A carbon-cured concrete wall forming system

Abstract

The present application relates to carbon dioxide solidification concrete technical field, disclose a kind of carbon solidification concrete wall forming system, comprising: by the unit integrated with pressure and temperature sensor carries out gas pulse injection, and initial strategy is set using pressure fluctuation to estimate water content before injection, in injection, the pressure attenuation data collected is calibrated and compensated using ambient pressure sensor simultaneously, closed-loop adaptive control to injection strategy is realized, the present application is coupled by gas injection and internal state perception calibrated by environment, so that each injection is adjusted according to the real physical response of wall, to actively inhibit the dominant penetration channel, change carbon dioxide from disorder diffusion to guided distribution, this design gets rid of the dependence of solidification process on external environment stability and internal initial condition uniformity, ensure the homogeneity and reliability of wall solidification under large-scale field construction.

Description

Technical Field

[0001] This invention relates to a carbon-cured concrete wall forming system, belonging to the field of carbon dioxide curing concrete technology. Background Technology

[0002] In current engineering practice, the use of carbon dioxide to react with cement hydration products to rapidly form carbonate cementitious materials has become a recognized technical approach that can improve early strength and has carbon sequestration value. It has shown its application potential, especially in precast components or specific repair scenarios. The basis of this technology is that by introducing carbon dioxide gas into freshly mixed or initially set concrete, it promotes a chemical reaction with alkaline substances such as calcium hydroxide, thereby generating a dense calcium carbonate crystal network inside the structure to bear the load. When this process is applied to laboratory-scale or small-sized components with regular shapes, the expected curing effect can usually be obtained by controlling the total air intake and the reaction time.

[0003] However, when this technology is applied to large-scale cast-in-place heterogeneous walls such as tunnel lining and mine support, a physical phenomenon that is not very noticeable in small-sized components becomes a major technical challenge restricting the reliability of the project. The concrete constructed on-site inevitably has unpredictable random heterogeneity in the distribution of density, porosity, and initial moisture content. According to the basic principles of fluid dynamics, when pressurized carbon dioxide gas infiltrates into such porous media, it will not disperse uniformly, but will instinctively follow the path of least resistance, such as microcracks or areas with high porosity, forming dominant infiltration channels, the so-called conduit effect. Once this effect is formed, most of the subsequently injected gas will continue to escape rapidly through these formed low-resistance channels, while the surrounding dense areas that need carbon dioxide to react will be in a gas-starved state because the local gas pressure cannot be effectively established. As a result, the greater the total energy and total gas volume input into the system, the more the conduit effect is strengthened, ultimately leading to localized over-accelerated carbonization and embrittlement of the wall after curing, while most areas are under-cured or even completely fail, bringing long-term, difficult-to-detect potential risks to the structure.

[0004] To address this issue, those skilled in the art have made some intuitive attempts. For example, they have tried to force gas into the dense zone by simply increasing the overall injection pressure or extending the injection time. However, engineering practice shows that this brute-force open-loop control method exacerbates the aforementioned channeling effect with higher energy efficiency, worsening the situation. Another seemingly feasible approach is to pre-embed a large number of distributed sensor networks inside the wall to accurately grasp the internal gas concentration distribution and perform zoned feedback control. However, this solution faces challenges in terms of economics and engineering feasibility when dealing with the harsh on-site construction environment, the high cost of sensors and wiring, and the significant difficulties in subsequent maintenance. This makes it difficult to become a universally applicable technology. Specifically, existing technologies have the following shortcomings: 1. They lack effective means for real-time identification and dynamic suppression of randomly formed dominant gas channels inside the wall; 2. They cannot transform the open gas injection process into a closed-loop adaptive control process without significantly increasing hardware complexity and cost; 3. Existing control methods are limited to macroscopic parameters at the inlet and are blind to the true solidification state of the microscopic areas inside the wall. Therefore, the technical problem to be solved by this invention is how to design a method that can detect and actively avoid the nonlinear transmission of carbon dioxide in large concrete matrices in harsh field environments in an economical, reliable and easy-to-implement manner, thereby avoiding the formation of the pipe effect. Summary of the Invention

[0005] This invention provides a carbon-cured concrete wall forming system, the main purpose of which is to solve the problem that the existing technology cannot effectively detect and actively avoid the advantageous penetration channels formed by gas inside the large concrete wall when performing carbon dioxide curing, which leads to serious uneven curing process.

