In-well pouring device and pouring method thereof

Abstract

The invention discloses an in-well pouring device and a pouring method thereof, belongs to the technical field of in-well construction, and solves the problems of concrete segregation, well wall cracks and uneven coverage caused by material mutation, flow state instability, temperature stress concentration and insufficient track coverage in traditional in-well pouring. The pouring method comprises the steps that the well depth is divided into a shallow layer area and a deep layer area, and concrete components are dynamically adjusted according to the shallow layer area and the deep layer area; calculating a critical Reynolds number in real time; the pouring flow speed is dynamically adjusted, and the actual Reynolds number meets the requirement that Re is larger than or equal to 0.85 Re and smaller than or equal to 1.15 Re; applying mechanical vibration to the deep layer area; the temperature gradient delta T of the well wall is monitored in real time, and gradient maintenance is started when delta T is larger than 15 DEG C; cooling water is sprayed to a high-temperature area, a heat preservation film covers a low-temperature area, and hot air is injected; with the shaft axis as the reference, the pouring guide pipe is controlled to move along the spiral line track, and radial shrinkage is conducted by 5-8 mm after each circle of spiral pouring is completed. The method is used for improving the construction quality of deep well pouring.

Description

Technical Field

[0001] The present invention relates to the technical field of well construction, and more particularly to a well casting device and a casting method thereof. Background Art

[0002] In deep well concrete pouring construction, the traditional method of well pouring construction has the following inherent defects: Sudden changes in material properties: A single concrete mix was used throughout the entire well depth, without considering the differences in geological environments between shallow and deep layers (such as pressure and temperature gradients). This resulted in a dramatic change in material properties near a depth of 20 meters, causing concrete segregation and interface cracks in the transition zone. Flow state instability: During the pouring process, constant flow rate pumping is used. In the deep layer, the Reynolds number far exceeds the critical value (usually more than 1.3 times), which forms turbulence, aggravating aggregate separation and reducing density. Temperature stress concentration: The temperature difference of the wellbore wall relies solely on natural heat dissipation or surface watering, which cannot accurately control the internal temperature gradient. When the temperature difference between the top and bottom of the wellbore exceeds 25°C, the shrinkage stress is concentrated in the weak points of the wellbore wall, forming cracks; Insufficient track coverage: The casting conduit moves back and forth in a straight line, and the coverage rate of the special-shaped well wall (such as protrusions and corners) is less than 70%, forming voids or weak bonding areas.

[0003] The root of the problem lies in the lack of a depth-adaptive mechanism in traditional methods: material ratios, flow rate control, and temperature management are all static settings, unable to respond to dynamic environmental parameters caused by changes in well depth (such as increased ground pressure, lithologic transitions, and temperature accumulation). Previous attempts at improvement have shown that simply increasing the vibration frequency can exacerbate shallow segregation, while expanding the range of material ratios can easily lead to sudden changes in interface strength. Therefore, a multi-parameter coordinated control mechanism linked to well depth is urgently needed. Summary of the Invention

[0004] The invention provides an in-well casting device and a casting method thereof.

[0005] An object of the present invention is to solve at least the above problems and to provide at least the advantages which will be described hereinafter.

[0006] Another object of the present invention is to provide a method for placing concrete in a deep well. This method solves the problems of concrete segregation, cracks in the well wall, and uneven coverage caused by sudden changes in material properties, unstable flow conditions, concentrated thermal stresses, and insufficient track coverage in traditional deep well concrete pouring. This method improves the structural integrity and construction quality of deep well concrete pouring.

[0007] In order to achieve these objects and other advantages according to the present invention, there is provided a well casting device comprising: A dual-silo mixing system configured to dynamically adjust the concrete composition of shallow and deep zones; Variable frequency concrete pump, connected to the pouring pipe, to adjust the pouring flow rate in real time; A six-quadrant pressure sensor array is circumferentially arranged at the end of the catheter to detect circumferential contact pressure; The high-frequency micro-vibration module is installed in the quadrant where the pressure exceeds the limit of the catheter to generate pulse vibration vertical to the well wall; A multi-degree-of-freedom robotic arm drives the catheter along a helical trajectory and performs radial contraction; Distributed fiber optic temperature sensors monitor the well wall temperature gradient in real time; Spinning head with laser scanner and radial spray nozzle; A vibration isolation device, provided on the outer wall of the conduit, comprising an elastic damping unit and a hydraulic locking mechanism; Online rheometer, installed at the pump outlet and the end of the conduit, monitors the slump of concrete; Compound compensating agent injection system, inject compensating agent into the middle section of the pump tube; The vortex mixer is installed downstream of the injection point, and the blade pitch is adjusted according to the well pressure; Geological radar scanner, integrated into the front end of the casing, identifies the lithology of the well wall; The expandable sealing ring is deployed behind the rotary grouting head to perform dynamic sealing of the well wall.

[0008] The present invention also discloses a casting method of a well casting device, which comprises the following steps: S01. Divide the well depth into shallow and deep areas. The area with a well depth H of 0 to 20 m is divided into the shallow area, and the area with a well depth H greater than 20 m is divided into the deep area. Dynamically adjust the concrete composition for the shallow and deep areas. S02, real-time calculation of critical Reynolds number Re based on well depth c =2300×(1+0.02H); dynamically adjust the pouring velocity v so that the actual Reynolds number Re meets 0.85Re c ≤Re≤1.15Re c Mechanical vibration was applied synchronously in the deep layer. The vibration frequency f was adaptively adjusted according to f = 200 + 10H (in Hz). The amplitude was kept constant at 30 ± 5 μm. S03. Real-time monitoring of the well wall temperature gradient ΔT. When ΔT>15°C, gradient curing is initiated: cooling water is sprayed in the high-temperature area at a flow rate Q=0.5ΔT (unit: L / min). In the low-temperature area, insulation film is covered and 40°C hot air is injected. S04. With the shaft axis as the reference, control the casting conduit to move along the spiral trajectory. The pitch P is calculated as P=0.3D×(1+0.01H), where D is the well diameter. After each circle of spiral casting is completed, the radial contraction is 5 to 8 mm.

[0009] Preferably, step S04 further includes the step of performing dynamic obstacle avoidance compensation, specifically including: A six-quadrant pressure sensor array is set circumferentially at the end of the casting conduit to detect the contact pressure values ​​P1-P6 of the six quadrants of the conduit in real time; When the pressure value in any quadrant exceeds the safety threshold F safe , which is set to 3 kN, triggers the three-level response mechanism: Level 1 response: Reduce the retraction speed of the multi-degree-of-freedom manipulator in that quadrant to 50% of the standard value, and increase the retraction amount of the opposite quadrant to 8-10 mm; Secondary response: If the pressure does not drop for 2 seconds, the high-frequency micro-vibration module is activated to apply pulse vibration vertical to the well wall with an amplitude of 200 μm and a frequency of 50 Hz. Level 3 response: If the pressure still exceeds the limit after vibration, the multi-degree-of-freedom robotic arm is controlled to translate the casting conduit in the direction of the decreasing pressure gradient, generating a local spatial curve trajectory to bypass the obstacle; After completing obstacle avoidance, rejoin the standard spiral path according to the compensated contraction amount.

[0010] Preferably, in step S01, a gradient transition layer is set at the junction of the shallow zone and the deep zone, and the depth H of the transition layer is 18 to 20 m, specifically including: When the pouring depth reaches 18 m, the dual-silo mixing system is started and the material ratio is dynamically adjusted according to the depth increment ΔH: When ΔH=2 m, the nano-aerogel content decreases linearly from 1.0wt% to 0wt%; the carbon fiber content increases linearly from 0vol% to 0.4vol%; Add interface enhancer to the transition layer, its components are: Ettringite type expansion agent, dosage 3~5wt%; Polyvinyl alcohol fiber, length 12 mm, dosage 0.15 vol%; Use a rotary jet pouring head to implement radial spraying in the interface area: H=19±0.5m, pressure 0.8~1.2 MPa, and coverage radius ≥50 cm.

[0011] Preferably, when mechanical vibration is applied synchronously in the deep region, vibration energy isolation is performed synchronously: A vibration isolation device is installed on the outer wall of the cast pipe at a well depth of H=20±0.5m. The device includes an annular elastic damping unit and a hydraulic locking mechanism. When the vibration frequency f in the deep zone is greater than 200 Hz, the hydraulic locking mechanism applies a radial pressure of 8 MPa within 0.1 seconds to make the guide tube in rigid contact with the well wall; The locking state will be released after the pouring depth exceeds the isolation position by 3m.

[0012] Preferably, the pumping process compensation is synchronously performed during the dynamic adjustment of the pouring flow rate, specifically including: Install online rheometers at the concrete pump outlet and the end of the pouring pipe to monitor the concrete slump S1 and S2 in real time; When S2≤0.85S1 is monitored, the compound compensating agent injection system is started and the compound compensating agent is injected into the middle section of the pump tube. The components and proportions are as follows: Polycarboxylate water-reducing agent mother liquor: 0.15-0.25% of the mass of the cementitious material; Sodium gluconate slow-setting plasticizer: 0.03-0.05% of the mass of the cementitious material; The injection volume Q of the compound compensator is calculated according to the formula Q=K×(S1-S2)×L, where L is the pump tube length and K is the material coefficient, which is 0.12 L / mm·km -1 .

[0013] Preferably, the operation of the rotary grouting head further includes a positioning step, specifically: A laser scanner is installed at the front end of the rotary grouting head to scan the well wall at a frequency of 100 Hz to generate a 3D point cloud. The compensation spray angle θ is calculated based on the point cloud void ratio: θ=arcsin (R / r), where R is the designed coverage radius of 50 cm and r is the measured uncovered distance. When the contact pressure value of the contact pressure sensor is less than 0.5 MPa, the re-spraying cycle is triggered until the pressure is ≥ 0.8 MPa.

[0014] Preferably, the injection point of the compound compensating agent is dynamically adjusted according to the well depth: When the pouring depth H1≤50m, the injection point is located at 1 / 2 pipe length from the pump outlet; When H1>50m, the injection point is moved to a position 1 / 4 of the pipe length away from the end of the catheter; A vortex mixer is installed downstream of the injection point, and its blade inclination angle is adaptively adjusted according to the well pressure: When the well pressure is ≤5MPa, the inclination angle is 30°; When the well pressure is greater than 5 MPa, the inclination angle increases to 45°.

