Remote quality control method and system for concrete in mixer truck tank

Abstract

The invention discloses a remote quality control method and system for concrete in a mixer truck tank, and aims to solve the problems of lack of state monitoring in concrete transportation, inaccurate metering of on-site admixture addition and high manual operation intensity. The system comprises a monitoring module, a control module and an additive adding system. The monitoring module acquires concrete video stream data through the in-tank monitoring unit and the unloading monitoring unit, and acquires mixing drum parameters in combination with the operation monitoring unit; the control module analyzes the video data to determine a slump value, and generates a control command containing an accurate addition amount; and the additive adding system automatically completes adding of additives inside and outside the tank according to the control command. According to the system, the concrete state can be remotely monitored in the transportation process, the additive adding precision is improved, the manual labor intensity is reduced, and stable concrete construction quality is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of concrete quality monitoring, and in particular to a method and system for remote quality control of concrete inside a mixer truck. Background Technology

[0002] Today, concrete has become one of the most widely used building materials, playing an irreplaceable role in the construction industry. Among them, ready-mixed concrete has the most applications, ranging from civil and rural buildings to urban infrastructure construction such as railways, highways, bridges, and tunnels. It plays a significant role in today's rapidly developing modern cities and the resettlement of large populations, making the quality of ready-mixed concrete particularly important.

[0003] Ready-mixed concrete requires a significant amount of transportation time between production and pouring. During this period, the concrete's workability gradually declines as the cement hydration reaction progresses, a phenomenon known as slump loss over time. Therefore, regulations typically stipulate that concrete mixer truck travel time should not exceed 1.5 hours. However, unavoidable emergencies such as traffic jams and construction site queues can occur, making it difficult to monitor changes in the concrete's workability during transportation and waiting.

[0004] After concrete arrives at the construction site, if admixtures are needed to adjust workability, the traditional method requires workers to manually determine whether and how much to add, then fill containers with the admixtures and climb onto the mixer truck's hopper to pour them in. On the one hand, manual judgment lacks precise data support, making accurate measurement of admixture dosage difficult and prone to quality fluctuations; on the other hand, the manual climbing method significantly increases labor intensity, making the process cumbersome and inefficient. For a long time, the inability to remotely monitor the concrete's working condition during transportation, inaccurate on-site admixture measurement, and the high intensity of manual labor have consistently affected the stable control of ready-mixed concrete construction quality. Summary of the Invention

[0005] In view of the above problems, the present invention provides a method and system for remote quality control of concrete in a mixer truck, which solves the problems of the inability to remotely monitor the working status of concrete during transportation, inaccurate metering of admixtures added on site, and high manual labor intensity.

[0006] To achieve the above objectives, in a first aspect, this application provides a remote quality control system for concrete inside a mixer truck. The mixer truck is equipped with a mixing drum, a feeding hopper, a rear suspension, a drive system, and a discharge system. The mixing drum is used for loading and mixing concrete. The feeding hopper is located above the mixing drum and communicates with the mixing drum through a feeding port. The rear suspension is located at the rear of the mixer truck and is used to support the discharge system. A mixing shaft is provided inside the mixing drum and is connected to the drive system for controlling the rotation of the mixing drum under the drive of the drive system.

[0007] The system includes:

[0008] The monitoring module includes:

[0009] The tank monitoring unit includes a first camera component, which is disposed between the feed hopper and the mixing drum or on the inner wall of the feed hopper, and is used to collect first video stream data of the concrete inside the mixing drum;

[0010] The unloading monitoring unit includes a second camera component, which is mounted on the rear suspension of the vehicle and is used to collect second video stream data of the concrete at the unloading port of the unloading system.

[0011] The operation monitoring unit includes a forward and reverse rotation sensor, which is installed at the rotating shaft of the stirring drum to detect the rotation direction and speed of the stirring drum.

[0012] The control module includes an image analysis unit and an instruction control unit. The image analysis unit is used to analyze the first video stream data to determine the first slump value of the concrete in the mixing drum and to analyze the second video stream data to determine the second slump value of the concrete at the discharge port. It also determines whether the difference between the first slump value and the second slump value exceeds a preset error. If so, it generates an addition control command based on the difference between the two values. The addition control command includes the amount of admixture to be added.

[0013] An admixture addition system includes:

[0014] The storage tank unit includes an admixture storage tank, and a water pump is installed inside the storage tank;

[0015] The dosage control unit is connected to the storage tank and the stirring drum via a water pipe. It controls the amount of admixture added according to the addition control command and delivers the corresponding dose of admixture to the stirring drum via the water pump.

[0016] Furthermore, the tank-in-tank monitoring unit also includes:

[0017] A bracket is provided, on which the first camera component is placed. A transparent mudguard is also connected to the bracket, and the transparent mudguard is positioned in front of the lens of the first camera component.

[0018] The telescopic mechanism includes a telescopic rod and a drive motor. The telescopic rod is connected to the bracket for transmission and is used to control the depth to which the first camera assembly extends out of or into the stirring drum under the drive of the drive motor.

[0019] A supplementary light includes a light source and a control switch. The control switch is used to control the light source to turn on and off, and the control switch is electrically connected to the control module.

[0020] Furthermore, the storage tank unit includes multiple admixture storage tanks, each storage tank is equipped with a level gauge, and the outlet pipeline of each storage tank is equipped with a solenoid valve. The level gauge, the solenoid valve and the control module are electrically connected.

[0021] When the level gauge detects that the level of the admixture in the storage tank is less than the preset height or less than the amount of admixture to be added as specified in the current addition control command, the control module automatically switches to the backup storage tank via the solenoid valve and issues a prompt message.

[0022] Furthermore, the mixer truck also includes a cab, and the system also includes a display module, which is disposed in the cab;

[0023] The display module is used to dynamically adjust and display relevant parameter information of the concrete in the mixer truck according to the alarm level. The relevant parameter information includes any one or more of the following: admixture addition amount, rotation direction and speed of the mixing drum, first slump value, second slump value, difference between the first slump value and the second slump value, first video stream data, and second video stream data.

[0024] Furthermore, the system also includes:

[0025] The positioning module is used to obtain the current geographical location information of the mixer truck in real time;

[0026] The time detection module is used to monitor the mixing duration or transit time of concrete in the mixing drum in real time. The transit time is the time from when the concrete is put into the mixing drum to when the mixer truck arrives at the destination.

[0027] The control module also includes a vehicle status determination unit, which is used to determine the current vehicle status information based on the current geographical location information, mixing duration information, and on-the-way duration information of the mixer truck. The status information includes any one of the following: resting status, waiting to leave the factory status, on-the-way status, arrived status, unloading status, and return status.

[0028] Furthermore, the system also includes:

[0029] The control module is also used to adjust the amount of admixture added, the speed of admixture addition, the rotation speed and direction of the mixing drum according to the operation command input by the user after receiving the operation command. After receiving an alarm event, it generates corresponding log information and uploads it to the cloud. The log information includes the current driving parameter information of the mixer truck, operation command record information, vehicle status information of the mixer truck, and the current geographical location information, mixing duration information and travel time information of the mixer truck.

[0030] The alarm event is triggered based on any of the following:

[0031] The current travel time of the mixer truck exceeds the preset travel time threshold;

[0032] The mixing drum of the current mixer truck is reversing for a duration exceeding the preset reversing time threshold.