[0006] To achieve the above objectives, the present invention provides a carbon-cured concrete wall forming system, the system comprising:

[0007] Multiple gas detection units are integrated at multiple locations on the concrete wall forming interface;

[0008] At least one ambient pressure sensor is disposed near the gas actuator detection unit; wherein each gas actuator detection unit includes Nozzle and The high-speed solenoid valve connected to the nozzle and Pressure sensor in fluid communication with nozzle and The nozzle integrates a temperature sensor and an edge controller; the edge controller is configured to: initiate high pressure Before gas pulse injection, the command pressure sensor collects weak ambient pressure fluctuation data, and based on the statistical characteristic analysis of the weak ambient pressure fluctuation data, determines the initial moisture content estimate for that unit location, and sets the initial pulse injection strategy based on this estimate; then, in each subsequent control cycle, the high-speed solenoid valve is controlled to inject high pressure. The gas pulse simultaneously acquires pressure decay data, real-time temperature, and ambient background pressure collected by an environmental pressure sensor; differential calibration is performed on the pressure decay data based on the ambient background pressure to obtain net pressure decay data, and temperature compensation is performed on the characteristic parameters of the net pressure decay data based on the real-time temperature to obtain the final decision parameters for decision-making; and the pulse injection strategy is updated based on the final decision parameters.

[0009] Preferably, the edge controller is further configured to: extract the time required for the pressure to decay to a pressure threshold stored in the edge controller and the peak pressure of the pressure decay curve from the net pressure decay data as characteristic parameters; when the temperature-compensated pressure decay time is less than a first time threshold stored in the edge controller, reduce or pause the pulse injection frequency when updating the pulse injection strategy; when the temperature-compensated pressure decay time is greater than a second time threshold stored in the edge controller, increase the frequency or intensity of the pulse injection when updating the pulse injection strategy.

[0010] Preferably, the edge controller follows these rules when performing temperature compensation: ,in, The pressure decay time used for decision-making after temperature compensation. This refers to the measured pressure decay time calculated based on net pressure decay data. This is real-time data collected by the temperature sensor.

[0011] Preferably, the edge controller performs statistical feature analysis, specifically by performing a fast Fourier transform on the weak fluctuation data of environmental pressure to obtain its spectral distribution, or by calculating its variance and skewness within a preset time window, in order to extract the water vapor damping feature fingerprint used to characterize the initial water content; and based on the water vapor damping feature fingerprint, querying a mapping table stored in the edge controller to obtain the estimated value of the initial water content.

[0012] Preferably, the environmental pressure sensor is a component of the same model as the pressure sensor in terms of physical structure and is connected to a valve that is always closed. This valve is used to collect the background noise signal composed of ambient air pressure fluctuations, mechanical vibrations at the construction site, and the sensor's own thermal drift. Differential calibration specifically involves subtracting the background noise signal collected by the environmental pressure sensor from the raw pressure data collected by the pressure sensor at the same time, to obtain a result that only reflects... Net pressure attenuation data of gas transport behavior within the wall.

[0013] Preferably, the gas actuator detection unit is encapsulated as a quick-replaceable modular component, and the modular component is integrated into a template for pouring concrete or an end effector of a robotic arm for spraying concrete.

[0014] Preferably, the high pressure injected by the high-speed solenoid valve A gas pulse, lasting from 1 ms to 20 ms, with a pressure rise rate at the pulse leading edge greater than 1 MPa / ms, this high pressure... After the gas pulse completes injection, it utilizes its rapid pressure drop process in A reverse suction force is generated at the nozzle, which is used to remove cement particles adhering to the inner wall of the nozzle.

[0015] Preferably, the system also includes a manifold network connected to all gas detection units and a system for supplying high pressure to the manifold network. The system includes a main gas source and a central controller that communicates with the edge controllers of each gas detection unit via wired or wireless means. The central controller issues initial control parameters, updates temperature compensation coefficients and mapping tables, and collects operational data uploaded by all edge controllers.

[0016] Preferably, the logic for updating the pulse injection strategy executed by the edge controller further includes a health state window defined by a first time threshold and a second time threshold; when the final decision parameter falls within the health state window, the edge controller maintains the current pulse injection strategy unchanged.

[0017] Preferably, the system is applied to rapid construction scenarios of emergency support or permanent lining in underground engineering projects such as tunnels or mines. Through the distributed collaborative work of multiple gas execution detection units, it enables rapid and uniform carbonization and curing of large-scale, heterogeneous, on-site cast or sprayed concrete walls.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] 1. This invention establishes a self-coupling mechanism for gas injection and internal state perception. By using intermittent high-pressure gas pulses as the execution medium and simultaneously utilizing the pressure decay curve formed by the pulse at the nozzle as real-time feedback on the microscopic pore structure inside the wall, each gas injection action instantly adjusts the timing and intensity of the next injection. This process actively suppresses the excessive development of dominant channels in the early stage of gas transmission path formation, transforming the carbon dioxide permeation process from disordered diffusion to a guided distribution under dynamic equilibrium.