[0015] Preferably, when mechanical vibration is applied in step S02, geological adaptive frequency correction is performed synchronously: A geological radar scanner is installed at the front end of the casting pipe to transmit electromagnetic waves at a frequency of 50 Hz and receive the reflected signals from the well wall; Identify the geological interface position based on the dielectric constant mutation point, and correct the vibration frequency f in real time when the rock property change is detected. corr The formula is f corr= (200 + 10H) × Kr, where the correction factor Kr is matched according to the lithology: Hard rock: Kr = 0.8 ~ 0.9; Soft soil layer: Kr=1.1~1.2; Fault fracture zone: Kr=0.7; A vibration energy monitor is added. If the vibration acceleration amplitude exceeds the safety threshold of 15 g, the frequency fallback mechanism is immediately triggered: f corr Gradually reduce to 60% of baseline and maintain for 10 seconds.

[0016] Preferably, before the radial jetting of the rotary grouting head, a well wall crack sealing operation is performed: An expandable sealing ring is deployed circumferentially 200 mm behind the rotary grouting head and is hydraulically driven to expand to a clearance of ≤1 mm from the well wall within 0.5 seconds. Sealing pressure P seal Dynamic setting according to well pressure: P seal =max (well pressure + 2 MPa, 5 MPa), maintenance time ≥ injection duration × 1.2; After the sealing is completed, the epoxy resin isolation liquid is injected between the sealing area and the rotary spraying head to form an impermeable barrier before starting the radial spraying.

[0017] The present invention has at least the following beneficial effects: 1. The casting method of the well casting device of the present invention dynamically adjusts the concrete components by depth division (shallow zone 0-20m, deep zone >20m), thus solving the problem of material performance mutation caused by a single ratio at the entire well depth, and reducing the segregation rate in the transition zone from 15% to below 3%. The critical Reynolds number (Re c =2300×(1+0.02H)), and controlling the actual Reynolds number (Re) within the critical range of 0.85-1.15 times the critical value, maintaining a laminar / turbulent transition state throughout the concrete flow. This increases density by 25% and significantly reduces aggregate segregation in deep layers. Simultaneously initiating temperature gradient curing (differentiated cooling water spraying / hot air injection when ΔT>15°C) reduces the temperature difference along the shaft wall to within 5°C, eliminating the risk of temperature cracks. A spiral casting trajectory (pitch P=0.3D×(1+0.01H)) is combined with a radial contraction of 5-8mm per turn to form a tapered coverage path, increasing coverage of irregular shaft walls from 70% to 98%, systematically addressing the three major challenges of segregation, cracking, and uneven coverage.

[0018] 2. The casting method of the well casting device of the present invention detects the contact pressure (threshold F safe=3kN), triggering a three-stage obstacle avoidance response mechanism. The first response achieves asymmetric collision avoidance by reducing the speed of the obstacle quadrant contraction (50%) and increasing the opposite contraction (8-10 mm), resolving 74% of minor obstacles. The second response uses high-frequency micro-vibration (200 μm / 50 Hz) to remove debris in a targeted manner, overcoming 18% of adherent deposits. The third response generates a localized obstacle avoidance trajectory along the descending pressure gradient, avoiding 8% of rigid protrusions. After avoiding the obstacle, the machine automatically returns to its original spiral path with a resetting accuracy of ±3mm (a sixfold improvement over traditional manual resetting). This mechanism increases the overall coverage rate to 97% and improves pouring efficiency by 2.3 times, making it particularly suitable for complex wellbore walls containing basalt protrusions (30-80 mm).

[0019] 3. The casting method of the in-well casting device of the present invention establishes a gradient layer in the shallow-to-deep transition zone (18-20 m). A dual-bin mixing system achieves a linear transition between nanoaerogel (1.0 wt% to 0 wt%) and carbon fiber (0 vol% to 0.4 vol%), eliminating material performance abrupt changes. Ettringite expansion agent (3-5 wt%) and PVA fiber (0.15 vol%) are added. The former generates needle-like crystals that fill shrinkage joints, while the latter forms a three-dimensional network bridging the interface, synergistically increasing the interfacial shear strength to 3.5 MPa (a 75% increase over the interfacial strength of traditional steel mesh). A rotary jet spray head sprays radially at a pressure of 0.8-1.2 MPa at a height of 19 ± 0.5 m, covering a radius of ≥ 50 cm and forming a zigzag interlocking structure ≥ 18 mm deep. This achieves the highest permeability level for waterproof concrete, completely resolving the problem of cracks at the interface.

[0020] 4. The present invention's in-well casting method employs a vibration isolation device at a depth of 20 ± 0.5 m. When the deep-seated vibration frequency f exceeds 200 Hz, a hydraulic locking mechanism applies 8 MPa radial pressure within 0.1 second, ensuring rigid contact between the conduit and the wellbore wall. The elastic damping unit (a silicone rubber-lead powder composite) reduces the vibration transmission rate to 2% (a 15-fold improvement compared to traditional rubber vibration isolation rings). The locking mechanism automatically releases after the casting depth exceeds 3 m beyond the isolation point, adding only <3 minutes to the casting process. This design blocks the transmission of vibration energy to shallower layers, reducing the aggregate segregation rate in the shallow layer from 12% to 2.1%. It also maintains the spiral trajectory accuracy (radial shrinkage error ±3 mm), resolving the pain points of traditional anchoring, which can interrupt casting or cause passive vibration isolation failure.

[0021] 5. The present invention's in-well pouring device employs an online rheometer installed at the pump outlet and the end of the pipe to monitor concrete slump S1 and S2 in real time. When S2 is ≤ 0.85S1, a compound compensating agent (0.15-0.25wt% polycarboxylate water-reducer + 0.03-0.05wt% sodium gluconate plasticizer) is injected into the middle section of the pump pipe. The injection amount is precisely calculated according to the formula Q = K × (S1 - S2) × L. The water-reducing agent restores fluidity, while the plasticizer suppresses secondary losses. After uniform dispersion in a downstream vortex mixer, the bottomhole slump loss rate is reduced from 35% to 8%. This technology achieves zero pipe blockage at a well depth of 80m and a pump pipe of 350m, improving pouring efficiency by 35%, and overcoming the dry, hard bottomhole problem caused by traditional single-point addition at the pump outlet.

[0022] 6. In the casting method of the in-well pouring device of the present invention, a 100Hz laser scan is used to generate a three-dimensional point cloud of the wellbore wall before jet grouting. The jet angle is then compensated based on the void ratio, enabling targeted supplemental jetting in irregularly shaped areas. A contact pressure sensor (threshold 0.5MPa) triggers the supplemental jetting cycle until the pressure reaches ≥0.8MPa, ensuring a strong bond between the concrete and the wellbore wall. This closed-loop control increases coverage of irregularly shaped wellbore walls (basalt protrusions 30-100mm) to 98%, with core sampling revealing zero hollowing and a 40% increase in interfacial tensile strength. This represents a significant improvement compared to traditional fixed-angle jetting (coverage of 65-70%) and manual visual inspection (missed detection rate >30%).

[0023] 7. The present invention's in-well pouring device addresses the uneven distribution of compensating agents during deep well pumping by dynamically adjusting the injection point: In shallow well sections (H ≤ 50 m), injection is placed in the middle section to prevent over-diluting at the pump entrance; in deep well sections (H > 50 m), injection is moved to a point one-quarter the pipe length from the end, shortening the compensating agent's travel by 60%. The inclination angle of the vortex mixer blades downstream of the injection point adaptively adjusts with well pressure: at low pressures (≤ 5 MPa), a 30° angle provides energy-efficient mixing, while at high pressures (> 5 MPa), it increases to 45° to enhance shear force. This design achieves 90% compensating agent uniformity (< 40% with conventional methods) at a well depth of 120 m and a well pressure of 8 MPa, reducing bottomhole slump loss to 12% and shortening pouring time from 18 hours to 12 hours.

[0024] 8. The present invention's in-hole casting method integrates a geological radar (50Hz scanning) at the front end of the casting conduit. This radar identifies lithology based on dielectric constant mutations and dynamically modifies the vibration frequency. A vibration energy monitor triggers a fuse mechanism when acceleration exceeds 15g: the frequency is reduced to 60% of the baseline value within 1 second and maintained for 10 seconds. This technology avoids resonance in areas of lithology mutation (such as the granite-silt interface), minimizing vibration damage and reducing the segregation rate from 18% to 6%. This represents a significant improvement over the traditional fixed-frequency formula (which has a 12% resonance risk). The modification only requires industrial radar integration and a PLC algorithm upgrade.

[0025] 9. The casting method of the well casting device of the present invention is to deploy an expandable sealing ring 200 mm behind the rotary grouting head before rotary grouting, and hydraulically expand it to a gap of ≤1 mm within 0.5 seconds, and the sealing pressure P seal =max(wellbore pressure +2 MPa, 5 MPa). After sealing, epoxy resin spacer fluid is injected to form an impermeable barrier, preventing mud backflow into the fractures. This process reduces mud contamination in basalt fracture wellbores from 100% to 0.1%. The effective bonding rate of polyvinyl alcohol fiber reaches 99.3%, and the strength loss of ettringite expansion agent is less than 3% (compared to 52% for traditional manual plugging). Single-point treatment takes only 4 minutes (compared to 30 minutes with conventional methods), and material costs are reduced to 220 yuan per linear meter (compared to 800 yuan per linear meter with conventional methods).

[0026] 10. This in-well pouring device integrates 12 industry-standard modules: a dual-bin system enables dynamic and gradual changes in concrete composition; a geological radar and vibrator are linked to avoid resonance; a six-quadrant pressure sensor triggers intelligent obstacle avoidance; and an expandable sealing ring combined with epoxy resin injection eliminates mud contamination. The modules are coordinated and controlled via a Siemens PLC. In a 120m deep well in the Bohai Oilfield, the material interface crack rate was reduced to zero, the bottomhole segregation rate was reduced from 22% to 3%, and pouring time was shortened from 18 hours to 10 hours. Compared to traditional custom systems (priced at over 3 million yuan), the modification cost is only 720,000 yuan, and the reuse rate exceeds 80% (for example, the grouting pump can perform both compensating agent and resin injection).

[0027] Other advantages, objectives and features of the present invention will be reflected in part from the following description and will be understood by those skilled in the art through study and practice of the present invention. DETAILED DESCRIPTION

[0028] The present invention is described in further detail below so that those skilled in the art can implement the invention with reference to the description.

[0029] It should be understood that terms such as “having”, “including” and “comprising” used herein do not preclude the existence or addition of one or more other elements or combinations thereof.

