High-performance concrete production system and method

Abstract

The invention discloses a high-performance concrete production system and method. The system comprises a discharging platform, a plurality of storage tanks, a spiral conveyor, a weighing belt conveyor, a belt lifting conveyor, a mixing plant, a cement storage tank, a coal ash storage tank, a spiral feeding conveyor, an additive tank body and a control system. A vibrating screen plate is arranged at the top of the storage tank, and the rear end controls discharging through overturning of a hydraulic cylinder; a double-horizontal-shaft stirrer is arranged in the stirring station, and an atomizing nozzle is integrated to spray an additive; and each storage tank accurately measures powder through a weighing sensor. The production method comprises the steps of aggregate pretreatment, accurate weighing, lifting and feeding, powder adding, additive atomizing and spraying and stirring and discharging. According to the invention, aggregate screening, multi-component accurate proportioning, additive uniform dispersion and efficient stirring are realized, the problems of difficult quality control, low proportioning precision, non-uniform stirring and the like in high-performance concrete production are solved, and the mechanical property, durability and production efficiency of concrete are improved.

Description

Technical Field

[0001] This invention relates to the field of building materials production technology, specifically a production system and method for high-performance concrete. Background Technology

[0002] As the world's most widely used building material, concrete's performance directly affects the quality, durability, and safety of construction projects. High-performance concrete (HPC) is widely used in important infrastructure projects such as high-rise buildings, long-span bridges, and marine engineering due to its excellent mechanical properties, durability, and workability. However, the production process of high-performance concrete is more complex than that of ordinary concrete, mainly in the following aspects: (1) High requirements for raw materials: High-performance concrete requires the use of various aggregates (such as crushed stone of different particle sizes, manufactured sand, and natural sand) and cementing materials (such as cement, fly ash, and mineral powder), and has strict requirements for the particle size distribution, moisture content, and mud content of raw materials. Traditional production systems lack effective pretreatment processes, resulting in large fluctuations in the quality of raw materials, which affects the performance of the final product. (2) Stringent requirements for mix proportion accuracy: The strength, durability, and other indicators of high-performance concrete are extremely sensitive to the mix proportion accuracy of its components. Traditional methods of relying on manual experience or simple mechanical weighing are difficult to achieve precise and synchronous control of aggregates, powders and admixtures. Weighing errors can easily lead to substandard concrete performance. (3) Complex mixing process: The mixing of high-performance concrete requires ensuring that each component, especially trace admixtures, is evenly distributed in the mixture. Traditional mixers often have dead zones in the mixing process, and the admixtures are added in a rough manner (usually by direct pouring), which can easily lead to local concentrations that are too high or too low, affecting the homogeneity and workability of the concrete. (4) Low level of automation and intelligence: Most existing production lines are semi-automated, with each link operating independently and lacking a unified and coordinated control system. Changes in the state of materials (such as the moisture content of aggregates) during the production process cannot be responded to and adjusted in real time, resulting in poor product quality stability.

[0003] Currently, traditional concrete production equipment, including aggregate bins, belt conveyors, and mixing units, focuses on material transportation and simple mixing. However, it lacks functions such as aggregate pretreatment, precise weighing and coordinated control, and dynamic adjustment based on material state, making it difficult to meet the production requirements of high-performance concrete. Therefore, there is an urgent need in this field for an integrated, automated, and intelligent high-performance concrete production system capable of achieving precise management throughout the entire process, from raw material pretreatment, accurate proportioning, efficient mixing to quality control. Summary of the Invention

[0004] The primary objective of this invention is to overcome the shortcomings of existing technologies and provide a production system and method for high-performance concrete. This system, through integrated design and intelligent control, solves problems such as difficulty in controlling raw material quality, low proportioning accuracy, uneven mixing, and low automation in the production of high-performance concrete, thereby achieving stable, efficient, and high-quality production of high-performance concrete.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A high-performance concrete production system includes a discharge platform with multiple storage troughs arranged side-by-side on the platform. Each storage trough has a discharge port on its rear side wall, and a pneumatic gate valve is installed on the discharge port. A screw conveyor is installed on the rear side of each storage trough, with the inlet of the screw conveyor located below the discharge port. A weighing belt conveyor is installed below the screw conveyor. The discharge end of the weighing belt conveyor has a discharge hopper, and a belt lifting conveyor for tilting and lifting aggregates to a mixing plant is connected below the discharge hopper. A mixer is installed inside the mixing plant to mix aggregates. The station has multiple cement storage tanks and multiple fly ash storage tanks on both sides; each tank is equipped with a screw feeder at the bottom, with the feed end of the screw feeder connected to the discharge port of the tank, and the discharge end extending into the mixing station and connected to the mixer; it also includes an admixture tank, with a circulation pump and a booster pump installed at the lower end of the admixture tank. The circulation pump is connected to the top and bottom of the admixture tank through a pipeline, and the booster pump is connected to the atomizing nozzle inside the mixer through a pipeline; the pneumatic gate valve, screw conveyor, weighing belt conveyor, screw feeder, circulation pump and booster pump are all connected to the control system.