[0020] 2. This invention adds an environmental pressure sensor that does not participate in gas injection near the gas detection unit and performs real-time differential calibration between the pressure attenuation data collected by the main pressure sensor and the environmental pressure data. This design transforms the unavoidable environmental air pressure fluctuations in tunnel or mine construction sites from an interference signal to the main sensor into a background reference system that can be stripped away. This allows the judgment of the actual gas transmission state inside the wall to avoid dependence on the stability of the external environment and ensures the accuracy of the core control logic's decision-making under complex working conditions.

[0021] 3. Before initiating gas pulse injection, this invention continuously collects subtle fluctuations in environmental pressure at various predetermined locations using a pressure sensor array. By performing statistical feature analysis on this data, which includes information on the initial moisture content inside the wall, areas with uneven water distribution within the wall are identified before the curing process begins. Based on this, the initial gas pulse injection strategy is differentiated. This approach transforms curing process control into a predictive optimization based on prior knowledge of the internal state, thereby avoiding uneven curing caused by differences in initial conditions. Furthermore, this invention integrates the gas pulse injection process, the detection process of the internal transmission state, and the calibration process of environmental pressure fluctuations into a distributed unit based on a low-cost microcontroller. This unit utilizes the physical characteristics of high-pressure pulses for nozzle self-cleaning, and its judgment logic based on pressure attenuation characteristics avoids complex physical modeling and extensive calculations. This inherent combination of technical features enables the system to not only regulate the curing process but also possess self-adaptive and corrective capabilities against real-world problems such as hardware blockage and environmental interference, reducing the requirements for on-site maintenance and computing resources. Attached Figure Description

[0022] Figure 1 This is a block diagram of the closed-loop adaptive control logic of the system of the present invention;

[0023] Figure 2 This is a diagram showing the hardware architecture and core component connections of the system of the present invention;

[0024] Figure 3 This is a flowchart of the adaptive operation and fault self-handling process of the edge controller of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be described in further detail below. It should be noted that the described embodiments are only some embodiments of this invention, not all embodiments, and are intended to explain this invention, and should not be construed as limiting this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0026] The present invention discloses a carbon-cured concrete wall forming system, which includes a distributed gas injection and state sensing network, a reference standard for environmental noise calibration, and a central control unit for global coordination and data management. The distributed network consists of multiple gas execution detection units, each integrated at multiple locations on the concrete wall forming interface, and connected to a high-pressure supply unit via a manifold network. The main gas source is fluidly connected; the environmental reference reference consists of at least one environmental pressure sensor, which is physically adjacent to the gas execution detection unit but does not participate in the gas injection process; the central control unit interacts with the edge controllers in each gas execution detection unit via wired or wireless communication links to issue initial control parameters and collect the operating data uploaded by all edge controllers.

[0027] In a typical application scenario, such as shotcrete molding of tunnel lining, the pore structure and moisture content distribution of freshly mixed concrete in its initial state exhibit heterogeneity due to the randomness of the construction process. This is a key physical constraint affecting the uniformity of subsequent carbonization and curing. To address this issue, this system is configured to activate high pressure... Before gas injection, an initial passive sensing process is executed. In this process, each gas detection unit's edge controller instructs its integrated pressure sensor to operate at a preset sampling frequency, such as... kHz, continuously collects subtle fluctuations in ambient pressure at the location and caches them for a specific time window, such as The edge controller then performs statistical feature analysis on the cached data sample, such as calculating its variance and skewness within this time window. Because areas with higher moisture content inside the wall have a stronger damping effect on small air pressure fluctuations, the variance of the fluctuation signal acquired by the pressure sensor will be relatively small. Therefore, by comparing the calculated variance value with a mapping table pre-stored in the controller, the initial moisture content estimate for that unit location can be retrieved. This mapping table is established through offline calibration experiments, and may define conditions for pressure signal variance less than 0.5%. At that time, the corresponding moisture content was higher than When the variance is greater than At that time, the moisture content was lower than The edge controller differentiates the initial pulse injection strategy for the unit based on the initial moisture content estimate obtained from the query. For example, it sets a low-frequency, high-intensity initial injection strategy for high moisture content areas and a high-frequency, low-intensity strategy for dry areas. This setting method based on prior knowledge of internal states helps to adjust the injection scheme in a targeted manner before the curing operation begins to cope with the differences in initial conditions.

