Device suitable for manufacturing annular concrete pole and manufacturing process

Abstract

The invention discloses a device suitable for manufacturing an annular concrete pole. The device comprises a centrifugal forming device, an extrusion compacting device, an intelligent monitoring device and a rapid curing device. The centrifugal forming device comprises a horizontal centrifugal machine and an annular steel mold. The extrusion compacting device comprises a hollow supporting rod capable of stretching into the hollow interior of the annular steel mold, a plurality of electric hydraulic jacks arranged on the hollow supporting rod in an array mode and a high-strength steel plate connected with the output ends of the electric hydraulic jacks. The high-strength steel plates can be spliced into a complete pressurizing ring through the telescopic movement of the electric hydraulic jacks; the intelligent monitoring device comprises a sensor group used for collecting data and a computer terminal used for processing the data and outputting a control instruction, and the forming quality of concrete in the annular steel mold can be effectively improved.

Description

Technical Field

[0001] This invention relates to an apparatus and manufacturing process suitable for manufacturing ring-shaped concrete poles, belonging to the field of ring-shaped concrete pole manufacturing technology. Background Technology

[0002] Ring-shaped concrete poles have been widely used in my country's power distribution network system. With a wide coverage area and diverse operating conditions, concrete poles are subjected to long-term combined effects of wind loads, ice loads, and different geological conditions under complex and varied operating conditions, which may lead to pole cracks, material deterioration, and other performance-affecting issues.

[0003] Circular concrete poles are mainly manufactured by centrifugal or extrusion processing methods.

[0004] When using centrifugal molding to produce ring-shaped concrete poles, the concrete is evenly distributed and moisture and air are expelled through a high-speed rotating mold, forming a hollow structure. For example, Chinese utility model patent CN223369675U discloses a centrifugal molding device for concrete poles, which includes a base and a reinforcing cage. A lower mold and an upper mold are symmetrically placed above the base. The lower mold has a connecting component for detachably connecting to the upper mold. When the upper and lower molds are fitted together, a horizontally placed, hollow, sealed cylindrical shell is formed. A first telescopic cylinder is fixed to the inner wall of each end of the lower mold, coaxially positioned with it. A disc is fixed to the output end of each first telescopic cylinder. The discs are coaxially positioned and slidably connected to the cylindrical shell. Multiple blind holes are evenly distributed in a ring around the central axis on the side of each disc that is close to it. The blind holes on the two discs correspond one-to-one and are coaxially positioned. The aforementioned patent discloses a device and method for forming ring-shaped concrete poles by centrifugation.

[0005] However, traditional centrifugation methods have the following problems: During centrifugation, the distribution of aggregates in the concrete changes due to differences in particle size and density under centrifugal force. Coarse aggregates, being heavier, tend to move to the outside of the mold, while fine aggregates and cement paste are relatively concentrated on the inside. This results in uneven distribution of concrete materials from the outside to the inside of the pole, affecting the consistency of mechanical properties in different parts of the pole and reducing overall strength and durability. In addition to aggregate segregation, concrete stratification may also occur during centrifugation, i.e., the outer layer contains more coarse aggregates and insufficient cement paste coating, while the inner layer contains more fine aggregates and less coarse aggregates. This reduces the bonding force between different layers of the pole, making it prone to failure along the stratification points when subjected to external forces.

[0006] When using the extrusion method to produce ring-shaped concrete poles, the pressure distribution inside the concrete is not very uniform due to factors such as mold structure and extrusion method. This results in some areas receiving insufficient extrusion pressure to squeeze out excess water, leaving these areas with more moisture and causing a decrease in the concrete strength of some areas. Summary of the Invention

[0007] In order to solve the above-mentioned problems in the prior art, the present invention provides an apparatus and manufacturing process suitable for manufacturing annular concrete poles, which can effectively improve the molding quality of concrete in annular steel molds.

[0008] An apparatus for manufacturing ring-shaped concrete poles includes a centrifugal molding device for initially molding the concrete mixture and removing air and excess moisture; an extrusion compaction device for applying radial pressure to the centrifugally molded concrete to compact it; an intelligent monitoring device connected to the extrusion compaction device for real-time monitoring and control of the extrusion process; and a rapid curing device for accelerating the curing of the molded concrete poles. The centrifugal molding device includes a horizontal centrifuge and a ring-shaped steel mold. The extrusion compaction device includes a hollow support rod that can extend into the hollow interior of the ring-shaped steel mold, multiple electro-hydraulic jacks arranged in an array on the hollow support rod, and high-strength steel plates connected to the output ends of each electro-hydraulic jack. The high-strength steel plates can be spliced ​​into a complete pressure ring through the telescopic movement of the electro-hydraulic jacks. The intelligent monitoring device includes a sensor array for data acquisition and a computer terminal for data processing and outputting control commands.

[0009] The annular steel mold has multiple threaded plug holes evenly formed along the axial direction on its mold wall. A first threaded plug with a drainage hole or a second threaded plug without a drainage hole can be selectively screwed into the threaded plug hole. The bottom of the second threaded plug is machined into an arc shape that matches the curvature of the inner wall of the annular steel mold.

