Control system of intelligent mortar grouting device

Abstract

The invention provides a control system for an intelligent mortar grouting device, and the system comprises a multi-source information sensing module which is used for obtaining the multi-dimensional state information of a grouting process in real time; the decision adaptive module is used for dynamically generating a grouting strategy based on the multi-dimensional state information; the execution driving module is used for executing the grouting strategy; and the man-machine interaction module is used for performing integrated management and interaction on the grouting strategy and the multi-dimensional state information, so that comprehensive real-time monitoring, dynamic strategy generation and accurate execution of the grouting process are realized, grouting parameters can be dynamically adjusted according to the multi-dimensional state information acquired in real time, the stability and consistency of grouting quality are ensured, and the grouting efficiency is improved. And meanwhile, the construction efficiency is improved, manual intervention is reduced, and the efficiency and the intelligent level of building engineering construction are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of construction engineering construction equipment, and particularly relates to a control system of an intelligent mortar grouting device. BACKGROUND

[0002] In traditional construction engineering construction, mortar grouting operations usually rely on manual operation or simple mechanical auxiliary equipment.

[0003] However, manual operation has many drawbacks, such as large differences in the skill levels of operators, leading to unstable grouting quality, and problems such as uneven mortar consistency, incomplete filling, and excessive air bubbles, which in turn affect the stability and durability of the building structure. In addition, manual grouting is low in efficiency and difficult to meet the strict requirements of modern construction engineering on construction progress and quality. With the continuous development of the construction industry, higher requirements are put forward for the precision, efficiency and automation level of mortar grouting, and the traditional manual operation method has been unable to meet the needs of modern construction engineering. SUMMARY

[0004] The present application provides a control system of an intelligent mortar grouting device to solve the technical problems of unstable grouting quality and low efficiency caused by manual operation in the prior art.

[0005] In one aspect, the present application provides a control system of an intelligent mortar grouting device, comprising: a multi-source information perception module for real-time acquisition of multi-dimensional state information of the grouting process; a decision adaptive module for dynamically generating a grouting strategy based on the multi-dimensional state information; an execution driving module for executing the grouting strategy; a human-computer interaction module for integrated management and interaction of the grouting strategy and the multi-dimensional state information.

[0006] Optionally, the multi-source information perception module comprises: a consistency perception unit for real-time detection of the consistency of the mortar, which comprises an ultrasonic-based rheological property sensor and a torque sensor mounted on the stirring shaft, and the consistency value of the current mortar is calculated through data fusion; a flow and pressure perception unit for real-time monitoring of the mortar flow and outlet pressure of the grouting pipeline; a positioning and filling state unit for identifying the spatial position of the grouting point and evaluating the filling fullness of the grouting area, which comprises a 3D vision sensor and a millimeter wave radar sensor integrated in the grouting gun head.

[0007] Optionally, the decision adaptive module comprises: a process knowledge base unit storing optimal grouting parameters under different working conditions and different material proportions; a real-time state analyzer unit configured to receive multi-dimensional state information and compare the information with data in the process knowledge base unit to identify a deviation between a current state and a target state; an adaptive strategy generator unit configured to dynamically adjust a pumping speed, a stirring speed, and a movement trajectory of the grout nozzle head to eliminate the deviation when the deviation is detected; wherein the adaptive strategy generator unit is configured to adjust a water adding device and / or a dry material adding device of the stirring unit to correct the consistency when the consistency perception unit detects that the consistency of the mortar exceeds a preset threshold.

[0008] Optionally, the system further comprises: a bubble monitoring and suppression module comprising a vibration sensor and an acoustic array embedded in a wall of the grouting pipeline, configured to detect a content and a size distribution of bubbles in the mortar; The decision adaptive module is further configured to control the execution driving module to adjust an inclination angle of the stirring blade, increase the stirring speed, and trigger the vibration sensor of the grouting pipeline to work to facilitate the bubbles to escape when the content of the bubbles exceeds a safety threshold.

[0009] Optionally, the positioning and filling state unit is configured to: perform a three-dimensional scanning of the grouting area by a 3D vision sensor to construct a three-dimensional point cloud model of the area to be filled; during the grouting process, dynamically calculate a filled volume and an unfilled volume by comparing real-time point cloud data with a preset three-dimensional model, and identify a filling blind area; the adaptive strategy generator unit plans a movement path of the grout nozzle head according to the filling blind area and controls the execution driving module to drive the grout nozzle head to perform supplementary grouting.

[0010] Optionally, the positioning and filling state unit is further configured to: after the filling blind area is identified, diagnose a form and a cause of the filling blind area in combination with data of the flow and pressure perception unit to obtain a diagnosis result; wherein the diagnosis includes: distinguishing a first blind area caused by insufficient flowability of the mortar from a second blind area caused by improper grouting path; the adaptive strategy generator unit adopts different supplementary grouting strategies according to different diagnosis results: for the first blind area, increase a local pumping pressure; for the second blind area, re-plan a path of the mechanical arm for multi-angle filling.

[0011] Optionally, distinguishing the first blind area caused by insufficient flowability of the mortar from the second blind area caused by improper grouting path includes: For each identified filling blind area, its multi-dimensional features are extracted to construct a blind area feature vector; wherein the multi-dimensional features include the volume-to-surface area ratio of the blind area calculated based on the three-dimensional point cloud model, the average included angle obtained by analyzing the normal direction of the blind area boundary point cloud and the main flow direction of the grouting gun head, and the average outlet pressure and fluctuation variance recorded by the flow and pressure sensing unit during grouting in the area; The blind area feature vector is input into a pre-trained classification model, which diagnoses according to a preset rule; The preset rule includes: When the volume-to-surface area ratio of the blind area is less than a first threshold value and the average outlet pressure is higher than a second threshold value, it is diagnosed as a first blind area caused by insufficient slurry fluidity; When the average included angle of the blind area boundary is greater than a third threshold value and the outlet pressure fluctuation variance is lower than a fourth threshold value, it is diagnosed as a second blind area caused by improper grouting path.