[0028] After completing initial state perception and setting the initial injection strategy, the system enters the closed-loop adaptive solidification control stage. In large construction sites, the operation of various machinery and the start / stop of ventilation systems cause nonlinear fluctuations in the ambient background pressure. These fluctuations are superimposed on the pressure attenuation signal used for decision-making, forming interference noise. Therefore, the system utilizes an ambient pressure sensor—a component of the same model as the pressure sensor in the gas actuator detection unit—connected to a always-closed valve to continuously collect this background noise signal. Within each control cycle, when the edge controller of the gas actuator detection unit instructs the high-speed solenoid valve to inject high pressure... While the gas pulse is being collected and the raw pressure decay data is being acquired, the background noise signal provided by the ambient pressure sensor is also being acquired simultaneously. Subsequently, the edge controller performs differential calibration, subtracting the ambient noise signal from the ambient pressure sensor at each sampling moment from the raw pressure data of the pressure sensor at that moment, to obtain the net pressure decay data. For example, at a certain moment, the main pressure sensor reading is... MPa, ambient pressure sensor reading is MPa, then the calibrated net pressure value is MPa, this design uses environmental pressure fluctuations as a peelable background reference, improving the accuracy of obtaining information on the gas transmission status inside the wall under complex operating conditions; in addition, The physical properties of gases are sensitive to temperature changes. Even with the same pore structure inside the wall, the measured pressure decay curves will differ at different temperatures. To account for this effect, each gas detection unit also integrates a temperature sensor, which... The nozzle is integrated to measure the real-time temperature at the injection point. During each control cycle, the edge controller simultaneously acquires real-time temperature data while obtaining net pressure decay data. The controller performs temperature compensation on the feature parameters extracted from the net pressure decay data; specifically, it extracts the time required for the pressure to decay from the peak to a preset pressure threshold as the measured pressure decay time. The pressure decay time used for decision-making after temperature compensation is calculated using the following formula. , ,in, For reference temperature, its typical value is , for Gas-related empirical compensation coefficients, which can be determined through offline calibration experiments, for example, can be set as follows: / If the system measures for ms, real-time temperature for After compensation for ms, this compensation This information is used as the basis for subsequent logical judgments, which helps ensure the consistency of the control system's judgment logic under different temperature conditions.

[0029] After obtaining calibrated and compensated decision parameters The edge controller then compares it with a first time threshold and a second time threshold stored in its memory. These two thresholds define a health state window. The first time threshold is, for example... ms represents the state where the resistance to gas transport within the wall is too low, potentially indicating the formation of a dominant permeation channel; the second time threshold, for example... ms indicates excessive gas transport resistance, suggesting the corresponding area may have already solidified or become dense. The values ​​of these two thresholds can be calibrated experimentally on samples with specific concrete mix proportions. Based on this, the decision logic of the edge controller is set as follows: when... When the pulse injection frequency is less than the first time threshold, it is determined that there is a risk of pipe effect at that location, and the pulse injection frequency of that unit is then reduced or suspended, for example from... Hz dropped to Hz, to suppress the development of this dominant channel, when When the time exceeds the second time threshold, it is determined that the degree of solidification at that location is relatively high, and the frequency or intensity of pulse injection is then increased, for example, by increasing the pulse duration from... ms increased to ms, when When the gas falls within a health state window defined by two thresholds, the current pulse injection strategy remains unchanged. This closed-loop control based on the physical response of the wall allows the gas injection process to be dynamically adjusted according to the solidification state. For ease of on-site installation and maintenance, the gas actuator detection unit is physically encapsulated as a quickly replaceable modular component. This component can be integrated onto a formwork used for pouring concrete or fixed to the end effector of a robotic arm used for shotcreting. Simultaneously, the high-pressure gas injected by the high-speed solenoid valve... The duration of the gas pulse is controlled within ms to Between ms, and the pressure rise rate at the pulse leading edge is greater than MPa / ms; this short pulse, after injection, exhibits a rapid pressure drop that can occur within [a certain range]. A reverse suction force is generated at the nozzle, which helps to remove cement particles adhering to the inner wall of the nozzle, thereby achieving self-cleaning of the nozzle. This helps to reduce the risk of system failure due to nozzle clogging.

[0030] Example 1: In an emergency support operation in a deep mine, a long section of... m, height After wet-mix shotcrete is applied to the sidewalls of the roadway (m), rapid carbonation and curing are required to establish initial support strength. The freshly mixed concrete wall exhibits two areas of heterogeneity: one in the middle of the wall, where the shotcrete operation created an area with a higher initial moisture content than the surrounding area; and the other in the upper part of the wall, where temperature stress creates a band approximately [width missing]. Microcracks of approximately mm; a large ventilation fan at the work site periodically starts and stops, causing an environmental background pressure of approximately The system first performs initial passive sensing after startup. During this period, all gas actuator detection units integrated on the wall use their pressure sensors to collect weak ambient pressure fluctuation data, while the ambient pressure sensors simultaneously collect background noise signals caused by the ventilator. The edge controllers of each unit perform differential calibration to obtain net pressure fluctuation data from the raw pressure fluctuation data containing background noise, so that subsequent moisture content analysis can be based on data unaffected by environmental interference. Subsequently, based on the statistical characteristic analysis of the net pressure fluctuation data, the system calculates that the pressure signal variance value in the central region is lower than that in the surrounding region, and marks it as a high moisture content region by querying the mapping table. Accordingly, the gas actuator detection units in this region are preset with a low-frequency initial pulse injection strategy.