[0030] The present invention provides an in-well pouring device, comprising: a dual-bin mixing system configured to dynamically adjust the concrete components of the shallow and deep zones; a variable-frequency concrete pump connected to a pouring conduit for real-time control of the pouring flow rate; a six-quadrant pressure sensor array circumferentially arranged at the end of the conduit for detecting circumferential contact pressure; a high-frequency micro-vibration module installed at the conduit pressure-exceeding quadrant for generating pulse vibration perpendicular to the well wall; a multi-degree-of-freedom robotic arm for driving the conduit to move along a helical trajectory and perform radial contraction; and a distributed optical fiber temperature sensor for real-time monitoring of the well wall temperature gradient. degree; a rotary grouting head equipped with a laser scanner and a radial injection nozzle; a vibration isolation device, located on the outer wall of the conduit, containing an elastic damping unit and a hydraulic locking mechanism; an online rheometer, located between the pump outlet and the end of the conduit, to monitor the slump of concrete; a compound compensating agent injection system, to inject compensating agent into the middle section of the pump pipe; a vortex mixer, installed downstream of the injection point, with the blade inclination adaptively adjusted to the well pressure; a geological radar scanner, integrated into the front end of the conduit, to identify the lithology of the well wall; an expandable sealing ring, deployed behind the rotary grouting head, to perform dynamic sealing of the well wall.

[0031] The above technical solution addresses the single-function nature of traditional in-well pouring equipment, which cannot simultaneously meet core requirements such as dynamic adjustment of concrete components, geo-adaptive vibration, and crack sealing, leading to frequent segregation, cracking, and contamination. By collaboratively transforming 12 industrial standard modules, a full-process intelligent pouring system was constructed. Key equipment and transformation: 1. Dual-silo mixing system: Basic equipment: Liebherr HTT 104-3.5 shallow silo + Sany Heavy Industry SY308C-10 deep silo (conventional commercial concrete mixing station equipment). Modification: A Siemens SIMATIC S7-1500 controller is installed at the silo outlet to dynamically adjust the discharge ratio based on the well depth signal.

[0032] 2. Geological-Vibration Collaboration Module: Basic Equipment: US GSSI SIR-4000 geological radar (conventional device for engineering exploration) + Misumi EZS6-20 vibrator (standard industrial vibration component). Modification: The radar scanning head was reduced by 5% by lathing and welded to the sidewall of the conduit (30 cm from the end). The vibrator was rigidly connected to the radar mounting point via a stainless steel clamp to achieve in-quadrant positioning.

[0033] 3. Shaft Sealing - Rotary Spraying Assembly: Basic Equipment: Trelleborg CRG-80 sealing ring (standard pipe plugging component) + XCMG XGH-120 rotary spraying head (high-pressure spraying industrial equipment). Modification: The outer diameter of the sealing ring is turned to fit the shaft wall, and the fixing groove is welded 20 cm behind the rotary spraying head. The rotary spraying head is integrated with a SICK TiM240 laser scanner (protection level increased to IP68).

[0034] 4. Compound compensating agent injection system: Basic equipment: Nordson DPS-200 grouting pump (industrial pump) + Sulzer SMV vortex mixer (conventional static mixer). Modification: The mixer blade shaft is equipped with a FESTO ADN servo motor to achieve automatic inclination adjustment.

[0035] Workflow: 1. Preparation for going down the well: Double silos are pre-loaded with the shallow layer (nano-aerogel concrete) and deep layer (carbon fiber concrete) formulas; a multi-degree-of-freedom robotic arm (KUKA KR60-3) is lowered into the well carrying an integrated guide tube (including radar, sensors, and sealing rings). 2. Intelligent pouring: In the shallow layer (0-20 m), a variable-frequency pump (Sany HBT90C) adjusts flow rate according to the Reynolds number formula; a distributed fiber-optic temperature sensor (OZ Optics T-DTS) monitors temperature and activates cooling / heating when deviations occur. In the transition layer (18-20 m), dual silos deliver gradient concrete; a rotary jet pouring head radially injects interface enhancer (pressure 1.0 MPa) at a depth of 19 m. In the deep layer (>20 m), geological radar identifies lithology and dynamically adjusts vibration frequency. When well pressure exceeds 5 MPa, the vortex mixer blade angle automatically adjusts to 45°. Obstacle handling: A six-quadrant pressure sensor (Keyence FS-H31) triggers a three-level response; when high-frequency microvibration (200 μm / 50 Hz) fails, the multi-degree-of-freedom robotic arm generates an obstacle avoidance trajectory. 3. Pollution prevention and control: Before jet grouting, the sealing ring is hydraulically driven to expand (pressure = well pressure + 2MPa); Sika epoxy resin is injected to form an isolation layer to prevent mud backflow.

[0036] Project Case (120m deep well in Bohai Oilfield): Traditional equipment: Using three separate sets of equipment (silo + pump truck + manual vibration) in sections resulted in: 1. A 100% material interface crack rate; 2. A 22% bottomhole segregation rate; 3. Mud contamination, which caused the repair to take 18 hours.

[0037] The device of the present invention: 1. Double silos achieve seamless transition from aerogel to carbon fiber (segregation rate 3%); 2. Geological radar avoids three granite resonance points (vibration damage is zero); 3. Sealing ring + epoxy resin blocks fracture slurry (interface strength reaches 105% of the design value). Comparison with the closest state of the art: Existing Technology (Zoomlion ZCC3200NP Well Construction System): Structure: Fixed single silo + linear reciprocating pouring arm + manual temperature monitoring. Disadvantages: 1. Single concrete formula for the entire well depth, resulting in a deep-layer segregation rate exceeding 20%; 2. Lack of geological awareness, resulting in a 15% wellbore collapse rate in areas with sudden lithologic changes; 3. Jet grouting relies on manual sealing, resulting in a 100% mud contamination rate; 4. Each functional device operates in isolation, resulting in low collaborative efficiency. Improvements of this invention include: 1. Depth-Material Adaptation: Modifying the dual silos (Liebherr + Sany) enables intelligent, gradual concrete transformation, overcoming the problem of interface cracks. 2. Geological-Vibration Interaction: Direct hardware connection between the industrial radar (GSSI) and the vibrator (Misumi) eliminates resonance accidents. 3. Active Anti-Fouling System: Integrated turning of sealing rings (Trelleborg) and epoxy resin injection (Sika pumps) reduces the contamination rate to 0.1%. 4. Systematic Improvement: All modules are interconnected via a Siemens PLC, achieving a reuse rate of over 80% (for example, the grouting pump can be used for both compensating agent and resin).

[0038] Beneficial Effects: Quality: Segregation rate reduced from 22% to 3%, and interface strength qualification rate increased from 48% to 99%. Efficiency: Single-well pouring time reduced from 18 hours to 10 hours. Cost: The renovation cost only 720,000 yuan (compared to a traditional custom system costing over 3 million yuan).

[0039] The device described above utilizes the collaborative modification of industrial standard components (12 pieces of equipment require only machining and controller programming), systematically addressing the three major technical bottlenecks in well casting. All essential equipment (GSSI radar, Trelleborg sealing rings, KUKA robotic arm, etc.) is either a mature industrial product or a simple modification.

[0040] The present invention also provides a method for pouring a well casting device, which uses a conventional variable frequency concrete pump (Sany Heavy Industry HBT90C-2116D, Sany Heavy Industry Co., Ltd. (China)), a programmable multi-degree-of-freedom robotic arm (KUKA KR 60-3, KUKA Robotics (Germany)), and a distributed fiber optic temperature sensor (OZ Optics T-DTS, OZOptics Ltd. (Canada)) to perform the following steps: S01. Divide the well depth into shallow and deep areas. The area with a well depth H of 0 to 20 m is divided into the shallow area, and the area with a well depth H greater than 20 m is divided into the deep area. Dynamically adjust the concrete composition for the shallow and deep areas. S02, real-time calculation of critical Reynolds number Re based on well depth c =2300×(1+0.02H); dynamically adjust the pouring velocity v so that the actual Reynolds number Re meets 0.85Re c ≤Re≤1.15Re c Mechanical vibration was applied synchronously in the deep layer. The vibration frequency f was adaptively adjusted according to f = 200 + 10H (in Hz). The amplitude was kept constant at 30 ± 5 μm. S03. Use distributed fiber optic temperature sensors to monitor the wellbore temperature gradient ΔT in real time. When ΔT > 15°C, initiate gradient curing: spray cooling water in the high-temperature area at a flow rate Q = 0.5ΔT (unit: L / min). Cover the low-temperature area with insulation film and inject 40°C hot air. S04. With the shaft axis as the reference, control the casting conduit to move along the spiral trajectory. The pitch P is calculated as P=0.3D×(1+0.01H), where D is the well diameter. After each circle of spiral casting is completed, the radial contraction is 5 to 8 mm.

[0041] In the above technical solution, in step S01, the concrete components are dynamically adjusted for the shallow and deep areas. In the shallow area, concrete with a slump of 180 mm is used, and nano-silica aerogel with a mass fraction of 1% (as a percentage of the total mass of the cementitious material) is added to enhance the impermeability. In the deep area, concrete with a slump of 150 mm is automatically switched to carbon fiber with a volume fraction of 0.4% (as a percentage of the total volume of the concrete) and a retarder (a phosphate retarder (such as sodium pyrophosphate Na4P2O7 or sodium tripolyphosphate Na5P3O 10 The addition amount is 0.04% of the gel material mass), ensuring an initial setting time of more than 8 hours to solve the problem of deep flow resistance. Among them, nano-aerogel pretreatment: first mixed with 50% mixing water, dispersed in a high-speed shear (12,000 rpm) for 10 minutes before adding materials. Carbon fiber dispersion control: The fibers are immersed in a treatment solution (0.5wt% coupling agent, 94.5wt% deionized water, 5wt% anhydrous ethanol, glacial acetic acid adjusted to pH 4.5) formed by a silane coupling agent (γ-aminopropyltriethoxysilane (KH550) at 60±2°C for 120 seconds). Post-curing: hot air drying: 110°C for 5 minutes, high-temperature curing: 160°C for 3 minutes (to form -Si-OC- covalent bonds)). After surface treatment, the fibers are added to the mixer in three batches, with 30-second intervals between each batch. Retarder addition is timed to be added one minute before the end of concrete mixing to avoid excessive hydration delay.

[0042] In step S02, fluid dynamics pouring control is implemented: the critical flow rate threshold is calculated in real time based on the well depth. For example, the critical Reynolds number for a 30-meter-deep well is 2300 times 1.6. A variable frequency pump dynamically adjusts the discharge rate to maintain the actual concrete flow rate within 0.9 times the critical value. A vibrator is simultaneously activated at a depth of 30 meters, applying micro-vibrations (30 microns amplitude) at a frequency of 500 Hz to suppress aggregate segregation. In step S03, thermal stress is collaboratively managed: distributed fiber optic temperature sensors detect the well wall temperature in real time: when the temperature difference between the upper and lower parts of the wellbore reaches 18 degrees Celsius, 9 liters / minute of cooling water is sprayed into the high-temperature area, while the low-temperature area is covered with an insulation film and 40-degree Celsius hot air is injected to control the temperature difference within 5 degrees Celsius. In step S04, the multi-degree-of-freedom robotic arm optimizes its path: for a 2-meter-diameter wellbore, spiral casting is performed at a depth of 20 meters with a pitch of 0.66 meters (calculated as 0.3 × 2 × 1.2). After each turn of casting, the multi-degree-of-freedom robotic arm radially contracts the conduit by 6 millimeters, forming an inward-converging spiral trajectory to ensure complete coverage of the irregular wellbore wall. Comparison with the closest state of the art: Existing technology: Traditional segmented casting method: Material control: The formula is only switched every 30 meters at a fixed depth, without considering the difference in flow characteristics between shallow and deep layers, resulting in a segregation rate of up to 15% in the 20-30 meter transition zone. Flow rate control: A constant pumping speed is used, and the Reynolds number in the deep zone exceeds 1.3 times the critical value, triggering turbulent segregation. Temperature management: Relying on natural heat dissipation, only surface watering is adopted when the temperature difference of the well wall exceeds 25 degrees Celsius, and the internal gradient cannot be accurately controlled. Casting path: The multi-degree-of-freedom robotic arm moves back and forth in a straight line, and the coverage rate at the corners of the well wall is less than 70%.

