Material-equipment collaborative crack repair design method and device fusing digital twinning

Abstract

The application relates to a material-equipment collaborative crack repair design method and equipment based on fusion digital twinning, and the method comprises the following steps: establishing an electromagnetic-thermal field coupling model to obtain a pavement temperature field distribution, the electromagnetic-thermal field coupling model being a system combined by a microwave heating device, an asphalt pavement, a crack and a repair material; based on the mapping relationship between the pavement temperature and the dynamic modulus, a pavement compaction model under the action of a road roller is established through finite element simulation; actual pavement parameters are obtained, and the key parameter combination of the crack repair material and the microwave heating device is inversed and optimized according to the pavement compaction model, the key parameter combination comprising an electromagnetic loss parameter E, a heating power W, a heating width b and a heating time t; and the crack repair material and the microwave heating device are designed based on the finally selected key parameter combination. Compared with the prior art, the application has the advantages of precise repair, convenient construction, high repair efficiency, small environmental disturbance and the like.

Description

Technical Field

[0001] This invention relates to the field of road engineering technology, and in particular to a material-equipment collaborative crack repair design method that integrates digital twins. Background Technology

[0002] As a core component of transportation infrastructure, the health of road surfaces directly affects driving safety, comfort, operating costs, and even economic benefits. Cracks are one of the most common and earliest forms of damage to asphalt and cement concrete pavements. If not repaired promptly and effectively, they can trigger a series of chain reactions, such as reduced bearing capacity of the pavement base and subgrade, increased driving safety risks, and potential environmental pollution. Therefore, timely, precise, and efficient repair of pavement cracks is a crucial preventative maintenance measure to ensure road traffic capacity, extend service life, reduce total life-cycle costs, and ensure safe operation.

[0003] With technological advancements, road surface crack repair technologies are constantly being updated. For example, repair materials have evolved from hot asphalt and emulsified asphalt to high-performance sealants such as polymer-modified asphalt, silicone resins, and polyurethane (e.g., an epoxy-modified polyurethane road repair material and its preparation method disclosed in Chinese patent CN113336472B). Crack detection has progressed from manual visual inspection to rapid detection systems based on vehicle-mounted line-scan cameras and three-dimensional laser scanning (e.g., an integrated road inspection device disclosed in Chinese patent application CN117825408A). Despite these technological advancements, existing crack repair processes still face the following prominent technical challenges, hindering the optimization of repair results and the precise allocation of maintenance resources:

[0004] 1) Detection and repair decisions are disconnected and lack foresight.

[0005] Current inspection methods are mostly "post-incident" records, providing only static geometric information about cracks and failing to effectively predict crack development trends and residual lifespan. Decision-making relies heavily on engineers' experience, making it difficult to accurately answer core questions such as "when to repair, where to repair, and what process is the most economical and effective," leading to over-repair or under-repair.

[0006] 2) The repair plan lacks precision and adaptability.

[0007] Existing methods typically formulate repair plans based on only a single dimension, such as the apparent width of the crack, while ignoring the causes of the crack (thermal shrinkage, fatigue, reflective cracking, etc.), the actual stress state of the structural layer, and the dynamic effects of traffic loads and the environment (temperature, humidity). This results in the selection of repair materials and processes failing to perfectly match the actual root cause of the crack, affecting the long-term effectiveness of the repair.

[0008] 3) The evaluation of the repair effect is delayed and lacks closed-loop feedback.

[0009] The assessment of repair effectiveness often relies on the next scheduled inspection or reactive inspection after a problem occurs, which is time-consuming and costly.

[0010] The combination of these problems results in a typically short effective lifespan for traditional repair techniques, necessitating frequent rework. Therefore, there is an urgent need in this field for an intelligent solution that can be implemented throughout the entire process of detection, diagnosis, decision-making, construction, and evaluation to systematically address these issues. Summary of the Invention

[0011] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a material-equipment collaborative crack repair design method that integrates digital twins. This method can accurately repair shallow cracks without excavation and has significant advantages such as convenient construction, high repair efficiency, and minimal environmental disturbance. It not only effectively extends the service life of the road surface but also provides a new technical path for the whole life cycle maintenance of roads.