[0031] After entering the closed-loop adaptive curing control stage, the gas actuator detection unit located on the upper part of the wall injects a high-pressure gas... Following the gas pulse, its edge controller detects a temperature-compensated pressure decay time. for ms, this value is less than the preset first time threshold. Based on this, the system determines that the gas has formed a dominant permeation channel along the microfracture at this location. Subsequently, the edge controller of this unit adjusts the pulse injection frequency from... Hz down Hz, to reduce the flow to the crack The supply volume guides the gas flow to areas with higher surrounding resistance; simultaneously, the gas detection unit located in the middle of the wall, due to its high initial moisture content, has its edge controller continuously monitoring the pressure decay time. exist For approximately ms, this value remains greater than the preset second time threshold. Based on this, the edge controller determines that the curing process in that area is slow, and therefore adjusts the pulse duration from ms. MS upgraded to The system increases the injection volume per unit time to accelerate the carbonization reaction in the high moisture content area. Throughout the curing process, the system couples gas injection with internal state sensing to achieve differentiated adjustments to the injection strategy for different areas, actively suppressing the development of microcracks in the upper part while strengthening the curing of the high moisture content area in the middle. After the curing process is completed, core sampling tests on the wall show that the carbonization depth of the entire wall is uniform, including the original high moisture content area and the area near the microcracks, and its early strength meets the design requirements.

[0032] Example 2: To objectively verify the effect of this technical solution on controlling the uniformity of carbonization and curing under heterogeneous conditions, a set of comparative experiments were conducted; two samples of the same size were prepared for the experiment. m m Concrete wall specimens were prepared in m-shape, and two non-homogeneous characteristics were pre-designed for each specimen. One of these characteristics was that the water-cement ratio in the lower left corner of the specimen was higher than the standard value. The first step involved pouring concrete to create a high moisture content area. The second step involved embedding a diameter strip in the upper right corner of the specimen during pouring and then extracting it after initial setting. Polymer rods of mm were used to form a low-resistance permeation channel to simulate microcracks; the experimental environment temperature was controlled at... The relative humidity is The experiment was divided into a control group and an experimental group. The control group used a conventional open-loop injection system for the specimens. Continuous injection at a constant pressure of MPa Gas, total injection time min; the test specimens of the experimental group were made using the carbon-cured concrete wall forming system of the present invention, and the system parameters were set as follows: Main gas source pressure MPa, the first time threshold set within the edge controller is ms, the second time threshold is ms, reference temperature for Temperature compensation coefficient for / The total running time is also min; after curing, at four characteristic locations on each specimen, namely the center of the standard area and the center of the high moisture content area, simulated cracks were observed. Core samples were taken from a point 1 cm away from the fracture and from the upper right edge, respectively, and their carbonization depth was tested. h Compressive strength.

[0033] Test results of the core samples after the experiment showed that there was a significant difference in the curing effect between the two groups of specimens; the control group specimens exhibited severe inhomogeneity, particularly near the simulated cracks. At a depth of cm, due to rapid gas permeation along the channel, the carbonization depth reaches... mm, but the compressive strength of this area is only MPa, while in the center of the high water content region, gas permeation is inhibited, and the carbonization depth is only [missing information]. mm, compressive strength is only MPa, the carbonization depth and compressive strength at the center of the standard region are respectively mm and MPa; in contrast, the test group specimens achieved uniform curing at all four measuring points, with a carbonization depth of [missing value] at the center of the standard area. mm, compressive strength is MPa, near the simulated fracture At cm, its carbonization depth is mm, compressive strength is MPa, while in the center of the high moisture content region, the carbonization depth still reaches mm, compressive strength reaches MPa, and the standard deviation of the performance values ​​at each measuring point was much smaller than that of the control group; the experimental data shows that the conventional open-loop injection method, when faced with the internal heterogeneity of concrete, leads to Uncontrolled gas transport path leads to uneven curing effect; the system of the present invention, through closed-loop adaptive control, can respond to local differences in internal pore structure and moisture content, dynamically adjust gas injection, suppress dominant permeation channels and strengthen difficult-to-curing areas, thereby obtaining a uniform carbonization and curing effect under heterogeneous initial conditions.