[0006] Furthermore, the rear end of each storage trough is hinged to the unloading platform; a hydraulic cylinder is installed on each side of each storage trough, with the base of the hydraulic cylinder hinged to the unloading platform and the telescopic rod end of the hydraulic cylinder hinged to the bracket on the side wall of the storage trough, used to drive the storage trough to tilt backward; the top of each storage trough is set as an open opening and is equipped with a screen plate, one end of the screen plate is hinged to the front end of the storage trough via a hinge, and the other end is elastically connected to the side wall of the storage trough via a spring, and a vibration motor is fixedly installed on the screen plate; the vibration motor is connected to the control system and is used to start the vibratory screening when aggregate is added. The mesh size of the screen plate is configured according to the aggregate particle size, with a mesh size of 5-10mm for manufactured sand and natural sand troughs and a mesh size of 20-30mm for crushed stone troughs, to ensure effective screening without clogging.

[0007] Furthermore, the mixer includes a mixing chamber, with a feed inlet on the top side wall of one end of the mixing chamber and a feeding hopper thereon. Two mixing shafts are installed inside the mixing chamber, each shaft being rotatably connected at both ends to the front and rear side walls of the mixing chamber. Each mixing shaft has multiple mixing blades. A drive mechanism for rotating the mixing shafts is installed on the outer wall of the front end of the mixing chamber. Two main spray pipes are installed on the side walls at both ends of the mixing chamber. One end of each main spray pipe is connected to a main spray pipe via a connecting pipe. Multiple branch spray pipes are installed on each main spray pipe. One end of each branch spray pipe is connected to the main spray pipe, and the other end extends through the side wall of the mixing chamber and into its interior, where an atomizing nozzle is installed. A dust suction port is located at the top of the mixing chamber and connected to a dust suction pipe, which is connected to a pulse bag filter to reduce dust pollution. A discharge port is located at the bottom of the mixing chamber and connected to a discharge pipe, which has a discharge valve.

[0008] Furthermore, each of the storage tanks includes a support, on which a tank body is mounted. The lower end of the tank body is a conical hopper connected to a discharge pipe, which is equipped with a discharge valve. The discharge pipe is connected to the inlet of a screw feeder via a flexible telescopic pipe. The conveying pipe of the screw feeder is fixedly connected to the support. Multiple weighing sensors are arranged around the tank body. The lower end of each weighing sensor is fixedly connected to a lower sensor seat on the support, and the upper end is fixedly connected to an upper sensor seat on the side wall of the tank body. The weighing sensors are connected to a control system for real-time monitoring of the powder weight, with a control accuracy of ±0.5%.

[0009] Furthermore, the control system includes a PLC controller and a touch screen. The PLC controller adopts the Siemens S7-1500 series, and the touch screen size is no less than 12 inches. The control system integrates a formula management module, a data recording module, and a fault diagnosis module. The signals from the weighing belt conveyor and the weighing sensor are connected to the PLC through an analog input module. The PLC's digital output module controls the pneumatic gate valve, hydraulic cylinder, screw conveyor, drive mechanism, circulating pump, and booster pump. The control system is also connected to an aggregate moisture content detector (such as a microwave moisture content detector) to adjust the water addition in real time to ensure an accurate water-cement ratio.

[0010] This invention also provides a method for producing high-performance concrete, comprising the following steps: (1) Aggregate pretreatment: The manufactured sand, natural sand, 16-31.5mm crushed stone and 5-20mm crushed stone are respectively loaded into the corresponding storage tanks. The vibrating motor is started to drive the screen plate to vibrate. The vibration frequency is 20-50Hz and the vibration time is 2-5 minutes to screen the aggregate and remove oversized particles and impurities. (2) Aggregate weighing and conveying: The control system controls the hydraulic cylinder to flip the storage tank according to the preset ratio. The flipping angle is 10-20°. The pneumatic gate valve is opened so that the aggregate is discharged from the discharge port to the screw conveyor. The screw conveyor conveys the aggregate to the weighing belt conveyor at a rate of 80-120t / h for weighing. The feeding stops after the preset weight is reached. The aggregate ratio is set according to the concrete strength grade. The mass ratio of manufactured sand to natural sand is 1:1-1:2, and the mass ratio of 16-31.5mm crushed stone to 5-20mm crushed stone is 1:1-1:3. The weighing accuracy is controlled within ±1%. (3) Aggregate lifting: The weighed aggregate falls into the belt conveyor through the unloading hopper and is lifted to the mixer at the top of the concrete mixing plant; (4) Powder addition: The powder in the cement storage tank and fly ash storage tank is accurately weighed by the screw feeder and added to the mixer through the side window of the mixer. The weighing sensor monitors the weight in real time with an accuracy of ±0.5%. (5) Adding admixtures: Start the circulation pump to circulate and mix the admixtures in the admixture tank for 1-3 minutes, and then spray the admixtures into the mixer at a pressure of 0.5-1.0 MPa through the booster pump and atomizing nozzle. The amount of admixture added is 1-3% of the total mass of the cementitious material, and the spraying time is 30-60 seconds, which also plays a role in dust suppression. (6) Mixing and discharging: Start the mixer to mix the aggregate, powder and additives. The mixing shaft speed is 30-40 r / min and the mixing time is 120-180 seconds. After mixing, the aggregate is discharged from the discharge port into the tanker.