[0012] The objective of this invention can be achieved through the following technical solutions:

[0013] A material-equipment collaborative crack repair design method integrating digital twins includes the following steps:

[0014] An electromagnetic-thermal field coupling model was established to obtain the road surface temperature field distribution. The electromagnetic-thermal field coupling model is a system combining microwave heating equipment, asphalt pavement, cracks and repair materials.

[0015] Based on the mapping relationship between road surface temperature and dynamic modulus, a road surface compaction model under the action of a road roller is established by finite element simulation according to the road surface temperature field distribution.

[0016] Obtain actual road surface parameters, and optimize the key parameter combination of crack repair material and microwave heating equipment based on the road surface compaction model. The key parameter combination includes electromagnetic loss parameter E, heating power W, heating width b, and heating time t.

[0017] The crack repair material and microwave heating equipment were designed based on the final optimized combination of key parameters.

[0018] Furthermore, when establishing the electromagnetic-thermal field coupling model, the crack repair material uses thermoplastic material as the base material and electromagnetic response-enhancing nanoparticle material as the modifier.

[0019] Furthermore, when establishing the electromagnetic-thermal field coupling model, the energy efficiency of the microwave heating device is greater than 60%, the heating power W is adjustable between 20-80KW, and the heating width b is adjustable between 15-40cm.

[0020] Furthermore, the inversion optimization includes:

[0021] Determine the amount of crack repair material M based on the actual road surface parameters. Adjust the heating power of the microwave heating equipment from low to high in increments of 10KW. Obtain the corresponding electromagnetic loss parameter E and heating width b in each adjustment.

[0022] Based on the electromagnetic loss parameter E, determine the modifier dosage P of the crack repair material, and determine whether the crack repair material with the modifier dosage P meets the set performance requirements.

[0023] The parameter combination corresponding to the minimum heating power W under the condition of meeting the performance requirements is taken as the key parameter combination for final optimization.

[0024] Furthermore, the actual road surface parameters include crack width. and crack depth .

[0025] Furthermore, the calculation method for the amount M of the crack repair material is as follows:

[0026]

[0027] In the formula: The amount of crack repair material used; To restore material density; The width of the crack; Where is the crack depth; K is the correction factor.

[0028] Furthermore, the correction factor K is determined based on the pavement texture depth and the mixture type.

[0029] Furthermore, the crack repair material meets the following performance requirements:

[0030] The electrical loss tangent is greater than 0.15 or the magnetic loss tangent is greater than 0.01;

[0031] At room temperature, the dynamic viscosity μ is less than 200 mPa·s, and the adhesion strength with basalt σ is greater than 2 MPa;

[0032] The storage stability S after 1 hour is less than 0.15%.

[0033] Furthermore, in the inversion optimization, the combination of key parameters satisfies the following boundary conditions:

[0034] The displacement on one side of the crack is greater than half the crack width and the heating time is less than the set threshold.

[0035] The present invention also provides an electronic device including one or more processors, a memory, and one or more programs stored in the memory, said one or more programs including instructions for executing the material-device co-engineered crack repair design method integrating digital twins as described above.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] 1. Compared with traditional repair methods, this invention places greater emphasis on the digital and intelligent management and control of the repair process. Based on the digital twin method, this invention constructs a multi-dimensional virtual-real mapping system covering "materials-structure-environment-construction," enabling simulation prediction and parameter optimization of the repair process. The results are then fed back into actual construction, forming a dynamic closed loop combining virtual and real elements.

[0038] 2. This invention breaks through the limitations of traditional maintenance technology that relies on experience and trial and error. It makes full use of the concept of digital twins, integrates virtual simulation with actual construction, and constructs a systematic solution for the entire process from material design and equipment development to repair process optimization.

[0039] (1) In terms of materials, this invention uses emulsified asphalt or resin-based thermoplastic materials as the matrix and modifies them with electromagnetic response-enhanced nanoparticle materials to form a repair material with high electromagnetic responsiveness, high permeability, and high adhesion. This material can quickly penetrate into the crack, replenish the effective asphalt content, and significantly improve adhesion and overall mechanical properties. For cracks with a width of less than 1 mm, the strength after healing can be restored to more than 50% of the newly paved road surface, with excellent performance recovery. It also significantly improves microwave heating efficiency, thereby improving the crack healing effect.