[0033] The mixer truck is currently unloading material and the additives have been added.

[0034] Furthermore, the system also includes:

[0035] The control module is located on the cloud server.

[0036] The monitoring module and the admixture addition unit are installed on the mixer truck, which is also equipped with a communication unit. The control module is connected to the communication module.

[0037] In a second aspect, this application provides a method for remote quality control of concrete inside a mixer truck tank, applicable to the remote quality control device for concrete inside a mixer truck tank as described in the first aspect of this application, the method comprising the following steps:

[0038] The first camera component acquires the first video stream data of the concrete inside the mixing drum, and the second camera component acquires the second video stream data of the concrete at the unloading port of the unloading system.

[0039] The image analysis unit analyzes the first video stream data to determine the first slump value of the concrete in the mixing drum and analyzes the second video stream data to determine the second slump value of the concrete at the discharge port.

[0040] The command control unit determines whether the difference between the first slump value and the second slump value exceeds a preset error. If so, it generates an addition control command based on the difference between the two, and the addition control command includes the amount of admixture to be added.

[0041] The dosage control unit delivers the corresponding dose of admixture to the mixing drum via the water pump.

[0042] Furthermore, an IMU sensor is also installed inside the stirring tank. The IMU sensor is used to collect IMU attitude data, including roll angle and rotational speed. At least three positioning markers are also provided on the inner wall of the stirring tank, and these positioning markers are spaced apart on the inner circumference of the tank opening.

[0043] The image analysis unit analyzes the first video stream data to determine the first slump value of the concrete currently inside the mixing drum, and analyzes the second video stream data to determine the second slump value of the concrete at the discharge port, including:

[0044] Using at least three positioning markers preset on the inner wall of the stirring drum as reference corner points, an affine transformation matrix is ​​constructed based on the pixel displacement of the reference corner points between adjacent video frame images in the first video stream data or the second video stream data. The video frame images are then redirected according to the affine transformation matrix to obtain the redirected video frame images.

[0045] In the redirected video frame image, a region of interest is defined on the concrete surface, and video features corresponding to the concrete are extracted from the region of interest. The video features include the wave wavelength of the concrete surface ripples, the aggregate settlement gradient, and the flow motion vector.

[0046] The video features are input into the trained neural network model, which outputs the initial slump value of the concrete in the mixing drum. The initial slump value is corrected using formula (1) to obtain the final slump value. Formula (1) is as follows:

[0047] S final =S pred ×(1+a×rpm / rpm base )+b×sin(θ);

[0048] Among them, S final For the final slump value, S pred This is the initial slump value, and rpm is the current rotational speed of the mixing drum. base The reference speed is set, a and b are experimental calibration parameters, the value range of a is [0.02, 0.05], the value range of b is [2, 5], and θ is the roll angle;

[0049] The collapse value after smoothing is output at a preset time period as the collapse value obtained from analyzing the first video stream data or the second video stream data, and the confidence level is marked.

[0050] Furthermore, the neural network model is a 3D-CNN network model. The video features are input into the trained neural network model, and the output of the preliminary slump value of the concrete in the mixing drum includes:

[0051] The 3D-CNN network model performs the following steps:

[0052] The continuously extracted surface ripple wavelengths, aggregate settling gradients, and flow motion vectors are aligned according to time steps to form a temporal feature matrix with a dimension of T×3, where T is the number of video frames. The feature dimensions are then standardized to obtain the standardized temporal feature matrix.

[0053] The standardized temporal feature matrix is ​​processed through a bidirectional LSTM layer to extract temporal dependent features, and then weighted by an attention mechanism to output the first-dimensional feature vector. The region of interest is then passed through a dilated convolutional layer and a spatiotemporal GRU layer in sequence to output the second-dimensional feature vector.

[0054] The first-dimensional feature vector and the second-dimensional feature vector are concatenated to obtain a fused feature vector. The fused feature vector is then input into a fully connected network. After regularization processing involving random neuron discarding, a preliminary collapse prediction value is output.

[0055] Furthermore, before acquiring the first video stream data, the method further includes:

[0056] A reference image of the calibration board is captured by the first camera component, and the sharpness index Q of the reference image is calculated. clarity and stain coverage R dirt ;

[0057] The clarity index Q clarity The variance is calculated using the Laplace method, and the formula is as follows:

[0058]

[0059] Where I is a grayscale image, For the Laplace operator;

[0060] The stain coverage R dirt The area percentage of the dirty region in the reference image;

[0061] When preset cleaning conditions are met, a cleaning alarm is triggered on the first camera component, and the subsequent slump value detection process is paused. The preset cleaning conditions include the sharpness index Q. clarity Less than the preset clarity or stain coverage R dirt Greater than the preset coverage;

[0062] When the preset cleaning conditions are not met, the pixels in the dirty area are masked during subsequent video feature extraction, and only the pixels in the non-dirty area are selected to participate in the collapse analysis and calculation.

[0063] Unlike existing technologies, the above technical solution provides a method and system for remote quality control of concrete inside a mixer truck drum, achieving high-precision dynamic detection by fusing visual and inertial measurement data. Specifically, the method includes: acquiring video streams and IMU attitude data of the concrete inside the mixing drum; detecting at least three preset positioning markers on the inner side of the drum opening; constructing an affine transformation matrix based on the pixel displacement of the markers between adjacent frames; performing motion compensation redirection on the video frames; dynamically delineating the region of interest on the concrete surface in the redirected stable image; extracting surface ripple wavelengths, aggregate settlement gradients, and flow motion vector features; inputting these video features into a trained neural network model to output preliminary slump values; dynamically calibrating the model in conjunction with the drum's motion state; and finally outputting a smoothed slump value with confidence markers. This invention solves the problems of significant interference from drum swaying and measurement lag in traditional methods, and is suitable for real-time quality monitoring during mixer truck operation.

[0064] The above description of the invention is merely an overview of the technical solution of the present invention. In order to enable those skilled in the art to better understand the technical solution of the present invention and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of the present invention easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of the present invention. Attached Figure Description

[0065] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of the present invention and other related contents, and should not be considered as limitations on the present invention.

[0066] In the accompanying drawings of the instruction manual:

[0067] Figure 1 This is a schematic diagram of the modules of the remote quality control system for concrete inside the mixer truck tank involved in a specific implementation method.

[0068] Figure 2 This is a schematic diagram of the overall structure of the mixer truck involved in the specific implementation method;

[0069] Figure 3 This is a schematic diagram of the admixture addition system involved in a specific implementation method;

[0070] Figure 4 This is a schematic diagram of the structure of the tank monitoring unit involved in the specific implementation method;

[0071] Figure 5This is a first flowchart of the remote quality control method for concrete inside a mixer truck tank, as described in a specific implementation.

[0072] Figure 6 This is a second flowchart of the remote quality control method for concrete inside a mixer truck tank, as described in a specific implementation.