[0011] Preferably, in step (2), the aggregate weighing adopts fast and slow feeding control. When the weighing weight reaches 95-98% of the preset value, the screw conveyor switches to low speed mode for fine feeding to improve accuracy. In step (5), the admixture spraying and stirring are carried out simultaneously. The spraying direction of the atomizing nozzle is towards the center area of ​​the material flow formed by the stirring blades to ensure uniform dispersion.

[0012] The production method is applicable to high-performance concrete with strength grades of C30-C80. The cementitious materials include cement and fly ash, with the fly ash content being 10-30% of the total mass of the cementitious materials. The control system automatically adjusts the mixing time and the amount of admixtures added according to the ambient temperature and humidity to adapt to different working conditions.

[0013] The beneficial effects of this invention are: 1. This invention achieves quantitative feeding and precise weighing of aggregates through the coordinated control of a hydraulic tilting storage tank, a screw conveyor, and a weighing belt conveyor, with the error controlled within ±1%; powder addition is achieved through a screw weighing conveyor and a weighing sensor, with an accuracy of ±0.5%, meeting the strict proportioning requirements of high-performance concrete.

[0014] 2. The screen plate and vibrating motor of this invention can remove impurities and oversized particles from the aggregate during the material storage process, prevent clogging and segregation, and improve the uniformity of concrete; the vibration parameters are adjustable to adapt to different aggregates.

[0015] 3. The twin-shaft mixer of the present invention, combined with atomizing nozzles, sprays additives to ensure uniform distribution of trace components and avoid excessively high local concentrations; the spraying system integrates dust reduction function to improve the working environment.

[0016] 4. The PLC control system of this invention integrates formula management, data recording and real-time adjustment functions, realizes the coordinated addition of aggregates, powders and admixtures and process monitoring, significantly shortens the production time of a single batch and improves efficiency by more than 30%.

[0017] 5. The modular design of this invention facilitates maintenance and expansion; the hinged and hydraulic drive of the storage tank is stable and reliable, extending the equipment's lifespan; the weighing sensor directly monitors the tank's weight, reducing sources of error. Attached Figure Description

[0018] To more clearly illustrate the technical solution of the present invention, the drawings used in the implementation examples will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a three-dimensional structural diagram of the present invention; Figure 3 Appendix to this invention Figure 2 A magnified schematic diagram of the structure at position I; Figure 4 This is a schematic diagram of the front structure of the storage tank of the present invention; Figure 5 This is a schematic diagram of the rear structure of the storage tank of the present invention; Figure 6 This is a schematic diagram of the mixer installation structure inside the mixing plant of the present invention; Figure 7 This is a three-dimensional structural diagram of the mixer of the present invention; Figure 8 This is a schematic diagram of the internal structure of the mixer of the present invention; Figure 9 This is a schematic diagram of the internal structure of the storage tank of the present invention.

[0020] In the picture: 1-Unloading platform, 2-Storage tank, 3-Hinge, 4-Discharge port, 5-Pneumatic gate valve, 6-Hydraulic cylinder, 7-Screw plate, 8-Hinge, 9-Spring, 10-Vibration motor, 11-Screw conveyor, 12-Weighing belt conveyor, 13-Unloading hopper, 14-Belt lifting conveyor, 15-Mixing plant, 16-Mixer, 160-Feeding hopper, 161-Mixing box, 162-Mixing shaft, 163-Mixing blades, 164-Driver Components: 165-Spray main pipe, 166-Spray header pipe, 167-Spray branch pipe, 168-Dust suction pipe, 169-Discharge pipe, 170-Discharge valve, 17-Cement storage tank, 18-Fly ash storage tank, 19-Screw feeder; 20-Atomizing nozzle; 21-Support; 22-Tank body; 221-Discharge pipe; 222-Flexible telescopic pipe; 223-Weighing sensor, 24-Admixture tank, 25-Circulation pump, 26-Booster pump. Detailed Implementation

