Intelligent maintenance system and maintenance method for subway station concrete

Abstract

The invention discloses an intelligent maintenance system and method for subway station concrete, and the maintenance system at least comprises a maintenance shed, a water energy moisturizing film, a spraying pipe, a steam pipe, a maintenance water heater, a temperature sensor and a central control system. Curing temperature and humidity are scientifically set, quality problems such as cracks caused by too large temperature difference of concrete are effectively avoided, the strength and durability of the concrete are improved, the curing quality is improved, further, the most appropriate curing environment can be provided according to the requirements of different curing stages of the concrete, fine management of the curing process is achieved, and the maintenance efficiency is improved. The condition of excessive or insufficient maintenance is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of concrete curing, in particular to a subway station concrete intelligent curing system and a curing method. BACKGROUND

[0002] In foreign countries, concrete intelligent curing technology has been widely applied to curing systems based on Internet of Things and sensor technology. The advantages of this technology are mature technology and high automation, but the equipment cost is high, and the adaptability of the system to the complex construction environment of subway stations needs to be improved.

[0003] In China, the current concrete curing still mainly relies on traditional manual curing combined with simple temperature control equipment. Traditional manual curing methods, such as watering curing and covering curing, have the disadvantages of high labor intensity, unstable curing effect, and difficulty in accurately controlling temperature and humidity changes during the curing process. Although some construction units have tried to introduce intelligent curing concepts, most of them are imitations of foreign technologies, and there are deficiencies in equipment integration, data processing capacity, and adaptation to the construction characteristics of subway stations. In addition, the existing curing methods cannot flexibly combine multiple curing devices according to the needs of different curing stages of concrete, effectively control temperature and humidity, easily cause over-curing or under-curing, lack accurate monitoring and calculation of key indicators during the curing process, and cannot provide reliable basis for curing decisions, which is not conducive to improving curing efficiency and reducing costs. SUMMARY

[0004] The purpose of the present application is to overcome the problem that the existing curing devices and methods cannot monitor the temperature of the core, surface and curing environment of concrete in real time and accurately, resulting in the inability to scientifically set the planned temperature and humidity of curing, and affecting the quality of concrete curing.

[0005] To achieve the above purpose, the present application provides a subway station concrete intelligent curing system, which comprises at least:

[0006] A curing shed, the shed body side of the curing shed is provided with a plurality of ventilation openings, and the temperature in the curing shed is adjusted by adjusting the ventilation amount;

[0007] A water energy moisturizing film, which is used to lay on the surface of the concrete to maintain the moisture state of the concrete surface;

[0008] A spray pipe, which is arranged in the curing area, is connected with a water supply system, and the opening time and flow of the water supply valve are controlled to spray the concrete surface;

[0009] A steam pipe, which is installed at the bottom of the curing shed, is connected with a steam generator, and the output amount of steam is controlled by adjusting the power of the steam generator and the opening ratio of the valve of the steam pipe;

[0010] A curing water heater is connected to the spray pipe and is used to heat the spray water.

[0011] A temperature sensor, wherein the temperature sensor is placed in the concrete core and on the surface;

[0012] A central control system is used to collect data from the temperature sensor.

[0013] Optionally, the temperature sensor includes an ambient temperature sensor, a surface temperature sensor, and a core temperature sensor.

[0014] Optionally, the core temperature sensor is a platinum resistance temperature sensor.

[0015] Optionally, the surface temperature sensor is a patch-type temperature sensor.

[0016] Optionally, the maintenance shed is made of aluminum alloy.

[0017] Optionally, it also includes a data transmission module, which is connected to the temperature sensor and the central control system.

[0018] Optionally, it also includes an integrated temperature and humidity sensor.

[0019] Optionally, an electric valve is installed at the vent.

[0020] This invention also provides a curing method for an intelligent concrete curing system for subway stations. After the concrete is poured, the intelligent curing system is activated. The central control system receives data from temperature sensors, and plots the concrete core temperature, surface temperature, and curing environment temperature in real time. Based on preset temperature difference thresholds and humidity ranges, it analyzes the data to determine whether the current curing status is normal. If it is not normal, the central control system automatically adjusts the curing measures.