[0073] The reference numerals used in the above figures are explained as follows:

[0074] 1. Feed hopper;

[0075] 2. Rear suspension;

[0076] 3. Crossbeam;

[0077] 4. Installation location; 41. Storage tank; 42. Water pump; 43. Storage tank support;

[0078] 5. Stirring drum;

[0079] 6. Stirring shaft;

[0080] 7. Driver's cab;

[0081] 8. Tank-in-tank monitoring unit; 81. Telescopic rod; 82. First camera assembly; 83. First bracket; 84. Second bracket;

[0082] 20. Remote quality control system for concrete inside the mixer truck tank;

[0083] 201. Monitoring module; 2012. Unloading monitoring unit; 2013. Operation monitoring unit;

[0084] 202. Admixture addition system; 2021. Storage tank unit; 2022. Dosage control unit;

[0085] 203. Control module;

[0086] 2031, Image Analysis Unit;

[0087] 2032, Command and Control Unit;

[0088] 2033, Vehicle Status Determination Unit

[0089] 204. Display module;

[0090] 205. Positioning Module

[0091] 206. Time detection module. Detailed Implementation

[0092] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this invention in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this invention and are therefore intended only as examples, not as limiting the scope of protection of this invention.

[0093] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this invention, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0094] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit the invention.

[0095] In the description of this invention, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " generally indicates that the preceding and following objects have an "or" logical relationship.

[0096] In this invention, terms such as “first” and “second” are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy, or order between these entities or operations.

[0097] Without further limitations, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this invention is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0098] In this invention, expressions such as "greater than", "less than", and "exceeding" are understood to exclude the stated number; expressions such as "above", "below", and "within" are understood to include the stated number. Furthermore, in the description of the embodiments of this invention, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times", unless otherwise explicitly specified.

[0099] In the description of the embodiments of the present invention, the spatially related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of the present invention or for the reader's understanding, and do not indicate or imply that the system or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention.

[0100] Unless otherwise explicitly stated or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this invention, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral arrangement; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this invention according to the specific circumstances.

[0101] In the first aspect, such as Figure 1-4 As shown, this application provides a remote quality control system 20 for concrete inside a mixer truck. The mixer truck is equipped with a mixing drum 5, a feeding hopper 1, a rear suspension 2, a crossbeam 3, a drive system, and a discharge system. The mixing drum 5 is used to load and mix concrete. The feeding hopper 1 is located above the mixing drum 5 and is connected to the mixing drum through a feeding port. The rear suspension 2 is located at the rear of the mixer truck and is used to support the discharge system. A mixing shaft 6 is provided inside the mixing drum. The mixing shaft 6 is connected to the drive system and is used to control the rotation of the mixing drum under the drive of the drive system.

[0102] The system includes:

[0103] Monitoring module 201, the monitoring module 201 includes:

[0104] The tank monitoring unit 8 includes a first camera component, which is disposed between the feed hopper and the mixing drum or on the inner wall of the feed hopper, and is used to collect first video stream data of the concrete inside the mixing drum;

[0105] The unloading monitoring unit 2012 includes a second camera component, which is mounted on the rear suspension of the vehicle and is used to collect second video stream data of concrete at the unloading port of the unloading system.

[0106] The operation monitoring unit 2013 includes a forward and reverse rotation sensor, which is installed at the rotating shaft of the stirring drum to detect the rotation direction and speed of the stirring drum.

[0107] The control module 203 includes an image analysis unit 2031 and an instruction control unit 2032. The image analysis unit is used to analyze the first video stream data to determine the first slump value of the concrete in the mixing drum and to analyze the second video stream data to determine the second slump value of the concrete at the discharge port. It also determines whether the difference between the first slump value and the second slump value exceeds a preset error. If so, it generates an addition control command based on the difference between the two values. The addition control command includes the amount of admixture to be added.

[0108] Admixture addition system 202 includes:

[0109] The storage tank unit 2021 includes an admixture storage tank, and a water pump 42 is installed inside the storage tank;

[0110] The dosage control unit 2022 is connected to the storage tank and the stirring drum via a water pipe. It controls the amount of admixture added according to the addition control command and delivers the corresponding dose of admixture to the stirring drum via the water pump.

[0111] During operation, the first camera component of the tank monitoring unit is installed between the feed hopper and the mixing drum or on the inner wall of the feed hopper to collect real-time video stream data of the concrete inside the mixing drum. The second camera component of the unloading monitoring unit is installed on the rear suspension to collect second video stream data of the concrete at the unloading port of the unloading system. Forward and reverse rotation sensors are installed at the shaft of the mixing drum. By sensing changes in the magnetic field of the rotating shaft or using other physical sensing methods, they detect the rotation direction and speed of the mixing drum and transmit this data to the control module.

[0112] After receiving the first and second video stream data, the image analysis unit of the control module uses image recognition algorithms, feature extraction techniques, and machine learning or deep learning-based models (such as convolutional neural networks) to analyze the concrete surface features, texture, and flow state in the video data, thereby determining the first slump value of the concrete in the mixing drum and the second slump value of the concrete at the discharge port. The command control unit obtains these two slump values, calculates their difference, and compares it with a preset error. If the difference exceeds the preset error, the command control unit generates an addition control command based on the difference and a pre-established mathematical model, specifying the amount of admixture to be added.

[0113] Preferably, when calculating the slump value of concrete, the YOLO object detection model is first used to analyze the video stream data to extract images of key areas of the concrete. These images are then fed into a multi-label classification model to perform structured processing on the concrete. Finally, the output of the multi-label classification network is combined with statistical analysis to determine the slump value best suited to the current state of the concrete. The classification label dimensions involved in the multi-label classification model include particle content, particle distribution, image texture boundaries, and moisture content. Particle content includes low, medium, and high levels; particle distribution includes sparse, moderate, and dense levels; image texture boundaries include clear or blurred levels; and moisture content includes dry, moderate, and sparse levels.

[0114] After receiving the addition control command sent by the control module, the dosage control unit of the admixture addition system delivers the corresponding dose of admixture from the admixture storage tank to the mixing drum through the water pipe by controlling the running time, frequency or other flow control methods of the water pump, thereby achieving precise control of the amount of admixture added.

[0115] In this embodiment, slump is a key indicator for measuring the fluidity and workability of concrete. Admixtures for adjusting slump mainly include water reducers, plasticizers, and slump-retaining agents. The conversion formula between slump difference and the dosage of admixtures is as follows:

[0116] Q = (k·ΔS) / (W / C) + C0;

[0117] Where Q represents the amount of admixture added, in kg / m³. 3 or L / m 3; ΔS=∣S1-S2∣, representing the slump difference in mm, where S1 represents the first slump value and S2 represents the second slump value; W / C represents the water-cement ratio, which affects the sensitivity of admixtures and needs to be used as a correction factor; k represents an empirical coefficient (related to the type of admixture and concrete material, and needs to be calibrated and determined); C0 represents the initial compensation amount.

[0118] The aforementioned solution, through the coordinated operation of the in-tank monitoring unit, unloading monitoring unit, and operation monitoring unit, can acquire real-time information on various aspects of the concrete's status during mixing, unloading, and the drum's operation, providing rich data support for a comprehensive understanding of concrete quality. The control module, through analysis of video stream data, accurately determines the concrete's slump value and precisely calculates the admixture dosage based on the slump difference. This effectively adjusts the concrete's performance, ensuring it maintains good workability throughout transportation and unloading, improving concrete quality stability, and reducing engineering quality risks caused by concrete performance issues. The system achieves automated data acquisition and analysis, as well as remote control of admixture addition, reducing manual intervention, significantly improving the efficiency of concrete quality control, and lowering labor costs.