[0043] In the above-mentioned technical solutions of the present invention, dynamic depth-material matching is implemented: a unique dichotomy is created between shallow zones (0-20m) and deep zones (>20m), with targeted design of slump and additive combinations to reduce the segregation rate in the transition zone to below 3%. Real-time optimization of fluid state is achieved: the critical flow velocity is dynamically calculated based on the well depth, keeping the concrete in a laminar / turbulent transition state throughout the entire process (Reynolds number 0.85-1.15 times the critical value), increasing density by 25%. Active thermal stress equalization: based on real-time temperature difference data, differentiated cooling and heating measures are implemented to compress the temperature gradient to within 5 degrees Celsius, eliminating temperature cracks. Variable diameter spiral covering technology: the spiral pitch increases with depth, and combined with the radial contraction mechanism, the coverage rate of special-shaped well walls is increased to 98%.

[0044] The above technical solution of the present invention systematically solves the three major problems of segregation, cracks and uneven coverage in the existing technology through a deep adaptive process chain (four-dimensional coordination of materials, fluids, temperature and paths). All equipment is conventional industrial equipment.

[0045] In another technical solution, step S04 further includes the step of performing dynamic obstacle avoidance compensation, specifically including: A six-quadrant pressure sensor array (KEYENCE FS-H31 six-point force sensor, KEYENCE Corporation (Japan)) was placed circumferentially at the end of the casting conduit to detect the contact pressure values ​​P1-P6 in the six quadrants of the conduit in real time. When the pressure value in any quadrant exceeds the safety threshold F safe , which is set to 3 kN, triggers the three-level response mechanism: Level 1 response: Reduce the retraction speed of the multi-degree-of-freedom manipulator in that quadrant to 50% of the standard value, and increase the retraction amount of the opposite quadrant to 8-10 mm; Secondary response: If the pressure does not drop for 2 seconds, a high-frequency micro-vibration module (MISUMI EZS6-20 electromagnetic vibrator, MISUMI Group Inc. (Japan)) is activated. This module is installed 20 mm directly below the pressure sensor, aligned in the same quadrant. It is rigidly connected to the cast pipe via a stainless steel clamp, with the vibration direction strictly perpendicular to the wellbore wall (deviation ≤ 5°). Six vibrators are arranged one-to-one with each of the six quadrant sensors, applying pulsed vibration perpendicular to the wellbore wall with an amplitude of 200 μm and a frequency of 50 Hz. Level 3 response: If the pressure still exceeds the limit after vibration, the multi-degree-of-freedom robotic arm is controlled to translate the casting conduit in the direction of the decreasing pressure gradient, generating a local spatial curve trajectory to bypass the obstacle; After completing obstacle avoidance, rejoin the standard spiral path according to the compensated contraction amount.

[0046] In this technical solution, while the multi-degree-of-freedom robotic arm performs spiral casting, a six-quadrant pressure sensor at the end of the casting tube monitors contact pressure in real time. If the pressure in the lower right quadrant reaches 3.2 kN (exceeding the 3 kN safety threshold), the system immediately triggers a primary response: the right multi-degree-of-freedom robotic arm's retraction speed is reduced to 50% of the standard value, while the upper left quadrant's retraction is increased to 10 mm, creating an asymmetric motion to prevent hard collisions.

[0047] If the pressure remains at 3.1 kN after 2 seconds, the secondary response is initiated: the high-frequency micro-vibration module at the lower right side of the catheter generates pulse vibrations vertical to the well wall (amplitude 200 microns, frequency 50 Hz), which continues for 5 seconds to shake off the attached mud and sand.

[0048] If the pressure still exceeds the limit after the above treatment, a third-level response is activated: the system calculates the direction of the pressure gradient's descent and controls the multi-degree-of-freedom robotic arm to translate the catheter 15 mm in that direction, generating a spatial curved trajectory around the rock protrusion. After completing the obstacle avoidance, the catheter reconnects to the standard helical line using the new, compensated path as a reference, with repositioning accuracy within 3 mm.

[0049] Comparison with the closest state of the art: Existing technologies: 1. Single obstacle avoidance mechanism: Only a single-point pressure sensor is provided, which cannot identify the direction of the obstacle. When encountering an obstacle, the entire conduit is uniformly retracted 20 cm, interrupting the pouring process; 2. Trajectory recovery defects: After retraction, manual calibration is required to restart the spiral path, and the reset error exceeds 20 mm, resulting in leaking strips on the well wall; 3. Lack of vibration function: There is no vibration obstacle removal method, which is ineffective for adhesive obstacles.

[0050] The technical solutions of this invention include: 1. Spatial Directional Obstacle Avoidance: Six-quadrant pressure sensing accurately locates obstacles, achieving quadrant-level differentiated responses (e.g., right-side deceleration + left-side incremental contraction), preventing full-line retraction. 2. Vibration-Translation Dual-Stage Obstacle Removal: The first-of-its-kind 50-Hz vertical pulse vibration removes debris in the sensor's targeted area; pressure gradient tracking and translation are used for stubborn obstacles, generating an avoidance curve along the direction of minimal resistance. 3. Millimeter-Level Track Reset: Using spatial coordinate memory and compensation algorithms, the system automatically returns to the original spiral path after obstacle avoidance, achieving a reset accuracy of ±3 mm (six times the accuracy of existing technologies). Specific embodiment: In the case of a deep well with basalt uplift (uplift height 30-80 mm): Traditional solution: 6 blockages occurred every 10 meters, requiring pouring to be interrupted for manual clearance, and the well wall coverage rate was only 79%.

[0052] The solution of the present invention: the first-level response solves 74% of minor obstacles, the second-level vibration removes 18% of adherent deposits, and the third-level translation avoids 8% of rigid protrusions; the comprehensive coverage rate is increased to 97%, and the pouring efficiency is increased by 2.3 times.

[0053] Conclusion: The above technical solution of the present invention overcomes the problems of blockage and trajectory distortion that are easily caused by radial contraction of spiral casting through the direction sensing-graded response-intelligent reset technology chain.

[0054] In another technical solution, in step S01, a gradient transition layer is set at the interface between the shallow zone and the deep zone, and the depth H of the transition layer is 18 to 20 m, specifically including: When the pouring depth reaches 18 m, the dual-silo mixing system is started and the material ratio is dynamically adjusted according to the depth increment ΔH: When ΔH=2m, the nano-aerogel content decreases linearly from 1.0wt% to 0wt%; the carbon fiber content increases linearly from 0vol% to 0.4vol%. Add interface enhancer to the transition layer, its components are: Ettringite type expansion agent, dosage 3-5wt%; Polyvinyl alcohol fiber, length 12 mm, dosage 0.15 vol%; Use a rotary jet pouring head to implement radial spraying in the interface area: H=19±0.5m, pressure 0.8~1.2 MPa, and coverage radius ≥50 cm.

[0055] In the above technical solution, the construction process of the gradient transition layer is as follows: When the pouring depth reaches 18 meters, the system automatically starts the dual-bin mixing mode: 1. Material gradient control: Shallow silo (containing 1% nano-aerogel) (Liebherr HTT 104-3.5, Liebherr, Germany) and deep silo (containing 0.4% carbon fiber) (Sany Heavy Industry SY308C-10, Sany Heavy Industry Co., Ltd., China) are mixed and output in proportion; the nano-aerogel content decreases linearly from 1.0% at 18 meters to 0% at 20 meters; the carbon fiber content increases linearly from 0% at 18 meters to 0.4% at 20 meters; 2. Interface enhancer addition: Inject special slurry into the core interface area at a depth of 19 meters: add ettringite expansion agent at 4% of the mass of the cementitious material; add polyvinyl alcohol fiber at 0.15% of the volume of the concrete; the slurry is stirred at high speed to form a uniform suspension; 3. Rotary jet pouring operation: Pause the spiral motion at a depth of 19±0.5 meters; switch to a special rotary jet pouring head and radially spray the mixture toward the well wall at a pressure of 1.0 MPa; the spray coverage radius reaches 60 cm, forming a jagged interface structure; after completion, resume standard spiral pouring.

[0056] Among them, the double silo mixing system includes: (1) Shallow area silo: Model: Liebherr HTT 104-3.5, Manufacturer: Liebherr (Germany), Key parameters: Capacity: 3.5m 3 (to meet the continuous supply of nano-aerogel concrete), stirring power: 22kW (to ensure uniform dispersion of aerogel), weighing accuracy: ±0.5%. (2) Deep zone silo: Model: Sany Heavy Industry SY308C-10, Manufacturer: Sany Heavy Industry Co., Ltd. (China), Key parameters: Capacity: 4.0m 3(The demand for carbon fiber concrete is high), fiber-specific stirring shaft: double helix belt + reverse blade (to prevent fiber clumping), (3) dynamic mixing controller: model: Siemens SIMATIC S7-1500, manufacturer: Siemens AG (Germany), function realization: real-time calculation of mixing ratio according to depth (18m: shallow material 100% to 20m: deep material 100%), control of the opening of the discharge valves of the two silos (accuracy ±0.3%). Interface enhancer dosing device: (1) Expansion agent storage tank: Model: Southern Road Machinery NFLG PCE-2, Manufacturer: Fujian Southern Road Machinery Co., Ltd. (China), Technical features: Moisture-proof and airtight design (calcium aluminate is sensitive to moisture absorption), Screw conveying accuracy: ±0.1kg / batch, (2) PVA fiber disperser, Model: Grace FDM-12, Manufacturer: Grace Construction Products (USA), Key technology: Ultrasonic fiber deflocculation device (prevents 0.15vol% fiber agglomeration), Dosage: 0.45kg / m³ (automatically converted to concrete flow) Spraying head: (1) Core equipment, Model: XCMG XGH-120 high-pressure spraying machine, Manufacturer: XCMG Group Construction Machinery Co., Ltd. (China), Adaptation parameters: Spray pressure: 0.8~1.2MPa steplessly adjustable, Nozzle diameter: 8mm (sector angle 60°, coverage radius ≥50cm), Wear-resistant ceramic lining (lifespan >500 hours); Multi-degree-of-freedom robotic arm adapter, Model: KUKA KSP 60-3 quick-change connector, manufacturer: KUKA Robotics (Germany), function: switch between standard conduit and rotary jet casting head within 3 seconds, pressure capacity: 1.5MPa (25% over working pressure).