[0021] Optionally, when the temperature difference is too large, open the electric valve at the ventilation opening of the curing shed to increase the ventilation volume and lower the temperature inside the curing shed; control the spray pipe to spray water or start the steam pipe according to the humidity data.

[0022] Compared to the prior art, the beneficial effects of the present invention include at least the following:

[0023] (1) This invention accurately monitors the temperature of the concrete core, surface and environment in real time, calculates the temperature difference, and scientifically sets the curing temperature and humidity, effectively avoiding quality problems such as cracks caused by excessive temperature difference in concrete, improving the strength and durability of concrete, and improving the curing quality.

[0024] (2) The present invention can flexibly combine curing devices, and can provide the most suitable curing environment according to the needs of different curing stages of concrete, realize the refined management of the curing process, and reduce the situation of over- or under-curing.

[0025] (3) Accurately monitor key indicators, reasonably control the operating time and parameters of the curing device, avoid resource waste, reduce energy consumption and labor costs during the curing process, and improve concrete quality to reduce later maintenance costs.

[0026] (4) The intelligent curing system of the present invention can quickly respond to the curing needs of concrete, automatically adjust the curing measures, shorten the curing cycle, and speed up the construction progress of subway stations. Attached Figure Description

[0027] Figure 1 This is a diagram showing the arrangement of the curing shed and temperature sensor according to the present invention.

[0028] Figure 2 This is a structural schematic diagram of the intelligent concrete curing system for subway stations according to the present invention. Detailed Implementation

[0029] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0030] like Figure 1 and Figure 2 As shown, the present invention provides an intelligent concrete curing system for subway stations, the curing system comprising at least:

[0031] The curing shed has multiple ventilation openings on its side, and the temperature inside the curing shed can be regulated by adjusting the ventilation volume.

[0032] A water-energy moisturizing membrane is used to lay on the concrete surface to maintain the moisture of the concrete surface.

[0033] A spray pipe is installed in the curing area and is connected to a water supply system. The opening time and flow rate of the water supply valve are controlled to spray and cure the concrete surface.

[0034] A steam pipe is installed at the bottom of the curing shed and is connected to a steam generator. The steam output is controlled by adjusting the power of the steam generator and the opening ratio of the valve on the steam pipe.

[0035] A curing water heater is connected to the spray pipe and is used to heat the spray water.

[0036] A temperature sensor, wherein the temperature sensor is placed in the concrete core and on the surface;

[0037] A central control system is used to collect data from the temperature sensor.

[0038] The temperature sensor system includes an ambient temperature sensor, a surface temperature sensor, and a core temperature sensor. A high-precision temperature sensor, such as a platinum resistance temperature sensor, is embedded in the concrete core, leveraging its high stability and measurement accuracy to acquire real-time internal concrete temperature data. A patch-type temperature sensor is used on the concrete surface to ensure close contact and accurate surface temperature measurement. Simultaneously, an integrated temperature and humidity sensor is installed in the curing environment to comprehensively monitor ambient temperature and humidity. Data collected by these sensors is transmitted in real-time to the central control system via a data transmission module.

[0039] The curing shed is a lightweight structure, constructed with a high-strength, lightweight aluminum alloy frame and thermal insulation materials, providing excellent heat retention and effectively reducing heat loss from the curing area. Multiple ventilation openings are located on the inner side of the shed, controlled by electric valves to regulate the internal temperature by adjusting the ventilation volume.

[0040] The water-energy moisturizing membrane has the characteristics of absorbing water, retaining water and slowly releasing water. After the water-energy moisturizing membrane is laid on the concrete surface, it can maintain the moist state of the concrete surface.

[0041] The spray pipes are arranged around the perimeter of the curing area, with nozzles evenly distributed on them. The spray pipes are connected to the water supply system, and the spray curing of the concrete surface is achieved by controlling the opening time and flow rate of the water supply valves.

[0042] The steam pipe is installed at the bottom of the curing shed and connected to the steam generator. By adjusting the power of the steam generator and the opening ratio of the steam pipe valve, the steam output is controlled to provide a suitable temperature and humidity environment for the concrete.

