Intelligent slope compensation tensioning and holding load detection system

Abstract

The invention relates to an intelligent slope compensation tensioning and holding load detection system which comprises a control host, a PLC, an oil pump motor, an electromagnetic valve set, a main jacking jack, a locking jacking jack, a pressure sensor and a displacement sensor. The three working modes of primary detection, compensation tensioning and secondary detection are supported, and parameters are independently stored in each mode; the PLC dynamically executes staged pressurization, load holding and pressure maintaining and closed-loop pressure supplementing based on a C02 / C03 threshold value according to the actually measured oil pressure and the displacement signal, and the elongation amount is automatically checked; the system has the functions of power-off continuation, abnormity self-inspection, local data recording and remote uploading, and safe reset is achieved through a pressure relief solenoid valve. According to the method, intelligentization, closed loop and data collaboration of the whole operation slope anchor cable tensioning process are achieved, and the engineering requirement for held load distribution type judgment is met.

Description

[Technical Field]

[0001] This invention relates to the field of geotechnical engineering and intelligent construction equipment, specifically to the technical field of an intelligent slope compensation tensioning and holding load detection system. [Background Technology]

[0002] In the construction of slope engineering for operating highways, prestressed anchor cables often experience effective prestress reduction due to material relaxation, ground creep, or construction defects, which affects the long-term stability of the slope.

[0003] Currently, compensating tensioning relies heavily on manual operation of hydraulic equipment. Pressure and load are applied by manually controlling oil pumps and valves, and force and elongation are read using pressure gauges and rulers. Data recording is delayed and prone to errors. This method lacks real-time feedback and closed-loop control, making it difficult to guarantee tensioning accuracy and to promptly identify abnormal working conditions.

[0004] In addition, although some semi-automatic tensioning equipment incorporates digital display instruments and timed load-bearing functions, it is still an open-loop control and cannot dynamically compensate for pressure based on the measured force value. Some solutions attempt to use PLC control, but these are mostly for single tensioning in new projects and lack multi-mode adaptive capabilities for the entire process of "detection-compensation-verification" of existing slopes. They also do not support intelligent functions such as power failure resumption of tensioning and abnormal alarms.

[0005] Furthermore, at present, especially in some areas where the testing and evaluation of prestressed anchor cable projects on highway slopes are carried out, it is necessary to upload the data to a management platform. This is to meet the synchronous cloud-based intelligent requirements for analyzing the distribution type of anchor cable loads (such as stable, decreasing, and mixed types).

[0006] Therefore, existing technologies cannot yet meet the comprehensive requirements of intelligent, closed-loop, and data-coordinated operation of anchor cable compensation tensioning for operational slopes. [Summary of the Invention]

[0007] This invention provides an intelligent slope compensation tensioning and holding load detection system, which aims to solve the problems of low automation, insufficient tensioning control accuracy, and disconnect between detection data and slope anchor cable condition assessment system in the existing technology.

[0008] To solve the above-mentioned technical problems, the present invention provides an intelligent slope compensation tensioning and holding load detection system, which adopts the following technical solution: An intelligent slope compensation tensioning and holding load detection system includes:

[0009] The control unit is used to select the working mode and set the tensioning parameters;

[0010] The PLC controller is communicatively connected to the control host.

[0011] The oil pump motor is controlled to start and stop by the PLC controller.

[0012] The solenoid valve assembly includes multiple solenoid valves for controlling the oil inlet of the main jack, the oil return of the main jack, the oil inlet of the lock jack, and the oil return of the lock jack, respectively. The solenoid valve assembly is driven by the PLC controller.

[0013] The main jack and the locking jack perform tensioning, locking, or releasing operations on the anchor cable through the action of the solenoid valve group, respectively.

[0014] Pressure sensors are configured to collect main top oil pressure and lock top oil pressure;

[0015] A displacement sensor, configured to collect the piston displacement of the main jack;

[0016] The PLC controller, based on the tensioning parameters and the real-time signals from the pressure and displacement sensors, controls the oil pump motor and solenoid valve group to perform staged pressurization, load holding, and pressure replenishment operations, and sends the tensioning process data to the control host.