[0119] like Figure 4 As shown, the tank monitoring unit 8 further includes:

[0120] The bracket includes a first bracket 83 or a second bracket 84. The first camera component 82 can be selectively mounted on either the first bracket 83 or the second bracket 84, depending on the vehicle model. Specifically, the second bracket 84 is installed on the inner wall of the feed hopper 1, suitable for all vehicle models. The first bracket 83 is installed in the gap between the feed hopper 1 and the mixing drum 5, suitable for mixer trucks with larger installation space, making installation more convenient. A transparent mudguard is also connected to the first or second bracket, and the transparent mudguard is positioned in front of the lens of the first camera component.

[0121] The telescopic mechanism includes a telescopic rod 81 and a drive motor. The telescopic rod 81 is connected to the bracket for transmission and is used to control the depth to which the first camera assembly 82 extends out of or into the stirring drum under the drive of the drive motor.

[0122] A supplementary light includes a light source and a control switch. The control switch is used to control the light source to turn on and off, and the control switch is electrically connected to the control module.

[0123] During installation, the bracket is securely installed at the predetermined position between the feed hopper and the mixing drum, ensuring the first camera component is aligned with the area to be monitored within the mixing drum. A transparent mudguard is fixed to the bracket using appropriate connection methods (such as clips or screws), ensuring it is positioned in front of the lens of the first camera component, forming an effective protective barrier. During the operation of the mixer truck, when mud, dust, or other impurities splash, the transparent mudguard prevents these impurities from contacting the lens, keeping the lens clean and thus ensuring the clarity of the captured image.

[0124] The telescopic mechanism works as follows: After receiving a control signal from the control module, the drive motor starts and drives the telescopic rod to extend and retract via a transmission device (such as gear transmission, chain transmission, etc.). The extension and retraction of the telescopic rod, in turn, changes the position of the first camera component mounted on it. For example, when it is necessary to observe the concrete at the bottom of the mixing drum more closely, the control module sends a command to make the drive motor rotate forward, the telescopic rod extends, and the first camera component moves closer to the bottom of the mixing drum; when it is necessary to observe the overall situation inside the mixing drum, the control module sends a command to make the drive motor rotate in reverse, the telescopic rod retracts, and the position of the first camera component is adjusted to a suitable height.

[0125] The control module also determines the light intensity of the shooting area using a light sensor or based on preset conditions such as shooting time and the environment inside the mixing tank. When the light intensity is below a set threshold, the control module sends an electrical signal to the control switch of the fill light, closing the switch and turning on the power to the light source, thus illuminating the shooting area. When the light intensity meets the shooting requirements, the control module sends a signal to turn off the control switch, extinguishing the fill light.

[0126] The above solution, by incorporating a transparent mudguard, effectively prevents mud, dust, and other impurities from contaminating the lens of the first camera component, reducing the frequency of lens cleaning and maintenance, extending the lifespan of the camera component, and lowering equipment maintenance costs. Simultaneously, protecting the lens helps ensure that the captured video stream data remains clear and reliable, providing accurate image information for concrete quality analysis.

[0127] The telescopic mechanism allows the first camera component to be flexibly adjusted within the mixing drum according to actual needs, acquiring video stream data from different angles and depths. This helps to observe the mixing process of concrete within the mixing drum, material distribution, and potential quality problems more comprehensively and meticulously, improving the accuracy and comprehensiveness of concrete quality monitoring.

[0128] The supplementary lighting provides ample illumination for filming in low-light conditions, ensuring the primary camera unit functions properly under various lighting conditions and captures clear video images. This allows the system to accurately monitor the state of concrete even at night or in situations with insufficient light inside the mixing drum, guaranteeing the continuity and reliability of concrete quality control.

[0129] In some embodiments, the storage tank unit is located at installation position 4, and the storage tank unit includes multiple admixture storage tanks 41. Multiple storage tanks 41 are mounted on storage tank support 43. Each storage tank 41 is also equipped with a level gauge. The outlet pipeline of each storage tank 41 is equipped with a solenoid valve. The level gauge, the solenoid valve and the control module are electrically connected.

[0130] When the level gauge detects that the level of the admixture in the storage tank is less than the preset height or less than the amount of admixture to be added as specified in the current addition control command, the control module automatically switches to the backup storage tank via the solenoid valve and issues a prompt message.

[0131] In this embodiment, the admixture storage tank can be made of materials such as polyethylene, polypropylene, or stainless steel, depending on the properties of the admixture and the usage requirements. Different types of admixtures (such as water-reducing agents, retarders, and accelerators) are stored in their respective storage tanks, and the connection between different storage tanks and the mixing drum can be switched using solenoid valves to meet the adjustment needs of concrete under different construction conditions and performance requirements. The spare storage tank refers to a tank that stores the same type of admixture and whose liquid level is higher than a preset height.

[0132] A level gauge is installed inside a storage tank to monitor the level of the admixture inside and outside the tank in real time. Common level gauges include magnetic level gauges, float level gauges, and capacitive level gauges. The level gauge detects changes in the liquid level, converts the level information into an electrical signal or other transmittable signal, and transmits it to the control module to promptly monitor the amount of admixture in stock.

[0133] Solenoid valves, installed on the outlet pipes of each storage tank, are electromagnetically controlled valves. The control module sends electrical signals to the solenoid valves to control their opening and closing, thereby controlling the on / off flow of the admixture outlet pipes. When an admixture needs to be added, the control module controls the solenoid valve on the corresponding storage tank's outlet pipe to open, allowing the admixture to be delivered to the mixing drum via the water pipe; when no admixture needs to be added or the type of admixture needs to be changed, the control module controls the solenoid valve to close.

[0134] In practical use, when the control module receives the liquid level signal from the level gauge, it compares it with the preset height or the amount of admixture to be added as specified in the current addition control command. When the level gauge detects that the admixture level in the storage tank is lower than the preset height or the amount required by the current addition control command, the control module immediately sends a closing signal to the solenoid valve on the outlet pipe of the current storage tank and an opening signal to the solenoid valve on the outlet pipe of the backup storage tank containing the same type of admixture, thus automatically switching to the backup storage tank. During the switching process, the control module also sends notification messages via the communication module to the terminal devices (such as mobile phones and computers) of relevant personnel (e.g., mixing plant managers, drivers), informing them of the admixture storage tank switching status and the need for timely admixture replenishment.

[0135] The above-mentioned solution utilizes multiple admixture storage tanks and an automatic switching function. When the admixture level in one tank is insufficient, the system can automatically and quickly switch to a backup tank, ensuring that the admixture addition process is unaffected and continuously providing the necessary admixtures for concrete performance adjustment. This guarantees the stability and continuity of concrete quality control. Through timely level monitoring and the automatic switching mechanism, the risk of admixture addition interruptions due to insufficient stock is effectively avoided, preventing untimely admixture addition from affecting concrete performance, reducing the probability of substandard concrete quality, and improving the reliability of construction projects. The control module sends alerts to relevant personnel, facilitating timely understanding of admixture usage by management personnel, enabling them to rationally plan admixture replenishment, improving the management efficiency of the mixing plant for admixtures, and reducing admixture supply problems caused by human error.

[0136] In some embodiments, the mixer truck further includes a cab 7, and the system further includes a display module 204 disposed within the cab 7;

[0137] The display module 204 is used to dynamically adjust and display relevant parameter information of the concrete in the mixer truck according to the alarm level. The relevant parameter information includes any one or more of the following: admixture addition amount, rotation direction and speed of the mixing drum, first slump value, second slump value, difference between the first slump value and the second slump value, first video stream data, and second video stream data.