[0010] The high-strength steel plate is fitted with an elastic sleeve on its outer side, and the thickness of the elastic sleeve is adjustable; the hollow support rod is a detachable splicing structure.

[0011] The annular steel mold is equipped with a detachable isolation door inside. The isolation door is closed during the centrifugation stage and is replaced with a perforated isolation door in the middle during the extrusion stage, so that the hollow support rod can pass through. The annular steel mold is also equipped with an exhaust valve connected to the gas storage tank.

[0012] The sensor group includes a stress sensor and a displacement sensor mounted on the high-strength steel plate, as well as a high-temperature piezoelectric ceramic ultrasonic sensor for monitoring the state of the concrete.

[0013] A process for manufacturing a ring-shaped concrete utility pole includes the following steps: S1: Raw material preparation and formwork filling: Pour the concrete mixture into the annular steel mold with the installed steel reinforcement cage, close the annular steel mold and install the first threaded plug with drainage holes; S2: Centrifugal molding: The annular steel mold is placed on a horizontal centrifuge and rotated through three stages: low speed, medium speed and high speed, to remove air and excess moisture and obtain pre-formed concrete. S3: Compacting preparation: Assemble the hollow support rod and pass it through the annular steel mold, connect it to the fixed base, and replace the threaded plug with a drainage hole with a second threaded plug without a drainage hole; S4: Extrusion Compaction and Intelligent Monitoring: The electric hydraulic jacks are activated to apply radial pressure to the concrete through high-strength steel plates. At the same time, the force, thickness and state of the concrete are monitored in real time by a sensor group. The intelligent monitoring device dynamically adjusts the pressure and pressurization time of each electric hydraulic jack according to the monitoring data. S5: Curing: The entire extrusion unit is moved into the curing furnace, and curing is carried out using a segmented temperature control strategy based on the concrete setting and hardening information fed back by the sensor group. S6: Demolding: After curing, remove the device and take out the formed ring-shaped concrete pole.

[0014] According to the process for manufacturing a ring-shaped concrete pole as described in claim 5, the three stages of low speed, medium speed and high speed in step S2 are as follows: first, run at a low speed of 200 rpm for 2 minutes to allow the concrete to initially distribute; then run at a medium speed of 500 rpm for 2 minutes to further expel air; and finally run at a high speed of 1100 rpm for 7 minutes to achieve concrete compaction.

[0015] In step S4, the intelligent monitoring device processes the data from the stress sensor and displacement sensor to obtain the real-time thickness of each area of ​​the concrete, and adjusts the pressure by controlling the corresponding electric hydraulic jack to ensure that the overall thickness of the concrete is uniform.

[0016] The segmented temperature control strategy in step S5 is as follows: the wave velocity and wave velocity change rate are calculated using the acoustic time data obtained by the high-temperature piezoelectric ceramic ultrasonic sensor. The time point with the maximum wave velocity change rate is characterized as the initial setting time, and the time point with the wave velocity change rate decreasing to 20% of the maximum value is characterized as the final setting time. Before the initial setting time, the curing temperature is controlled at 60℃. After the initial setting time, the temperature is increased to 80℃ at a heating rate of 20℃ / hour, and curing continues until 2 hours after the final setting time.

[0017] The arrangement spacing of the high-temperature piezoelectric ceramic ultrasonic sensors is 20cm.

[0018] The present invention has the following beneficial effects: This invention employs three speed settings—low speed, medium speed, and high speed—to achieve initial concrete distribution, air expulsion, and compaction molding, respectively. This targeted speed control can effectively improve the molding quality of concrete within the annular steel mold, ensuring the uniformity and strength of all parts of the pole.

[0019] This invention features multiple bolt plugs evenly distributed on a ring-shaped steel mold. These plugs are either first threaded plugs with drainage holes or second threaded plugs without drainage holes. The first threaded plug with drainage holes can be opened during centrifugation of the concrete and installed using a digital wrench for drainage. During extrusion, it is replaced with the second threaded plug without drainage holes, ensuring uniform and sufficient stress on the concrete and preventing appearance defects and stress concentration caused by concrete overflowing from the drainage holes. This invention combines centrifugation and extrusion methods to produce ring-shaped concrete poles. A three-stage centrifugation process removes air and moisture from the concrete, resulting in concrete with densely packed aggregate particles. This effectively solves the problem of difficulty in removing air and moisture in the extrusion method. An intelligent system controls the jacks to uniformly load the concrete, ensuring uniform and sufficient stress on the aggregate particles. This effectively avoids the uneven aggregate distribution and stratification problems associated with centrifugation, fully leveraging the advantages of both centrifugation and extrusion methods while overcoming their respective drawbacks. This significantly improves the quality of the concrete and eliminates some potential hazards, resulting in a substantial increase in the strength and reliability of the utility pole.