[0017] Furthermore, the control host is also configured to upload the tensioning process data to a remote management platform via a network.

[0018] Furthermore, the working modes include "single detection", "compensation tensioning" and "secondary detection", each working mode corresponds to an independently stored parameter set, the parameter set including at least the target tension force, holding time and preset deviation threshold.

[0019] Furthermore, the parameter set also includes an elongation calculation mode option, which includes a calculation method based on national standards and a calculation method based on industry standards; the theoretical elongation is automatically calculated according to the selected calculation mode and its consistency is checked with the measured displacement.

[0020] Furthermore, the pressure replenishment operation is dynamically executed based on the preset deviation threshold: pressure replenishment is started when the measured tension force is less than the sum of the target tension force and the lower deviation CO2, and pressure replenishment is stopped when the measured tension force is greater than the sum of the target tension force and the upper deviation CO3, where CO2<0 and CO3>0.

[0021] Furthermore, the PLC controller performs data verification before starting automatic tensioning. The verification includes determining whether the main jacking oil pressure and the locking jacking oil pressure are within the range of 0 to 60 MPa, whether the main jacking displacement is within the range of 0 to 225 mm, whether the target tension force does not exceed 110% of the design anchoring force, and whether the communication status between the control host and the PLC is normal.

[0022] Furthermore, when the data verification fails, the current parameter interface is maintained, allowing the user to correct the parameters or check the equipment before re-triggering the verification, and the entered station number, borehole number, and working mode are retained.

[0023] Furthermore, the PLC controller has a built-in non-volatile storage unit for caching the current tensioning stage, applied force value, holding time, and displacement data; when power is restored after a power outage, the system automatically loads the breakpoint state and continues to execute the remaining tensioning process from the point of interruption.

[0024] Furthermore, the pressure sensor and displacement sensor are connected to the PLC controller through an analog input module. Each input channel of the analog input module has an independent common terminal and is connected to the sensor through a shielded cable. The shielding layer is connected to the shielding grounding terminal of the module.

[0025] Furthermore, the solenoid valve assembly also includes a pressure relief solenoid valve, used to control the hydraulic circuit to quickly release pressure when tensioning is completed or an abnormal working condition is detected, so as to reduce the amount of anchor cable retraction when the main jack and locking jack are reset.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] 1. This invention integrates the control host, PLC, dual jacks, sensors, and solenoid valve assembly to construct a locally closed-loop intelligent tensioning execution unit. The system no longer relies on manual meter reading and operation; instead, it automatically completes graded pressurization, load holding judgment, and pressure replenishment actions based on measured oil pressure and displacement, fundamentally avoiding the risks of over-tensioning, under-tensioning, or misoperation.

[0028] Meanwhile, all process data is transmitted back to the control host in real time, providing a structured data foundation for anchor cable condition assessment and determination of the load distribution type.

[0029] 2. Building upon this foundation, the system further integrates capabilities such as multi-mode independent parameter management, power outage tension resumption, cloud data synchronization, automatic elongation verification, and anomaly self-checking, covering the full lifecycle needs of operational slope anchor cables from "detection to evaluation to compensation to verification." It can meet the data requirements for determining load distribution types during the detection and evaluation of prestressed anchor cable projects on highway slopes, and also significantly improves the robustness and safety of field operations. [Attached Image Description]

[0030] Figure 1 This is a schematic diagram of the tensioning process in this invention;

[0031] Figure 2 This is a schematic diagram of the control power supply and communication connection in this invention;

[0032] Figure 3This is a schematic diagram of the PLC input terminal wiring in this invention;

[0033] Figure 4 This is a schematic diagram of the wiring for signal acquisition of the pressure and displacement sensors in this invention;

[0034] Figure 5 This is a schematic diagram of the wiring between the solenoid valve and the oil pump drive in this invention;

[0035] Figure 6 This is a schematic diagram of the wiring for locking the return oil and depressurizing valve drive in this invention;

[0036] Figure 7 This is a schematic diagram of the high-voltage control wiring for the grouting pump motor and hydraulic solenoid valve in this invention.