[0012] Optionally, the adaptive strategy generator unit is also used for: Performing dynamic pressure ramp control logic for optimizing the stability of the filling front at the beginning of grouting or at the beginning of supplementary grouting, including: After the grouting gun head moves to a new filling starting point according to the planned path, the control execution driving module is controlled to start the outlet pressure of the grouting pipeline at an initial pressure lower than the stable working pressure; The initial flow front morphology of the slurry in the area to be filled is monitored by the positioning and filling state unit; If the initial flow front morphology is uniformly advanced, the outlet pressure is raised to the stable working pressure at a preset first slope; If the initial flow front morphology shows a phenomenon of uneven diffusion or uneven diffusion, the outlet pressure is adjusted back to a stable pressure lower than the initial pressure and maintained for a preset time, and then the pressure is raised to the stable working pressure at a second slope smaller than the first slope after the flow front morphology is restored to be uniform.

[0013] Optionally, it also includes: A material adaptability module is used to control the execution driving module to perform a trial pumping cycle before each grouting operation starts, and record the trial pumping data of the multi-source information sensing module during the trial pumping cycle; By pattern matching the trial pumping data with historical successful case data, the initial control parameters of this operation are automatically adjusted to adapt to the fluctuation of batch raw material characteristics.

[0014] Optionally, the human-computer interaction module includes: An augmented reality display terminal unit is used to virtually display the filling state, grouting path planning information and equipment operating parameters generated by the positioning and filling state unit in the real grouting scene in a see-through superimposed manner; The remote operation and maintenance center interface unit is used for encrypting and transmitting the multi-dimensional state information, the device operation log and the fault alarm information to a remote server.

[0015] The control system of the intelligent mortar grouting device provided by the application realizes comprehensive real-time monitoring, dynamic strategy generation and precise execution of the grouting process through integration of a multi-source information perception module, a decision self-adaptive module, an execution driving module and a man-machine interaction module, can dynamically adjust grouting parameters according to real-time acquired multi-dimensional state information, ensures stability and consistency of grouting quality, improves construction efficiency and reduces manual intervention, and improves efficiency and intelligent level of construction of building engineering. BRIEF DESCRIPTION OF DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the application or prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0017] Figure 1 is one of the structural schematic diagrams of the control system of the intelligent mortar grouting device provided by the embodiment of the application; Figure 2 is the second structural schematic diagram of the control system of the intelligent mortar grouting device provided by the embodiment of the application; Figure 3 is the flow schematic diagram of the control method of the intelligent mortar grouting device provided by the embodiment of the application; Figure 4 is the structural schematic diagram of the electronic device provided by the embodiment of the application. DETAILED DESCRIPTION

[0018] In order to make the purpose, technical scheme and advantages of the application clearer, the technical scheme in the application will be clearly and completely described below in combination with the drawings in the application. Obviously, the described embodiments are some of the embodiments of the application, not all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor belong to the protection scope of the application.

[0019] The intelligent mortar grouting device is a robotic construction platform integrating perception, decision-making and execution capabilities. The hardware core includes an automatic batching and mixing system, a high-precision variable frequency pumping unit and a six-degree-of-freedom mechanical arm with a multifunctional sensor gun head at the end. The entire device is commanded by a central control system, which obtains real-time multi-dimensional information such as mortar consistency, flow pressure and filling state through a torque sensor on the mixing shaft, a flow and pressure sensor on the pipeline and a 3D vision and millimeter wave radar integrated on the gun head. Based on this information, the control system dynamically adjusts the motion trajectory of the mechanical arm, the output parameters of the pump and the working conditions of the mixer, so as to intelligently cope with complex situations such as filling blind area and excessive bubbles, and finally realize the full-process automation, precision and intelligent operation from material preparation to regional filling.

[0020] Figure 1 Figure 1 is a structural schematic diagram of the control system of the intelligent mortar grouting device provided by the embodiment of the present application; Figure 2 Figure 2 is another structural schematic diagram of the control system of the intelligent mortar grouting device provided by the embodiment of the present application.

[0021] Referring to Figure 1 and Figure 2 , the control system 100 of the intelligent mortar grouting device includes a multi-source information perception module 110, a decision adaptive module 120, an execution driving module 130 and a human-computer interaction module 140.

[0022] The multi-source information perception module 110 is used to obtain real-time multi-dimensional state information of the grouting process.

[0023] Among them, the multi-source information perception module 110 refers to a sensor network deployed at the key nodes of the grouting device, which can be realized by combining ultrasonic sensors, torque sensors, pressure sensors and 3D vision sensors, and is used to collect multi-element data such as mortar rheological properties, pipeline pressure and filling state.

[0024] The decision adaptive module 120 is used to dynamically generate a grouting strategy based on multi-dimensional state information.

[0025] Among them, the decision adaptive module 120 refers to a control algorithm module with dynamic optimization capability, which can be realized by a fuzzy logic controller based on a process knowledge base unit 121, and generates adjustment instructions by comparing real-time data with target parameters.

[0026] The execution driving module 130 is used to execute the grouting strategy.

[0027] Among them, the execution driving module 130 refers to a power output and an execution mechanism, which can be realized by a variable frequency motor driving pumping device and a six-degree-of-freedom mechanical arm, and accurately controls the mortar flow and grouting trajectory.

[0028] The human-computer interaction module 140 is used for integrated management and interaction of the grouting strategy and multi-dimensional state information.

[0029] The human-computer interaction module 140 is a data visualization and operation interface, which can be implemented by an augmented reality terminal and a remote communication interface, and supports bidirectional interaction of on-site operation and remote monitoring.

[0030] Specifically, the system continuously collects key parameters such as mortar consistency, pipeline pressure, and filling volume through the multi-source information perception module 110, and transmits the data to the decision adaptive module 120 in real time. The decision module analyzes the current state deviation in combination with the preset process rules, and dynamically calculates control parameters such as pumping speed and mixing intensity. The execution driving module 130 adjusts the output power of the pumping device and the motion trajectory of the mechanical arm according to the generated strategy instructions. The human-computer interaction module 140 integrates and displays real-time working condition data and equipment state information, and supports the operator to view the filling progress and adjust the control threshold. The modules realize data intercommunication through an industrial bus, forming a closed-loop control circuit of perception, decision, execution, and feedback.