[0138] In practical applications, the control module collects various concrete-related data, organizes and processes it, and sends it to the display module via communication lines (such as CAN bus, Ethernet, etc.). Upon receiving the data, the display module displays it on the screen in graphical, numerical, and chart formats according to preset display formats and rules. Simultaneously, the display module dynamically adjusts the displayed content based on the alarm level information sent by the control module. For example, when the slump difference of the concrete exceeds the preset error and is at a high alarm level, the display module will display relevant parameter information (such as slump value, admixture dosage, etc.) in a prominent color (such as red), or alert the driver through flashing, pop-up windows, etc.; when the alarm level is low or there is no alarm, the display module displays the data in normal colors and formats.

[0139] By dynamically adjusting the type and quantity of relevant parameter information displayed according to the alarm level, drivers can quickly identify whether there are quality problems with the concrete and the severity of the problems. When abnormalities occur, drivers can take timely measures, such as notifying technicians for handling, adjusting the vehicle's route to reach the construction site as quickly as possible, effectively avoiding construction delays or quality accidents caused by concrete quality problems.

[0140] In some embodiments, the system further includes:

[0141] The positioning module 205 is used to obtain the current geographical location information of the mixer truck in real time;

[0142] The time detection module 206 is used to monitor the mixing duration or transit time of concrete in the mixing drum in real time. The transit time is the time from when the concrete is put into the mixing drum to when the mixer truck arrives at the destination.

[0143] The control module 203 further includes a vehicle status determination unit 2033, which is used to determine the current vehicle status information based on the current geographical location information, mixing duration information, and on-the-way duration information of the mixer truck. The status information includes any one of the following: resting status, waiting to leave the factory status, on-the-way status, arrived status, unloading status, and return status.

[0144] In this embodiment, the resting state refers to the mixer truck being parked in the mixing plant, not loaded with concrete and not performing transportation tasks, with its location information within the electronic fence of the mixing plant, and both the mixing duration and the transit time being zero.

[0145] The "awaiting delivery" status means that the mixer truck has completed the concrete loading and is waiting to leave the batching plant. The location information is still within the electronic fence of the batching plant, the cumulative mixing time has increased, and the time spent on the road has not yet started counting.

[0146] "On the way" status means that the mixer truck has left the electronic fence of the mixing plant and is on its way to the construction destination. The location information is continuously updated, the on-the-way time begins to accumulate, and the mixing drum continues to rotate in the forward mixing state.

[0147] "Arrival status" refers to the mixer truck arriving at the construction destination and entering the electronic fence of the construction site, but not yet starting to unload materials. The location information is stable within the construction site area, the travel time stops accumulating, and the mixing duration continues to accumulate as needed.

[0148] The unloading status refers to the start of the unloading system of the mixer truck, the mixing drum being in reverse, the unloading monitoring unit starting to work, and the location information being within the electronic fence of the construction site. At this time, the main focus is on recording the duration of unloading.

[0149] The return journey status refers to the time after unloading is completed, the mixer truck leaves the electronic fence of the construction site and is on its way back to the mixing plant. The location information moves in the direction of the mixing plant, and the time spent on the journey starts to accumulate again (distinct from the time spent on the way).

[0150] The positioning module employs technologies such as the Global Positioning System (GPS) and the BeiDou Navigation Satellite System to obtain the real-time geographical location information of the concrete mixer truck, including longitude, latitude, and altitude. By receiving satellite signals, processing and calculating them, the positioning module determines the precise location of the mixer truck on the Earth's surface and transmits this location information to the control module.

[0151] The time detection module is used to monitor the real-time mixing duration or transit time of concrete in the mixing drum. The mixing duration is recorded from the moment the concrete raw materials enter the mixing drum, recording the total mixing time. The transit time is recorded from the moment the concrete is placed in the mixing drum until the mixer truck arrives at its destination. In conjunction with the positioning module, it determines whether the mixer truck has reached its destination based on changes in vehicle position and stops the timer.

[0152] like Figure 6 As shown, the concrete transport process by a mixer truck can be divided into the following stages:

[0153] From Rest to Ready for Shipment: When there are no transport tasks, the mixer truck is in a resting state. Upon receiving an order from the mixing plant, the corresponding vehicle status automatically switches to ready for shipment and enters the queuing process for loading. During the queuing period, staff can check for water accumulation inside the mixing drum through the monitoring unit inside the drum to prevent water from affecting the accuracy of the concrete mix proportions.

[0154] From Factory Outgoing to On-Road: After the mixer truck completes loading and leaves the electronic fence of the mixing plant, the GPS positioning module triggers a state switch, and the vehicle enters the on-road state. At this time, the system automatically controls the telescopic boom to extend, and the first camera component of the monitoring unit inside the tank captures video of the concrete inside the mixing drum and uploads it to the cloud server. The cloud reads the video image frames by skipping frames, converts them into grayscale images, enhances the contrast using AI algorithms, analyzes the relative displacement of feature values ​​using video analysis algorithms to calculate the slump value, and compares it with the preset allowable deviation range. If the slump value exceeds the allowable deviation, a warning will pop up on the mobile APP and PC web version. The staff can judge the concrete status through the terminal: if it meets the requirements, the warning is canceled; if it does not meet the requirements, the corresponding admixture is selected on the terminal and the amount to be added is entered. After receiving the signal, the control module controls the water pump to extract the admixture through an electrical signal. After the addition is completed, the water pump automatically stops working, and at the same time, the horn in the cab is triggered to remind the driver to control the mixing drum to quickly mix for 1 minute. In some embodiments, after the admixture is added and the solenoid valve of the corresponding liquid outlet pipeline is closed, the control module can also automatically control the mixing shaft of the mixing drum to start rotating through the drive system to complete the rapid mixing of concrete. If the liquid level in the storage tank is insufficient during the addition process, the system will immediately pop up a liquid level warning to prevent the water pump from being damaged by dry pumping; the liquid level gauge monitors the storage level in real time and continuously warns and reminds you to replenish when the level is lower than the set value.

[0155] Monitoring during transit: When the transit time exceeds 30 minutes, the system will automatically pop up an alert to prompt staff to check the concrete condition; when the mixer truck travels to a distance of 1 kilometer from the construction site, the control module will again operate the telescopic rod to extend, and the monitoring unit inside the tank will take a second video and perform AI slump recognition. If any abnormality occurs, the alert mechanism will be triggered again.

[0156] The vehicle's status changes from "on the way" to "on site" and then back to "unloading": Once the positioning module senses the vehicle entering the construction site's electronic fence, the status switches to "on site." When the forward / reverse sensors detect that the mixing drum has entered reverse mode, the vehicle switches to "unloading," and the unloading monitoring unit automatically records the unloading video and stores it in the cloud. If the "unloading" status continues for more than 30 minutes, the system will display a warning prompting staff to investigate the anomaly.

[0157] The process involves switching from unloading to return journey and then back to rest: After the vehicle leaves the construction site's electronic fence, its status changes to return journey; upon re-entering the mixing plant's electronic fence, it returns to resting mode, awaiting the next task. Throughout the entire workflow, staff can view the monitoring screen inside the tank at any time via a terminal and remotely add admixtures based on the real-time status of the concrete, achieving dynamic quality control throughout the entire process.