[0037] Figure 8 This is a schematic diagram of the startup screen of the control host operation interface of the present invention;

[0038] Figure 9 This is a diagram of the interface for selecting the working mode and setting parameters of the control host in this invention;

[0039] Figure 10 This is a schematic diagram of the control host parameter setting interface in this invention;

[0040] Figure 11 This is a schematic diagram of the tension monitoring control host in this invention;

[0041] Figure 12 This is a schematic diagram of the remote management platform query interface in this invention;

[0042] Figure 13 This is a schematic diagram of the data query interface on the control host in this invention;

[0043] Figure 14 This is a schematic diagram of the interface for querying detailed data and curves for each station number and borehole number in this invention;

[0044] Figure 15 This is a schematic diagram of the data export interface in this invention.

Detailed Implementation Methods

[0045] The present invention will be further described in detail below with reference to the accompanying drawings of the embodiments.

[0046] This invention provides an intelligent slope compensation tensioning and holding load detection system, which includes a control host, a PLC controller, an oil pump motor, a solenoid valve group, a main jack, a locking jack, a pressure sensor, and a displacement sensor.

[0047] The control host is used to select the working mode and set the tensioning parameters. The PLC controller communicates with the control host and controls the start and stop of the oil pump motor and the operation of the solenoid valve group according to the tensioning parameters to drive the main jack to apply tension to the anchor cable and the locking jack to perform locking or releasing operations. Pressure sensors collect the main jack oil pressure and the locking jack oil pressure respectively, and displacement sensors collect the piston displacement of the main jack. Based on the above real-time signals, the PLC controller performs staged pressurization, load holding and pressure maintenance and dynamic pressure compensation control, and sends the tensioning process data to the control host, which is then uploaded to the remote management platform.

[0048] The main jack and locking jack are common double-acting through-hole jack structures found in existing hydraulic tensioning equipment, sharing the same anchor clamping mechanism. The main jack actively applies tension force; its piston rod is connected to the steel strand bundle, and high-pressure oil drives the piston to extend, achieving pull-out. The locking jack surrounds the outside of the main jack or is integrated into the same cylinder. After the main jack stabilizes under load, the locking jack extends its piston via high-pressure oil to push the working clamp into the anchor plate hole to anchor the steel strand. Then, the main jack is allowed to safely depressurize and retract. This operation first anchors the steel strand before unloading the main jack, thus ensuring no force loss. This dual-jack collaborative mechanism is a key foundation for achieving non-destructive testing and compensatory tensioning, and has been widely used in existing slope engineering, belonging to a mechanical structure well-known to those skilled in the art.

[0049] The following provides a detailed explanation of the specific operation process and implementation method. Please refer to the provided text for further information. Figure 1 After the system is powered on, it first completes initialization via the control host. For example... Figure 2 As shown, the control host establishes a communication connection with the PLC controller via an RS485 or Ethernet interface, while simultaneously providing the PLC with a 24V DC power supply. This communication link is used not only to send tensioning parameters but also to transmit sensor data and equipment status back in real time, ensuring the reliability of the control closed loop.

[0050] In addition to analog signals, the system also monitors key safety and status signals in real time through the PLC's digital input terminals. For example... Figure 3 As shown, the emergency stop button SB1 is connected to terminal X0 as a normally closed contact; pressing it immediately cuts off the control enable. The return positions of the main jack and the locking jack are detected by limit switches SQ1 and SQ2, respectively, and connected to terminals X1 and X2 to determine whether the jacks have completed their reset. The thermal relay overload signal for the oil pump motor is connected to terminal X3 to prevent the motor from running under overcurrent for extended periods. In this application example, before starting tensioning, the PLC not only verifies the sensor value range but also confirms that the emergency stop has not been triggered, the jacks are in their initial positions, and the motor is not overloaded before allowing the process to continue. This multi-input verification mechanism significantly improves the operational safety and process reliability of the system.