[0031] In the embodiment, the intelligent mortar grouting device control system integrates the multi-source information perception module 110, the decision adaptive module 120, the execution driving module 130, and the human-computer interaction module 140, realizes comprehensive real-time monitoring, dynamic strategy generation, and accurate execution of the grouting process, dynamically adjusts the grouting parameters according to the real-time multi-dimensional state information, ensures the stability and consistency of the grouting quality, improves the construction efficiency and reduces the manual intervention, and improves the efficiency and intelligent level of construction engineering.

[0032] In an embodiment of the present application, the multi-source information perception module 110 includes: The consistency perception unit 111 is used for real-time detection of the consistency of the mortar, which includes an ultrasonic-based rheological property sensor and a torque sensor installed on the stirring shaft, and the consistency value of the current mortar is calculated through data fusion. The ultrasonic-based rheological property sensor is a device for measuring the rheological properties of mortar by emitting ultrasonic waves and receiving reflected signals, which can be implemented by a pulse echo ultrasonic probe. The viscosity and yield stress of the mortar are derived by analyzing the propagation speed and attenuation degree of the ultrasonic waves in the mortar. The torque sensor on the stirring shaft is a device for measuring the torque on the shaft during stirring, which can be implemented by a strain gauge or a magnetoelastic sensor. The consistency state of the mortar is reflected by the correlation between the torque value and the resistance of the mortar. The data fusion calculation is an algorithm for weighted fusion of ultrasonic measurement data and torque data, which can be implemented by Kalman filtering or a neural network model to eliminate measurement errors of a single sensor and improve the consistency detection accuracy.

[0033] a flow and pressure sensing unit 112 for monitoring the mortar flow and outlet pressure of the grouting pipeline in real time; a positioning and filling state unit 113 for identifying the spatial position of the grouting point and evaluating the filling degree of the grouting area, which includes a 3D visual sensor integrated in the grouting gun head and a millimeter wave radar sensor.

[0034] The 3D visual sensor refers to a device that acquires three-dimensional spatial information through multi-view vision or structured light technology, which can be implemented by a binocular camera combined with a laser speckle projector, and is used to construct a three-dimensional point cloud model of the grouting area. The millimeter wave radar sensor refers to a device that measures distance and speed using millimeter wave electromagnetic waves, which can be implemented by a frequency-modulated continuous wave radar module, and evaluates the filling density by detecting the phase change of the reflected signal during the filling process.

[0035] Specifically, the consistency sensing unit 111 can capture the rheological properties and mixing resistance changes of the mortar in real time through the cooperative work of the ultrasonic sensor and the torque sensor, and eliminate environmental interference and measurement noise by combining data fusion algorithms, so as to accurately reflect the actual working state of the mortar. The flow and pressure sensing unit 112 continuously monitors the mortar conveying dynamics in the grouting pipeline through high-precision flow meters and pressure transmitters, providing basic parameters for subsequent strategy adjustment. The positioning and filling state unit 113 uses the 3D visual sensor to model the grouting area in three dimensions, and combines the penetration detection of the filling interface by the millimeter wave radar, which can identify the position and shape of the unfilled area in real time, and avoid the misjudgment caused by traditional manual visual inspection.

[0036] In this embodiment, through the combined application of multi-modal sensors, the mortar performance, conveying state and filling effect are comprehensively monitored. In particular, the combination of optical three-dimensional scanning and millimeter wave radar technology solves the problem of being unable to penetrate the surface layer of the slurry to detect the internal filling quality. The dual-sensor fusion mechanism of the consistency sensing unit 111 significantly improves the anti-interference ability of the measurement results, and the spatial detection combination of the positioning and filling state unit 113 effectively avoids the filling state misjudgment caused by visual obstruction or surface slurry film coverage, thereby improving the accuracy and reliability of the grouting quality control as a whole.

[0037] In an embodiment of the present specification, the decision self-adaptive module 120 includes: a process knowledge base unit 121 storing optimal grouting parameters under different working conditions and different material ratios; The process knowledge base unit 121 refers to a pre-calibrated grouting parameter database, which can be implemented by a relational database or a time series database, and is used to save the best pumping pressure, mixing speed and other parameter combinations under different mortar ratios, environmental temperature and filling structure morphology.

[0038] a real-time state analyzer unit 122 configured to receive the multi-dimensional state information and compare the received information with data in the process knowledge base unit 121 to identify a deviation between a current state and a target state; The real-time state analyzer unit 122 refers to a data comparison and deviation identification unit, which can be implemented by using an edge computing device to carry an edge computing device to carry a pattern recognition algorithm. The deviation between the real-time collected mortar consistency and flow data and the reference value of the corresponding working condition in the knowledge base is calculated.

[0039] An adaptive strategy generator unit 123 is configured to dynamically adjust the pumping speed, the stirring speed and the movement trajectory of the grouting gun head to eliminate the deviation when the deviation is detected. The adaptive strategy generator unit 123 is configured to adjust the water adding device and / or the dry material adding device of the stirring unit to correct the consistency when the consistency sensing unit 111 detects that the mortar consistency exceeds the preset threshold.

[0040] The adaptive strategy generator unit 123 refers to a dynamic control instruction generation unit, which can be implemented by using a fuzzy PID controller or a reinforcement learning model to trigger corresponding actuator adjustment actions according to the type of deviation. The water adding device refers to an actuator for precise measurement of liquid input, which can be implemented by using an electromagnetic proportional valve and a flowmeter closed-loop control; the dry material adding device refers to a solid material supply mechanism, which can be implemented by using a screw conveyor and a weighing sensor linkage control.