[0158] The above solution enables visualized tracking of the entire process of concrete production, loading, transportation, arrival, unloading and return trip through precise vehicle status classification and real-time monitoring. Managers can view the current status of each mixer truck in real time on the cloud platform, solving the problems of low efficiency and information lag in traditional manual tracking.

[0159] Meanwhile, by combining status information, key time periods can be precisely controlled. For example, when the "in transit status" exceeds a preset threshold (such as 1.5 hours), the system automatically triggers a slump detection and early warning mechanism; when the "unloading status" exceeds a timeout (such as more than 30 minutes), it reminds users to check for unloading abnormalities, effectively reducing quality risks.

[0160] Vehicle status can also serve as a trigger condition for other system functions. For example, in the "on-the-go" state, the timed shooting function of the tank monitoring unit can be automatically started, and in the "unloading" state, the unloading monitoring and admixture addition linkage control can be activated to realize the coordinated work of various modules and improve the system's automation level.

[0161] In some embodiments, the system further includes:

[0162] The control module is also used to adjust the amount of admixture added, the speed of admixture addition, the rotation speed and direction of the mixing drum according to the operation command after receiving the operation command, and to generate corresponding log information and upload it to the cloud after receiving an alarm event. The log information includes the current driving parameter information of the mixer truck, operation command record information, vehicle status information of the mixer truck, and the current geographical location information, mixing duration information and travel time information of the mixer truck.

[0163] In this embodiment, the operation command refers to the instruction input by the user (such as the batching plant technicians and managers) to the control module through the software system (mobile APP version or PC web version) to adjust relevant parameters in the concrete quality control process. These instructions can be settings for the amount and speed of admixture addition, or changes to the mixing drum speed and rotation direction, to adapt to different concrete quality requirements and construction conditions.

[0164] Log information refers to the record files generated by the control module during system operation, containing various information related to the mixer truck and concrete quality control. Log information is stored in the cloud for easy retrieval, analysis, and traceability.

[0165] An alarm event is a warning signal triggered by the system when it detects an abnormal situation. These abnormal situations may affect concrete quality or construction progress. When preset alarm conditions are met, the system automatically triggers an alarm event to remind relevant personnel to handle the situation promptly. The alarm event is triggered based on any of the following conditions:

[0166] The current travel time of the mixer truck exceeds the preset travel time threshold; the current reverse mixing time of the mixer drum of the mixer truck exceeds the preset reverse mixing time threshold; the current mixer truck is in the unloading state and the admixture has been added.

[0167] In actual use, the control module monitors the various operating parameters and status information of the mixer truck in real time. When the time the mixer truck is in transit exceeds the preset transit time threshold, it indicates that the concrete may experience performance degradation due to excessive transportation time, and the system immediately triggers an alarm event. When the reverse mixing time of the mixing drum exceeds the preset reverse mixing time threshold, it indicates that there may be an abnormality in the unloading process, and the system triggers an alarm event. When the mixer truck is in the unloading state and the admixture has been added, the system will also trigger an alarm event to ensure that the driver can perform subsequent operations (such as rapid mixing) in a timely manner.

[0168] Upon receiving an alarm, the control module immediately initiates a log generation program, summarizing and organizing information such as the current driving parameters of the mixer truck, recorded operation commands, vehicle status, geographical location, mixing duration, and travel time to form a complete log. Subsequently, the control module uploads the log information to a cloud server via the communication module. The cloud server stores and manages the log information, ensuring its security and accessibility. Relevant personnel can query and view the log information from the cloud through the software system.

[0169] The log information meticulously records all key information during system operation and uploads it to the cloud, providing complete traceability for the concrete quality control process. Analysis of the log information allows for a clear understanding of the transportation, mixing, and unloading of each concrete truckload, facilitating the identification of root causes of quality problems, summarizing lessons learned, and continuously optimizing the quality control process. The alarm event triggering mechanism promptly issues warnings when abnormalities occur during concrete transportation and unloading, reminding relevant personnel to take swift action to prevent the escalation of abnormalities from leading to substandard concrete quality and construction delays, thus improving construction safety and reliability.

[0170] In some embodiments, the system further includes:

[0171] The control module is located on the cloud server.

[0172] The monitoring module and the admixture addition unit are installed on the mixer truck, which is also equipped with a communication unit. The control module is connected to the communication module.

[0173] Preferably, each mixer truck is also equipped with a central control software system, which is available in a mobile app version and a PC web version. The control module of the cloud server can communicate with the communication unit of the mixer truck to send corresponding control commands to the central control software system on each mixer truck, thereby further controlling the monitoring module and admixture addition system on each mixer truck. At the same time, the monitoring module of the mixer truck can upload the collected first or second video stream data to the cloud server. The cloud server, through the AI ​​image analysis algorithm built into the control module, can perform image analysis on the uploaded video stream data and determine the slump value of the concrete in the mixer truck's tank. This value is then fed back to the corresponding mixer truck and displayed on the visual operation interface of the mixer truck's central control software system.

[0174] In the second aspect, such as Figure 5 As shown, this application provides a method for remote quality control of concrete in a mixer truck tank. The method is applicable to the remote quality control device for concrete in a mixer truck tank as described in the first aspect of this application. The method includes the following steps:

[0175] S101: The first camera component collects the first video stream data of the concrete inside the mixing drum, and the second camera component collects the second video stream data of the concrete at the discharge port of the unloading system.

[0176] S102: The image analysis unit analyzes the first video stream data to determine the first slump value of the concrete in the mixing drum and analyzes the second video stream data to determine the second slump value of the concrete at the discharge port.

[0177] S103: The command control unit determines whether the difference between the first slump value and the second slump value exceeds a preset error. If so, it generates an addition control command based on the difference between the two, and the addition control command includes the amount of admixture to be added.

[0178] S104: The dosage control unit delivers the corresponding dose of admixture to the mixing drum via the water pump.

[0179] The above approach establishes a complete closed-loop system for remote control of concrete quality, encompassing video stream data acquisition, slump value analysis, control command generation, and admixture delivery. This closed-loop process allows for real-time monitoring of concrete quality changes and timely implementation of control measures to ensure that concrete quality remains within a controllable range.

[0180] Image analysis technology combined with machine learning models is used to analyze and determine the slump value of concrete. Compared with traditional manual testing methods, this reduces the interference of human factors and improves the accuracy and objectivity of slump value detection, providing reliable data support for precise control of concrete quality. Simultaneously, an addition control command is generated based on the slump value difference, and the dosage control unit precisely controls the amount of admixture added. This avoids the inaccuracy of traditional manual addition methods, ensuring that admixtures are added accurately according to actual needs, effectively improving concrete performance and reducing quality risks caused by improper admixture addition.

[0181] In some embodiments, an IMU sensor is further provided inside the stirring tank. The IMU sensor is used to collect IMU attitude data, including roll angle and rotational speed. At least three positioning markers are also provided on the inner wall of the stirring tank, and these positioning markers are spaced apart on the inner circumference of the tank opening.

[0182] The image analysis unit analyzes the first video stream data to determine the first slump value of the concrete currently inside the mixing drum, and analyzes the second video stream data to determine the second slump value of the concrete at the discharge port, including:

[0183] Using at least three positioning markers preset on the inner wall of the stirring drum as reference corner points, an affine transformation matrix is ​​constructed based on the pixel displacement of the reference corner points between adjacent video frame images in the first video stream data or the second video stream data. The video frame images are then redirected according to the affine transformation matrix to obtain the redirected video frame images.