[0051] refer to Figure 3 The PLC's digital input terminals also receive signals from the oil pump start / stop and main jack / lock manual operation buttons. In automatic mode, these signals are shielded by the software and only take effect in manual debugging mode to ensure that the automatic process is not disturbed.

[0052] When applying, refer to Figure 8 Users select the current operating mode on the control host interface, including "one-time detection" ( Figure 8 The system offers three operating modes: "Select by Click," "Compensation Tensioning," and "Secondary Detection." Each mode corresponds to an independently stored set of parameters, including the target tension force, holding time, compensation deviation thresholds C02 / C03, and elongation calculation mode. For example, in "Compensation Tensioning" mode, the target force value is typically set as the prestress value that needs to be supplemented after evaluation, while in "Secondary Detection," it is used to verify the compensation effect. This multi-mode independent parameter management mechanism avoids the tedious manual resetting required by traditional equipment, significantly improving adaptability to the entire "detection-compensation-verification" operation cycle.

[0053] For example, the "single test" mode is used to obtain the current load reference value of the anchor cable, and the target tension force is usually set to 70% of the design value. The "compensation tensioning" mode sets a supplementary tension value based on the evaluation results to restore the prestress. The "second test" mode then re-tensions the cable to the same force value after compensation to verify whether the anchor cable response is stable.

[0054] In the elongation calculation mode options ( Figure 8 In step 2), which includes calculation methods based on national standards and industry standards, the theoretical elongation is automatically calculated according to the selected calculation mode, and its consistency is checked with the measured displacement. Then, the system parameters are entered (…). Figure 8 3) Further parameter settings.

[0055] refer to Figure 9 , Figure 10 After the parameters are set, the system enters the automatic verification phase. The PLC controller first reads the initial signals from the pressure sensor and displacement sensor. For example... Figure 4 As shown, the main top hydraulic pressure is acquired by SP1, the lock top hydraulic pressure by SP2, and the main top piston displacement by LL1. All three are connected to the PLC controller through the DVP04AD-S analog input module. To suppress strong electromagnetic interference in the field, each channel of this module uses an independent common terminal (COM1~COM3), and the sensor signal lines are laid with shielded cables. The shielding layer is uniformly connected to the FG (Frame Ground) terminal of the module, effectively improving the stability and accuracy of analog signal acquisition.

[0056] At this point, the PLC determines whether the main jacking / locking hydraulic pressure is within the effective range of 0-60MPa, whether the main jacking displacement is within the stroke range of 0-225mm, whether the target tension force does not exceed 110% of the design anchoring force, and whether the communication between the control host and the PLC is normal. If any condition is not met, the system pops up an error message (such as "sensor disconnection" or "parameter over-limit"), and maintains the current parameter interface, allowing the user to correct and re-verify without clearing the entered station number, borehole number, and working mode, greatly improving on-site fault tolerance. Correspondingly, refer to Figure 7 The oil pump motor has a rated power of 2.2kW, which meets the system's maximum flow rate of 2L / min and pressure requirement of 60MPa.

[0057] After the verification is passed, the PLC starts the automatic tensioning process, such as... Figure 1 As shown. First, control the start and stop of the oil pump motor, and drive the solenoid valve assembly to operate. For example... Figure 5 and Figure 7 As shown, the solenoid valve group includes YV1 (main jack oil inlet), YV2 (main jack oil return), YV3 (lock jack oil inlet), YV4 (lock jack oil return), and YV5 (pressure relief solenoid valve). The PLC controls the energization of each solenoid valve through intermediate relays KA1 to KA6. In the initial stage, YV1 is energized and YV2 is de-energized, the main jack jack injects oil and pressurizes, applying tension to the anchor cable. When the force value approaches the target value, it enters the load-holding and pressure-maintaining stage; if the measured tension force drops below the target value +CO2 (CO2 is a negative value, such as -5kN) due to material relaxation or leakage, the PLC automatically triggers pressure compensation, reopening YV1. When the force value rises back to above the target value +CO3 (CO3 is a positive value, such as +3kN), pressure compensation stops. This dynamic pressure compensation mechanism based on CO2 / CO3 achieves true closed-loop control, fundamentally solving the problem of compensation difficulties in manual operation.