[0041] Specifically, the process knowledge base unit 121 establishes a parameter mapping relationship by accumulating historical grouting engineering data. During the grouting process, the real-time state analyzer unit 122 continuously receives the monitoring values uploaded by the consistency sensing unit 111 and the flow and pressure sensing unit 112, and compares them with the target parameters in the knowledge base that match the current working condition. When it is detected that the mortar consistency deviates from the preset range, the adaptive strategy generator unit 123 generates control instructions according to the deviation direction and magnitude: if the consistency is too high, the opening time ratio of the water adding device is increased or the dry material adding device is started to supplement the fine aggregate; if the consistency is too low, the water supply is reduced or the cementitious material adding amount is increased. At the same time, the pumping speed and the movement trajectory of the grouting gun head are adjusted synchronously according to the real-time filling state, for example, the pumping speed is reduced in the consistency abnormal area to avoid splashing of the slurry.

[0042] In the embodiment, the parameter standardization management is realized by constructing the process knowledge base unit 121, combined with real-time data comparison and automatic control strategy, which can complete the consistency abnormality detection and correction in a short time, and avoid the adjustment overshoot or deficiency caused by manual intervention. The application can quickly trigger the compensation mechanism when the mortar consistency fluctuates, and keep the material rheological properties stable through closed-loop control, thereby effectively preventing the problems of grouting pipe blockage, filling not dense and other problems caused by consistency abnormality, and ensuring the continuity of grouting process and consistency of molding quality.

[0043] In an embodiment of the present specification, the control system 100 of the intelligent mortar grouting device further comprises: The bubble monitoring and suppression module 150 comprises a high-frequency vibration sensor and a micro acoustic array embedded in the wall of the grouting pipeline, which is used to detect the content and size distribution of bubbles in the mortar. The high-frequency vibration sensor refers to a device that detects the vibration frequency spectrum change of the slurry flowing through the pipe wall to identify the bubble characteristics, which can be realized by a piezoelectric ceramic sensor array, which judges the bubble size distribution by analyzing the amplitude attenuation characteristics of a specific frequency band. The micro acoustic array refers to an ultrasonic emission and reception unit arranged at different positions of the pipeline cross section, which can be realized by a micro MEMS microphone array, which locates the spatial position of the bubble by the time difference of sound wave flight.

[0044] The decision adaptive module 120 is further used to: when it is detected that the bubble content exceeds the safety threshold, control the execution driving module 130 to adjust the inclination angle of the stirring blade, increase the stirring speed, and trigger the high-frequency micro vibrator of the grouting pipeline to work, so as to promote the bubble to escape.

[0045] The stirring blade inclination angle adjustment refers to changing the included angle between the stirring blade and the stirring shaft by a hydraulic push rod, which can be realized by a linkage mechanism driven by a servo motor, which enhances the slurry turbulent effect by increasing the blade flow area. The high-frequency micro vibrator refers to a vibration device that can generate mechanical vibration above 20 kHz, which can be realized by an electromagnetic vibrator, which breaks the bubble aggregates and accelerates the gas discharge through high-frequency mechanical waves.

[0046] Specifically, during the grouting operation, the high-frequency vibration sensor collects pipeline vibration signals in real time, and the miniature acoustic array synchronously acquires sound wave propagation data. After fusion processing of the data of the two, a three-dimensional bubble content distribution map is generated. When it is detected that the local area bubble volume ratio exceeds the preset threshold, the decision adaptive module 120 sends a control instruction to the execution driving module 130: first, adjust the stirring blade angle to 45 degrees to enhance the slurry shearing action, and at the same time, increase the stirring speed to 120% of the rated speed; then activate the high-frequency micro-vibrator embedded in the grouting pipeline, and promote the coalescence and floating of micro-bubbles through intermittent vibration for 5 seconds. The process continues until the bubble monitoring data shows that the content falls below the safety threshold.

[0047] In this embodiment, three-dimensional dynamic monitoring of bubbles is achieved through multi-modal sensor fusion technology, and the synergistic effect of mechanical stirring and high-frequency vibration can reduce the bubble content from a dangerous value to a safe range within 30 seconds without interrupting the grouting process. The application realizes real-time monitoring and active inhibition of bubble content during grouting, effectively avoiding the problem of reduced mortar structure strength caused by residual bubbles.

[0048] In an embodiment of the present specification, the positioning and filling state unit 113 is configured to: construct a three-dimensional point cloud model of the to-be-filled area by three-dimensional scanning of the grouting area through a 3D vision sensor; During the grouting process, the filled volume and the to-be-filled volume are dynamically calculated by comparing the real-time point cloud data with the preset three-dimensional model, and the filling blind area is identified; The adaptive strategy generator unit 123 plans the optimal movement path of the grouting gun head according to the filling blind area, and controls the execution driving module 130 to drive the grouting gun head to perform supplementary grouting.

[0049] The three-dimensional point cloud model refers to a three-dimensional data set composed of a large number of spatial coordinate points, which can be generated by point cloud registration and reconstruction algorithm, and is used to accurately represent the three-dimensional structure of the to-be-filled area. The filling blind area refers to a local area that is not covered by the mortar, which can be identified by a difference detection algorithm between real-time point cloud and preset model, and is used to locate the grouting defect position. The optimal movement path refers to a trajectory that meets the coverage of the blind area and has the shortest movement distance, which can be generated by an ant colony algorithm-based path planning method, and is used to guide the precise supplementary grouting operation of the grouting gun head.

[0050] Specifically, before the grouting operation, the 3D vision sensor scans the target area and generates a three-dimensional point cloud model, which contains the volume, shape and spatial position information of the area to be filled. During the grouting process, the real-time collected point cloud data of the grouting area is compared with the preset model, and the filled area and the unfilled area are dynamically identified by calculating the point cloud density difference and the spatial distribution change. When the filling blind area is detected, the adaptive strategy generator unit 123 generates path instructions including moving speed, angle and dwell time based on the location, size and morphological characteristics of the blind area, to drive the six-degree-of-freedom mechanical arm to control the grouting gun head to implement multi-angle supplementary grouting on the blind area.

[0051] In this embodiment, through dynamic comparison of three-dimensional point cloud model and real-time data, the filling progress can be accurately quantified and the blind area can be located, and at the same time, the intelligent path planning algorithm is combined to realize the optimized control of the spatial trajectory of the grouting gun head, effectively solving the problem of incomplete filling in hidden areas. The application can automatically detect three-dimensional filling defects in the grouting process and realize precise supplementary grouting through spatial path planning, thereby eliminating the local unfilled phenomenon caused by complex structure or line-of-sight obstruction.