[0043] The curing water heater is used to heat the spray water to ensure that the spray water temperature meets the curing requirements in a low-temperature environment. The curing water heater is equipped with a temperature control system that can automatically adjust the heating power according to the set temperature.

[0044] In the early stages of concrete curing, when the heat of hydration is high, lightweight curing sheds combined with water-based moisturizing membranes are preferred. The temperature inside the shed is regulated through ventilation openings, while the water-based moisturizing membrane maintains surface humidity. As the concrete strength increases, spray water to cool and moisturize the concrete as needed, depending on the temperature difference. In low-temperature environments, steam pipes and curing water heaters are activated to increase the temperature and humidity of the curing environment.

[0045] The central control system calculates the following key indicators based on the real-time collected temperature and humidity data:

[0046] Lightweight curing shed curing time: Based on the temperature difference between the concrete core and surface, and the temperature difference between the surface and the environment, when the temperature difference exceeds the set range, start the lightweight curing shed and record its running time until the temperature difference returns to normal.

[0047] Water-energy moisturizing membrane curing time: By monitoring the humidity of the concrete surface, when the humidity is lower than the set lower limit, water is replenished into the water-energy moisturizing membrane.

[0048] Spraying frequency of the sprinkler pipes: Based on the changes in concrete surface temperature and humidity, and combined with preset temperature and humidity thresholds, the interval between each spraying of water by the sprinkler pipes is calculated, i.e., the spraying frequency. For example, when the surface temperature is too high and the humidity is low, the spraying interval is shortened; conversely, it is lengthened.

[0049] Steam pipe jetting frequency: The jetting interval of the steam pipe is calculated using an algorithm based on the ambient temperature and the temperature difference between the concrete core and surface. When the ambient temperature is low and the temperature difference between the concrete interior and surface is large, the jetting frequency is increased; when the temperature tends to stabilize, the jetting frequency is decreased.

[0050] Curing water heater temperature value: Based on the ambient temperature and the water temperature required for concrete curing, the control system automatically calculates and sets the target temperature value of the curing water heater to ensure that the spray water temperature is appropriate.

[0051] 1. Construction preparation stage

[0052] Sensor Selection and Procurement: Based on the requirements, a high-precision platinum resistance temperature sensor was selected as the concrete core temperature sensor, with a measurement accuracy of ±0.1℃, meeting the need for accurate monitoring of the concrete core temperature. For the concrete surface patch temperature sensor, a product with fast response speed and good adhesion was chosen.

[0053] Customization and Preparation of Curing Equipment: A lightweight curing shed will be customized based on the actual dimensions and shape of the concrete pouring area in the subway station. The aluminum alloy frame material must meet strength requirements, and the insulation material must have a low thermal conductivity. After customization, the welding quality of the frame and the firmness of the insulation material installation will be checked. A water-based moisture-retaining membrane will be prepared, ensuring good water retention and no damage. Spray pipes and steam pipes of suitable diameter, as well as a steam generator and curing water heater with appropriate power, will be purchased. All equipment will be checked for external damage and completeness of accessories.

[0054] Site Layout Planning: A dedicated concrete curing area will be planned at the subway station construction site. The ground in the curing area will be cleaned to ensure it is flat and firm, facilitating the construction of lightweight curing sheds and the installation of other curing equipment. The placement of equipment such as steam generators and curing water heaters will be rationally arranged, ensuring both convenient operation and safe operation.

[0055] 2. Installation and debugging phase

[0056] Sensor Installation: Before concrete pouring, accurately embed the concrete core temperature sensors according to the designed depth and spacing by binding them to the reinforcing steel frame. Sufficient length of sensor leads should be reserved, and waterproof and anti-squeezing protection measures should be taken. After the concrete has initially set, attach patch-type temperature sensors to the surface at predetermined positions, ensuring a tight fit between the sensors and the concrete surface without air bubbles or gaps. During the construction of the lightweight curing shed, simultaneously install an integrated temperature and humidity sensor for the curing environment, fix it in the preset position, and adjust the angle to ensure accurate sensing of ambient temperature and humidity.