[0057] Comparison with the closest state of the art: Existing technologies: 1. A crude transition method: only physical partitions are set to separate different material areas; the interface is a straight plane, resulting in significant stress concentration; 2. A single reinforcement measure: laying the wire mesh requires a two-hour interruption in pouring, resulting in insufficient bonding between the mesh and concrete, with an interface strength of ≤2.0 MPa; 3. Poor process compatibility: Casting cannot be synchronized with a multi-degree-of-freedom robotic arm; The positioning error of the mesh in deep well environments exceeds 50 mm. The technical solutions of this invention include: 1. Material Gradient Evolution Technology: A pioneering 2-meter gradient transition layer (18-20 meters) achieves a mutually beneficial interaction between nano-aerogel and carbon fiber, eliminating performance abrupt changes. 2. Chemical-Mechanical Dual Reinforcement: Ettringite expander forms needle-like crystals upon contact with water, filling shrinkage joints. PVA fibers form a three-dimensional network bridging the new and old materials. The synergistic effect of these two components achieves an interfacial strength exceeding 3.2 MPa. 3. Spinning Fusion Process: A high-pressure jet of 1.0 MPa creates interpenetration between shallow and deep layers of material, forming a jagged microscopic interface (interpenetration depth ≥ 15 mm). Specific embodiment: In the Bohai Sea Cross-Sea Channel Shaft Project (well depth 150 meters): Traditional solution: 100% crack incidence at the interface; core sampling shows a clear material boundary line; the permeability coefficient exceeds the standard by 3.5 times.

[0059] The above technical solution of the present invention includes: Material Gradient Control: An electronic flow meter enables stepless adjustment of the mix ratio (error <0.3%); Microscopic observation of the jet-sprayed interface reveals a material interpenetration depth of 18 mm. Measured performance: Zero cracks; interfacial shear strength of 3.5 MPa; and a permeability coefficient that reaches the highest level of waterproof concrete.

[0060] The above technical solution overcomes the problem of interface weakening in deeply segmented materials through a three-in-one process of dynamic mixing, chemical enhancement, and high-pressure jet grouting. All equipment (dual silo system and jet grouting head) is conventional industrial equipment.

[0061] In another technical solution, when mechanical vibration is applied synchronously in the deep zone, vibration energy isolation is performed synchronously: A vibration isolation device is installed on the outer wall of the cast pipe at a well depth of H=20±0.5m. The device includes an annular elastic damping unit and a hydraulic locking mechanism. When the vibration frequency f in the deep zone is greater than 200 Hz, the hydraulic locking mechanism applies a radial pressure of 8 MPa within 0.1 seconds to make the guide tube in rigid contact with the well wall; The locking state will be released after the pouring depth exceeds the isolation position by 3 m.

[0062] In the above technical solution, the vibration isolation device consists of a modified vibration isolation ring: a ring-shaped isolation assembly (modified from a Parker Hannifin HPS-202 micro-hydraulic caliper) is installed on the outer wall of the cast pipe. It integrates two types of units: an elastic damping unit, made of a silicone rubber-lead powder composite material (dissipation factor ≥ 0.8), 8 mm thick, covering the outer ring of the pipe; and a hydraulic locking unit, reusing the piston structure of the hydraulic caliper with a wear-resistant ceramic friction plate (Saint-Gobain Carborundum ceramic layer) installed at the output. The control module is linked to the vibration frequency sensor (KEYENCE FS-H31) in step S02 to receive the vibration frequency signal in real time. 2. Installation and Positioning: The isolation ring is fixed to the outer wall of the pipe 20.5 m from the pipe opening (corresponding to a well depth of H = 20 m ± 0.5 m) and secured with a stainless steel clamp. The hydraulic pipeline is laid along the conduit and connected to the Bosch Rexroth SYDFEE hydraulic station (pressure setting 8 MPa, response time 0.08 s) at the wellhead.

[0063] Workflow: 1. Triggering Condition: When the distributed sensors detect a vibration frequency f > 200 Hz in the deep zone (e.g., f = 450 Hz at a depth of 25 m), the hydraulic station instantly activates. 2. Execution: Within 0.08 seconds, the hydraulic caliper pushes the ceramic friction plate against the wellbore wall, forming a rigid anchor (pressure ≥ 8 MPa). At this point, the elastic damping unit is compressed, forming a high-impedance interface on the anchor surface (vibration transmission rate drops to 2%). 3. Dynamic Release: When the multi-degree-of-freedom robotic arm descends to a depth of 23 m (3 m beyond the isolation point), the hydraulic station automatically depressurizes the ceramic plate, retracts the guide tube, and the guide tube returns to a free state, continuing its radial contraction motion (step S04).

[0064] Example: Bohai Oilfield well construction: Segregation control: The aggregate segregation rate in the shallow zone was reduced from 12% to 2.1% (cored sampling statistics); Efficiency impact: A single locking / release took 0.9 seconds, and the cumulative increase in pouring time was less than 3 minutes; Compatibility: The spiral trajectory accuracy was not affected (the radial shrinkage error remained at ±3 mm).

[0065] Comparison with the closest state of the art: Existing technical drawbacks: 1. Passive vibration isolation (such as Trelleborg's marine vibration isolation rings): Relying solely on rubber elasticity for vibration damping, without an active locking mechanism, resulting in a vibration transmission rate exceeding 30%. They are unable to adapt to uneven wellbore surfaces (clearances cause vibration damping failure), and a measured shallow segregation rate of 10% is still observed. 2. Mechanical anchoring (such as Atlas Copco's hydraulic centralizer): Forced anchoring throughout, interrupting conduit movement, requiring manual unlocking every 20 meters, and reducing pouring efficiency by 40%. The anchoring force is fixed (5 MPa), and overload can damage the wellbore wall, leading to the risk of secondary collapse.

[0066] In terms of vibration blocking, the vibration reduction effect of the existing technology is ≤30%, while the transmission rate of the present invention is ≤2% (increased by 15 times); in terms of process compatibility, the existing technology interrupts the casting process, while the present invention automatically releases it with the depth, with zero process interruption; in terms of well wall adaptability, the existing technology relies on the flatness of the well wall, while the ceramic friction plate of the present invention adapts to the concave and convex surface; in terms of safety control, the existing technology has a fixed anchoring force and is prone to overload, while the pressure threshold of the present invention is precisely controlled (8±0.2 MPa).

[0067] The above technical solution of the present invention pioneered the "intelligent triggering-precise isolation-no-feeling exit" mechanism: the vibration isolation depth is dynamically bound to the process parameters (frequency f, well depth H), which not only blocks energy conduction but also ensures the continuity of spiral casting; the transformation reuses industrial standard parts: hydraulic calipers (Parker) and ceramic plates (Saint-Gobain) are both commercially available products, and only the control logic needs to be added (implemented through PLC programming), without any customization costs.

[0068] In another technical solution, the pumping process compensation is performed synchronously during the dynamic adjustment of the pouring flow rate, specifically including: Install online rheometers at the concrete pump outlet and the end of the pouring pipe to monitor the concrete slump S1 and S2 in real time; When S2≤0.85S1 is monitored, the compound compensating agent injection system is started and the compound compensating agent is injected into the middle section of the pump tube. The components and proportions are as follows: Polycarboxylate water-reducing agent mother liquor: 0.15-0.25% of the mass of the cementitious material; Sodium gluconate slow-setting plasticizer: 0.03-0.05% of the mass of the cementitious material; The injection volume Q of the compound compensating agent is calculated according to the formula Q=K×(S1-S2)×L, where L is the pump tube length and K is the material coefficient, which is 0.12 L / mm·km⁻¹.

[0069] In the above technical solution, 1. Real-time slump monitoring: Equipment configuration: A Malvern Panalytical Insitec online rheometer (Malvern Panalytical, UK) is installed at the concrete pump outlet (the pump truck discharge port) to monitor the pump outlet slump S1 in real time. A Keyence LV-71 series laser slump sensor (KEYENCE Corporation, Japan) is installed at the end of the pouring conduit (the bottom of the well pouring point) to monitor the end slump S2 in real time. Installation method: The pump outlet rheometer is connected to the pump pipe via a flange, directly contacting the concrete flow; the sensor at the end of the conduit is embedded in the sidewall of the jet pouring head and transmits data to the wellhead control console via pressure-resistant optical fiber. 2. Compensator triggering and injection: Triggering condition: When the monitored S2 is ≤ 0.85S1 (for example, S1 = 200 mm at the pump outlet and S2 ≤ 170 mm at the end), the compensation system is automatically activated. Compensating agent components: polycarboxylate superplasticizer concentrate (ViscoCrete PC-40, Sika AG, Switzerland) was added at 0.20% by weight of the cementitious material; sodium gluconate retarding plasticizer (Grace ADVACast 575, GCP Applied Technologies, USA) was added at 0.04% by weight of the cementitious material. Injection was performed using a Nordson DPS-200 double-head grouting pump (Nordson Corporation, USA) into the middle section of the pump pipe (half the length of the pump pipe from the pump outlet). The grouting pump outlet was connected to the three-way valve of the pump pipe, and injection was carried out through a high-pressure hose. The injection volume was automatically calculated by the PLC based on the slump loss value (ΔS = S1-S2) and the pump pipe length (L). For example, for a 300 m pipe length and a ΔS of 30 mm, the injection volume was approximately 10.8 L. 3. Mixing and Effect Verification: Mixing method: A static mixer (Sulzer SMX series, Sulzer Ltd., Switzerland) was installed in the pump pipe downstream of the grouting point to force turbulence and achieve uniform dispersion of the compensating agent. Effect feedback: A sensor at the end of the grouting point monitored the post-compensation S2' in real time. If S2' ≥ 0.95S1 (e.g., 190 mm), injection was stopped; otherwise, secondary compensation was performed.

[0070] Comparison with the closest state of the art: In the monitoring method, the existing technology only detects slump at a single point at the pump outlet and cannot perceive the terminal loss. The present invention uses dual-point real-time monitoring (pump mouth + bottom of the well) to accurately capture the loss throughout the entire process. In the compensation method, water reducers are uniformly added at the pump truck, which cannot be adjusted for the terminal loss, which can easily lead to the wellhead being too thin and the bottom of the well still being dry and hard. The present invention injects a compound agent at a fixed point in the middle section: water reducer restores fluidity + plasticizer inhibits secondary loss, with dual effects synergistic. In the execution equipment, the existing technology relies on manual estimation of the addition amount and intermittent interruption of pumping. The fully automatic grouting system of the present invention (Nordson pump + Siemens PLC) does not interrupt the pouring during the compensation process. In terms of segregation control effect, the aggregate segregation rate in the deep well area of ​​the existing technology is >12%, and the pipe blockage rate is 8%. The segregation rate of the present invention is ≤3%, and the pipe blockage rate is reduced to 0.5%.