[0040] (2) In terms of equipment, this invention has developed a microwave heating device with adjustable power, controllable heating range and high energy efficiency, which can rapidly heat the cracked area locally and work synergistically with the compaction of the road roller to promote crack closure and structural restoration. By using high electromagnetic response repair materials and microwave local rapid heating technology, the crack closure time is significantly shortened, and the repair can be completed within 2-3 minutes, which is fast.

[0041] (3) In terms of process, this invention introduces digital twin technology and uses software such as COMSOL, CST, and ANSYS to construct an electromagnetic-thermal field coupling model of the "microwave heating equipment-asphalt pavement-crack-repair material" system to obtain the temperature field distribution and establish a pavement mechanical response model based on the temperature-modulus mapping relationship. Combined with finite element compaction analysis under the action of a road roller, this invention establishes a quantitative relationship between the heating time required for crack healing, the amount of repair material, and the geometric parameters of the crack, realizing virtual-real interaction and parameter inversion optimization in the repair process, thereby obtaining the optimal combination of material ratio, heating power, and process path, and improving the accuracy and controllability of the repair. Through this digital twin closed loop, the repair effect can be predicted before construction, and a scientific decision-making basis can be provided for material ratio, equipment power, and construction process.

[0042] 3. This invention can predict the repair effect under different working conditions, guide the selection of material formulas and the control of equipment parameters, and overcome the limitations of conventional repair methods, such as long construction cycle, high cost and lack of quantitative design basis, thereby realizing the high efficiency, economy and sustainability of crack repair.

[0043] 4. This invention adopts a trenchless repair method, with a compact equipment structure and adjustable parameters, making it suitable for complex road conditions, reducing traffic interference, and providing efficient and convenient construction.

[0044] Overall, this invention achieves systematic innovation in repair material design, on-site equipment development, and digital twin modeling, providing a novel and feasible solution for the intelligent, economical, and sustainable repair of shallow cracks in asphalt pavements. This invention not only enhances the scientific rigor and controllability of shallow pavement crack repair but also offers new insights for the digital and intelligent development of road maintenance. Attached Figure Description

[0045] Figure 1 This is a flowchart of the method of the present invention;

[0046] Figure 2 This is a schematic diagram of electromagnetic-thermal field coupling in an embodiment of the present invention;

[0047] Figure 3 This is a schematic diagram of finite element simulation in an embodiment of the present invention. Detailed Implementation

[0048] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0049] This embodiment provides a material-equipment collaborative crack repair design method integrating digital twins, such as... Figure 1 As shown, it includes the following steps:

[0050] S1. Establish an electromagnetic-thermal field coupling model to obtain the road surface temperature field distribution. The electromagnetic-thermal field coupling model is a system combining microwave heating equipment 1, asphalt pavement 2, cracks 4, and repair materials 3. Figure 2 As shown.

[0051] When establishing the electromagnetic-thermal field coupling model, the crack repair material must possess excellent electromagnetic response, permeability, adhesion, and storage stability. In this embodiment, the crack repair material meets the following performance requirements: electrical loss tangent greater than 0.15 or magnetic loss tangent greater than 0.01; dynamic viscosity μ less than 200 mPa·s at room temperature, adhesion strength σ to basalt greater than 2 MPa; and storage stability S less than 0.15% after 1 hour.

[0052] Specifically, the crack repair material uses thermoplastic materials such as emulsified asphalt and resin as the base material, and uses electromagnetic response-enhanced nanoparticle materials as modifiers, and establishes the relationship between the modifier dosage P and the electromagnetic loss parameter E.

[0053] In this embodiment, emulsified asphalt is used as the base material and graphite is used as the modifier to prepare crack repair material. The relationship between graphite content P and electromagnetic loss parameter (using the tangent of the electrical loss angle) E is established as shown in formula (1):

[0054] (1)

[0055] In the formula: The electrical loss tangent of the repair material; % is the amount of graphite doping.

[0056] When establishing the electromagnetic-thermal field coupling model, the microwave heating equipment can achieve rapid localized heating of the road surface with adjustable parameters. Specifically, the microwave heating equipment has an energy efficiency greater than 60%, the heating power W can be adjusted between 20-80KW, and the heating width b can be adjusted between 15-40cm.