[0057] Installation of curing equipment: Construct a lightweight curing shed, assembling the aluminum alloy frame and surface polycarbonate panels according to the design plan, ensuring the frame structure is stable. Install thermal insulation materials, firmly attaching them with special adhesive and sealing all joints. Install electric valves for ventilation openings on the sides of the shed and connect the control circuitry. Lay steam pipes, ensuring the pipe connections are sealed and there is no risk of leakage. Install sprinkler pipes, adjusting the nozzle angles to ensure even water coverage. Connect the curing water heater to the water supply pipes, ensuring tight connections and no leaks. Lay a water-energy moisture-retaining membrane on the concrete surface, starting from one end and slowly unfolding it, smoothing out wrinkles to ensure complete coverage of the concrete surface.

[0058] System Debugging: After installing the sensors and curing devices, system debugging is performed. The data transmission module is activated to check if sensor data can be transmitted normally to the central control system, and to verify the accuracy and stability of the data display. Each curing device is tested individually. For example, the steam generator is started, and the steam output from the steam pipe is observed. The steam valve opening is adjusted to check the sensitivity of the control. The sprinkler system is started, and the operation of the water pump and the spraying of the nozzles are tested. The water supply valve is adjusted to check the flow control effect. The curing water heater is tested, and different temperatures are set to check if its heating and temperature control functions are normal. The electric valves of the ventilation openings of the lightweight curing shed are operated to check if the opening and closing are smooth. Problems encountered during debugging are promptly investigated and resolved to ensure the normal operation of all parts of the system.

[0059] 3. Maintenance and Operation Phase

[0060] Data Monitoring and Analysis: After concrete pouring, the intelligent curing system is officially activated. The central control system continuously receives data transmitted from sensors and plots real-time curves of concrete core temperature, surface temperature, and ambient temperature and humidity changes. Based on preset temperature difference thresholds and humidity ranges, the system automatically analyzes the data to determine whether the current curing status is normal. If the temperature difference between the concrete core and surface, or between the surface and the environment, is abnormal, the system determines the temperature difference is abnormal and issues an early warning signal.

[0061] Automatic Adjustment of Curing Measures: Based on data analysis, the central control system automatically adjusts curing measures. When the temperature difference is too large, the electric valves of the ventilation openings in the lightweight curing shed are opened to increase ventilation and lower the temperature inside the shed. Simultaneously, depending on the humidity, the system controls the spray pipes to spray water or activates the steam pipes to supplement humidity. For example, if the surface temperature is too high and the humidity is too low, the system automatically shortens the spray interval and increases the water volume; if the ambient temperature is low, the system activates the steam generator and curing water heater to raise the temperature and humidity of the curing environment. Throughout the curing process, the system dynamically adjusts the operating parameters of the curing devices according to the characteristics of different curing stages of concrete (such as the heating period, constant temperature period, and cooling period) to ensure that the curing environment always meets the requirements for concrete curing.

[0062] Key performance indicator (KPI) recording and evaluation: The system records key performance indicators in real time, including curing time in the lightweight curing shed, curing time in the water-energy moisturizing film, spray frequency from the sprinkler pipes, steam jet frequency from the steam pipes, and temperature of the curing water heater. These indicators are periodically summarized and analyzed to evaluate the curing effect. Based on feedback on the curing effect, the system's preset parameters are optimized and adjusted. For example, if slow concrete strength growth is observed in a certain area, and analysis indicates that the curing temperature is too low, the steam jet frequency or the curing water heater temperature setting can be appropriately increased to improve the curing effect.

[0063] 4. End of maintenance phase

[0064] Curing effect testing: After the concrete reaches the curing age required for its design strength, various performance tests are conducted on the concrete test blocks cured under the same conditions, including compressive strength and impermeability. Simultaneously, the concrete surface is inspected for defects such as cracks and sandblasting, and the impact of the curing process on the appearance quality of the concrete is assessed.