[0034] Example 3: This example combines Figures 1 to 3 A description of a carbon-cured concrete wall forming system, such as... Figure 1 As shown, the system consists of a high-voltage supply The main gas source is activated, and pulses are injected into the concrete wall via a high-speed solenoid valve. Before injection, the system performs a pre-sensing and initial setting process. This process begins with passive sensing of the initial state, i.e., collecting data on slight fluctuations in environmental pressure. Then, it enters the initial moisture content estimation stage, determining the moisture content by analyzing statistical characteristics and consulting a mapping table, and finally setting the initial injection strategy. Differential settings are made based on the moisture content. This process involves the central controller issuing initial parameters, updating the mapping table, and collecting data. During injection, the system synchronously collects data from multiple sources, acquiring pressure decay, real-time temperature, and environmental background pressure collected by an independent environmental pressure sensor. The collected data enters the data processing and calibration stage, and the final decision parameters are obtained by performing differential calibration and temperature compensation. These parameters are compared with a healthy state window threshold in the decision analysis stage, and the result guides the pulse injection strategy update, i.e., adaptively adjusting the injection frequency and intensity or keeping it unchanged. This update continuously acts on the pulse injection stage through a feedback loop, thereby ensuring that the final product is a uniform and reliable carbon-cured wall.

[0035] like Figure 2 As shown, its core is a high-voltage... The main gas source 11, with a pressure of 2 MPa, supplies gas to the gas actuator detection unit through the manifold network 3. This unit features a modular design that allows for quick replacement, and internally integrates... Nozzle 4, high-speed solenoid valve 5, pressure sensor 6, temperature sensor 8, and edge controller 9. The high-speed solenoid valve 5 performs pulse injection with a duration of 1 ms to 20 ms and a pressure rise rate greater than 1 MPa / ms. The pressure sensor 6 operates at a sampling frequency of 1 kHz. The temperature sensor 8 provides real-time data for temperature compensation, with a reference temperature of 20°C. The compensation coefficient is 0.0075 / An ambient pressure sensor 7, physically isolated from the main pressure sensor, is connected to a always-closed valve to collect background noise for calibration. An edge controller 9 is responsible for executing local control logic and communicating with a central controller 1 containing a data processing unit 2. The entire system ultimately acts on the concrete wall 10.

[0036] like Figure 3 As shown, the process begins with passive sensing in the initial state. After analyzing environmental pressure fluctuations to estimate the initial moisture content, initial sensing is completed and an initial strategy is set. Subsequently, the system enters the main control loop, first waiting for injection, and then waiting for the trigger of the next control cycle based on the current strategy. After triggering, pulse injection and acquisition are performed, i.e., injection. The system pulses and collects data synchronously. After the pulse injection is completed, it enters the data processing and decision-making stage, where the data is calibrated and compensated, and the pressure decay time is analyzed. If the analysis results are normal, the process returns to waiting for injection. If a specific condition occurs where the decay time far exceeds the fault threshold and the adjacent units are normal, the process switches to the fault diagnosis and handling stage. The system determines that the nozzle is blocked and executes the cleaning procedure. If the system returns to normal after the cleaning pulse, the process returns to waiting for injection. If the cleaning fails, the system enters a failure state and sends a maintenance request.

[0037] Example 4: This example describes a standardized engineering calibration procedure for determining key control parameters in the system of this invention, so that the system's perception and decision-making logic has a traceable physical basis when applied to concrete with different mix proportions. This procedure aims to address the issue that the statistical characteristics of slight fluctuations in environmental pressure data, such as signal variance, and the quantitative relationship between them and the actual concrete moisture content change with variations in concrete composition during the initial moisture content estimation step before system startup. Therefore, a reproducible process is needed to generate or calibrate the mapping table stored in the edge controller. The execution of this calibration procedure requires the preparation of a set of standard concrete test blocks with identical components and processes except for the initial moisture content. This procedure includes preparing 6 sets of test blocks with dimensions of... mm mm A cubic test block of mm was prepared, and the initial moisture content was adjusted by controlling the amount of mixing water. , , , , and After demolding, the moisture content of each group was checked by drying and weighing. The procedure was carried out in a temperature and humidity controlled environment and a gas execution detection unit of the same model as the one deployed on site was used, with its edge controller set to data acquisition mode.