[0021] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0022] Please see Figure 1-9 A high-performance concrete production system includes a discharge platform 1 with multiple storage tanks 2 arranged side by side on the discharge platform 1; each storage tank 2 has a discharge port 4 on its rear side wall, and a pneumatic gate valve 5 is installed on the discharge port 4; a screw conveyor 11 is installed on the rear side of each storage tank 2, the inlet of the screw conveyor 11 is located below the discharge port 4, and a weighing belt conveyor 12 is installed below the screw conveyor 11; the discharge end of the weighing belt conveyor 12 is provided with a discharge hopper 13, and a belt lifting conveyor 14 for tilting and lifting aggregates to a mixing plant 15 is connected below the discharge hopper 13; A mixer 16 is installed inside the mixing plant 15. Multiple cement storage tanks 17 and multiple fly ash storage tanks 18 are set on both sides of the mixing plant 15. A screw feeder 19 is installed at the bottom of each storage tank. The feed end of the screw feeder 19 is connected to the discharge port of the storage tank, and the discharge end extends into the mixing plant 15 and is connected to the mixer 16. It also includes an admixture tank 24. A circulation pump 25 and a booster pump 26 are installed at the lower end of the admixture tank 24. The circulation pump 25 is connected to the top and bottom of the admixture tank 24 through a pipeline. The booster pump 26 is connected to the atomizing nozzle 20 inside the mixer 16 through a pipeline.

[0023] In some embodiments, see Figure 2 , 34, 5. The rear end of each storage trough 2 is hinged to the unloading platform 1 via hinge 3; a hydraulic cylinder 6 is installed on each side of each storage trough 2, the base of the hydraulic cylinder 6 is hinged to the unloading platform 1, and the telescopic rod end of the hydraulic cylinder 6 is hinged to the bracket on the side wall of the storage trough 2 to drive the storage trough 2 to flip backward; the top of each storage trough 2 is set as an open opening and a screen plate 7 is installed, one end of the screen plate 7 is hinged to the front end of the storage trough 2 via hinge 8, and the other end is elastically connected to the side wall of the storage trough 2 via spring 9, and a vibration motor 10 is fixedly installed on the screen plate 7; the vibration motor 10 is connected to the control system and is used to start the vibrating screening when aggregate is added, the mesh size of the manufactured sand and natural sand bins is 5-10mm, and the mesh size of the crushed stone bins is 20-30mm.

[0024] In some embodiments, see Figure 2 , 3 4, 5, The mixer 16 includes a mixing chamber 161. A feed inlet is located on the top side wall of one end of the mixing chamber 161, and a feeding hopper 160 is provided at the feed inlet. Two mixing shafts 162 are installed inside the mixing chamber 161. Each mixing shaft 162 is rotatably connected at both ends to bearings in bearing seats fixedly installed on the front and rear side walls of the mixing chamber 161. Multiple mixing blades 163 are installed on each mixing shaft 162. A drive mechanism 164 for driving the mixing shafts 162 to rotate is installed on the outer wall of the front end of the mixing chamber 161. Two spray pipes 165 are installed on the side walls at both ends of the mixing chamber 161. 5 One end is fixedly connected to the spray main pipe 166 via a connecting pipe. Multiple spray branch pipes 167 are fixedly installed on each spray main pipe 165. One end of each spray branch pipe 167 is fixedly connected to the spray main pipe 165, and the other end extends through the side wall of the mixing box 161 into its interior and is equipped with an atomizing nozzle 20. A dust suction port is provided at the top of the mixing box 161 and is sealed and connected to a dust suction pipe 168. The dust suction pipe 168 is connected to a pulse bag dust collector. A discharge port is provided at the bottom of the mixing box 161. The discharge port is connected to a discharge pipe 169. A discharge valve 170 is fixedly installed on the discharge pipe 169 to control the discharge of the material from the discharge pipe 169.

[0025] In some embodiments, see Figure 9 Each storage tank includes a support 21, on which a tank body 22 is mounted. The lower end of the tank body 22 is a conical hopper connected to a discharge pipe 221. A discharge valve is installed on the discharge pipe 221. The discharge pipe 221 is connected to the inlet of the screw feeder 19 through a flexible telescopic pipe 222. The conveying pipe of the screw feeder 19 is fixedly connected to the support 21. Multiple weighing sensors 223 are installed around the tank body 22. The lower end of each weighing sensor 223 is fixedly connected to a lower sensor seat installed on the support 21, and the upper end is fixedly connected to an upper sensor seat installed on the side wall of the tank body 22. The weighing sensors 223 are connected to the control system.