[0052] In an embodiment of the present specification, the positioning and filling state unit 113 is further configured to: After identifying the filling blind area, the morphology and cause of the filling blind area are diagnosed based on the data of the flow and pressure sensing unit 112 to obtain a diagnosis result; Wherein, the diagnosis includes: distinguishing the first blind area caused by insufficient flowability of the grout from the second blind area caused by improper grouting path; The adaptive strategy generator unit 123 adopts differentiated supplementary grouting strategies according to different diagnosis results: For the first blind area, the instruction increases the local pumping pressure; For the second blind area, the instruction re-plans the mechanical arm path for multi-angle filling.

[0053] Wherein, the morphology and cause diagnosis of the filling blind area refers to establishing a correlation model of the blind area formation mechanism by fusing three-dimensional point cloud data and fluid mechanics parameters, which can be specifically implemented by using a multi-sensor data fusion algorithm combined with a machine learning classifier, for accurately identifying two different failure modes of grout physical property abnormality and equipment motion trajectory defect. The first blind area refers to the flow blocked area caused by abnormal viscosity or insufficient water content of the grout, which can be specifically judged by detecting the abnormal pressure drop of the pipeline through the pressure sensor. The second blind area refers to the unfilled area formed by the motion trajectory of the grouting gun head failing to effectively cover the complex structure, which can be specifically identified by deviation analysis of the three-dimensional point cloud model and the preset path. The differentiated supplementary grouting strategy refers to formulating corresponding control parameter adjustment schemes for different failure mechanisms, which can be specifically implemented by using a decision tree algorithm based on an expert system to ensure accurate matching of the treatment measures and the fault type.

[0054] Specifically, when the filling state unit 113 finds an unfilled area through three-dimensional scanning, the system automatically calls the flow and pressure historical data during the construction of the area, and combines the geometric characteristics of the blind area to perform pattern recognition. If it is determined that the slurry fluidity is insufficient, the local pressure is increased through the frequency conversion pump drive to overcome the flow resistance; if it is determined that the path planning is defective, the six-degree-of-freedom mechanical arm is used to adjust the grouting angle to implement multi-directional supplementary grouting. The whole process does not need manual intervention, and the system selects the optimal processing scheme according to the real-time diagnosis result.

[0055] In the embodiment, by establishing the mapping relationship between the blind area characteristics and the causes, the treatment measures are accurately corresponding to the specific failure modes, which not only avoids the energy waste caused by invalid pressurization, but also prevents the repeated defects caused by path errors. The application effectively solves the quality hidden danger caused by the single treatment mode of the blind area in the traditional grouting operation, can implement targeted treatment for the two different problem sources of slurry performance abnormalities and equipment motion errors, and significantly improves the filling integrity and construction reliability of complex structure grouting.

[0056] In an embodiment of the present application, the first blind area caused by insufficient slurry fluidity and the second blind area caused by improper grouting path are distinguished, comprising: For each identified filling blind area, its multi-dimensional characteristics are extracted to construct a blind area feature vector; wherein the multi-dimensional characteristics include the ratio of the volume and surface area of the blind area calculated based on the three-dimensional point cloud model, the average included angle obtained based on the analysis of the normal direction of the blind area boundary point cloud and the main flow direction of the grouting gun head, and the outlet pressure average and fluctuation variance recorded by the flow and pressure sensing unit 112 during grouting in the area; The blind area feature vector is input into a pre-trained classification model, and the classification model diagnoses according to a preset rule; The preset rule includes: When the volume-to-surface area ratio of a blind area is less than a first threshold value and the outlet pressure average is higher than a second threshold value, the blind area is diagnosed as a first blind area caused by insufficient slurry fluidity; When the average included angle of the blind area is greater than a third threshold value and the outlet pressure fluctuation variance is lower than a fourth threshold value, the blind area is diagnosed as a second blind area caused by improper grouting path.

[0057] The volume-surface area ratio refers to the ratio of the volume of the blind area to the surface area thereof, and can be calculated by using a three-dimensional point cloud processing algorithm. The ratio reflects the compactness of the shape of the blind area. The blind area formed due to insufficient fluidity usually has a long and narrow shape, resulting in a low ratio. The average included angle refers to the average included angle between the normal direction of the point cloud of the boundary of the blind area and the main flow direction of the nozzle head. The average included angle can be obtained by vector space calculation. The boundary of the blind area caused by improper path usually has a direction mutation, resulting in an increased included angle. The average outlet pressure and the fluctuation variance refer to statistical parameters recorded by the pressure sensor during the grouting process. The statistical parameters can be obtained in real time by using a data acquisition system. When the fluidity is insufficient, a higher pressure is required to maintain the flow, resulting in an increased average value. The pressure fluctuation caused by improper path is small, resulting in a decreased variance.

[0058] Specifically, during the grouting process, when the positioning and filling state unit 113 detects a filling blind area, the volume-surface area ratio, the average included angle of the boundary normal, and the outlet pressure data of the corresponding region of the blind area are first extracted. After standardization, these features form a feature vector, which is input into a classification model trained by historical data in advance. The model makes a judgment according to a preset threshold rule: if the volume-surface area ratio is lower than a set value and the average pressure is higher than a threshold value, it is determined that the first type of blind area is caused by insufficient fluidity of the grout; if the average included angle exceeds the threshold value and the pressure variance is lower than the threshold value, it is determined that the second type of blind area is caused by improper grouting path. The diagnosis result triggers the adaptive strategy generator unit 123 to execute a differentiated supplementary grouting strategy, for example, increasing the pump pressure for the first type of blind area and adjusting the mechanical arm path for the second type of blind area. The size of each threshold value can be set according to experience, which is not limited here.

[0059] In this embodiment, by quantitatively analyzing the geometric features and pressure parameters of the blind area, and combining a machine learning model to achieve objective diagnosis, different types of defects caused by different reasons are effectively distinguished, providing data support for precise regulation. The application can accurately identify the formation mechanism of the filling blind area, and avoid invalid supplementary grouting operations caused by misjudgment. For example, if insufficient fluidity is misjudged as a path problem, blindly adjusting the mechanical arm path will only exacerbate the filling defects. By combining the feature vector and the classification model, the diagnosis reliability is significantly improved, ensuring the pertinence of the supplementary grouting strategy, thereby improving the grouting quality and construction efficiency.