[0020] This invention, by arranging stress and displacement sensors on a steel plate and connecting them to an intelligent monitoring system, allows for the monitoring of the stress, displacement, and thickness of various parts of the concrete. If the thickness in some areas differs from other parts, the system can apply pressure to an electric hydraulic jack for adjustment. Simultaneously, the real-time concrete thickness is obtained, ensuring that the thickness and uniformity of the resulting ring-shaped concrete pole meet standards. These measures further improve the strength and reliability of the ring-shaped concrete pole and guarantee the quality stability of the obtained product.

[0021] This invention utilizes a high-temperature piezoelectric ceramic ultrasonic sensor attached to a steel plate and connected to a smart terminal via wiring. Software processing allows for clear determination of the initial and final setting times of the concrete. Based on these times, the oven temperature and curing time are adjusted to obtain high-quality ring-shaped concrete poles within a shorter curing period. By combining ultrasonic software with optimized oven temperature and curing time, employing a two-stage curing process, the hydration reaction of the concrete is accelerated, the curing time of the concrete poles is shortened, the likelihood of cracking is reduced, production efficiency is improved, production costs are reduced, and concrete quality is enhanced, making it suitable for large-scale industrial production. Attached Figure Description

[0022] Figure 1 This is a partial schematic diagram of the external structure of the present invention; Figure 2 This is a schematic diagram of the second threaded plug structure without drainage holes according to the present invention; Figure 3 This is a schematic diagram of the extrusion compaction of the present invention; Figure 4 This is a schematic diagram of the structural deformation of the hollow support rod and extrusion assembly of the present invention; Figure 5 This is a schematic diagram of the hollow support rod and extrusion assembly structure of the present invention; Figure 6 This is a waveform diagram of the ultrasonic signal of the present invention; Figure 7 This is a graph showing the change rate of wave velocity over time in this invention.

[0023] The reference numerals in the figure are as follows: 1. Circular steel mold; 2. Hollow support rod; 4. Electric hydraulic jack; 5. High-strength steel plate; 6. Fixed base; 7. Sensor group; 3. Threaded plug hole; 8. Isolation door; 9. Exhaust valve; 10. Second threaded plug. Detailed Implementation

[0024] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0025] Please see Figures 1 to 7 The present invention provides a technical solution: Apparatus suitable for manufacturing ring-shaped concrete poles includes a centrifugal molding device for initially molding the concrete mixture and removing air and excess moisture; an extrusion compaction device for applying radial pressure to the centrifugally molded concrete to compact it; a rapid curing device for accelerating the curing of the molded concrete poles; and an intelligent monitoring device connected to the extrusion compaction device and the rapid curing device for real-time monitoring and control of the extrusion and curing processes.

[0026] The centrifugal forming device includes a horizontal centrifuge and an annular steel mold 1. The horizontal centrifuge is the source of centrifugal power, and its function is to receive and drive the annular steel mold 1 to rotate at high speed.

[0027] The annular steel mold 1 is typically made of high-strength steel to ensure sufficient rigidity and durability during centrifugation and extrusion. Multiple threaded plug holes 3 are uniformly formed along the axial direction on the mold wall of the annular steel mold 1. A first threaded plug with a drainage hole or a second threaded plug 10 without a drainage hole can be selectively screwed into each threaded plug hole 3. Multiple threaded plug holes 3 are uniformly machined at regular intervals along the circumference of the annular steel mold 1. During the centrifugation stage, the first threaded plug is screwed into these holes, providing a controlled path for the discharge of water and air during centrifugation. Before the extrusion stage, the second threaded plug 10 is replaced to prevent leakage of concrete slurry due to extrusion. The bottoms of the first and second threaded plugs 10 are machined into an arc shape consistent with the curvature of the inner wall of the annular steel mold 1.

[0028] Specifically, during the manufacturing process of the annular steel mold 1, six threaded plug holes 3 are machined along the circumference every 2 meters along the axial direction on the surface of the annular steel mold 1. The first threaded plug has a drainage hole with a diameter of 2 cm, and the diameter of the threaded plug hole 3 is set to 5 cm. In order to reinforce the structure weakened by the bolt plug holes and to better screw in the bolt plugs, preferably, the template thickness can be increased around the threaded plug holes 3 to form a protruding platform, i.e., a reinforcement platform. In order to ensure that the bottom of the bolt plug fits the shape of the steel mold perfectly after it is screwed in, the bottom of the first threaded plug and the second threaded plug 10 need to be machined into an arc shape that is completely consistent with the annular steel mold 1, i.e., the radius of curvature is the same. In order to avoid excessive screwing angle, a digital display wrench is used to display the screwing angle in real time.

[0029] The coarse aggregate used to make the concrete ring pole has a diameter of 20-40mm, which is smaller than the diameter of the drainage hole. Centrifugal force causes the coarse aggregate and cement slurry to move radially outward (adhering to the wall), while the leakage direction of the drainage hole is from the inner wall of the steel mold through the drainage hole and then outward. Although they appear to be in the same direction, in reality, the cement slurry is "pressed against the inner wall of the ring steel mold 1" by centrifugal force, rather than "pushed towards the drainage hole opening." That is, the drainage hole opening is only exposed on the "surface" of the cement slurry, not "inside." The slurry lacks the force to "squeeze" into the hole and therefore will not leak.