[0065] System Equipment Dismantling and Maintenance: After curing is completed and the concrete test results are satisfactory, dismantle the intelligent curing system equipment. First, turn off the power to all curing devices, drain the water from the steam pipes, spray pipes, and curing water heaters to prevent freezing and cracking in winter. Dismantle the lightweight curing shed, sort and organize the aluminum alloy frame and insulation materials, and store them properly for future use. Disassemble the sensors, clean them, and check their performance; replace any damaged or degraded sensors. Perform comprehensive maintenance on all equipment, such as adding lubricating oil to the steam generator and curing water heater, checking for loose circuit connections, and replacing any worn parts to prepare for future use.

[0066] In summary, this invention provides an intelligent concrete curing system for subway stations. The system includes at least: a curing shed, a water-energy moisturizing membrane, spray pipes, steam pipes, a curing water heater, temperature sensors, and a central control system. By accurately monitoring the concrete core, surface, and ambient temperature in real time, it precisely calculates the temperature difference and scientifically sets the curing temperature and humidity, effectively preventing quality problems such as cracks caused by excessive temperature differences in the concrete. This improves the strength and durability of the concrete, enhances the curing quality, and further, provides the most suitable curing environment according to the needs of different curing stages, achieving refined management of the curing process and reducing over- or under-curing.

[0067] Although the present invention has been described in detail through the preferred embodiments above, it should be understood that the above description should not be considered as a limitation of the present invention. Various modifications and substitutions to the present invention will be apparent to those skilled in the art after reading the above description. Therefore, the scope of protection of the present invention should be defined by the appended claims.

Claims

1. A smart concrete curing system for subway stations, characterized in that, The maintenance system includes at least: a maintenance shed, wherein multiple ventilation openings are provided on the side of the maintenance shed, and the temperature inside the maintenance shed is regulated by adjusting the ventilation volume; A water-energy moisturizing membrane is used to lay on the concrete surface to maintain the moisture of the concrete surface. A spray pipe is installed in the curing area and is connected to a water supply system. The opening time and flow rate of the water supply valve are controlled to spray and cure the concrete surface. A steam pipe is installed at the bottom of the curing shed and is connected to a steam generator. The steam output is controlled by adjusting the power of the steam generator and the opening ratio of the valve on the steam pipe. A curing water heater is connected to the spray pipe and is used to heat the spray water. A temperature sensor, wherein the temperature sensor is placed in the concrete core and on the surface; A central control system is used to collect data from the temperature sensor.

2. The intelligent concrete curing system for subway stations as described in claim 1, characterized in that, The temperature sensor includes an ambient temperature sensor, a surface temperature sensor, and a core temperature sensor.

3. The intelligent concrete curing system for subway stations as described in claim 2, characterized in that, The core temperature sensor is a platinum resistance temperature sensor.

4. The intelligent concrete curing system for subway stations as described in claim 2, characterized in that, The surface temperature sensor is a patch-type temperature sensor.

5. The intelligent concrete curing system for subway stations as described in claim 1, characterized in that, The maintenance shed is made of aluminum alloy.

6. The intelligent concrete curing system for subway stations as described in claim 1, characterized in that, It also includes a data transmission module, which is connected to the temperature and humidity sensor and the central control system.

7. The intelligent concrete curing system for subway stations as described in claim 1, characterized in that, It also includes an integrated temperature and humidity sensor.

8. The intelligent concrete curing system for subway stations as described in claim 1, characterized in that, An electric valve is installed at the ventilation opening.

9. A curing method for a concrete intelligent curing system for subway stations as described in claims 1 to 8, characterized in that, After the concrete is poured, the intelligent curing system is activated. The central control system receives data from the temperature sensor and plots the concrete core temperature, surface temperature, and curing environment temperature in real time. It analyzes the data based on preset temperature difference thresholds and humidity ranges to determine whether the current curing status is normal. If it is not normal, the central control system automatically adjusts the curing measures.

10. The maintenance method as described in claim 9, characterized in that, When the temperature difference is too large, open the electric valve at the ventilation opening of the curing shed to increase the ventilation volume and lower the temperature inside the curing shed; control the spray pipe to spray water or start the steam pipe according to the humidity data.

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