[0060] In an embodiment of the present specification, the adaptive strategy generator unit 123 is further configured to: execute a dynamic pressure ramp control logic for optimizing the stability of the filling front at the initial stage of grouting or at the beginning of supplementary grouting. The logic includes: After the nozzle head moves to a new filling starting point according to the planned path, the control execution driving module 130 is controlled to start the outlet pressure of the grouting pipeline at an initial pressure lower than the stable operation pressure; The initial flow front morphology of the slurry in the to-be-filled region is monitored by the positioning and filling state unit 113; If it is monitored that the initial flow front morphology is uniformly advancing, the outlet pressure is raised to the stable working pressure at a preset first slope; If it is monitored that the initial flow front morphology appears to be advancing or unevenly spreading, the outlet pressure is immediately lowered to a stable pressure that is less than the initial pressure and is maintained for a preset time period, and after the flow front morphology returns to be uniform, the pressure is raised to the stable working pressure at a second slope that is less than the first slope.

[0061] The dynamic pressure slope control logic refers to a control strategy for optimizing the slurry flow behavior by adjusting the grouting pressure in stages, and can be realized by the linkage of a pressure sensor and a programmable logic controller, and the outlet pressure is accurately controlled by adjusting the speed of a variable frequency pump in real time. The initial pressure refers to a starting pressure value that is lower than the conventional working pressure, and can be obtained by statistical analysis of historical data, and serves to avoid splashing or stagnation of the slurry at the initial stage of cavity filling due to sudden pressure change. The flow front morphology refers to the spreading boundary geometric characteristics of the slurry in the filling region, and can be identified by capturing the change of the slurry edge profile by a 3D vision sensor, and is used to judge the uniformity of the filling process. The first slope and the second slope refer to the rate of pressure change per unit time, and can be realized by a piecewise linear control algorithm, and the pressure adjustment requirements in different flow states are matched by different slopes.

[0062] Specifically, when the grouting gun head is positioned to a new filling region, the system first starts grouting at a lower initial pressure. At this time, the 3D vision sensor installed on the grouting gun head continuously collects the spreading morphology data of the flow front of the slurry. When it is detected that the slurry is uniformly expanded in the form of concentric circles, the control system gradually raises the pressure to the standard working pressure at a faster first slope, ensuring the filling efficiency. If abnormal morphology such as tree-like branching or local accumulation of the slurry is found, the system immediately lowers the pressure to a stable pressure and maintains it for a preset time period, so that the slurry is redistributed in a low disturbance state. After the morphology returns to be uniform, the pressure is slowly increased at a slower second slope, and the gradual pressure adjustment avoids secondary disturbance.

[0063] In this embodiment, through the closed-loop linkage of pressure slope control and morphology monitoring, dynamic optimization of the filling process is realized, and the non-steady state flow problem of the slurry in the cavity is effectively solved. The application can accurately control the spreading behavior of the slurry at the initial stage of grouting, and prevent filling defects caused by sudden pressure change. Through the hierarchical pressure adjustment mechanism, the working efficiency under normal conditions is ensured, and timely intervention is made when abnormal flow occurs, which significantly improves the integrity and compactness of grouting of complex structures, and reduces the material waste caused by rework.

[0064] In an embodiment of the present specification, the control system 100 of the intelligent mortar grouting device further comprises: A material adaptability module 160 is configured to control the execution driving module 130 to perform a trial pumping cycle before each grouting operation starts, and record the trial pumping data of the multi-source information perception module 110 in the trial pumping cycle; By pattern matching the trial pumping data with the historical successful case data, the initial control parameters of the current operation are automatically adjusted to adapt to the fluctuation of the batch raw material characteristics.

[0065] The trial pumping cycle refers to a test process for obtaining material flow characteristics by simulating the pumping process before the actual grouting operation. Specifically, the execution driving module 130 can be used to run the pumping system with preset reference parameters, while collecting data such as flow, pressure, consistency, etc. Pattern matching refers to similarity calculation of the current trial pumping data and successful cases of the same type of material in the historical database through machine learning algorithms. Specifically, a feature comparison method based on dynamic time warping algorithm can be used. The initial control parameters include pumping speed, stirring torque, grouting pressure and other core process parameters, and the adjustment range is determined by the parameter distribution interval in the historical data.

[0066] Specifically, after the grouting equipment is started, the material adaptability module 160 first triggers the execution driving module 130 to run the trial pumping cycle with standard parameters, and the multi-source information perception module 110 synchronously collects the flow resistance, pumping pressure fluctuation curve and consistency change data of the mortar during the trial pumping cycle. After preprocessing, these trial pumping data are compared with the successful cases in the historical database, and the similarity between the current data and the historical optimal data set is calculated to identify the dimension of the deviation of the raw material characteristics from the standard value. For example, when significant differences are detected between the rheological property curve of the current mortar and the historical reference, the module will automatically correct the initial speed setting value of the pumping motor to match the actual operation parameters with the current material characteristics.

[0067] In some embodiments, the duration of the trial pumping cycle can be dynamically adjusted according to the material type, for example, for a new batch of aggregate, the trial pumping time can be extended to more than three times the complete pumping pipeline cycle; In the pattern matching process, the weighted similarity calculation is used, and the matching weight of the pressure fluctuation data is set to twice that of the consistency data, so as to more accurately reflect the influence of the flowability change of the raw material on the system.

[0068] In this embodiment, by real-time matching of pump test data with historical cases, the device automatically adapts to the current material properties at the beginning of the operation, avoiding abnormal grouting pressure or incomplete filling problems caused by fluctuations in raw materials. The application realizes active adaptation to batch differences of raw materials, solves the problem of unstable grouting quality caused by fluctuations in sand-cement ratio, aggregate gradation and other parameters in traditional methods, ensures that the process parameters of each operation always maintain optimal matching state with the current material properties, significantly reduces the frequency of manual parameter adjustment and the risk of operation errors.