[0030] The electric hydraulic jacks 4 are arranged in an array on the hollow support rod 2, meaning multiple electric hydraulic jacks 4 are installed at certain intervals along the length of the hollow support rod 2. The fixed ends of the electric hydraulic jacks 4 are directly fixed to the hollow support rod 2 by bolts. Their telescopic rods are connected to high-strength steel plates 5. The hydraulic lines of all the electric hydraulic jacks 4 pass through the hollow support rod 2 from the inside, converge at one end of the hollow support rod 2, and then connect to the external main hydraulic power system through a centralized quick connector.

[0031] An elastic sleeve is fitted around the outer side of the high-strength steel plate 5. The thickness of the elastic sleeve can be selected according to the situation. Specifically, although the concrete surface is annular after centrifugation, it is microscopically rough and uneven. If an absolutely rigid pressure head is used, it will only contact some high points, leading to stress concentration, crushing of aggregates, and uneven pressure distribution. Under high pressure, the elastic sleeve undergoes a small, controllable elastic deformation, conforming to the microscopic contour of the concrete surface, transforming the concentrated force applied by the jack into a uniformly distributed surface pressure. The elastic deformation of the elastic sleeve is very small, and it is wrapped between the rigid arc-shaped high-strength steel plate 5 and the rigid annular steel mold 1. The final shape and size are precisely defined by the inner diameter of the rigid annular steel mold 1 (which determines the outer diameter) and the final displacement of the rigid high-strength steel plate 5 (which determines the inner diameter). The elastic sleeve is merely a "force transmission medium" filling the space between the rigid pressure head and the concrete surface. Its presence ensures the uniformity of pressure transmission but does not change the final geometric boundaries set by the rigid system.

[0032] The intelligent monitoring device includes a sensor group 7 for data acquisition and a computer terminal for data processing and outputting control commands. The sensor group 7 includes a stress sensor and a displacement sensor mounted on a high-strength steel plate 5. The stress sensor is used to monitor the reaction force of the concrete on the high-strength steel plate 5 during the extrusion process in real time, i.e., the pressure data. The displacement sensor is used to accurately measure the radial displacement of the steel plate. Through the displacement data and using an external computer terminal system, the actual thickness and uniformity of the annular concrete can be indirectly calculated. The device also includes a high-temperature piezoelectric ceramic ultrasonic sensor for monitoring the state of the concrete.

[0033] Specifically, displacement sensors are installed on the back of the piston rod of each electro-hydraulic jack 4. The back refers to the side of the high-strength steel plate 5 that does not contact the concrete. Installing the sensors here allows for precise monitoring of the displacement of the piston rod pushing the pressure plate, while simultaneously monitoring the synchronicity of the displacement of each jack. This serves two main purposes: first, by precisely controlling the displacement of all electro-hydraulic jacks 4, it ensures that the diameter of the inner wall of the concrete is consistent after extrusion, thereby accurately controlling the wall thickness tolerance of the jack rods; second, it monitors whether the displacements of several groups of electro-hydraulic jacks 4 are synchronized. If a displacement sensor shows a displacement lag, the control system will instruct the corresponding hydraulic servo valve to compensate for the pressure, ensuring that the entire annular extrusion surface contacts the concrete synchronously and applies uniform pressure.

[0034] The stress sensor is directly embedded or installed on the working surface of the high-strength steel plate 5, i.e., the back side of the side in contact with the concrete. It measures the actual reaction force experienced by the high-strength steel plate 5. It serves two main purposes: first, the consistency of concrete may fluctuate slightly, and controlling displacement alone may lead to uneven actual pressure. The stress sensor provides accurate pressure feedback, complementing the displacement signal; second, it ensures that the pressure remains stable within a preset optimal range. Too low a pressure results in poor compaction; too high a pressure may damage the already formed concrete structure. It also serves as the direct basis for the system's real-time pressure compensation.

[0035] The high-temperature piezoelectric ceramic ultrasonic sensors are installed on the inner wall of the annular steel mold 1. One sensor emits ultrasonic waves, and the other receives them. Both the transmitting and receiving ends of the high-temperature piezoelectric ceramic ultrasonic sensors are installed on the inner wall of the annular steel mold 1. Holes need to be pre-drilled in the mold for placement, and the sensor spacing is 20cm.

[0036] The core principle of ultrasonic sensors is to "reflect the properties of concrete through wave velocity," so it is necessary to ensure that the ultrasonic waves only come into contact with the concrete and do not pass through other unrelated materials.

[0037] If installed on the back of steel plate 5, it will cause data distortion: the back of high-strength steel plate 5 is separated from the concrete by the "body of high-strength steel plate 5 + elastic sleeve". The ultrasonic wave must first penetrate the high-strength steel plate 5 (rigid metal, wave velocity much higher than concrete) and the elastic sleeve (flexible material, wave velocity unstable) before entering the concrete. The final received signal is the superimposed wave velocity of "steel plate + elastic sleeve + concrete", which cannot distinguish the performance changes of the concrete itself, and the initial and final setting judgment will be completely distorted. During the extrusion stage, high-strength steel plate 5 will move radially with the extension and retraction of jack 4 (approaching / moving away from the concrete). The ultrasonic sensor installed on the back of high-strength steel plate 5 will move synchronously with high-strength steel plate 5, causing the distance between the transmitter and receiver and the ultrasonic wave propagation angle to change continuously.