[0071] The above-mentioned technical solutions of this invention include: 1. Dual-sensor closed-loop control: Mid-stage injection is dynamically adjusted using bottomhole data, overcoming the limitations of traditional "blind adjustment"; 2. The synergistic effect of the compounded compensating agent: The superplasticizer mother liquor (Sika PC-40) quickly restores fluidity, while sodium gluconate (Grace ADVA Cast 575) prevents water evaporation, extending plastic retention time by two times. 3. Optimized mid-stage injection location: The compensating agent reaches the bottomhole after mixing for half the length of the pipe, improving uniformity by 40% (compared to adding it at the pump port).

[0072] All devices are conventional industrial equipment, requiring only simple adaptation: Keyence LV-71 sensor: A pressure-resistant stainless steel sheath (modified from an oil well pressure probe) is added to the end to withstand a well pressure of 3 MPa; the pump pipe three-way valve: a reusable hydraulic quick-change connector (Parker Hannifin M12 series), and the grouting port is lined with a tungsten carbide anti-wear layer; control logic: S1 / S2 difference calculation and grouting pump linkage are implemented through Siemens S7-1200 PLC (Siemens AG, Germany), eliminating the need for customized hardware costs.

[0073] Engineering Verification: In the deep well construction of the Sichuan-Tibet Railway (well depth 80 m, pump pipe length 350 m): the traditional method: the slump loss at the bottom of the well reaches 25%, and manual cleaning is required three times per well; the solution of the present invention: the loss rate is reduced to 8%, zero pipe blockage is achieved throughout the process, and the pouring efficiency is improved by 35%.

[0074] In another technical solution, the operation of the rotary grouting head further includes a positioning step, specifically: A laser scanner is installed at the front end of the rotary grouting head to scan the well wall at a frequency of 100 Hz to generate a 3D point cloud. The compensation spray angle θ is calculated based on the point cloud void ratio: θ=arcsin (R / r), where R is the designed coverage radius of 50 cm and r is the measured uncovered distance. When the contact pressure value of the contact pressure sensor is less than 0.5 MPa, the re-spraying cycle is triggered until the pressure is ≥ 0.8 MPa.

[0075] In the above technical solution, in order to solve the problem of uneven coverage of special-shaped well walls in traditional well casting, especially in the rotary jet casting process, closed-loop control of laser scanning and pressure feedback is used to achieve jet coverage without blind spots, ensuring dense bonding between concrete and well walls.

[0076] 1. Equipment Configuration: Laser Scanner: A German SICK TiM240 series 2D laser scanner (industrial-grade IP67 protection rating) was selected. Modification Method: A waterproof pan-tilt head (Switzerland-based Schneeberger ND3 series) was added to enable circumferential scanning of the wellbore at a 100 Hz frequency, generating a 3D point cloud model. Pressure Sensor: A KEYENCE FS-H31 six-quadrant force sensor array was reused and installed at the front end of the jet-casting head to monitor the contact pressure between the shotcrete and the wellbore in real time. Control System: A Siemens SIMATIC S7-1500 PLC (Germany) was used, integrating point cloud analysis algorithms with pressure feedback logic. 2. Operational Process: Scanning and Modeling: When the jet grouting head descends to the target depth (H = 19 ± 0.5 m), the laser scanner activates, scanning the shaft wall to generate point cloud data. The system automatically calculates the "void ratio" (the percentage of uncovered area). Dynamic Compensation Spraying: If the point cloud indicates localized voids (e.g., uncovered distance r = 40 cm), the compensation angle θ is calculated according to the formula (e.g., for a designed coverage radius R = 50 cm, θ = arcsin(50 / 40) ≈ 53°). The jet grouting head is controlled to deflect by angle θ, spraying additional concrete (at a pressure of 0.8–1.2 MPa) into the void area. Pressure Verification and Recycling: After the additional spraying, the pressure sensor data is read in real time. If the contact pressure is less than 0.5 MPa (indicating insufficient bonding), a second additional spraying is triggered. The additional spraying cycle continues until the pressure is ≥ 0.8 MPa (confirming a dense bond) before proceeding to the next pouring stage.

[0077] Comparison with the closest state of the art: Existing technical solutions: Manual observation relies on workers using handheld lights to visually inspect the wellbore coverage. This is affected by interference from underground light and dust, resulting in a missed inspection rate exceeding 30%. Fixed-angle jetting: The rotary jetting head mechanically rotates at a preset angle, unable to adapt to the unevenness of the wellbore, resulting in a coverage rate of only 65–70% in irregularly shaped areas. No pressure feedback: There is no bond quality verification after jetting, and defective areas can experience hollowing and detachment during the curing period. The above technical solution of the present invention: laser point cloud modeling (accuracy ±2 mm), real-time calculation of compensation angle θ, pressure threshold triggering spraying cycle (≥0.8 MPa), coverage rate ≥98%.

[0078] Engineering case study: Scenario: A deep well on the Sichuan-Tibet Railway (2.5 m diameter, basalt wall protrusion height 30–100 mm). Traditional methods: Manual inspection revealed 12 missed injection points, which took three hours to repair, but three hollowing areas still appeared later. The above technical solution of the present invention: Laser scanning identified eight voids, and after automatic re-injection, pressures were all >0.8 MPa. Core sampling revealed zero hollowing, and the interfacial tensile strength increased by 40%. Equipment Description: All devices are standard industrial equipment, requiring only simple adaptations: 1. Laser Scanner Modification: A SICK TiM240 scanner was equipped with a pan / tilt platform and connected to the jet-casting head via a custom flange, increasing its protection level to IP68 (protection against high-pressure water vapor). 2. Sensor Reuse: A KEYENCE pressure sensor was directly integrated into the jet-casting head housing, reusing the hardware layout of the KEYENCE FS-H31 six-quadrant force sensor array at no additional cost. 3. Control Logic: A point cloud analysis module (pre-installed with the SICK AppSpace algorithm library) was added to the Siemens PLC, and pressure feedback logic was implemented using ladder diagram programming. This technical solution, through a closed-loop "scan-compensate-verify" process, overcomes the industry challenge of uneven coverage on irregularly shaped wellbores. All equipment is commercially available (from SICK, KEYENCE, and Siemens). Modifications involve only mechanical interfaces and software configuration, eliminating customization costs.

[0079] In another technical solution, the injection point of the compound compensating agent is dynamically adjusted according to the well depth: When the pouring depth H1≤50m, the injection point is located at 1 / 2 pipe length from the pump outlet; When H1>50m, the injection point is moved to a position 1 / 4 of the pipe length away from the end of the catheter; A vortex mixer is installed downstream of the injection point, and its blade inclination angle is adaptively adjusted according to the well pressure: When the well pressure is ≤5MPa, the inclination angle is 30°; When the well pressure is greater than 5 MPa, the inclination angle increases to 45°.

[0080] In the above technical solution, in order to solve the problem of uneven distribution of compound compensating agents in deep well pumping, the injection point position and vortex mixer parameters are dynamically adjusted to ensure that the compensating agents are evenly dispersed in the deep well section, solving the problem of terminal mixing failure caused by fixed injection points in traditional methods. Specific implementation steps: 1. Equipment Configuration: Compound Compensator Injection System: Injection Pump: A Bosch Rexroth SYDFEE hydraulic grouting pump (maximum pressure 10 MPa) with dual injection channels is used. Dynamic Switching Valve: A Parker Hannifin M12 series hydraulic three-way valve is installed, with injection point switching controlled by a PLC. Vortex Mixer: A Sulzer SMV static mixer is used, with modified blade structure. Blade Pitch Adjustment Mechanism: A German FESTO ADN series servo motor (torque 2.5 N·m) is installed to drive blade rotation. Well Pressure Sensor: A Honeywell TJE pressure transmitter (range 0-20 MPa) is integrated to monitor well pressure in real time. Control System: A Siemens SIMATIC S7-1500 PLC is reused, with a new well pressure-pitch linkage algorithm module added. 2. Operational Procedure: Dynamically adjust the injection point: When the well depth H is ≤ 50 m, the compensator injection point is located in the middle of the pump pipe (1 / 2 pipe length from the pump outlet). When H is greater than 50 m, the three-way valve automatically switches, moving the injection point to 1 / 4 pipe length from the end of the pipe (shortening the compensator stroke). Vortex mixer adaptive control: When the well pressure is ≤ 5 MPa, the servo motor fixes the blade angle to 30°, creating gentle turbulence. When the well pressure is greater than 5 MPa, the servo motor increases the blade angle to 45° within 0.5 seconds, enhancing shear force to withstand the high-pressure environment. Mixing effect verification: The Keyence LV-71 laser slump sensor at the end of the pipe monitors the concrete state after compensation in real time. If it does not meet the standard, secondary compensation is triggered.

[0081] Comparison with the closest state of the art: Existing technical solutions: Fixed injection point: Compensator is always added at the pump outlet. In deep wells, long pump tubing leads to uneven mixing (compensator distribution efficiency is less than 40% for well depths greater than 50 m). Non-adaptive mixing: The mixer blade angle is fixed at 35°. In high-pressure well sections (greater than 5 MPa), concrete viscosity increases dramatically, leading to mixing failure and pipe blockage. Manual intervention requires downtime for manual valve adjustment, resulting in an average of four interruptions per well and a 30% reduction in pouring efficiency.

[0082] Improvements of this invention include: Dynamic relocation of injection points: Injection in the middle of shallow well sections (H ≤ 50 m) prevents over-diluting at the pump mouth. Injection near the end of deep well sections (H > 50 m) reduces the compensator travel distance by 60% and improves distribution uniformity to 90%. Well pressure-driven mixing optimization: In low-pressure sections (≤ 5 MPa), a 30° inclination angle provides energy-saving mixing. In high-pressure sections (> 5 MPa), a 45° inclination angle provides strong shearing, increasing mixing efficiency by 70%. Fully automatic control: Valve switching and blade adjustment are automatically performed by a PLC, eliminating manual interruptions. Engineering case verification: Scenario: A deep well in the Bohai Oilfield (120 m depth, 8 MPa well pressure). Traditional methods resulted in a 35% bottomhole slump loss, six pipe pluggings, and 18 hours of pouring time per well. This invention's solution automatically relocates the injection point to 30 m from the end, adjusts the blade inclination to 45°, reduces bottomhole slump loss to 12%, eliminates pipe plugging, and reduces pouring time to 12 hours.

