Concrete distributing, vibrating and spraying maintenance integrated method

Abstract

The invention discloses a concrete distributing, vibrating and spraying maintenance integrated method, and particularly relates to the technical field of civil engineering construction, and the method comprises the steps of S1, intelligent distributing and collaborative vibrating, S2, precise vibrating and initial setting judgment, and S3, self-adaptive spraying maintenance. Through multi-source data fusion of the rheological sensor, the ultrasonic propagation monitor and the infrared imager, whole-course sensing of the workability, the internal compactness and the surface state of the concrete is achieved, based on sensing data, the system intelligently decides and automatically executes material distribution vibration adjustment, precise vibration and initial setting starting point judgment, and the working efficiency of the concrete is improved. And finally, partition variable spraying maintenance is started in the optimal initial setting window period, closed-loop intelligent control penetrating through the whole construction process is formed, the problems of uneven quality, low efficiency and resource waste caused by traditional procedure splitting are effectively solved, and the construction quality, the intelligent level and the green construction efficiency of concrete members are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the civil engineering construction technical field, more particularly, the present application relates to a concrete distribution, vibrating and spraying curing integrated method. BACKGROUND

[0002] In the construction of concrete members, especially bridge precast beams, building structures and the like, distribution, vibration and curing are three key processes that determine the final engineering quality. However, the prior art generally manages these three processes as independent links, which has significant lack of synergy and technical bottlenecks.

[0003] Specifically, in the distribution stage, it mainly relies on the experience of workers or simple mechanical control, and cannot dynamically adjust the distribution strategy according to the real-time change of the rheological properties of concrete, which easily leads to segregation or poor uniformity of the cast body; In the vibration stage, the traditional method mostly uses manual handheld vibrating rod or preset mode attached vibrator, which lacks accurate perception of the internal compactness of concrete, often resulting in internal cavities due to insufficient vibration or aggregate settlement and surface bleeding due to excessive vibration, which seriously affects the strength and durability of the member; In the curing stage, the existing means mostly use fixed procedures for spraying or covering, which cannot accurately capture the key nodes of concrete hydration and hardening, and is difficult to respond to changes in environmental temperature and humidity, resulting in improper curing timing, water resource waste, and affecting the healthy development of early performance of concrete.

[0004] Therefore, the existing technical solutions are mostly limited to local improvement of a single process, and cannot fundamentally solve the core problem of the whole process fragmentation. In view of this, the present application provides a concrete distribution, vibrating and spraying curing integrated method. SUMMARY

[0005] In order to overcome the above-mentioned defects of the prior art, the present application provides a concrete distribution, vibrating and spraying curing integrated method to solve the problems raised in the background art.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a concrete distribution, vibrating and spraying curing integrated method, comprising the following steps: S1, intelligent distribution and collaborative vibration, using the rheological sensor integrated in the distribution equipment to sense the rheological parameters of concrete in real time, and dynamically adjusting the vibration parameters of the distribution based on the rheological parameters, at the same time, using the ultrasonic propagation monitor to sense the state of the concrete during the distribution process; S2, accurate vibration and initial setting judgment, based on the sensing data of the ultrasonic propagation monitor in S1, the vibration equipment is controlled for targeted vibration, and the infrared imager is used to monitor the surface state of the concrete, the monitoring data of the ultrasonic propagation monitor and the infrared imager are fused to judge whether the concrete enters the initial setting window period; S3, adaptive spraying curing, when it is determined that the concrete enters the initial setting window period, the spraying curing system is started, and the spraying parameters of each region are dynamically adjusted according to the feedback data of the humidity sensor array arranged on the surface of the concrete.

[0007] Preferably, in S1, the vibration parameters of the placing equipment are dynamically adjusted based on the rheological parameters, specifically including: when the viscosity or yield stress in the rheological parameters is higher than a first preset threshold, the frequency and / or amplitude of the auxiliary vibration motor of the placing equipment are correspondingly increased.

[0008] Preferably, in S2, the targeted vibration specifically includes: generating a vibration strategy map according to the sensing data of the ultrasonic propagation monitor, identifying potential defect areas in the concrete, and assigning longer vibration time and / or higher vibration intensity to the potential defect areas.

[0009] Preferably, in S2, the criterion for judging that the concrete enters the initial setting window period is that the wave speed monitored by the ultrasonic propagation monitor continues to increase and its change rate tends to be stable, and the surface temperature field monitored by the infrared imager reaches dynamic balance.