[0038] The transmitting sensor emits ultrasonic waves into the concrete, and the receiving end receives the ultrasonic signals that penetrate the concrete. The propagation speed of ultrasonic waves in concrete (wave velocity) is directly related to the elastic modulus and density of the concrete, and these two parameters will continue to increase with the cement hydration reaction (setting and hardening). The system calculates and tracks the wave velocity change rate in real time: the inflection point of the wave velocity change rate corresponds to the initial setting time of the concrete, and the wave velocity change rate drops to the maximum value of 20% corresponding to the final setting time. This judgment result serves as a decision signal for automatically switching the curing stage (e.g., the curing temperature is 60℃ before initial setting, and the temperature is increased to 80℃ at 20℃ / hour after initial setting), supporting the segmented temperature control strategy of the curing stage.

[0039] The propagation speed (wave velocity) of ultrasound waves in concrete is directly related to the concrete's elastic modulus and density, both of which increase continuously with the hydration reaction (setting). By tracking the rate of change of the ultrasound wave velocity in real time, the system can accurately determine the initial and final setting times of the concrete. An inflection point in the wave velocity change corresponds to initial setting; a gradual plateau corresponds to final setting. This phenomenon serves as a decision signal for automatically switching the curing stage (e.g., from static curing to heating).

[0040] The computer terminal serves as the system's data processing and control center. It receives all data from sensor group 7, processes, analyzes, and displays it graphically in real time. More importantly, it can automatically generate control commands based on preset thickness and pressure thresholds, feeding them back to the hydraulic system of the electric hydraulic jacks 4 to adjust the duration of each jack 4, thus forming a closed-loop intelligent control system to ensure the uniformity and stability of product quality.

[0041] Specifically, centrifugation occurs in the initial stage of concrete pouring. At this time, the concrete is freshly mixed and in a highly fluid, plastic state. During this stage, the water in the concrete is free water. Its bond with cement and aggregates is weak, primarily serving as lubricant and providing an environment for the hydration reaction. To meet workability requirements (pouring and centrifugation capability), concrete typically contains more water than is needed for complete cement hydration (i.e., an excessively high water-cement ratio). If this excess water is not drained, it will form pores within the concrete, severely reducing the density and strength of the final product.

[0042] Extrusion occurs after centrifugation. At this point, the centrifuged and dehydrated concrete has lost most of its free water, existing in a semi-dry, plastic state between its initial setting and its final setting. Some of the remaining water in the concrete has begun to hydrate with the cement particles, becoming adsorbed or chemically bound water; the rest is confined within the nascent microstructure network. The water is no longer a freely flowing liquid. The primary function of extrusion pressure is no longer drainage, but rather, through powerful mechanical pressure, to cause the already centrifuged and compacted concrete particles (aggregate, cement paste) to undergo microscopic slippage and rearrangement, squeezing out the tiny pores and capillaries remaining after centrifugation.

[0043] The annular steel mold 1 is equipped with a detachable isolation door 8. The isolation door 8 is closed during the centrifugation stage and is replaced by a perforated isolation door with a hole in the middle during the extrusion stage, so that the hollow support rod 2 can pass through. The annular steel mold 1 is also equipped with an exhaust valve 9 connected to the gas storage tank.

[0044] This invention connects an electric hydraulic jack 4 to a high-strength steel plate 5, and adds an elastic sleeve to the outside of the high-strength steel plate 5. When the electric hydraulic jack 4 extends, the steel plates are assembled into a complete ring, which can uniformly compress the initially formed concrete. At the same time, the thickness of the elastic sleeve can be adjusted to obtain ring concrete poles with different wall thicknesses.

[0045] This invention mounts an electric hydraulic jack 4, a sensor assembly 7, a high-strength steel plate 5, and integrated wiring onto a high-strength steel hollow support rod 2. The hollow support rod 2 passes through an annular steel mold 1 and is connected to a fixing device. The hollow support rod 2 can also be connected by bolts, facilitating the installation of the elastic sleeve and the assembly of hollow support rods 2 of different lengths.

[0046] The process for manufacturing a ring-shaped concrete pole using the above-described apparatus in this embodiment includes the following steps: S1: Raw material preparation and template filling: Pour the concrete mixture into the annular steel mold 1 with the steel reinforcement cage installed, close the annular steel mold 1 and install the first threaded plug with drainage holes. S2: Centrifugal molding: The annular steel mold 1 is placed on a horizontal centrifuge and rotated through three stages: low speed, medium speed and high speed, to remove air and excess moisture and obtain pre-formed concrete. Step S2 consists of three stages: low speed, medium speed, and high speed. First, run at a low speed of 200 rpm for 2 minutes to allow the concrete to initially distribute. Then, run at a medium speed of 500 rpm for 2 minutes to further expel air. Finally, run at a high speed of 1100 rpm for 7 minutes to achieve concrete compaction.