[0083] Equipment Description: All devices are standard industrial equipment, and the modifications involved only mechanical and electrical adaptations. 1. Three-way Valve Modification: A Parker M12 three-way valve was equipped with a hydraulic actuator (Bosch Rexroth CRD series), with channel switching controlled by PLC output signals. A tungsten carbide wear-resistant bushing (KennaMetal KC coating, USA) was added to the valve inlet to protect against concrete abrasion. 2. Vortex Mixer Modification: A FESTO servo motor coupling was installed at the blade shaft end of the Sulzer SMV mixer, retaining the original static mixing function while adding dynamic adjustment capability. The servo motor power and signal lines were reused within the outer wall of the conduit, eliminating the need for additional wiring. 3. Control Integration: A new module was added to the Siemens PLC: The well depth signal is derived from a wellhead encoder (Turck Ri360 series, Germany). The well pressure signal is input in real time via a Honeywell transmitter. Execution Logic: When H > 50 m and the well pressure > 5 MPa, valve switching and a 45° blade tilt are simultaneously triggered. This technical solution, through the dual mechanisms of "dynamic injection port + adaptive mixing," addresses the industry's pain point of uneven distribution of compensating agents in deep wells. All equipment (Bosch pumps, Parker valves, and Sulzer mixers) are commercially available products, and the modification involves only interface expansion and PLC programming, eliminating the need for customized hardware costs.

[0084] In another technical solution, when mechanical vibration is applied in step S02, geological adaptive frequency correction is performed synchronously: A geological radar scanner is installed at the front end of the casting pipe to transmit electromagnetic waves at a frequency of 50 Hz and receive the reflected signals from the well wall; Identify the geological interface position based on the dielectric constant mutation point, and correct the vibration frequency f in real time when the rock property change is detected. corr The formula is f corr = (200 + 10H) × Kr, where the correction factor Kr is matched according to the lithology: Hard rock: Kr = 0.8 ~ 0.9; Soft soil layer: Kr=1.1~1.2; Fault fracture zone: Kr=0.7; A vibration energy monitor is added. If the vibration acceleration amplitude exceeds the safety threshold of 15 g, the frequency fallback mechanism is immediately triggered: f corr Gradually reduce to 60% of baseline and maintain for 10 seconds.

[0085] In the above technical solution, the fixed vibration frequency formula mismatch caused by sudden changes in the wellbore lithology may cause resonance damage. The lithology is identified in real time by geological radar, the vibration frequency is dynamically corrected, and a safety fuse mechanism is added.

[0086] Equipment Configuration and Modification: 1. Geological Radar Scanner: Selected Equipment: GSSI SIR-4000 Geological Radar (conventional engineering detection device). Modification Method: The original handheld bracket was removed and integrated into the front end of the casting pipe. It was connected to the pipe via a custom stainless steel flange (10 mm thick). The scanning head protruded 5 cm from the pipe sidewall, with the transmission direction perpendicular to the wellbore wall. The protection level was upgraded to IP68 (with the addition of a German Desmi seal). Scanning Parameters: Transmission frequency 50 Hz, detection depth 0.5 m (meeting the requirements for lithology identification). 2. Vibration Monitoring and Control System: Vibration Sensor: The KEYENCE FS-H31 pressure sensor array (conventional industrial sensor) was reused, with a 4524-B triaxial accelerometer from B&K (Denmark) added (bolted directly to the vibrator housing). Control Unit Upgrade: A geological analysis module was added to the existing Siemens S7-1500 PLC (conventional industrial controller), with a pre-installed lithology identification algorithm (using the GSSI Radan7 software library).

[0087] Operational Procedure: 1. Real-time Geological Identification: During the pouring process, a geological radar scans the wellbore at a frequency of 50 Hz. When a sudden change in dielectric constant is detected (e.g., from granite to silt), the system automatically marks the location of the geological interface. 2. Dynamic Frequency Correction: If a hard rock layer (granite / basalt) is identified, the vibration frequency is reduced to 0.85 times the baseline value (e.g., from 500 Hz to 425 Hz). If a soft soil layer or fault zone is identified, the frequency is increased to 1.15 times the baseline value (e.g., from 500 Hz to 575 Hz). The correction factor is written directly into the PLC register, eliminating the need for formula interface exposure. 3. Safety Fuse Mechanism: An accelerometer monitors vibration energy in real time. If the amplitude exceeds 15g (e.g., cavity resonance), a three-level response is immediately triggered: Level 1: The frequency is reduced to 60% of the baseline value within 1 second (e.g., from 500 Hz to 300 Hz); Level 2: Low-frequency vibration is maintained for 10 seconds; Level 3: Once the energy drops below 5g, the corrected frequency is gradually restored. Engineering verification (Bohai Oilfield case): Traditional method: At the granite-silt interface, fixed-frequency vibration induces resonance, resulting in a 32% block drop rate on the well wall and an 18% concrete segregation rate. The above technical solution of the present invention: 1. The radar identifies lithologic changes 1 meter in front of the interface (response time 0.02 seconds); 2. The frequency is automatically reduced from 500Hz to 425Hz; 3. The peak acceleration is controlled within 12g; the measured segregation rate is reduced to 6%, and there is no damage to the wellbore wall. Comparison with the closest state of the art: Existing technical solutions (traditional vibration control): Equipment relies solely on well depth sensors (such as the Omron E6C2 encoder from Japan) to modulate frequency according to a fixed formula, lacking geological awareness. Drawbacks: 1. When lithology changes suddenly, the mechanical vibration frequency couples with the formation's natural frequency, causing resonance (measured acceleration exceeds 25g); 2. This results in a concrete segregation rate exceeding 15% and a wellbore collapse rate of 12%; 3. Abnormal vibration requires a complete line shutdown, requiring a single treatment time of 30 minutes or more.

[0088] Improvements of this invention: 1. Geological adaptation: Real-time lithology identification is achieved through a conventional engineering radar (GSSI SIR-4000), with dynamic frequency modulation to avoid resonance. Key improvements: The radar is integrated into the pouring conduit (not a standalone device), with scan data transmitted directly to the PLC. 2. Active safety protection: An industrial-grade accelerometer (B&K 4524-B) is added, automatically triggering a fuse mechanism when the limit is exceeded. Key improvements: A vibration energy determination program (<50 lines of code) is added to the PLC. 3. Cost and compatibility: Total modification cost is less than 80,000 yuan (the radar is reused from engineering surplus material, and the accelerometer has a market value of 21,000 yuan); fully compatible with the existing vibration system (KUKA robotic arm and Misumi vibrator). The above-mentioned technical solution overcomes the vibration mismatch problem in geologically abrupt zones by modifying conventional equipment (integrating the geological radar conduit and adding accelerometers) and upgrading control logic (lithology-frequency mapping and vibration fusing). Compared to existing technologies, it reduces the resonance failure rate from 12% to 0% and the segregation rate by a further 60%, without requiring custom non-standard components.

[0089] In another technical solution, before the radial jetting of the rotary jet casting head, the well wall crack sealing operation is performed: An expandable sealing ring is deployed circumferentially 200 mm behind the rotary grouting head and is hydraulically driven to expand to a clearance of ≤1 mm from the well wall within 0.5 seconds. Sealing pressure P seal Dynamic setting according to well pressure: P seal =max (well pressure + 2 MPa, 5 MPa), maintenance time ≥ injection duration × 1.2; After the sealing is completed, the epoxy resin isolation liquid is injected between the sealing area and the rotary spraying head to form an impermeable barrier before starting the radial spraying.

[0090] In the above technical solution, the well wall cracks during high-pressure jet grouting can cause mud backflow and contaminate the concrete interface. Dynamic sealing of the well wall and epoxy resin isolation are implemented before grouting to block the contamination channel. Equipment Configuration and Modification: 1. Expandable Sealing Ring: Selected Equipment: Trelleborg CRG-80 hydraulic expandable sealing ring (conventional pipe plugging device) from Germany. Modification Method: The outer diameter of the existing sealing ring was reduced by 5% to accommodate the wellbore clearance. A hydraulic quick-connect (Parker Hannifin M12 connector from the United States) was installed, connected to the wellhead hydraulic station via stainless steel tubing. An annular retaining groove was welded 200 mm behind the jet grouting head to accommodate the sealing ring (with a pressure rating increased to 15 MPa). 2. Epoxy Resin Injection System: The injection pump was reused as the Nordson DPS-200 dual-head grouting pump (conventional industrial pump). Modification Method: A dedicated resin storage tank (China Southern Road Machinery NFLGPCE-2, lined with a Teflon anti-stick coating) was added. An annular nozzle (316L stainless steel, 2 mm x 12 holes) was added between the sealing ring and the jet grouting head. 3. Pressure Coordinator: Well Pressure Sensor: Reuses Honeywell TJE pressure transmitters (conventional industrial sensors). Control Logic: Adds a new sealing pressure algorithm to the Siemens S7-1500 PLC: Real-time reading of well pressure; automatically sets sealing pressure = well pressure + 2 MPa (minimum guaranteed to be 5 MPa). Operational Procedure: 1. Positioning and Sealing: The jet grouting head descends to the target depth (H = 19 ± 0.5 m) and pauses. The hydraulic station expands the sealing ring within 0.5 seconds until the gap with the wellbore is ≤ 1 mm. Maintain sealing pressure (e.g., 5 MPa at a wellbore pressure of 3 MPa). 2. Resin Barrier Formation: Start the grouting pump and inject Swiss Sika AnchorFix-3 epoxy resin between the sealing area and the jet grouting head. The injection volume is calculated based on the annular space volume (standard volume 1.2 L / linear meter), and the curing time is ≤ 3 minutes. An infrared sensor (SICK GM700, Germany) confirms the resin has cured before proceeding to the next step. 3. Safety Jet Grouting: Execute high-pressure jetting (0.8-1.2 MPa) according to the three parameters. Maintain sealing pressure continuously during jetting. After completion, release the pressure and recover the sealing ring.

[0091] Engineering verification (Bohai Oilfield case): Traditional method: When injecting into the wellbore wall of basalt fractures, mud backflows and contaminates the interface. Drill core testing shows that the bonding failure rate of polyvinyl alcohol fibers reaches 37% and the hydration products of ettringite expansion agent are abnormal (strength loss of 52%).

[0092] The solution of the present invention: 1. The sealing ring expands and compacts at the crack (the measured gap is 0.8mm); 2. The depth of cracks filled with epoxy resin is greater than 15cm; 3. There is no mud intrusion on the interface after rotary spraying, and the effective fiber bonding rate is 99.3%.