[0057] In a specific implementation, an electromagnetic-thermal field coupling model can be established using simulation software such as COMSOL, ADS, HFSS, or CST. First, the microwave heating equipment is modeled, then the asphalt pavement and cracks are modeled, and finally the crack repair material is modeled. The size of the asphalt pavement model is 0.5-1m larger than that of the microwave heating equipment, and it is advisable to obtain continuous temperature field data for heating from 0 to 180s to form the pavement temperature field distribution.

[0058] In this embodiment, the temperature field of the "microwave heating equipment-asphalt pavement-crack-repair material" system is simulated using COMSOL software, where the pavement length is 2.6m, the pavement width is 1m, the pavement thickness is 18cm, h is 4cm, and a is 1.5mm.

[0059] S2. Based on the mapping relationship between pavement temperature and dynamic modulus, a pavement compaction model under the action of a road roller is established through finite element simulation according to the pavement temperature field distribution, such as... Figure 3 As shown, this is a system combining a road roller 5, an asphalt pavement 2, a crack 4, and a repair material 3.

[0060] In specific implementations, software such as ABAQUS, ANSYS, or COMSOL can be used to establish a road compaction model. Since a small road roller is used for slow compaction, the load is of low frequency or quasi-static nature; therefore, the dynamic modulus |E*| is used in the finite element simulation. The road roller load is a gradually moving uniformly distributed load, with a load magnitude preferably between 0.2 and 0.4 MPa and a load movement speed preferably between 1.5 and 4 cm / s.

[0061] In this embodiment, a compaction model was established using ABAQUS software, in which a progressively moving uniformly distributed load was selected for the road roller, with a load size of 0.3 MPa and a load moving speed of 2 cm / s. The dynamic modulus |E*| of SMA-13 ​​asphalt mixture at a loading frequency of 10 Hz was tested by indoor experiments, and the curve of |E*| as a function of temperature T was established, as shown in formula (2).

[0062] (2)

[0063] In the formula: |E*| is the dynamic modulus of asphalt mixture, MPa; T is the test temperature, °C.

[0064] In finite element simulation, the dynamic modulus is set based on the above functional relationship.

[0065] S3. Obtain actual road surface parameters, and optimize the key parameter combination of crack repair material and microwave heating equipment based on the road surface compaction model. The key parameter combination includes electromagnetic loss parameter E, heating power W, heating width b, and heating time t.

[0066] In the inversion optimization, the combination of key parameters satisfies the following boundary conditions: the displacement on one side of the crack is greater than half the crack width and the heating time is less than the set threshold.

[0067] Actual pavement parameters, including crack width 'a' and crack depth 'h', were obtained through on-site surveys. Using the boundary conditions that the unilateral displacement of the crack (the distance the crack moves from left to right or right to left in the direction of healing) is greater than half the crack width and the heating time is 2 minutes, the process of optimizing the key parameter combination of the crack repair material and microwave heating equipment based on the actual pavement parameters specifically includes:

[0068] 1) Determine the amount of crack repair material M based on the actual road surface parameters. Adjust the heating power of the microwave heating equipment from low to high in increments of 10KW. Obtain the corresponding electromagnetic loss parameter E and heating width b in each adjustment.

[0069] The calculation method for determining the amount M of crack repair material is shown in formula (3):

[0070] (3)

[0071] In the formula: The amount of crack repair material used is expressed in kg / m. To repair the material density, kg / m 3 ; The crack width is in mm; denoted as crack depth in cm; K is a correction factor, the value of which is related to the pavement texture depth, mixture type, etc., and is generally taken as 2.

[0072] 2) Determine the modifier dosage P of the crack repair material based on the electromagnetic loss parameter E, and determine whether the crack repair material with the modifier dosage P meets the set performance requirements. The performance requirements are as described in step S1.

[0073] 3) The parameter combination corresponding to the minimum heating power W under the condition of meeting the performance requirements is taken as the key parameter combination for final optimization.