[0047] S3: Compacting preparation: Assemble the hollow support rod 2 and pass it through the annular steel mold 1. Connect both ends of the hollow support rod 2 to the external fixed base 6, and replace the threaded plug with a drainage hole with a second threaded plug 10 without a drainage hole. S4: Extrusion compaction and intelligent monitoring: The electric hydraulic jack 4 is activated to apply radial pressure to the concrete through the high-strength steel plate 5. At the same time, the stress sensor and displacement sensor in the sensor group 7 monitor the force, thickness and state of the concrete in real time. The intelligent monitoring device dynamically adjusts the pressure and pressurization time of each electric hydraulic jack 4 according to the monitoring data. Increased oil pressure directly leads to an increase in the output thrust (i.e., the compressive force on the concrete) of the electro-hydraulic jack 4. The stronger pressure can more effectively compress the loose area, further squeezing out the moisture and air, making its density match that of other areas, thereby reducing the thickness in that area to the target range.

[0048] The intelligent monitoring device in step S4 processes data from stress sensors and displacement sensors to obtain the real-time thickness of each area of ​​the concrete, and adjusts the pressure and pressurization time by controlling the corresponding electric hydraulic jacks 4 to ensure that the overall thickness of the concrete is uniform.

[0049] S5: Curing: The entire extrusion unit is moved into the curing furnace of the rapid curing unit. Based on the concrete setting and hardening information fed back by the high-temperature piezoelectric ceramic ultrasonic sensor in sensor group 7, a segmented temperature control strategy is adopted for curing. The segmented temperature control strategy in step S5 is as follows: the wave velocity and wave velocity change rate are calculated using the acoustic time data obtained by the high-temperature piezoelectric ceramic ultrasonic sensor. The time point with the maximum wave velocity change rate is characterized as the initial setting time, and the time point with the wave velocity change rate decreasing to 20% of the maximum value is characterized as the final setting time. Before the initial setting time, the curing temperature is controlled at 60℃. After the initial setting time, the temperature is increased to 80℃ at a heating rate of 20℃ / hour, and curing continues until 2 hours after the final setting time.

[0050] The arrangement spacing of the high-temperature piezoelectric ceramic ultrasonic sensors is 20cm.

[0051] S6: Demolding: After curing, remove the device and take out the formed ring-shaped concrete pole.

[0052] Specifically, the first step is the basic preparation stage of the process. First, based on the product design strength requirements, the concrete mix proportion must be accurately calculated and prepared. A forced mixer is used to thoroughly mix the raw materials such as cement, aggregates, admixtures, and water to obtain a concrete mixture with good workability. Simultaneously, the pre-tied and designed steel reinforcement cage is accurately placed into the cleaned annular steel mold 1. Then, the mixed concrete mixture is evenly poured into the annular steel mold 1 containing the steel reinforcement cage using a concrete placing device. After filling, high-strength bolts are used to tightly close the mold joint of the annular steel mold 1, ensuring the overall rigidity and sealing of the mold. Next, using precision tools such as a digital wrench, the first threaded plug with drainage holes is screwed into all the pre-machined threaded plug holes 3 on the wall of the annular steel mold 1. The purpose of installing the first threaded plug at this stage is to establish a channel for the subsequent centrifugal process to remove air and excess moisture. When screwing in, the torque or rotation angle needs to be controlled to ensure that the bottom of the first threaded plug fits against the arc-shaped surface of the inner wall of the annular steel mold 1, so as to avoid unnecessary turbulence or structural stress concentration during centrifugation.

[0053] The specific implementation methods and principles of step S2 and the subsequent low-speed, medium-speed, and high-speed three-stage centrifugal process can be further explained as follows: This stage is the core of the initial concrete forming process. The ring-shaped steel mold 1, which has been filled and sealed, is hoisted onto the support roller assembly of the horizontal centrifuge and started.

[0054] The low-speed stage (200 rpm, lasting 2 minutes) is the material spreading stage. The lower rotation speed allows the concrete mixture to be initially and evenly distributed along the inner wall of the annular steel mold 1 under the action of centrifugal force, overcoming the influence of gravity and achieving a roughly uniform circumferential spreading, laying the foundation for subsequent compaction, while avoiding material splashing or segregation due to excessive rotation speed.

[0055] Medium-speed stage (500 rpm, 2 minutes): Based on the initial distribution, the rotation speed is increased to increase centrifugal force. The main functions of this stage are air release and initial compaction. The increased centrifugal force effectively removes most of the air bubbles and some free water from the mixture through the drain hole of the first threaded plug, making the concrete structure initially stable.

[0056] High-speed stage (1100 rpm, lasting 7 minutes): This is the final compaction stage. The extremely high centrifugal force gives the concrete particles maximum kinetic energy, causing them to assemble tightly together, squeezing out excess water, and achieving high density. At this point, the aggregate and cement paste within the concrete are more evenly distributed, forming a hollow cylindrical prototype with a certain structural strength.