[0058] After the load stabilizes, the system performs a locking operation. Specifically, YV3 is energized, the locking jack injects oil to clamp the anchor, and the current tension is transferred to the locking jack. Subsequently, YV1 is de-energized and YV2 is energized, the main jack depressurizes and retracts, achieving a non-destructive exit. Throughout the process, the displacement sensor continuously monitors the piston stroke of the main jack. The system automatically calculates the theoretical elongation based on the selected elongation calculation mode (national standard or industry standard formula) and verifies its consistency with the measured value. For example, the system converts the measured oil pressure into tension force based on the regression equation (such as F=a1×P+b1) in the jack calibration report, and then calculates the theoretical elongation by combining the elastic modulus E, anchor cable length L, and cross-sectional area A. If the deviation is too large, it can indicate possible abnormalities such as slippage or jamming, assisting technicians in judging the condition of the anchor cable.

[0059] It's worth noting that the PLC controller has a built-in non-volatile memory unit that caches the current tensioning stage, applied force value, holding time, and displacement data in real time. Even in the event of a sudden power outage in the field, the system can automatically load the interrupted state after power is restored and continue executing the remaining process from the point of interruption, avoiding duplicate operations or data loss, and greatly enhancing the system's robustness. For example, this memory unit can be integrated inside the PLC or connected to an external EEPROM module, and can save the most recent 10 sets of tensioning interruption data even after a power outage.

[0060] All data from the entire tensioning process—including time, force, displacement, hydraulic pressure, mode, station number, and borehole number—are sent from the PLC to the control host, and then... Figure 11 The curve is displayed in real time on the monitoring interface. Furthermore, the control host uploads structured data to the remote management platform via 4G / WiFi network, meeting the data synchronization requirements for determining the load distribution type (such as stable, decreasing, and mixed) during the inspection and evaluation of prestressed anchor cables on highway slopes, thus truly establishing a data link between on-site construction and cloud-based evaluation.

[0061] In addition, such as Figure 6 As shown, the pressure relief solenoid valve YV5 can be forcibly triggered by the PLC when tensioning is completed or when an abnormal working condition (such as overpressure or communication interruption) is detected. This quickly opens the hydraulic circuit to release pressure, driving the main jack and locking jack to reset rapidly, preventing the equipment from operating under pressure for a long time and ensuring the safety of personnel and equipment.

[0062] Furthermore, the system supports multi-level data query and export functions, enabling end-to-end data collaboration from on-site operations to remote evaluation. For example... Figure 12 As shown, the remote management platform query interface provides global data retrieval based on project, station number, hole number, and other dimensions. Technicians can view the tensioning history, status trend, and abnormal alarm records of each anchor cable in real time through the web interface, meeting the needs of long-term monitoring and centralized management of highway slope engineering.

[0063] At the same time, such as Figure 13 As shown, the control host's data query interface is used for local device data backtracking. Specific tasks can be filtered by tensioning time period on the control host, facilitating on-site verification and quality traceability. For example... Figure 14As shown, the interface for querying detailed data and curves for each station and borehole number supports in-depth analysis of the tensioning process for any station or borehole number, including force-time curves, displacement-time curves, statistics of the number of pressure replenishments, and elongation verification results. Technicians can observe the trend of the force-time curve during the load-bearing phase to determine the current load level and decay pattern of the anchor cable: if the curve remains stable, it indicates that the anchor cable is in a stable state; if the force value continuously decreases over time, it is a decreasing type, suggesting material relaxation or ground creep; if it shows a phased decay followed by stabilization, it is classified as a mixed type. This analysis result can be directly used for long-term slope stability assessment and provides a basis for decision-making regarding whether to initiate compensatory tensioning.