[0184] In the redirected video frame image, a region of interest is defined on the concrete surface, and video features corresponding to the concrete are extracted from the region of interest. The video features include the wave wavelength of the concrete surface ripples, the aggregate settlement gradient, and the flow motion vector.

[0185] The video features are input into the trained neural network model, which outputs the initial slump value of the concrete in the mixing drum. The initial slump value is corrected using formula (1) to obtain the final slump value. Formula (1) is as follows:

[0186] S final =S pred ×(1+a×rpm / rpm base )+b×sin(θ);

[0187] Among them, S final For the final slump value, S pred This is the initial slump value, and rpm is the current rotational speed of the mixing drum. baseThe reference speed is set, a and b are experimental calibration parameters, the value range of a is [0.02, 0.05], the value range of b is [2, 5], and θ is the roll angle;

[0188] The collapse value after smoothing is output at a preset time period as the collapse value obtained from analyzing the first video stream data or the second video stream data, and the confidence level is marked.

[0189] In some embodiments, three high-contrast QR code markers (such as ArUco markers) can be equidistantly arranged on the inner circumference of the stirring drum. The pixel coordinates of the markers in each frame are detected using the OpenCV library. For example, the marker diameter is 10cm, and adjacent markers are distributed at 120° intervals on the inner circumference of the stirring drum opening, ensuring that at least two markers are visible at any rotation angle. Then, based on the pixel displacement (such as Δx, Δy) of the markers between adjacent frames, translation, rotation, and scaling parameters are calculated to construct the affine transformation matrix M, for example, the expression for M is as follows:

[0190]

[0191] Where α represents the relative rotation angle of the mixing tank between adjacent video frames, in radians, and its magnitude can be calculated from the pixel displacement of the positioning marker point. Δx and Δy represent the translation amount (in pixels) of the marker point between adjacent video frames, used to compensate for the translational motion of the tank.

[0192] In some embodiments, the neural network model is a 3D-CNN network model. Inputting the video features into the trained neural network model and outputting the preliminary slump value of the concrete in the mixing drum includes:

[0193] The 3D-CNN network model performs the following steps:

[0194] The continuously extracted surface ripple wavelengths, aggregate settling gradients, and flow motion vectors are aligned according to time steps to form a temporal feature matrix with a dimension of T×3, where T is the number of video frames. The feature dimensions are then standardized to obtain the standardized temporal feature matrix.

[0195] The standardized temporal feature matrix is ​​processed through a bidirectional LSTM layer to extract temporal dependent features, and then weighted by an attention mechanism to output the first-dimensional feature vector. The region of interest is then passed through a dilated convolutional layer and a spatiotemporal GRU layer in sequence to output the second-dimensional feature vector.

[0196] The first-dimensional feature vector and the second-dimensional feature vector are concatenated to obtain a fused feature vector. The fused feature vector is then input into a fully connected network. After regularization processing involving random neuron discarding, a preliminary collapse prediction value is output.

[0197] In some embodiments, before acquiring the first video stream data, the method further includes:

[0198] A reference image of the calibration board is captured by the first camera component, and the sharpness index Q of the reference image is calculated. clarity and stain coverage R dirt ;

[0199] The clarity index Q clarity The variance is calculated using the Laplace method, and the formula is as follows:

[0200]

[0201] Where I is a grayscale image, For the Laplace operator;

[0202] The stain coverage R dirt The area percentage of the dirty region in the reference image;

[0203] When preset cleaning conditions are met, a cleaning alarm is triggered on the first camera component, and the subsequent slump value detection process is paused. The preset cleaning conditions include the sharpness index Q. clarity Less than the preset clarity or stain coverage R dirt Greater than the preset coverage;

[0204] When the preset cleaning conditions are not met, the pixels in the dirty area are masked during subsequent video feature extraction, and only the pixels in the non-dirty area are selected to participate in the collapse analysis and calculation.

[0205] In this way, the model only performs slump calculation when the camera captures a clear image of the concrete to ensure accurate results. If the captured image is dirty, the visual sensor will trigger a cleaning alarm and suspend the subsequent slump value detection process. The slump value calculation will only be restarted after the dirt in the captured image is effectively resolved.

[0206] Preferably, when preset cleaning conditions are met, an automatic coating replacement system is activated to replace the lens protective film of the vision sensor. The automatic coating replacement system includes:

[0207] A feed reel, used to store unused cleaning films, is driven to rotate by a first servo motor, which is electrically connected to a control board.

[0208] Waste reel, used to recycle contaminated diaphragms, provides a constant tension of 0.5-1N through a magnetic powder brake, which is connected to a tension sensor. A peeling blade is also provided on the diaphragm movement path between the waste reel and the lens.

[0209] The guide roller assembly includes at least two rollers supported by bearings to maintain the flatness of the film conveying path. The two rollers are symmetrically distributed between the feed reel and the waste reel.

[0210] The membrane positioning mechanism includes an infrared beam sensor and a main drive wheel. The infrared beam sensor is installed at a preset distance in front of the lens to detect the edge position of the membrane. The preset distance ranges from [3,5] mm. The main drive wheel is coaxially connected to a second servo motor to control the stepping transport of the cleaning membrane according to the feedback signal from the infrared beam sensor.

[0211] The hot press bonding head includes an annular heating element and a pressure sensor. The annular heating element maintains the heating temperature within a preset temperature range through a temperature control module. The pressure sensor is used to provide real-time feedback of the bonding pressure to the control board.

[0212] The ultrasonic cutting blade is driven to rise and fall by a thin cylinder. The distance between the cutting trajectory and the edge of the lens is in the range of [1.8, 2.2] mm. The thin cylinder is connected to the solenoid valve air circuit.

[0213] The control board is used to issue a material shortage alarm when the amount of waste material recycled from the waste roll reaches a preset percentage threshold of the initial length of the feed roll, or to stop the film replacement process when the pressure sensor detects that the pressure abnormality has lasted for a preset duration.

[0214] During operation, the automatic film changing system first sends a pulse signal to the first servo motor to drive the feed roll to rotate. Unused clean film sheets are flattened and unfolded by the guide roller group. After the infrared photoelectric sensor detects that the clean film sheet has reached a position of about 3 mm in front of the lens, the main drive wheel intervenes and achieves a repeatability of 0.05 mm through a 17-bit absolute encoder.

[0215] The magnetic powder brake dynamically adjusts the current based on feedback from the tension sensor (sampling period 10ms). Under the tension of 0.5-1N provided by the magnetic powder brake, the waste roll rotates counterclockwise. The peeling blade contacts the contaminated diaphragm at a 30° angle, and the peeling force is controlled within the range of 1.2-1.5N. The peeling blade is fixed on the diaphragm path between the lens and the waste roll.

[0216] The control board then controls the hot-press bonding head to press down, and the annular heating plate activates for 2 seconds to bond the unused clean film to the edge of the lens. The pressure sensor monitors the bonding pressure in real time to ensure that the bonding pressure remains constant at around 5N. Then, the control board controls a thin cylinder to push the ultrasonic cutting blade to cut off the remaining part of the contaminated film. After cutting, the limit switch resets the device.

[0217] Preferably, the automatic film changing system is encapsulated in an aluminum alloy protective shell, and a detachable dust collection box is provided at the bottom of the shell to collect film debris generated during cutting.