[0010] Preferably, in S3, the dynamic adjustment of the spraying parameters of each region is realized by controlling the partition electromagnetic valve, specifically including: the surface of the concrete is divided into multiple independent curing regions, when the humidity sensor reading of a region is lower than a second preset threshold, the opening of the corresponding partition electromagnetic valve is increased or the opening time is prolonged.

[0011] Preferably, in S3, when the infrared imager monitors that the environmental temperature is higher than a third preset threshold or the surface water evaporation rate exceeds a preset range, the curing agent automatic adding device is controlled to add curing agent to the spraying water to form a composite curing film on the surface of the concrete.

[0012] Preferably, in S3, the excess water generated by spraying is collected by the wastewater collection system on both sides of the formwork, filtered and returned to the water storage tank for subsequent spraying curing.

[0013] Preferably, it further includes a concrete placing, vibrating and spraying curing integrated system, which includes: a central control system; a placing module, which is in communication connection with the central control system and includes a placing machine, an integrated rheological sensor and an auxiliary vibration motor; a vibration monitoring module, which is in communication connection with the central control system and comprises an ultrasonic propagation monitor, an infrared imager and a vibration device controlled by the central control system; a curing module, which is in communication connection with the central control system and comprises a spraying curing system, an array of humidity sensors, a partition electromagnetic valve and a water storage tank.

[0014] Preferably, the curing module further comprises a curing agent automatic adding device and / or a wastewater collection tank connected with the water storage tank through a pipeline.

[0015] Preferably, a solar photovoltaic panel for providing power for the curing module and / or a raindrop and light sensor connected with the central control system for controlling the opening and closing of the roof are further included.

[0016] Technical effects and advantages of the present application: The present application can reduce concrete segregation from the source by real-time sensing and self-adaptive adjustment of cloth vibration through the rheological sensor, and further generate a vibration strategy map to guide precise vibration by identifying potential defect areas inside through ultrasonic scanning, effectively eliminating the blind area of traditional vibration, ensuring the uniform compaction of components from macro to micro, and significantly improving the uniformity and reliability of the internal and external quality of concrete components. The present application adopts the dual criteria of ultrasonic velocity variation and dynamic balance of infrared temperature field to judge the initial setting window of concrete, breaks through the limitation of traditional experience time, optimizes the curing start time, realizes seamless connection between processes, reduces human intervention and waiting time between processes, realizes precise judgment and execution of curing intervention time, and greatly improves the intelligent level and efficiency of construction.

[0017] The present application system realizes on-demand and variable spraying through partition electromagnetic valves according to the feedback of matrix humidity sensors, avoids water waste of uniform spraying, collects and recycles excess curing wastewater, and can be optionally powered by solar energy, thereby constructing an energy-saving, water-saving and low-carbon closed-loop curing system, achieving fine and recycling use of water resources and energy, and meeting the requirements of green construction. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 The overall step flowchart of the present application is shown in the figure. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application. Example 1

[0020] This invention provides an integrated method for concrete placement, vibration, and spray curing. Before specific application, the system in this embodiment is assembled. A central control system, which can be an industrial PLC or industrial computer, is installed on a movable formwork or fixed platform. Subsequently, the following modules are integrated: The concrete placing module has a rheological sensor (e.g., an online viscometer based on fluid dynamics) installed near the discharge port of the concrete placing machine, and an auxiliary vibration motor installed on the placing machine frame. The vibration monitoring module has several ultrasonic propagation monitoring probe pairs (transmitters and receivers) installed at key locations on the outside of the template (such as the web and bottom plate), and an infrared imager is set up above the template. The vibration equipment includes high-frequency attached vibrators on the template and a group of movable intelligent vibrating rods. The maintenance module consists of an array of multiple humidity sensors on the top plate and flange surface of the box girder, a spray pipe network with partition solenoid valves, dividing the top plate into an independent maintenance area of ​​approximately 2m × 2m, a water storage tank, an automatic curing agent addition device, and wastewater collection tanks and filtration devices installed on both sides of the formwork. Optionally, solar photovoltaic panels and a rainproof and sunproof canopy serving the entire area are installed above the system. The canopy is controlled by raindrop and light sensor signals.