[0057] In step S3, after the centrifugation process, the extrusion compaction preparation stage begins. First, a pre-selected elastic sleeve of suitable thickness is fitted onto the high-strength steel plate 5. Then, the hollow support rods 2 are assembled by bolting to ensure overall rigidity and straightness. The isolation door 8 inside the annular steel mold 1 is disassembled and replaced with a perforated isolation door to make room for the hollow support rods 2 to be inserted. The assembled hollow support rods 2, equipped with components such as the electric hydraulic jack 4, high-strength steel plate 5, and sensor group 7, are precisely inserted into the hollow interior of the annular steel mold 1, ensuring that one end is reliably connected to the fixed base 6 on the other side. The fixed base 6 provides reaction force support for the extrusion process. Specifically, the structure of the fixed base 6 can be any structure, as long as it can support the hollow support rods 2. Subsequently, sealing rings are installed at both ends of the annular steel mold 1 and tightened with bolts to seal the mold ends and prevent slurry leakage during extrusion. Finally, using a digital wrench, remove all the first threaded plugs with drainage holes on the wall of the annular steel mold 1 one by one, and replace them with second threaded plugs 10 without drainage holes. This operation is crucial, as it seals off the drainage channels during the centrifugal stage, ensuring that the concrete mixture is compacted only within the sealed cavity during subsequent extrusion processes and does not overflow from the threaded plug holes 3.

[0058] The specific implementation of step S4 is further explained as follows: After the preparation work is completed, the compaction process is initiated. Simultaneously, all electric hydraulic jacks 4 are activated, their push rods extending outwards to drive each high-strength steel plate 5 to move synchronously and smoothly towards the center, applying uniform radial pressure to the initially formed inner wall of the concrete. During this process, the sensor group 7 integrated on the high-strength steel plate 5 begins to operate in real time. The stress sensor monitors the reaction force of the concrete on the high-strength steel plate 5 in real time, i.e., the compressive stress; the displacement sensor accurately measures the actual displacement of the high-strength steel plate 5 from its initial position towards the center. This real-time data is transmitted to the computer terminal of the intelligent monitoring device via a data cable. The operator can set a target thickness value and its allowable tolerance range. The computer terminal continuously compares the real-time thickness with the set value. If the system detects that the concrete thickness in a certain area or several areas is too large, it will automatically send a command to the electric hydraulic jack 4 controlling that area to appropriately increase its output pressure or extend the pressurization duration until the concrete in that area is compacted to the target thickness. Conversely, if the thickness in a certain area is already up to standard or too thin, the system will maintain or reduce the pressure at that point. This closed-loop feedback control mechanism ensures that the final pole has a highly uniform wall thickness and density.

[0059] In step S5, after the compaction is completed, the entire system, including the annular steel mold 1 and the internal extrusion device, is moved into a program-controlled curing furnace. During this stage, dynamic and precise segmented temperature control is performed based on the information about the internal physical state changes of the concrete fed back by a high-temperature piezoelectric ceramic ultrasonic sensor.

[0060] High-temperature piezoelectric ceramic ultrasonic sensors embedded in concrete continuously transmit and receive ultrasonic signals. A computer terminal records the time required for the ultrasonic waves to travel through a predetermined distance and calculates the wave velocity. Subsequently, software analyzes the wave velocity variation curve over time and calculates its rate of change. Numerous experiments show that the time point at which the wave velocity variation rate reaches its maximum value is highly correlated with the initial setting time of the concrete; while the time point at which the wave velocity variation rate decreases from the peak value to 20% of that peak value corresponds to the final setting time. This provides a quantitative indicator for objectively and accurately determining the setting state of concrete.

[0061] Segmented temperature control is implemented based on the aforementioned real-time determination of the condensation point: Pre-setting stage: The control system maintains the curing furnace temperature at 60°C. At this stage, the concrete is still in a plastic state. The gentle temperature increase aims to accelerate the early process of cement hydration, but avoids the risk of uneven internal stress and microcracks caused by excessively high temperatures.

[0062] From initial setting to final setting: During the critical period when concrete begins to lose plasticity and its strength rapidly increases, the control system raises the curing temperature from 60℃ to 80℃ at a steady rate of 20℃ / hour and maintains this temperature until 2 hours after the final setting time. The higher temperature during this stage greatly promotes cement hydration, rapidly increasing concrete strength. The controlled heating rate and determined holding time effectively prevent volume deformation and cracking caused by sudden temperature changes, thus shortening the curing period while ensuring the final strength and durability of the product.

[0063] The embodiments described above are merely illustrative of specific implementations of the present invention, and while the descriptions are detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. An apparatus suitable for manufacturing annular concrete poles, comprising a centrifugal molding device, said centrifugal molding device comprising a horizontal centrifuge and an annular steel mold (1), characterized in that: The centrifugal molding device is used to initially shape the concrete mixture. The wall of the annular steel mold (1) is evenly opened with multiple threaded plug holes (3) along the axial direction. The threaded plug holes (3) can be selectively screwed with a first threaded plug with a drainage hole to discharge air and excess water when the centrifugal molding device is centrifuged. The extrusion compaction device can extend into the inner cavity of the annular steel mold (1) to apply radial pressure to the concrete that has been initially shaped by centrifugation to make it compact. A rapid curing device is used to accelerate the curing of concrete poles after they have been formed. An intelligent monitoring device is connected to the extrusion compaction device and the rapid curing device for real-time monitoring and control of the extrusion and curing processes.