[0038] At the start of the calibration process, the nozzle end of the gas actuator detection unit is placed sequentially on the center surface of each standard test block. For each test block, the edge controller is activated to execute the initial state passive sensing process. Continuous acquisition at a sampling frequency of kHz The system collects data on subtle fluctuations in environmental pressure and calculates the variance of the time series. It then measures six test blocks with different moisture contents to obtain a data pair consisting of known initial moisture content values ​​and the corresponding variance of the measured pressure signals. In one measurement of this process, the moisture content is... The signal variance corresponding to the test block is The moisture content is The signal variance corresponding to the test block is After obtaining this calibration dataset, a mathematical model is established by performing regression analysis on the dataset, thereby generating a mapping table for use by the edge controller; the data is fitted to an inverse proportional relationship model: initial moisture content Using the measured data, the coefficients for that specific concrete mix proportion were calculated using the least squares method. The value is Thus, the mathematical model is embedded into the edge controller, enabling it to transform the measured pressure signal variance into an initial moisture content estimate with physical calibration in subsequent engineering applications. Furthermore, during the subsequent hydration and hardening process of these standard test blocks, continuous monitoring of their... Pulse injection pressure decay time By analyzing the changes in these values ​​and combining them with physical methods to determine the initial and final setting states, a corresponding first and second time threshold can be determined for the concrete mix of this proportion.

[0039] Example 5: This example describes the dynamic monitoring and adaptive adjustment procedure for hardware status during the curing process of the system of the present invention; in a tunnel lining curing operation with a long duration, one of the gas detection units deployed at the bottom of the wall... The nozzles may gradually become clogged due to cement slurry splashing during construction. If this situation is not identified, it may lead to insufficient curing of the area covered by the unit, creating weak points in the structure. This may occur when the curing process is approximately [time period missing]. At the specified time, the edge controller of the congested unit continuously monitored the temperature-compensated pressure decay time while executing its closed-loop control logic. Exceeded ms, this value is much larger than the preset second time threshold used to determine that the concrete has become dense. ms; simultaneously, the edge controller of this unit acquires the operating status of the four units physically adjacent to it, and discovers their The values ​​are all in ms to Within the range of ms; based on itself Given the combined condition that the value far exceeds the upper limit while the neighboring units are in normal condition, the edge controller's built-in diagnostic procedure determines this abnormal state as a hardware failure caused by nozzle blockage, rather than rapid curing of a large area of ​​concrete.

[0040] After determining a hardware fault, the edge controller immediately pauses the regular curing pulse injection and automatically executes a preset nozzle unblocking program, which involves controlling its high-speed solenoid valve to... Continuous injection at a frequency of Hz The duration is A cleaning pulse with a pressure of ms and the maximum pressure of the gas source is applied; after the cleaning pulse is applied, the system injects another probe pulse, and if the measured pressure is... If the value returns to the normal range, the unit resumes normal curing operations; if The value is still higher than If the fault threshold of milliseconds is reached, the system confirms that the blockage cannot be cleared on its own, marks the unit as failed, stops its injection activity, and simultaneously sends a maintenance request for the specific location to the operator console via the central controller. To address the solidified area left by the failed unit, the edge controller of that unit sends compensation commands to all its normally functioning adjacent units, causing them to increase their respective pulse injection intensity beyond the original adaptive adjustment during the subsequent solidification time. This series of fault diagnosis and repair attempts, as well as the collaborative compensation mechanism, helps to maintain the uniformity and continuity of the overall curing process when faced with sudden hardware problems on site.

[0041] Example 6: This example describes a pre-deployment calibration procedure performed to establish a baseline response model for a new concrete mix using local aggregates before applying the carbonation curing system of the present invention to such a mix. This model includes the core control parameters required for the edge controller to perform adaptive adjustments, aiming to match its decision logic with the actual physical properties of the material to be cured. The procedure first determines the thermal response component of the baseline response model, i.e., quantifies the temperature compensation coefficient. This step uses a target concrete mix design specimen that has undergone 7 days of standard curing and whose internal structure has stabilized. This specimen, along with a gas detection unit, is placed in a temperature-controlled environmental test chamber. The chamber temperature is initially set to a reference temperature. Right now The sample was kept warm until the temperature was uniform, and then a set of tests were performed. The pulse injection was performed and its average pressure decay time was measured and recorded as the reference decay time. Then adjust the temperature inside the chamber to another set point. ,like After the test block temperature stabilized again, the same set of pulse injections was performed, and the average measured pressure decay time was measured. ;based on The temperature compensation coefficient can be calculated based on the relationship. If in for Time measured for ms, in for Time measured for ms, then the calculation can be obtained The value is approximately / .

[0042] The procedure then determines the setting behavior component of the baseline response model, namely, calibrating the first and second time thresholds; this step uses a freshly mixed specimen prepared with the target concrete mix proportion, and its setting state is simultaneously measured using a penetration resistance meter; the freshly mixed specimen is placed... In a standard environment, the gas-actuated detection unit operates at a rate of... A probe pulse is injected into it once every minute, and the pressure decay time is recorded. The dynamic changes; simultaneously, the initial setting time of the specimen was measured using a penetration resistance meter; the initial setting time points measured on the penetration resistance meter were mapped to... The corresponding time point on the dynamic change curve, that point The value is then set as the second time threshold; if the measured initial setting time is 240 minutes, the corresponding value is... If the value is 150ms, then the second time threshold is set to 150ms; the first time threshold is based on the value measured by the specimen in its initial fully plastic state. An initial value is used as the criterion for excessively rapid gas permeation; if measured... The initial value is 130ms, so the first time threshold is set to approximately After completing these two calibration steps, a baseline response model containing core control parameters corresponding to a specific concrete mix proportion is established and can be loaded as a parameter matrix into the edge controller to be used in the project.