[0064] like Figure 15 As shown, the data export interface allows users to choose to export the current task or all historical data as CSV, Excel or PDF format. The exported content includes complete original data tables and corresponding graphs, ensuring that the data is portable, auditable and shareable, and meets the acceptance requirements of third-party testing agencies or regulatory agencies.

Claims

1. An intelligent slope compensation tensioning and holding load detection system, characterized in that... include: The control unit is used to select the working mode and set the tensioning parameters; The PLC controller is communicatively connected to the control host. The oil pump motor is controlled to start and stop by the PLC controller. The solenoid valve assembly includes multiple solenoid valves for controlling the oil inlet of the main jack, the oil return of the main jack, the oil inlet of the lock jack, and the oil return of the lock jack, respectively. The solenoid valve assembly is driven by the PLC controller. The main jack and the locking jack perform tensioning, locking, or releasing operations on the anchor cable through the action of the solenoid valve group, respectively. Pressure sensors are configured to collect main top oil pressure and lock top oil pressure; A displacement sensor, configured to collect the piston displacement of the main jack; The PLC controller, based on the tensioning parameters and the real-time signals from the pressure and displacement sensors, controls the oil pump motor and solenoid valve group to perform staged pressurization, load holding, and pressure replenishment operations, and sends the tensioning process data to the control host.

2. The intelligent slope compensation tensioning and holding load detection system as described in claim 1, characterized in that... The control host is also configured to upload the tensioning process data to a remote management platform via a network.

3. The intelligent slope compensation tensioning and holding load detection system as described in claim 1, characterized in that... The working modes include "single detection", "compensation tensioning" and "secondary detection". Each working mode corresponds to an independently stored parameter set, which includes at least the target tension force, holding time and preset deviation threshold.

4. The intelligent slope compensation tensioning and holding load detection system as described in claim 3, characterized in that... The parameter set also includes elongation calculation mode options, which include calculation methods based on national standards and calculation methods based on industry standards; the theoretical elongation is automatically calculated according to the selected calculation mode and its consistency is checked with the measured displacement.

5. The intelligent slope compensation tensioning and holding load detection system as described in claim 3, characterized in that... The pressure replenishment operation is dynamically executed based on the preset deviation threshold: pressure replenishment is started when the measured tension force is less than the sum of the target tension force and the lower deviation CO2, and pressure replenishment is stopped when the measured tension force is greater than the sum of the target tension force and the upper deviation CO3, where CO2<0 and CO3>0.

6. The intelligent slope compensation tensioning and holding load detection system as described in claim 1, characterized in that... Before starting automatic tensioning, the PLC controller performs data verification, which includes determining whether the main jacking oil pressure and the locking jacking oil pressure are within the range of 0-60MPa, whether the main jacking displacement is within the range of 0-225mm, whether the target tension force does not exceed 110% of the design anchoring force, and whether the communication status between the control host and the PLC is normal.

7. The intelligent slope compensation tensioning and holding load detection system as described in claim 6, characterized in that... If the data verification fails, the current parameter interface is maintained, allowing the user to correct the parameters or check the equipment and then re-trigger the verification, while retaining the entered station number, borehole number, and working mode.

8. The intelligent slope compensation tensioning and holding load detection system as described in claim 1, characterized in that... The PLC controller has a built-in non-volatile storage unit for caching the current tensioning stage, applied force value, holding time, and displacement data. When power is restored after a power outage, the system automatically loads the breakpoint state and continues the remaining tensioning process from the point of interruption.

9. The intelligent slope compensation tensioning and holding load detection system as described in claim 1, characterized in that... The pressure sensor and displacement sensor are connected to the PLC controller through an analog input module. Each input channel of the analog input module has an independent common terminal and is connected to the sensor through a shielded cable. The shielding layer is connected to the shielding grounding terminal of the module.

10. The intelligent slope compensation tensioning and holding load detection system as described in claim 1, characterized in that... The solenoid valve assembly also includes a pressure relief solenoid valve, which is used to control the hydraulic circuit to quickly release pressure when tensioning is completed or an abnormal working condition is detected, so as to reduce the amount of anchor cable retraction when the main jack and locking jack are reset.

Images