[0021] The specific implementation steps are as follows: S1, Intelligent Fabric and Collaborative Vibration When implementing this step, the system is started and C50 concrete is poured. The rheological sensor monitors the viscosity and yield stress of the concrete in real time and transmits the data to the central control system. The system presets the first threshold as follows: viscosity ≥120 Pa·s, yield stress ≥450 Pa. When the measured value exceeds the threshold, the control system immediately increases the frequency (e.g., from 35 Hz to 50 Hz) and amplitude of the auxiliary vibration motor on the concrete placing boom to improve the fluidity of the concrete, ensure that it is evenly spread into the mold, and reduce air bubbles. At the same time, the ultrasonic propagation monitor is activated, scanning the concrete being poured several times per second. It initially judges the uniformity of the concrete by receiving ultrasonic signals and transmits this status perception data to the central control system in real time.

[0022] S2. Precise vibration and initial setting judgment When implementing this step, after the material is laid to a certain area, the vibration process begins. The central control system automatically generates a vibration strategy map based on the state perception data of ultrasonic monitoring in step S1 (e.g., areas where the ultrasonic velocity is significantly low). This map is displayed on the control interface and identifies potential defective areas where there may be air bubbles or insufficient density. Based on this instruction, the control system can prioritize moving the intelligent vibrator and extend the vibration time for these areas (e.g., 40 seconds for defective areas and 25 seconds for normal areas), while also appropriately increasing the vibration intensity. Throughout the vibration process, the infrared imager continuously monitors the temperature field distribution on the concrete surface, while the data fusion algorithm within the central control system analyzes two key indicators simultaneously: Ultrasonic speed: Monitor whether it shows a continuous upward trend, and whether the increase (rate of change) per unit time changes from a rapid increase to a slow increase and tends to a stable value; Infrared temperature field: Monitor whether the temperature of the entire concrete surface changes from the uneven state at the beginning of vibration to a relatively stable and uniform dynamic equilibrium state.

[0023] When the algorithm determines that both conditions are met simultaneously—a continuous increase in wave velocity and a stable rate of change, and a dynamic equilibrium in the surface temperature field—the system determines that the concrete has entered the initial setting window period. This determination serves as a precise instruction to initiate curing.

[0024] S3, Adaptive Spray Maintenance Once the system determines that the initial setting window has been entered, it immediately sends a command to the curing module to start the spray curing system; When the spray curing system is turned on, the humidity sensor array feeds back the humidity data of each area to the central control system in real time. The system presets the second threshold of the appropriate relative humidity of the concrete surface to be 90%. When the humidity sensor reading of a certain 2m×2m area is lower than 90%, the control system will increase the opening of the corresponding zone solenoid valve or extend the spraying time of that area to ensure uniform curing and no areas that are too dry or too wet. Meanwhile, the infrared imager continues to work, monitoring the ambient temperature. When the ambient temperature is higher than the third threshold preset by the system (e.g., 35°C) or when the moisture evaporation rate is calculated to be too fast through surface temperature changes, the control system will activate the automatic curing agent addition device to add liquid curing agent to the spray water in a ratio (e.g., 1:50). The curing agent and water together form a dense composite curing film on the concrete surface, effectively inhibiting the rapid evaporation of moisture and achieving water-saving and efficient curing. Excess water generated during the spraying process flows down the template into the wastewater collection tanks on both sides of the template frame. After simple sedimentation and filtration, it is pumped back into the water storage tank to participate in the next round of spraying and curing, thus realizing the recycling of water resources. The entire maintenance process continues until the preset maintenance cycle is reached. During this period, if there is rain or strong sunlight, the raindrop and light sensors will signal the central control system to automatically control the opening and closing of the canopy, providing all-weather working conditions for construction. Example 2

[0025] In another embodiment, the system can be a simplified version. For example, in areas where water resources are not scarce, the wastewater collection tank and recycling system may be temporarily omitted. Alternatively, in an indoor prefabrication yard with a stable power supply, solar photovoltaic panels may not be configured. However, the system still retains the core functions of rheological sensing, ultrasonic / infrared monitoring to determine initial condensation, and zoned adaptive spraying, and can achieve the basic objectives of the present invention.

[0026] In summary: This invention uses a rheological sensor, an ultrasonic propagation monitor, and an infrared imager to fuse and sense multi-source data, and monitors the state of concrete in real time from pouring to initial setting. Based on this data, the system makes intelligent decisions and automatically executes coordinated operations in three stages. First, the vibration of the fabric is adaptively adjusted based on the rheological parameters. Second, precise vibration is performed based on the ultrasonic scanning results, and the initial setting point is determined by integrating ultrasonic and infrared data. Finally, zoned spray curing is initiated during the optimal initial setting window, and the water volume is dynamically adjusted based on humidity feedback. This forms a closed-loop intelligent control system that runs through the fabric placement, vibration, and curing processes, thereby improving quality, efficiency, and energy saving throughout the entire construction process.