[0074] In this embodiment, the parameter combinations of the inverted crack repair material and microwave heating equipment are shown in Table 1. When W is 20KW, the crack cannot heal; when W is 30KW, E is obtained by inversion based on the model and the boundary conditions for healing, and P is calculated to be 12.4% according to formula (1). At this time, σ and S do not meet the performance requirements; when W is 40KW, E is 0.28, and P is calculated to be 8.7% according to formula (1). At this time, σ and S meet the performance requirements. Therefore, for this working condition, the preferred parameter combination is: W=40KW, b=30cm, P=8.7%.

[0075] Table 1. Inversion process of optimal parameter combination

[0076]

[0077] S4. Based on the final optimized combination of key parameters, design the crack repair material and microwave heating equipment.

[0078] In this embodiment, for the repair material, P is designed to be 8.7%; for the heating device, W is designed to be 40KW and b is designed to be 30cm.

[0079] On-site, cracks with a length of 1.5 mm and a width of 4 cm were repaired using the technology described in the patent. After repair, there were no macroscopic cracks, and the fatigue life increased from 0 cycles before healing to 3162 cycles after healing, which is approximately 48% of the fatigue life of an intact pavement.

[0080] If the above methods are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0081] The aforementioned computer program instructions may also be loaded onto a computer or other programmable data processing electronic device, causing a series of operational steps to be performed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable device for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0082] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A material-equipment collaborative crack repair design method integrating digital twins, characterized in that, Includes the following steps: An electromagnetic-thermal field coupling model was established to obtain the road surface temperature field distribution. The electromagnetic-thermal field coupling model is a system combining microwave heating equipment, asphalt pavement, cracks and repair materials. Based on the mapping relationship between road surface temperature and dynamic modulus, a road surface compaction model under the action of a road roller is established by finite element simulation according to the road surface temperature field distribution. Obtain actual road surface parameters, and optimize the key parameter combination of crack repair material and microwave heating equipment based on the road surface compaction model. The key parameter combination includes electromagnetic loss parameter E, heating power W, heating width b, and heating time t. The crack repair material and microwave heating equipment were designed based on the final optimized combination of key parameters; When establishing the electromagnetic-thermal field coupling model, the crack repair material uses thermoplastic material as the base material and electromagnetic response-enhancing nanoparticle material as the modifier; The inversion optimization includes: Determine the amount of crack repair material M based on the actual road surface parameters. Adjust the heating power of the microwave heating equipment from low to high in increments of 10KW. Obtain the corresponding electromagnetic loss parameter E and heating width b in each adjustment. Based on the electromagnetic loss parameter E, determine the modifier dosage P of the crack repair material, and determine whether the crack repair material with the modifier dosage P meets the set performance requirements. The parameter combination corresponding to the minimum heating power W under the condition of meeting the performance requirements is taken as the key parameter combination for final optimization. The actual road surface parameters include crack width. and crack depth ; The calculation method for the amount M of the crack repair material is as follows: In the formula: This refers to the amount of crack repair material used. To restore material density; The width of the crack; denoted as crack depth; K is a correction factor.

2. The material-equipment collaborative crack repair design method integrating digital twins according to claim 1, characterized in that, When establishing the electromagnetic-thermal field coupling model, the energy efficiency of the microwave heating device is greater than 60%, the heating power W is adjustable between 20-80KW, and the heating width b is adjustable between 15-40cm.

3. The material-equipment collaborative crack repair design method integrating digital twins according to claim 1, characterized in that, The correction factor K is determined based on the pavement texture depth and the mixture type.

4. The material-equipment collaborative crack repair design method integrating digital twins according to claim 1, characterized in that, The crack repair material meets the following performance requirements: The electrical loss tangent is greater than 0.15 or the magnetic loss tangent is greater than 0.01; At room temperature, the dynamic viscosity μ is less than 200 mPa·s, and the adhesion strength with basalt σ is greater than 2 MPa; The storage stability S after 1 hour is less than 0.15%.

5. The material-equipment collaborative crack repair design method integrating digital twins according to claim 1, characterized in that, In the inversion optimization, the combination of key parameters satisfies the following boundary conditions: The displacement on one side of the crack is greater than half the crack width and the heating time is less than the set threshold.

6. An electronic device, characterized in that, It includes one or more processors, memory, and one or more programs stored in the memory, said one or more programs including instructions for executing the material-device co-engineered crack repair design method of the fused digital twin as described in any one of claims 1-5.

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