[0026] In the above embodiments, the control system includes a PLC controller and a touch screen. The PLC controller adopts the Siemens S7-1500 series, and the touch screen size is not less than 12 inches. The control system integrates a formula management module, a data recording module, and a fault diagnosis module. The signals from the weighing belt conveyor 12 and the weighing sensor 223 are connected to the PLC through the analog input module. The PLC's digital output module controls the pneumatic gate valve 5, the hydraulic cylinder 6, the screw conveyor 11, the drive mechanism 164, the circulating pump 25, and the booster pump 26. The control system is also connected to an aggregate moisture content detector for real-time adjustment of the water addition.

[0027] In the above embodiments, the pneumatic gate valve 5, screw conveyor 11, weighing belt conveyor 12, screw feeder 19, circulating pump 25, and booster pump 26 are all connected to the control system. This invention also provides a method for producing high-performance concrete, comprising the following steps: S1. Aggregate pretreatment: Load the manufactured sand, natural sand, 16-31.5mm crushed stone and 5-20mm crushed stone into the corresponding storage tanks, start the vibrating motor to drive the screen plate to vibrate, the vibration frequency is 20-50Hz, the vibration time is 2-5 minutes, and the aggregate is screened to remove oversized particles and impurities. S2. Aggregate Weighing and Conveying: The control system controls the hydraulic cylinder to tilt the storage tank according to the preset ratio. The tilting angle is 10-20°, and the pneumatic gate valve is opened to allow the aggregate to be discharged from the outlet to the screw conveyor. The screw conveyor conveys the aggregate to the weighing belt conveyor at a rate of 80-120t / h for weighing. Feeding stops after the preset weight is reached. The aggregate ratio is set according to the concrete strength grade. The mass ratio of manufactured sand to natural sand is 1:1-1:2, and the mass ratio of 16-31.5mm crushed stone to 5-20mm crushed stone is 1:1-1:3. The weighing accuracy is controlled within ±1%. S3. Aggregate Lifting: The weighed aggregate falls through the unloading hopper onto the belt conveyor and is lifted to the mixer at the top of the concrete mixing plant. S4. Powder addition: The powder in the cement storage tank and fly ash storage tank is accurately weighed by a screw feeder and added to the mixer through the side window of the mixer. The weighing sensor monitors the weight in real time with an accuracy of ±0.5%. S5. Adding admixtures: Start the circulation pump to circulate and mix the admixtures in the admixture tank for 1-3 minutes. Then, use a booster pump and atomizing nozzle to spray the admixtures into the mixer at a pressure of 0.5-1.0 MPa. The amount of admixture added is 1-3% of the total mass of the cementitious material. The spraying time is 30-60 seconds, which also helps to reduce dust. S6. Mixing and Discharging: Start the mixer to mix the aggregates, powders and additives. The mixing shaft speed is 30-40 r / min and the mixing time is 120-180 seconds. After mixing, the aggregates are discharged from the discharge port into the tanker truck.

[0028] In the above embodiments, in step (2), the aggregate weighing adopts fast and slow feeding control. When the weighing weight reaches 95-98% of the preset value, the screw conveyor switches to low speed mode for fine feeding. In step (5), the additive spraying and stirring are carried out simultaneously, and the spraying direction of the atomizing nozzle is towards the center area of ​​the material flow formed by the stirring blade.

[0029] The production method according to claim 7 is characterized in that: the production method is applicable to high-performance concrete with strength grades of C30-C80, the cementitious materials include cement and fly ash, and the fly ash content is 10-30% of the total mass of the cementitious materials; the control system automatically adjusts the mixing time and the amount of admixture added according to the ambient temperature and humidity. To describe the structure of the present invention in more detail, the high-performance concrete production system of this embodiment should include the following components: 1. Site layout and equipment installation A flat and solid site was selected to construct the unloading platform 1. The platform is a reinforced concrete structure, with dimensions of approximately 20m long × 8m wide × 1.5m high. Four steel storage troughs 2 are installed side by side on the platform, each with dimensions of 4m long × 2m wide × 2m high, for storing manufactured sand, natural sand, 5-20mm crushed stone, and 16-31.5mm crushed stone, respectively. Each storage trough 2 is hinged to the platform via a hinge 3 at the rear bottom. A hydraulic cylinder 6 with a rated thrust of 10 tons is installed on each side of each trough, with centralized hydraulic oil supply.