[0069] In an embodiment of the present specification, the human-computer interaction module 140 comprises: An augmented reality display terminal unit 141 is configured to virtually display the filling state, grouting path planning information and device operation parameters generated by the positioning and filling state unit 113 in the real grouting scene in a see-through superimposed manner; A remote operation center interface unit 142 is configured to encrypt and transmit multi-dimensional state information, device operation logs and fault alarm information to a remote server.

[0070] The augmented reality display terminal unit 141 refers to a visual device with a see-through superimposed function, which can be implemented by a head-mounted device equipped with an optical see-through display module, and can render a fusion picture of real-time three-dimensional space data and physical scene. Through the display mode of virtual and real fusion, the operator can intuitively perceive the filling progress of the grouting area and the mechanical motion trajectory.

[0071] The remote operation center interface unit 142 refers to a communication module with data encryption transmission function, which can be implemented by an industrial Internet of Things gateway based on TLS protocol, and can transmit device operation data through a secure tunnel. The interface ensures the integrity and confidentiality of construction data during remote interaction through the encryption transmission mechanism.

[0072] Specifically, during the grouting operation, the augmented reality display terminal unit 141 receives the three-dimensional point cloud data generated by the positioning and filling state unit 113 in real time, and superimposes the filling state heat map on the actual grouting surface in the operator's field of view through spatial coordinate registration technology. At the same time, the planned moving path of the grouting gun head is projected in the real scene in the form of dynamic arrows, and the device operation parameters are displayed in the form of a floating information box next to the corresponding mechanical components. The remote operation center interface unit 142 continuously collects sensor data streams of the multi-source information perception module 110, packages them according to the preset compression algorithm and encryption strategy, and transmits them to the cloud server through cellular network or satellite link for remote experts to analyze the device state and diagnose faults.

[0073] In this embodiment, the augmented reality display terminal unit 141 uses spatial projection technology to accurately overlay information with the physical scene, allowing operators to obtain key parameters without interrupting their work. The remote operation and maintenance center interface unit 142 constructs an end-to-end encrypted data channel, effectively preventing construction data from being stolen or tampered with during public network transmission compared to traditional unencrypted wireless transmission methods. This application achieves a three-dimensional and intuitive presentation of grouting operation information, enabling operators to simultaneously perceive virtual guidance information and the real construction environment, significantly reducing the cognitive load of human-computer interaction. The remote encrypted transmission mechanism ensures secure sharing of construction data across regions, providing a reliable channel for multi-team collaborative operations and remote technical support. The virtual-real fusion interaction method effectively solves the problem of misoperation caused by the fragmentation of information in traditional interfaces, improving the operational accuracy and response speed of complex grouting processes.

[0074] In one embodiment of this specification, the execution driver module 130 includes: Variable frequency pump drive is used to control the speed of screw pumps or piston pumps to achieve stepless and smooth flow regulation; The intelligent mixing drive is used to control the speed and direction of the mixing motor, and can periodically reverse forward and reverse according to the instructions of the decision adaptive module 120 to break the settling and crusting of the mortar. A six-degree-of-freedom robotic arm is used to manipulate the grouting gun head and execute a spatial trajectory jointly planned by the positioning and filling state unit 113 and the decision-adaptive module 120.

[0075] Based on the same general inventive concept, this invention also protects a control method for an intelligent mortar grouting device, such as... Figure 3 As shown, Figure 3 This is a flowchart illustrating the control method of the intelligent mortar grouting device provided in an embodiment of the present invention. The control method of the intelligent mortar grouting device provided by the present invention will be described below. The control method of the intelligent mortar grouting device described below can be referred to in correspondence with the control system of the intelligent mortar grouting device described above. The control method of the intelligent mortar grouting device can be applied to the control system of the intelligent mortar grouting device in any of the above embodiments.

[0076] The control methods for intelligent mortar grouting devices include: Step 301: Acquire multi-dimensional status information of the grouting process in real time; Step 302: Based on the multi-dimensional state information, dynamically generate a grouting strategy; Step 303: Execute the grouting strategy; Step 304: Integrate and manage the grouting strategy and the multi-dimensional status information.

[0077] Figure 4This is a schematic diagram of the structure of the electronic device provided in an embodiment of the present invention.

[0078] like Figure 4 As shown, the electronic device may include a processor 410, a communication interface 420, a memory 430, and a communication bus 440. The processor 410, communication interface 420, and memory 430 communicate with each other via the communication bus 440. The processor 410 can call logical instructions from the memory 430 to execute the control method of the intelligent mortar grouting device.

[0079] Furthermore, the logical instructions in the aforementioned memory 430 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0080] On the other hand, the present invention also provides a computer program product, which includes a computer program that can be stored on a non-transitory computer-readable storage medium. When the computer program is executed by a processor, the computer is able to execute the control method of the intelligent mortar grouting device provided by the above methods.

[0081] In another aspect, the present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements a control method for the intelligent mortar grouting device provided by the methods described above.

[0082] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0083] Those skilled in the art can clearly understand the implementation of the various embodiments by means of software and necessary general hardware platforms through the above description of the embodiments, and of course, the embodiments can also be implemented by hardware. Based on such understanding, the above technical solutions, essentially or in other words, the part of the prior art that makes a contribution, can be embodied in the form of a software product, which can be stored in a computer readable storage medium, such as a ROM / RAM, a magnetic disk, an optical disk, etc., and includes a number of instructions to make a computer device (which can be a personal computer, a server, or a network device, etc.) execute the methods described in the various embodiments or some parts of the embodiments.

[0084] Finally, it should be noted that: the above examples are only used to illustrate the technical solutions of the present application, and not to limit them; although the present application has been described in detail with reference to the foregoing examples, those skilled in the art should understand that: it can still modify the technical solutions recorded in the foregoing examples, or make equivalent replacement for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A control system for an intelligent mortar grouting device, characterized in that, include: The multi-source information sensing module is used to acquire multi-dimensional status information of the grouting process in real time; The decision-adaptive module is used to dynamically generate grouting strategies based on the multi-dimensional state information; An execution driver module is used to execute the grouting strategy; The human-computer interaction module is used for integrated management and interaction of the grouting strategy and the multi-dimensional status information.