[0043] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A carbon-cured concrete wall forming system, comprising: The system comprises: a plurality of gas execution probe units, each integrated at a plurality of locations of a concrete wall forming interface; at least one ambient pressure sensor disposed near the gas injection probe units; wherein each gas injection probe unit comprises a nozzle a high-speed solenoid valve in communication with the nozzle a pressure sensor in fluid communication with the nozzle a temperature sensor integrated with the nozzle and an edge controller; the edge controller is configured to: instruct the pressure sensor to collect ambient pressure fluctuation data before starting high-pressure gas injection, determine an initial water content estimation value at the unit location based on statistical feature analysis of the ambient pressure fluctuation data, and set an initial pulse injection strategy according to the estimation value; and in each subsequent control cycle, control the high-speed solenoid valve to inject high-pressure gas pulses, simultaneously collect pressure decay data, real-time temperature, and ambient background pressure collected by the ambient pressure sensor; based on the ambient background pressure, the pressure decay data is differentially calibrated to obtain net pressure decay data, and based on the real-time temperature, the characteristic parameters of the net pressure decay data are temperature compensated to obtain final decision parameters for decision-making; and based on the final decision parameters, the pulse injection strategy is updated; and the edge controller is further configured to: extract, from the net pressure decay data, a time required for the pressure decay to reach a pressure threshold stored in the edge controller and a peak pressure of the pressure decay curve as characteristic parameters; decrease or suspend the pulse injection frequency when updating the pulse injection strategy when the temperature-compensated pressure decay time is less than a first time threshold stored in the edge controller; increase the pulse injection frequency or intensity when updating the pulse injection strategy when the temperature-compensated pressure decay time is greater than a second time threshold stored in the edge controller; The edge controller follows the following rules when performing temperature compensation: wherein, is the pressure decay time used for decision making after temperature compensation, is the measured pressure decay time calculated based on the net pressure decay data, is the real-time collected by the temperature sensor; The environmental pressure sensor is physically the same type of component as the pressure sensor and is connected to a valve that is always closed, which is used to collect background noise signals composed of fluctuations in atmospheric pressure, mechanical vibrations on the construction site, and thermal drift of the sensor itself; differential calibration, specifically subtracting the background noise signals collected by the environmental pressure sensor from the raw pressure data collected by the pressure sensor at the same time, to obtain only the pressure data reflecting CO 2 Net pressure decay data of gas transmission behavior inside the wall High pressure injected by high speed solenoid valve a gas pulse with a duration of 1 ms to 20 ms and a pressure rise rate of the pulse front larger than 1 MPa / ms, the high pressure the gas pulse, after the completion of the injection, utilizes its rapid pressure drop process to generate a reverse suction force at the nozzle, the reverse suction force being used to clean the cement particles adhered to the inner wall of the nozzle.

2. A carbonized concrete wall forming system according to claim 1, wherein the edge controller performs statistical feature analysis, specifically, fast Fourier transform on the ambient pressure weak fluctuation data to obtain its frequency spectrum distribution, or calculates its variance and skewness within a preset time window, to extract the water vapor damping characteristic fingerprint for representing the initial moisture content; and according to the water vapor damping characteristic fingerprint, queries an initial moisture content estimation value from a mapping table stored in the edge controller.

3. A carbonized concrete wall forming system according to claim 1, wherein The gas execution probe units are integrally packaged as a quick-change modular assembly, and the modular assembly is integrated on a formwork for pouring concrete or an end effector of a mechanical arm for spraying concrete.

4. The carbonized concrete wall forming system of claim 1, wherein, The system further comprises a manifold network connected to all the gas execution detection units and a high-pressure gas source for providing high-pressure gas to the manifold network The system further comprises a central controller in wired or wireless communication with the edge controller of each gas execution detection unit for issuing initial control parameters, updating temperature compensation coefficients and mapping tables, and collecting operation data uploaded by all the edge controllers.

5. The carbonized concrete wall forming system of claim 1, wherein, The logic of the edge controller for updating the pulse injection strategy further includes a health state window defined by the first time threshold and the second time threshold; when the final decision parameter falls within the health state window, the edge controller maintains the current pulse injection strategy unchanged.

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