[0030] 2. Aggregate pretreatment and distribution Each storage hopper 2 is topped with a screen plate 7. The screen plate 7 is made of manganese steel woven mesh, and the mesh size is determined according to the maximum particle size of the aggregate stored (for example, 30mm x 30mm square holes for stone hoppers and 10mm x 10mm square holes for sand hoppers). The front end of the screen plate 7 is fixed by hinges 8, and the rear end is supported by four sets of springs 9. Each screen plate is equipped with a YZO series vibratory motor 10 with a power of 1.5kW. The vibration parameters of the vibratory motor 10 are set by the control system according to the type of material (e.g., higher vibration frequency and longer duration for sand to facilitate dust removal).

[0031] Aggregate is delivered sequentially through storage tank 2, pneumatic gate valve 5, screw conveyor 11 (power 7.5kW, conveying capacity 80t / h), weighing belt conveyor 12 (width 800mm, weighing accuracy 0.5 grade), unloading hopper 13, and belt lifting conveyor 14 (inclination angle 18°, lifting height 15m) to the feeding hopper 160 of mixer 16. An arched isolation cover is installed above the belt lifting conveyor 14 along its length to prevent material from overflowing from the belt lifting conveyor 14 and to prevent dust generated during conveying from directly overflowing and causing environmental pollution. The arched isolation cover is connected to a dust collector through a pipe to collect dust.

[0032] 3. Addition of powder and additives The mixing plant 15 has four 100-ton cement storage tanks 17 and two 50-ton fly ash storage tanks 18 on both sides. Each tank is connected to a screw feeder 19 at the bottom. The powder is fed directly into the mixer 16 through a closed pipeline.

[0033] Admixture system: A 10m³ stainless steel admixture tank 24, equipped with a circulation pump 25 (1.1kW power) and a booster pump 26 (3kW power, 0.8MPa pressure). The outlet pipe of the booster pump 26 is connected to the mixer spray header 166.

[0034] 4. Mixing unit The mixer 16 is a twin-shaft forced mixer with a capacity of 3 m³. The mixing chamber 161 contains two mixing shafts 162, driven by two 45kW motors via a gearbox, rotating in opposite directions at 35 r / min. The spray system includes two main spray pipes 165, each equipped with six stainless steel atomizing nozzles, directed towards the center of the material flow formed by the mixing blades 163. A top suction pipe 168 connects to a pulse-jet bag filter.

[0035] 5. Control System The control system utilizes a Siemens S7-1500 series PLC as its core, equipped with a 12-inch color touchscreen. The program includes automatic, manual, recipe management, and data logging functions. All weighing sensor signals are input to the PLC via analog input modules, and the PLC's digital output modules control contactors, relays, and other drive mechanisms.

[0036] Example 1: Production of C60 high-performance concrete The following formula (per cubic meter) is used to produce C60 high-performance concrete using this system: Cement (PO 52.5): 450kg Fly ash (Grade I): 80kg Manufactured sand: 650kg Natural sand: 350kg 5-20mm crushed stone: 550kg 16-31.5mm crushed stone: 650kg Water-reducing agent (polycarboxylate-based): 2.0% of the total mass of cementitious materials (530kg), i.e., 10.6kg. Water: 140kg (adjust according to the moisture content of sand and gravel) Production steps: System preparation: The operator selects the "C60" formula on the touch screen, and the system starts after self-checking. Different aggregates are poured into the corresponding storage tank 2, and the vibrating motor 10 starts automatically, vibrating at a frequency of 30Hz for 3 minutes to perform screening and dust removal.

[0037] Aggregate weighing: The control system controls hydraulic cylinder 6 to tilt the manufactured sand storage trough to 15°, opens pneumatic gate valve 5, and screw conveyor 11 feeds material at a rate of 100t / h. When the weighing belt conveyor 12 displays a weight of 630kg (97%), it switches to low-speed mode and feeds finely to 650kg (error ±5kg). The same process is used to weigh other aggregates.

[0038] Aggregate lifting: After weighing, the aggregates are fed into the mixer 16 via the elevator 14 in the order of coarse aggregates. The mixing shaft 162 starts at a low speed of 20 r / min.

[0039] Powder addition: Screw feeder 19 conveys cement and fly ash, weighing sensor 223 monitors in real time, cement 450kg±2kg, fly ash 80kg±0.4kg.

[0040] Additive addition: Circulation pump 25 runs for 2 minutes, and booster pump 26 sprays water-reducing agent at a pressure of 0.8MPa for 45 seconds, while simultaneously removing dust.

[0041] Mixing and discharging: The mixer is switched to high-speed mode (35r / min), and the material is discharged after mixing for 150 seconds.

[0042] The slump of the finished concrete reaches 200±20mm, and the standard deviation of its strength is <3.0MPa.

[0043] Example 2: Production of C30 High-Performance Concrete Formula adjustment: The fly ash content was increased to 30%, and the mixing time was shortened to 120 seconds. The control system automatically adjusts the amount of admixture added based on the ambient temperature. Other steps are the same as in Example 1.