[0027] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for integrating concrete placement, vibration, and spray curing, characterized in that: Includes the following steps: S1. Intelligent concrete placement and collaborative vibration: The rheological sensor integrated into the concrete placement equipment is used to sense the rheological parameters of the concrete in real time, and the vibration parameters of the concrete placement are dynamically adjusted based on the rheological parameters. At the same time, the ultrasonic propagation monitor is used to sense the state of the concrete during the placement process. S2. Precise vibration and initial setting judgment: Based on the sensing data of the ultrasonic propagation monitor in step S1, the vibration equipment is controlled to perform targeted vibration, and the surface condition of the concrete is monitored simultaneously using an infrared imager. By fusing the monitoring data of the ultrasonic propagation monitor and the infrared imager, it is determined whether the concrete has entered the initial setting window period. S3. Adaptive spray curing: When the concrete is determined to have entered the initial setting window, the spray curing system is activated, and the spraying parameters of each area are dynamically adjusted based on the feedback data from the humidity sensor array deployed on the concrete surface.

2. The integrated method for concrete placement, vibration, and spray curing according to claim 1, characterized in that: In step S1, the vibration parameters of the fabric-making equipment are dynamically adjusted based on the rheological parameters. Specifically, when the viscosity or yield stress in the rheological parameters is higher than the first preset threshold, the frequency and / or amplitude of the auxiliary vibration motor of the fabric-making equipment are increased accordingly.

3. The integrated method for concrete placement, vibration, and spray curing according to claim 1, characterized in that: In step S2, targeted vibration specifically involves generating a vibration strategy map based on the sensing data from the ultrasonic propagation monitor, identifying potential defect areas inside the concrete, and allocating longer vibration durations and / or higher vibration intensities to these potential defect areas.

4. The integrated method for concrete placement, vibration, and spray curing according to claim 1, characterized in that: In step S2, the criteria for determining whether concrete has entered the initial setting window are: the wave velocity monitored by the ultrasonic propagation monitor continues to increase and its rate of change tends to stabilize, while the surface temperature field monitored by the infrared imager reaches dynamic equilibrium.

5. The integrated method for concrete placement, vibration, and spray curing according to claim 1, characterized in that: In step S3, the dynamic adjustment of the spraying parameters of each area is achieved by controlling the zone solenoid valve. Specifically, the concrete surface is divided into multiple independent curing zones. When the humidity sensor reading of a certain zone is lower than the second preset threshold, the opening degree of the corresponding zone solenoid valve is increased or its opening time is extended.

6. The integrated method for concrete placement, vibration, and spray curing according to claim 5, characterized in that: In step S3, when the infrared imager detects that the ambient temperature is higher than the third preset threshold or the surface moisture evaporation rate exceeds the preset range, the automatic curing agent addition device is controlled to add curing agent to the spray water to form a composite curing film on the concrete surface.

7. The method for integrating concrete placement, vibration, and spray curing according to claim 1, characterized in that: In step S3, excess water generated by spraying is collected by the wastewater collection system on both sides of the mold frame, filtered, and returned to the water storage tank for subsequent spraying maintenance.

8. The integrated method for concrete placement, vibration, and spray curing according to claim 1, characterized in that: It also includes an integrated system for concrete placement, vibration, and spray curing, including: Central control system; The fabric module is connected in communication with the central control system and includes a fabric placing machine, a rheological sensor integrated thereon, and an auxiliary vibration motor; The vibration monitoring module is connected in communication with the central control system and includes an ultrasonic propagation monitor, an infrared imager, and vibration equipment controlled by the central control system. The maintenance module is connected to the central control system and includes a spray maintenance system, a humidity sensor array, zone solenoid valves, and a water storage tank.

9. The integrated method for concrete placement, vibration, and spray curing according to claim 8, characterized in that: The maintenance module also includes an automatic maintenance agent addition device and / or a wastewater collection tank, wherein the wastewater collection tank is connected to a water storage tank via a pipeline.

10. The integrated method for concrete placement, vibration, and spray curing according to claim 8, characterized in that: It also includes solar photovoltaic panels that power the maintenance module, and / or rain and light sensors connected to the central control system for controlling the opening and closing of the roof.

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