2. The control system of the intelligent mortar grouting device according to claim 1, characterized in that, The multi-source information sensing module includes: The consistency sensing unit is used to detect the consistency of mortar in real time. It includes an ultrasonic-based rheological property sensor and a torque sensor mounted on the mixing shaft. The current consistency value of the mortar is calculated through data fusion. The flow and pressure sensing unit is used to monitor the mortar flow and outlet pressure of the grouting pipeline in real time. The positioning and filling status unit is used to identify the spatial location of the grouting point and assess the fullness of the grouting area. It includes a 3D vision sensor and a millimeter-wave radar sensor integrated into the grouting gun head.

3. The control system of the intelligent mortar grouting device according to claim 2, characterized in that, The decision-adaptive module includes: The process knowledge base unit stores the optimal grouting parameters under different working conditions and material ratios. The real-time status analyzer unit is used to receive the multi-dimensional status information and compare it with the data in the process knowledge base unit to identify the deviation between the current status and the target status. An adaptive strategy generator unit is used to dynamically adjust the pumping speed, stirring speed, and grouting nozzle movement trajectory when a deviation is detected, in order to eliminate the deviation. The adaptive strategy generator unit is configured to adjust the water addition device and / or dry material addition device of the mixing unit to correct the consistency when the consistency sensing unit detects that the mortar consistency exceeds a preset threshold.

4. The control system of the intelligent mortar grouting device according to claim 3, characterized in that, Also includes: The bubble monitoring and suppression module includes a vibration sensor and an acoustic array embedded in the wall of the grouting pipeline, used to detect the content and size distribution of bubbles in the mortar; The decision-adaptive module is also used to: when the detected bubble content exceeds the safety threshold, control the execution drive module to adjust the tilt angle of the stirring blades, increase the stirring speed, and trigger the vibration sensor of the grouting pipeline to work, so as to promote the escape of bubbles.

5. The control system of the intelligent mortar grouting device according to claim 3, characterized in that, The positioning and filling state unit is configured as follows: A 3D vision sensor is used to perform a 3D scan of the grouting area to construct a 3D point cloud model of the area to be filled. During the grouting process, the filled volume and the volume to be filled are dynamically calculated by comparing real-time point cloud data with the preset 3D model, and filling blind spots are identified. The adaptive strategy generator unit plans the movement path of the grouting gun head based on the filling blind zone, and controls the execution drive module to drive the grouting gun head to perform supplementary grouting.

6. The control system of the intelligent mortar grouting device according to claim 5, characterized in that, The positioning and filling state unit is further configured as follows: After identifying the filling blind zone, the morphology and cause of the filling blind zone are diagnosed by combining the data from the flow and pressure sensing units, and a diagnostic result is obtained. The diagnosis includes: distinguishing between the first blind zone caused by insufficient grout fluidity and the second blind zone caused by improper grouting path; The adaptive strategy generator unit adopts differentiated supplementation strategies based on different diagnostic results: For the first blind zone, increase the local pumping pressure; For the second blind spot, the robotic arm path is replanned to fill the area from multiple angles.

7. The control system of the intelligent mortar grouting device according to claim 6, characterized in that, The distinction between the first blind zone caused by insufficient grout fluidity and the second blind zone caused by improper grouting path includes: For each identified filling blind zone, its multidimensional features are extracted to construct a blind zone feature vector; wherein the multidimensional features include the ratio of the volume to the surface area of ​​the blind zone calculated based on the three-dimensional point cloud model, the average angle obtained based on the analysis of the normal direction of the blind zone boundary point cloud and the mainstream direction of the grouting gun head, and the mean and fluctuation variance of the outlet pressure recorded by the flow and pressure sensing unit when grouting for the area. The blind zone feature vector is input into a pre-trained classification model, which then performs a diagnosis based on preset rules. The preset rules include: When the volume-to-surface area ratio of the blind zone is less than the first threshold and its average outlet pressure is higher than the second threshold, it is diagnosed as the first blind zone caused by insufficient slurry fluidity. When the average included angle of the boundary of the blind zone is greater than the third threshold and its outlet pressure fluctuation variance is lower than the fourth threshold, it is diagnosed as a second blind zone caused by improper grouting path.

8. The control system of the intelligent mortar grouting device according to claim 5, characterized in that, The adaptive policy generator unit is also used for: Execute dynamic pressure slope control logic to optimize the stability of the filling front during the initial stage of grouting or at the start of supplementary grouting, including: After the grouting gun head moves to the new filling starting point according to the planned path, the execution drive module is controlled to start the grouting pipeline outlet pressure at an initial pressure lower than the stable operating pressure. The initial flow front morphology of the slurry in the area to be filled is monitored by positioning and filling state units; If the initial flow front is detected to be advancing uniformly, the outlet pressure is increased to the stable operating pressure with a preset first slope. If fingering or uneven diffusion is detected in the initial flow front morphology, the outlet pressure will be adjusted back to a stable pressure lower than the initial pressure and maintained for a preset duration. After the flow front morphology returns to uniformity, the pressure will be increased to the stable operating pressure with a second slope lower than the first slope.

9. The control system of the intelligent mortar grouting device according to claim 1, characterized in that, Also includes: The material adaptability module is used to control the execution drive module to perform a test pumping cycle before each grouting operation begins, and to record the test pumping data of the multi-source information sensing module during the test pumping cycle. By matching the trial pumping data with historical successful case data, the initial control parameters for this operation are automatically adjusted to adapt to the fluctuations in the characteristics of batch raw materials.

10. The control system of the intelligent mortar grouting device according to claim 2, characterized in that, The human-computer interaction module includes: Augmented reality display terminal unit is used to virtually display the filling status, grouting path planning information and equipment operating parameters generated by the positioning and filling status unit in a real grouting scene in a perspective overlay manner; The remote operation and maintenance center interface unit is used to encrypt and transmit multi-dimensional status information, equipment operation logs, and fault alarm information to a remote server.

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