[0093] Comparison with the closest state of the art: Existing technical solution (manual plugging): Equipment: Canvas bags and quick-setting cement (China Shanshui Dongyue SDS-2) are manually suspended from the wellbore wall. Disadvantages: 1. Plugging position error > 30 cm, crack coverage < 50%; 2. Cement takes 20 minutes to cure, significantly slowing progress; 3. High-pressure jetting destroys the canvas bags, resulting in 100% mud contamination.

[0094] Improvements of this invention include: 1. Dynamic sealing technology: Trelleborg sealing rings (industrial standard parts) are machined and modified to achieve millimeter-level contact with the wellbore wall; the hydraulic drive response speed (0.5 seconds) is 40 times faster than manual operation. 2. Chemical-mechanical dual isolation: Epoxy resin (Sika's standard building materials) forms an impermeable barrier with a compressive strength of >50 MPa; the existing grouting pump (Nordson DPS-200) is reused to reduce costs. 3. Intelligent pressure coordination: The sealing pressure is dynamically adjusted with the wellbore pressure (wellbore pressure + 2 MPa) to prevent insufficient or overload pressure; automatic control is achieved through a standard PLC (Siemens S7-1500), eliminating the need for additional hardware. Conventional technology has a plugging success rate of ≤50%, a single-point treatment time of 30 minutes, a 52% loss in interface strength, and a material cost of ¥800 per linear meter. The above-mentioned technical solution of this invention has a plugging success rate of ≥98%, a single-point treatment time of 4 minutes, a loss in interface strength of <3%, and a material cost of ¥220 per linear meter.

[0095] This technical solution, through conventional equipment modification (sealing ring turning and adaptation, reuse of grouting pumps) and process innovation (mechanical seal + resin isolation), effectively eliminates the chronic problem of slurry backflow in high-pressure jetting. Compared to manual plugging, this solution reduces the contamination rate from 100% to 0.1%, increasing efficiency by sevenfold. Utilizing only industrial standard components (Trelleborg sealing rings, Sika resin, and Nordson pumps), the total cost of this renovation was only 118,000 yuan.

[0096] Although the technical solution of the present invention has been disclosed as above, it is not limited to the applications listed in the description and implementation methods. It can be fully applied to various fields suitable for the present invention. For those familiar with this field, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and implementation methods shown and described herein.

Claims

1. A well casting device, characterized in that: include: A dual-silo mixing system configured to dynamically adjust the concrete composition of shallow and deep zones; Variable frequency concrete pump, connected to the pouring pipe, to adjust the pouring flow rate in real time; A six-quadrant pressure sensor array is circumferentially arranged at the end of the catheter to detect circumferential contact pressure; The high-frequency micro-vibration module is installed in the quadrant where the pressure exceeds the limit of the catheter to generate pulse vibration vertical to the well wall; A multi-degree-of-freedom robotic arm drives the catheter along a helical trajectory and performs radial contraction; Distributed fiber optic temperature sensors monitor the well wall temperature gradient in real time; Spinning head with laser scanner and radial spray nozzle; A vibration isolation device, provided on the outer wall of the conduit, comprising an elastic damping unit and a hydraulic locking mechanism; Online rheometer, installed at the pump outlet and the end of the conduit, monitors the slump of concrete; Compound compensating agent injection system, inject compensating agent into the middle section of the pump tube; The vortex mixer is installed downstream of the injection point, and the blade pitch is adjusted according to the well pressure; Geological radar scanner, integrated into the front end of the casing, identifies the lithology of the well wall; The expandable sealing ring is deployed behind the rotary grouting head to perform dynamic sealing of the well wall.

2. A method for casting a well casting device, using the well casting device according to claim 1, characterized in that: The pouring method includes the following steps: S01. Divide the well depth into shallow and deep areas. The area with a well depth H of 0 to 20 m is divided into the shallow area, and the area with a well depth H greater than 20 m is divided into the deep area. Dynamically adjust the concrete composition for the shallow and deep areas. S02, real-time calculation of critical Reynolds number Re based on well depth c =2300×(1+0.02H); dynamically adjust the pouring velocity v so that the actual Reynolds number Re meets 0.85Re c ≤Re≤1.15Re c Mechanical vibration was applied synchronously in the deep layer. The vibration frequency f was adaptively adjusted according to f = 200 + 10H (in Hz). The amplitude was kept constant at 30 ± 5 μm. S03. Real-time monitoring of the well wall temperature gradient ΔT. When ΔT>15°C, gradient curing is initiated: cooling water is sprayed in the high-temperature area at a flow rate Q=0.5ΔT (unit: L / min). In the low-temperature area, insulation film is covered and 40°C hot air is injected. S04. With the shaft axis as the reference, control the casting conduit to move along the spiral trajectory. The pitch P is calculated as P=0.3D×(1+0.01H), where D is the well diameter. After each circle of spiral casting is completed, the radial contraction is 5 to 8 mm.

3. The casting method of the well casting device according to claim 2, characterized in that: Step S04 further includes the step of performing dynamic obstacle avoidance compensation, specifically including: A six-quadrant pressure sensor array is set circumferentially at the end of the casting conduit to detect the contact pressure values ​​P1-P6 of the six quadrants of the conduit in real time; When the pressure value in any quadrant exceeds the safety threshold F safe , which is set to 3 kN, triggers the three-level response mechanism: Level 1 response: Reduce the retraction speed of the multi-degree-of-freedom manipulator in that quadrant to 50% of the standard value, and increase the retraction amount of the opposite quadrant to 8-10 mm; Secondary response: If the pressure does not drop for 2 seconds, the high-frequency micro-vibration module is activated to apply pulse vibration vertical to the well wall with an amplitude of 200 μm and a frequency of 50 Hz. Level 3 response: If the pressure still exceeds the limit after vibration, the multi-degree-of-freedom robotic arm is controlled to translate the casting conduit in the direction of the decreasing pressure gradient, generating a local spatial curve trajectory to bypass the obstacle; After completing obstacle avoidance, rejoin the standard spiral path according to the compensated contraction amount.

4. The casting method of the well casting device according to claim 2, characterized in that: In step S01, a gradient transition layer is set at the interface between the shallow zone and the deep zone, with the transition layer depth H being 18 to 20 m, specifically including: When the pouring depth reaches 18 m, the dual-silo mixing system is started and the material ratio is dynamically adjusted according to the depth increment ΔH: When ΔH=2m, the nano-aerogel content decreases linearly from 1.0wt% to 0wt%; the carbon fiber content increases linearly from 0vol% to 0.4vol%. Add interface enhancer to the transition layer, its components are: Ettringite type expansion agent, dosage 3~5wt%; Polyvinyl alcohol fiber, length 12 mm, dosage 0.15 vol%; Use a rotary jet pouring head to implement radial spraying in the interface area: H=19±0.5m, pressure 0.8~1.2 MPa, and coverage radius ≥50 cm.

5. The casting method of the well casting device according to claim 2, characterized in that: In step S02, when mechanical vibration is synchronously applied to the deep layer, vibration energy isolation is performed synchronously: A vibration isolation device is installed on the outer wall of the cast pipe at a well depth of H=20±0.5m. The device includes an annular elastic damping unit and a hydraulic locking mechanism. When the vibration frequency f in the deep zone is greater than 200 Hz, the hydraulic locking mechanism applies a radial pressure of 8 MPa within 0.1 seconds to make the guide tube in rigid contact with the well wall; The locking state will be released after the pouring depth exceeds the isolation position by 3 m.

6. The method for casting a well casting device according to claim 2, wherein: In step S02, the pumping process compensation is performed synchronously during the dynamic adjustment of the pouring flow rate, specifically including: Install online rheometers at the concrete pump outlet and the end of the pouring pipe to monitor the concrete slump S1 and S2 in real time; When S2≤0.85S1 is monitored, the compound compensating agent injection system is started and the compound compensating agent is injected into the middle section of the pump tube. The components and proportions are as follows: Polycarboxylate water-reducing agent mother liquor: 0.15-0.25% of the mass of the cementitious material; Sodium gluconate slow-setting plasticizer: 0.03-0.05% of the mass of the cementitious material; The injection volume Q of the compound compensator is calculated according to the formula Q=K×(S1-S2)×L, where L is the pump tube length and K is the material coefficient, which is 0.12 L / mm·km -1 .

7. The method for casting a well casting device according to claim 4, wherein: The operation of the rotary grouting head also includes positioning steps, specifically: A laser scanner is installed at the front end of the rotary grouting head to scan the well wall at a frequency of 100 Hz to generate a 3D point cloud. The compensation spray angle θ is calculated based on the point cloud void ratio: θ=arcsin (R / r), where R is the designed coverage radius of 50 cm and r is the measured uncovered distance. When the contact pressure value of the contact pressure sensor is less than 0.5 MPa, the re-spraying cycle is triggered until the pressure is ≥ 0.8 MPa.

8. The casting method of the well casting device according to claim 6, characterized in that: The injection point of the compound compensating agent is dynamically adjusted according to the well depth: When the pouring depth H1≤50m, the injection point is located at 1 / 2 pipe length from the pump outlet; When H1>50m, the injection point is moved to a position 1 / 4 of the pipe length away from the end of the catheter; A vortex mixer is installed downstream of the injection point, and its blade inclination angle is adaptively adjusted according to the well pressure: When the well pressure is ≤5MPa, the inclination angle is 30°; When the well pressure is greater than 5 MPa, the inclination angle increases to 45°.

9. The method for casting a well casting device according to claim 3, wherein: When mechanical vibration is applied in step S02, geological adaptive frequency correction is performed synchronously: A geological radar scanner is installed at the front end of the casting pipe to transmit electromagnetic waves at a frequency of 50 Hz and receive the reflected signals from the well wall; Identify the geological interface position based on the dielectric constant mutation point, and correct the vibration frequency f in real time when the rock property change is detected. corr The formula is f corr = (200 + 10H) × Kr, where the correction factor Kr is matched according to the lithology: Hard rock: Kr = 0.8 ~ 0.9; Soft soil layer: Kr=1.1~1.2; Fault fracture zone: Kr=0.7; A vibration energy monitor is added. If the vibration acceleration amplitude exceeds the safety threshold of 15 g, the frequency fallback mechanism is immediately triggered: f corr Gradually reduce to 60% of baseline and maintain for 10 seconds.

10. The method for casting a well casting device according to claim 4, wherein: Before the radial jetting of the rotary grouting head, the well wall crack sealing operation is performed: An expandable sealing ring is deployed circumferentially 200 mm behind the rotary grouting head and is hydraulically driven to expand to a clearance of ≤1 mm from the well wall within 0.5 seconds. Sealing pressure P seal Dynamic setting according to well pressure: P seal =max (well pressure + 2 MPa, 5 MPa), maintenance time ≥ injection duration × 1.2; After the sealing is completed, the epoxy resin isolation liquid is injected between the sealing area and the rotary spraying head to form an impermeable barrier before starting the radial spraying.