Therefore, the value of the weight index is not fixed and will be adaptively adjusted according to different applications and equipment parameters.

[0082] Furthermore, this embodiment also includes the pouring speed. The steps for comprehensive optimization of multi-objective functions are as follows, and the comprehensive optimization is achieved using the following weighted comprehensive objective function: ;

[0083] in, It is the temperature influence coefficient. It is the construction progress pressure coefficient. It is a risk sensitivity coefficient, and In the above formula, Preset verification coefficients for the system. For the sensor to collect temperature, To predict the probability of pipe blockage risk.

[0084] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A smart casting system for node piles, used for intelligent casting of node piles in deep strata, characterized in that: include The perception layer is used for data acquisition and monitoring in the system, including a pile hole scanning module, a flow perception module, a displacement suppression module, a pipe blockage prediction module, and a visualization monitoring module. The transport layer is used to enable real-time data interaction between the perception layer and the decision layer, including TSN switches for time synchronization and real-time data transmission. The decision layer is an edge computing hub that receives and processes data sent from the TSN switch. The edge computing hub is communicatively connected to the cloud digital twin platform and the execution layer. The execution layer includes a servo driver and an execution mechanism for parsing and executing commands sent from the edge computing hub, respectively. The execution mechanism includes a vibration supply unit, a pulse supply unit, and a clearing unit for cleaning pipes; a fixing unit for adjusting the reinforcing cage; and a pouring unit for pouring concrete. The pile hole scanning module includes a detachable multibeam sonar array that is fixed near the bottom of the reinforcing cage; the flow sensing module includes a microwave slump meter installed at the outlet of the concrete conveying duct to detect the state of the concrete entering the pile hole, and vibrating wire pressure sensors installed at the bottom and middle of the duct to detect the concrete pressure; the displacement suppression module includes UWB positioning tags and distributed strain gauges installed at the four corners of the top of the reinforcing cage to detect the displacement of the reinforcing cage. It also includes a mold mechanism for limiting the deflection of the reinforcing cage and the cross-sectional shape of the node pile. The mold mechanism includes four hollow molds arranged in a circular array around the center of the pile hole. The hollow molds include a mold body with radial reinforcing ribs and a mold joint for connecting two adjacent mold bodies. The cross-section of the mold body consists of an arc adapted to the diameter of the inner wall of the pile hole, two symmetrical inclined sides distributed at both ends of the arc and extending radially along the direction of the pile hole radius, and a bottom edge connecting the two inclined sides.

2. The intelligent casting system for node piles according to claim 1, characterized in that: The pipe blockage prediction module includes an LSTM neural network analysis unit for analyzing pressure time-series characteristics, and the LSTM neural network analysis unit is communicatively connected to the edge computing hub.

3. A method for intelligent casting of node piles, implemented using the casting system described in claim 2, characterized in that, The following pouring steps are included: Step STP100: Lower the rebar cage and mold. Temporarily fix the rebar cage of equal length and the mold mechanism to form the first unit segment. Install a multi-beam sonar array at the lower end of the first unit segment. Hoist and lower it into the pile hole. When the upper end of the first unit segment is 1-1.5m from the ground, fix it with a pipe pulling machine. Then hoist the second unit segment above the first unit segment and align it. Weld the rebar cages respectively and connect the mold mechanism. Repeat the unit segment docking until the entire rebar cage touches the bottom. Step STP200: Information collection before pouring. Install the pile hole scanning module, flow perception module, and displacement suppression module according to the structure and position of the node pile intelligent pouring system. After initialization and debugging, collect the thickness distribution information of sediment at the bottom of the pile hole through the pile hole scanning module. Step STP300, initial grouting and sealing condition judgment: In step STP200, the pile hole scanning module uses a multi-beam sonar array to scan the thickness of the sediment at the bottom of the pile hole. If the actual sediment thickness... ≤Preset sediment thickness If the actual sediment thickness is... >Preset sediment thickness Then proceed to step STP400. Step STP400: Jet cleaning. Increase the pressure of the mud conduit to 20MPa to the bottom of the pile hole to disturb the sediment. At the same time, use the return mud pump to extract and clean the sediment-containing mud at the bottom of the pile hole, and replace the sediment at the bottom of the pile hole. The replacement time is maintained for 5 minutes. Then repeat step STP300. Step STP500: High-pressure jet-assisted bottom sealing. Adjust the outlet pressure of the concrete delivery duct to 25MPa for bottom grouting. Simultaneously, monitor the return grout density in real time. When the actual return grout density... ∈[ , Stop jet grouting when [the time is right]. Step STP600: Pressure thixotropic determination. If the pressure at the bottom of the concrete delivery duct exceeds the system's preset bottom sealing pressure for 15 seconds, then proceed to step STP800; otherwise, proceed to step STP700. Step STP700, incremental replenishment, increase the concrete pouring volume by 20% and continue pouring until the pressure holding requirements of step STP600 are met; Step STP800 involves continuous pouring, with the concrete delivery duct depth intelligently adjusted based on the slump. burial depth The intelligent adjustment constraints are: ;in, Represents the real-time catheter burial depth, in meters (m). Represents the pouring speed, in meters (m). 3 / min; Represents the cross-sectional area of ​​the pile hole, in meters. 2 ; This represents the catheter lifting speed, measured in m / min. Represents the pouring time, in minutes; In step STP900, after initial setting and pipe removal, when the pouring depth reaches 1.5 unit section length, reduce the pouring speed to 10%-15%. Hold for 60 minutes, then continue pouring until the pouring is complete; when the pouring time reaches the initial setting time of the concrete. When the length is an integer multiple of the given length, the tube pulling machine is used to pull out the length of the unit segment of the mold mechanism separately or simultaneously until the pulling is completed.

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