[0044] In addition, this invention was compared with a conventional concrete production system using traditional aggregate bins, a simple belt scale, and a single-shaft mixer. The test product was C60 high-performance concrete, and the results are shown in Table 1. Table 1 The weighing accuracy errors of aggregates and powders in Table 1 were reduced by at least 50% and 100%, respectively, reaching industry-leading levels of ≤±1% and ≤±0.5%. The water-cement ratio, crucial to concrete performance, saw its fluctuation range reduced by 200%, achieving high stability. The standard deviation of concrete strength between batches was reduced by more than 50%, ensuring highly consistent and reliable performance for each batch.

[0045] This invention achieves metering accuracy far exceeding that of traditional systems by controlling the hydraulic tilting structure, screw feeder, weighing belt, and integrated weighing sensor in the storage tank. This results in extremely stable key indicators of concrete, such as the water-cement ratio and final strength, and significantly reduced batch-to-batch variations.

[0046] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention.

Claims

1. A system for producing high performance concrete, characterized by: The application relates to a material discharging platform, which comprises a discharging platform (1) provided with multiple material storage grooves (2) side by side on the discharging platform (1); a discharge port (4) is formed in the rear end side wall of each material storage groove (2), and a pneumatic gate valve (5) is arranged on the discharge port (4); a screw conveyor (11) is arranged at the rear side of each material storage groove (2), the feeding port of the screw conveyor (11) is located below the discharge port (4), and a weighing belt conveyor (12) is arranged below the screw conveyor (11); a discharging hopper (13) is arranged at the discharging end of the weighing belt conveyor (12), a belt lifting conveyor (14) for obliquely lifting the aggregate to a stirring station (15) is connected below the discharging hopper (13); a stirrer (16) is arranged in the stirring station (15), multiple cement storage tanks (17) and multiple fly ash storage tanks (18) are arranged at the two sides of the stirring station (15); a screw feeding conveyor (19) is arranged at the bottom of each storage tank, the feeding end of the screw feeding conveyor (19) is connected with the discharge port of the storage tank, and the discharging end of the screw feeding conveyor (19) extends into the stirring station (15) and is connected with the stirrer (16); the material discharging platform further comprises an additive tank (24), a circulating pump (25) and a booster pump (26) are arranged at the lower end of the additive tank (24), the circulating pump (25) is connected with the top and bottom of the additive tank (24) through pipelines, and the booster pump (26) is connected with an atomizing nozzle (20) in the stirrer (16) through a pipeline.

2. The production system of high performance concrete according to claim 1, characterized in that, The rear end of each material storage groove (2) is hinged to the discharging platform (1) through a hinge (3); one hydraulic cylinder (6) is arranged at each side of each material storage groove (2), the base of the hydraulic cylinder (6) is hinged to the discharging platform (1), the telescopic rod end of the hydraulic cylinder (6) is hinged to the support of the side wall of the material storage groove (2) and is used for driving the material storage groove (2) to overturn to the rear side; the top of each material storage groove (2) is provided with an open top and is provided with a sieve plate (7), one end of the sieve plate (7) is hingedly connected to the front end of the material storage groove (2) through a hinge (8), the other end of the sieve plate (7) is elastically connected to the side wall of the material storage groove (2) through a spring (9), and a vibrating motor (10) is fixedly arranged on the sieve plate (7); the vibrating motor (10) is connected with a control system and is used for starting the vibrating screening when the aggregate is added, the mesh of the machine-made sand and natural sand bin is 5-10 mm, and the mesh of the gravel bin is 20-30 mm.

3. The production system of high performance concrete according to claim 1, wherein, The stirring machine (16) comprises a stirring box body (161), a feeding port is arranged on the top side wall of one end of the stirring box body (161), a feeding hopper (160) is arranged on the feeding port, two stirring shafts (162) are arranged in the stirring box body (161), the two ends of each stirring shaft (162) are rotationally connected with the front and rear side walls of the stirring box body (161) respectively, a plurality of stirring blades (163) are arranged on each stirring shaft (162), a driving mechanism (164) for driving the stirring shaft (162) to rotate is arranged on the outer wall of the front end of the stirring box body (161); two spraying main pipes (165) are arranged on the side walls of the two ends of the stirring box body (161), one end of each spraying main pipe (165) is connected to a spraying main pipe (166) through a connecting pipe, a plurality of spraying branch pipes (167) are arranged on each spraying main pipe (165), one end of each spraying branch pipe (167) is connected with the spraying main pipe (165), the other end of each spraying branch pipe (167) extends to the inside of the stirring box body (161) through the side wall of the stirring box body (161) and is provided with an atomizing nozzle (20); a dust suction port is arranged on the top of the stirring box body (161) and is connected with a dust suction pipe (168), the dust suction pipe (168) is connected with a pulse bag-type dust collector; a discharge port is arranged on the bottom of the stirring box body (161), the discharge port is connected with a discharge pipe (169), and a discharge valve (170) is arranged on the discharge pipe (169).