2. The apparatus for manufacturing ring-shaped concrete poles as described in claim 1, characterized in that: The threaded plug hole (3) can selectively screw on a second threaded plug (10) with or without a drain hole; the bottom of both the first threaded plug and the second threaded plug (10) are machined into an arc shape that matches the curvature of the inner wall of the annular steel mold (1).

3. The apparatus for manufacturing ring-shaped concrete poles as described in claim 2, characterized in that: The extrusion compaction device includes a hollow support rod (2) that can extend into the hollow interior of the annular steel mold (1), a plurality of electric hydraulic jacks (4) arranged in an array on the hollow support rod (2), and a high-strength steel plate (5) connected to the output end of each of the electric hydraulic jacks (4); each of the high-strength steel plates (5) can be spliced ​​into a complete pressure ring by the telescopic movement of the electric hydraulic jacks (4).

4. The apparatus for manufacturing ring-shaped concrete poles as described in claim 3, characterized in that: The high-strength steel plate (5) is fitted with an elastic sleeve on the outside, and the elastic sleeve is selected with different thicknesses according to the specifications of the annular concrete pole; the hollow support rod (2) is a detachable splicing structure.

5. The apparatus for manufacturing ring-shaped concrete poles as described in claim 4, characterized in that: The annular steel mold (1) is provided with a detachable isolation door (8). The isolation door (8) is closed during the centrifugal stage and is replaced by a perforated isolation door with a hole in the middle during the extrusion stage, so that the hollow support rod (2) can pass through. The annular steel mold (1) is also provided with an exhaust valve (9) connected to the gas storage tank.

6. The apparatus for manufacturing ring-shaped concrete poles as described in claim 5, characterized in that: The intelligent monitoring device includes a sensor group (7) for collecting data and a computer terminal for processing data and outputting control commands; the sensor group (7) includes a stress sensor and a displacement sensor, as well as a high-temperature piezoelectric ceramic ultrasonic sensor for monitoring the state of concrete.

7. A process for manufacturing annular concrete poles using the apparatus as described in claim 6, characterized in that, Includes the following steps: S1: Raw material preparation and template filling: Put the concrete mixture into the annular steel mold (1) with the steel reinforcement skeleton installed, close the annular steel mold (1) and install the first threaded plug with drainage hole; S2: Centrifugal molding: The annular steel mold (1) is placed on a horizontal centrifuge and rotated through three stages of low speed, medium speed and high speed in sequence to remove air and excess water and obtain pre-formed concrete; S3: Compacting preparation: Assemble the hollow support rod (2) and pass it through the annular steel mold (1), connect it to the fixed base (6), and replace the first threaded plug with a drainage hole with a second threaded plug (10) without a drainage hole. S4: Extrusion compaction and intelligent monitoring: The electric hydraulic jack (4) is activated to apply radial pressure to the concrete through the high-strength steel plate (5). At the same time, the force, thickness and state of the concrete are monitored in real time through the sensor group (7). The intelligent monitoring device dynamically adjusts the pressure and pressurization time of each electric hydraulic jack (4) according to the monitoring data. S5: Curing: The entire extrusion unit is moved into the curing furnace. Based on the concrete setting and hardening information fed back by the sensor group (7), a segmented temperature control strategy is adopted for curing. S6: Demolding: After curing, remove the device and take out the formed ring-shaped concrete pole.

8. The process for manufacturing a ring-shaped concrete pole as described in claim 7, characterized in that, The three stages of low speed, medium speed and high speed in step S2 are as follows: First, run at a low speed of 200 rpm for 2 minutes to allow the concrete to initially distribute; then run at a medium speed of 500 rpm for 2 minutes to further expel air; finally, run at a high speed of 1100 rpm for 7 minutes to achieve concrete compaction.

9. The process for manufacturing a ring-shaped concrete pole as described in claim 7, characterized in that, In step S4: the intelligent monitoring device processes the data from the stress sensor and displacement sensor to obtain the real-time thickness of each area of ​​the concrete, and adjusts the pressure by controlling the corresponding electric hydraulic jack (4) to ensure that the overall thickness of the concrete is uniform.

10. The process for manufacturing a ring-shaped concrete pole as described in claim 7, characterized in that, The segmented temperature control strategy in step S5 is as follows: the wave velocity and wave velocity change rate are calculated using the acoustic time data obtained by the high-temperature piezoelectric ceramic ultrasonic sensor. The time point with the maximum wave velocity change rate is characterized as the initial setting time, and the time point with the wave velocity change rate decreasing to 20% of the maximum value is characterized as the final setting time. Before the initial setting time, the curing temperature is controlled at 60℃. After the initial setting time, the temperature is increased to 80℃ at a heating rate of 20℃ / hour, and curing continues until 2 hours after the final setting time.

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