[0218] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A remote quality control system for concrete inside a mixer truck tank, characterized in that, The mixer truck is equipped with a mixing drum, a feeding hopper, a rear suspension, a drive system, and a unloading system. The mixing drum is used to load and mix concrete. The feeding hopper is located above the mixing drum and is connected to the mixing drum through a feeding port. The rear suspension is located at the rear of the mixer truck and is used to support the unloading system. A mixing shaft is installed inside the mixing drum and is connected to the drive system to control the rotation of the mixing drum under the drive of the drive system. The system includes: The monitoring module includes: The tank monitoring unit includes a first camera component, which is disposed between the feed hopper and the mixing drum or on the inner wall of the feed hopper, and is used to collect first video stream data of the concrete inside the mixing drum; The unloading monitoring unit includes a second camera component, which is mounted on the rear suspension of the vehicle and is used to collect second video stream data of the concrete at the unloading port of the unloading system. The operation monitoring unit includes a forward and reverse rotation sensor, which is installed at the rotating shaft of the stirring drum to detect the rotation direction and speed of the stirring drum. The control module includes an image analysis unit and an instruction control unit. The image analysis unit is used to analyze the first video stream data to determine the first slump value of the concrete in the mixing drum and to analyze the second video stream data to determine the second slump value of the concrete at the discharge port. It also determines whether the difference between the first slump value and the second slump value exceeds a preset error. If so, it generates an addition control command based on the difference between the two values. The addition control command includes the amount of admixture to be added. An admixture addition system includes: The storage tank unit includes an admixture storage tank, and a water pump is installed inside the storage tank; The dosage control unit is connected to the storage tank and the stirring drum via a water pipe. It controls the amount of admixture added according to the addition control command and delivers the corresponding dose of admixture to the stirring drum via the water pump.

2. The remote quality control system for concrete inside the mixer truck as described in claim 1, characterized in that, The in-tank monitoring unit also includes: A bracket is provided, on which the first camera component is placed. A transparent mudguard is also connected to the bracket, and the transparent mudguard is positioned in front of the lens of the first camera component. The telescopic mechanism includes a telescopic rod and a drive motor. The telescopic rod is connected to the bracket for transmission and is used to control the depth to which the first camera assembly extends out of or into the stirring drum under the drive of the drive motor. A supplementary light includes a light source and a control switch. The control switch is used to control the light source to turn on and off, and the control switch is electrically connected to the control module.

3. The remote quality control system for concrete inside the mixer truck as described in claim 1, characterized in that, The storage tank unit includes multiple admixture storage tanks, each of which is equipped with a level gauge. The outlet pipeline of each storage tank is equipped with a solenoid valve, and the level gauge and solenoid valve are electrically connected to the control module. When the level gauge detects that the level of the admixture in the storage tank is less than the preset height or less than the amount of admixture to be added as specified in the current addition control command, the control module automatically switches to the backup storage tank via the solenoid valve and issues a prompt message.

4. The remote quality control system for concrete inside the mixer truck as described in claim 1, characterized in that, The mixer truck also includes a cab, and the system also includes a display module, which is installed in the cab. The display module is used to dynamically adjust and display relevant parameter information of the concrete in the mixer truck according to the alarm level. The relevant parameter information includes any one or more of the following: admixture addition amount, rotation direction and speed of the mixing drum, first slump value, second slump value, difference between the first slump value and the second slump value, first video stream data, and second video stream data.

5. The remote quality control system for concrete inside the mixer truck as described in claim 1, characterized in that, The system also includes: The positioning module is used to obtain the current geographical location information of the mixer truck in real time; The time detection module is used to monitor the mixing duration or transit time of concrete in the mixing drum in real time. The transit time is the time from when the concrete is put into the mixing drum to when the mixer truck arrives at the destination. The control module also includes a vehicle status determination unit, which is used to determine the current vehicle status information based on the current geographical location information, mixing duration information, and on-the-way duration information of the mixer truck. The status information includes any one of the following: resting status, waiting to leave the factory status, on-the-way status, arrived status, unloading status, and return status.

6. The remote quality control system for concrete inside the mixer truck as described in claim 5, characterized in that, The system also includes: The control module is also used to adjust the amount of admixture added, the speed of admixture addition, the rotation speed and direction of the mixing drum according to the operation command input by the user after receiving the operation command. After receiving an alarm event, it generates corresponding log information and uploads it to the cloud. The log information includes the current driving parameter information of the mixer truck, operation command record information, vehicle status information of the mixer truck, and the current geographical location information, mixing duration information and travel time information of the mixer truck. The alarm event is triggered based on any of the following: The current travel time of the mixer truck exceeds the preset travel time threshold; The mixing drum of the current mixer truck is reversing for a duration exceeding the preset reversing time threshold. The mixer truck is currently unloading material and the additives have been added.

7. The remote quality control system for concrete inside the mixer truck as described in claim 5, characterized in that, The system also includes: The control module is located on the cloud server. The monitoring module and the admixture addition unit are installed on the mixer truck, which is also equipped with a communication unit. The control module is connected to the communication module.

8. A method for remote quality control of concrete inside a mixer truck tank, characterized in that, The method is applicable to the remote quality control device for concrete inside a mixer truck as described in any one of claims 1-7, and the method includes the following steps: The first camera component acquires the first video stream data of the concrete inside the mixing drum, and the second camera component acquires the second video stream data of the concrete at the unloading port of the unloading system. The image analysis unit analyzes the first video stream data to determine the first slump value of the concrete in the mixing drum and analyzes the second video stream data to determine the second slump value of the concrete at the discharge port. The command control unit determines whether the difference between the first slump value and the second slump value exceeds a preset error. If so, it generates an addition control command based on the difference between the two, and the addition control command includes the amount of admixture to be added. The dosage control unit delivers the corresponding dose of admixture to the mixing drum via the water pump.

9. The method for remote quality control of concrete in a mixer truck as described in claim 8, characterized in that, The image analysis unit analyzes the first video stream data to determine the first slump value of the concrete currently inside the mixing drum, and analyzes the second video stream data to determine the second slump value of the concrete at the discharge port, including: The YOLO object detection model is used to analyze the first or second video stream data to extract images of key areas of concrete. These images are then fed into a multi-label classification model to perform structuring of the concrete. The output of the multi-label classification network is combined with data statistics to obtain the slump value that best matches the current state of the concrete. The output dimensions of the multi-label classification model include any one or more of the following: particle content, particle distribution, image texture boundary, and moisture content.

10. The method for remote quality control of concrete in a mixer truck as described in claim 8, characterized in that, Before acquiring the first video stream data, the method further includes: A reference image of the calibration board is captured by the first camera component, and the sharpness index Q of the reference image is calculated. clarity and stain coverage R dirt ; The clarity index Q clarity The variance is calculated using the Laplace method, and the formula is as follows: Where I is a grayscale image, For the Laplace operator; The stain coverage R dirt The area percentage of the dirty region in the reference image; When preset cleaning conditions are met, a cleaning alarm is triggered on the first camera component, and the subsequent slump value detection process is paused. The preset cleaning conditions include the sharpness index Q. clarity Less than the preset clarity or stain coverage R dirt Greater than the preset coverage rate; When the preset cleaning conditions are not met, the pixels in the dirty area are masked during subsequent video feature extraction, and only the pixels in the non-dirty area are selected to participate in the collapse analysis and calculation.

Images