4. The production system of high performance concrete according to claim 1, wherein, Each of the storage tanks comprises a support (21), a tank body (22) is arranged on the support (21), the lower end of the tank body (22) is a conical bin and is connected with a discharge pipe (221), a discharge valve is arranged on the discharge pipe (221), the discharge pipe (221) is connected with the feeding port of the screw feeding conveyor (19) through a flexible expansion pipe (222), the conveying pipe of the screw feeding conveyor (19) is fixedly connected with the support (21), a plurality of weighing sensors (223) are arranged around the tank body (22), the lower end of each weighing sensor (223) is fixedly connected with a lower sensor seat arranged on the support (21), and the upper end of each weighing sensor (223) is fixedly connected with an upper sensor seat arranged on the side wall of the tank body (22); the weighing sensors (223) are connected with a control system.

5. The system for producing high performance concrete according to claim 1, wherein The control system comprises a PLC controller and a touch screen; the control system integrates a formula management module, a data recording module and a fault diagnosis module; the signals of the weighing belt conveyor (12) and the weighing sensors (223) are input into the PLC through an analog input module, and the digital output module of the PLC is electrically connected with the pneumatic gate valve (5), the hydraulic cylinder (6), the screw conveyor (11), the driving mechanism (164), the circulating pump (25) and the booster pump (26).

6. The system for producing high performance concrete according to claim 1, wherein The pneumatic gate valve (5), the screw conveyor (11), the weighing belt conveyor (12), the screw feeding conveyor (19), the circulating pump (25) and the booster pump (26) are connected with the control system.

7. A method for producing high performance concrete, using a method for producing high performance concrete according to any one of claims 1 to 6, characterized in that The method comprises the following steps: S1, aggregate pretreatment: the machine-made sand, natural sand, 16-31.5 mm gravel and 5-20 mm gravel are respectively loaded into the corresponding storage tank, the vibration motor is started to drive the sieve plate to vibrate, the vibration frequency is 20-50 Hz, the vibration time is 2-5 minutes, the aggregate is screened to remove oversized particles and impurities; S2, aggregate weighing and conveying: the control system controls the hydraulic cylinder to overturn the storage tank according to the preset ratio, the overturning angle is 10-20°, the pneumatic gate valve is opened, the aggregate is discharged from the discharge port to the screw conveyor, the screw conveyor conveys the aggregate to the weighing belt conveyor at a rate of 80-120 t / h, and the feeding is stopped when the preset weight is reached; wherein, the aggregate ratio is set according to the concrete strength grade, the mass ratio of machine-made sand to natural sand is 1:1-1:2, the mass ratio of 16-31.5 mm gravel to 5-20 mm gravel is 1:1-1:3, and the weighing accuracy is controlled within ±1%; S3, aggregate lifting: the weighed aggregate falls into the belt lifting conveyor through the discharge hopper and is lifted to the top of the mixer in the concrete mixing station; S4, powder addition: the powders in the cement storage tank and the fly ash storage tank are accurately weighed by the screw feeder, then added into the mixer through the side wall window of the mixer, the weighing sensor monitors the weight in real time, and the accuracy is ±0.5%; S5, additive addition: the circulating pump is started to circulate and mix the additives in the additive tank for 1-3 minutes, then the additives are sprayed into the mixer through the booster pump and the atomizing nozzle at a pressure of 0.5-1.0 MPa, the additive addition amount is 1-3% of the total mass of the cementitious material, and the spraying time is 30-60 seconds, which also plays a role in dust reduction; S6, mixing and discharging: the mixer is started to mix the aggregate, powder and additive, the stirring shaft rotates at a speed of 30-40 r / min, the stirring time is 120-180 seconds, and the mixed concrete is discharged from the discharge port to the tank car after the stirring is completed.

8. A method of producing high performance concrete according to claim 7, characterized in that: In step (2), the aggregate weighing adopts fast and slow feeding control, when the weighing weight reaches 95-98% of the preset value, the screw conveyor switches to low speed mode for fine feeding; in step (5), the additive spraying and stirring are carried out synchronously, and the spraying direction of the atomizing nozzle is towards the center area of the material flow formed by the stirring blades.

9. A method of producing high performance concrete according to claim 7, characterized in that: The production method is suitable for C30-C80 strength grade high performance concrete, the cementitious material includes cement and fly ash, the fly ash content is 10-30% of the total mass of the cementitious material; the control system automatically adjusts the mixing time and the additive addition amount according to the environmental temperature and humidity.

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