Concrete quality judgment system and method

Abstract

The invention discloses a concrete quality judgment system and method, and belongs to the technical field of concrete quality detection.The concrete quality judgment system comprises a communication terminal arranged on a mixer truck, an acquisition system and a mixing station data cloud platform, and the acquisition system comprises a real-time torque value acquisition device, a temperature and humidity sensor, a rotating speed sensor and a vibration sensor; concrete state and working condition data can be collected, real-time data, basic information of transportation tasks and historical data samples with quality results are stored in a cloud end, and the concrete quality judgment method comprises the steps that the real-time data are obtained through a collection system, and the basic information and the historical samples are obtained through the cloud end; the obtained data is preprocessed; according to the method, real-time monitoring of the whole concrete transportation process is achieved, the judgment accuracy is improved, and potential engineering quality hazards and economic losses are effectively reduced.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of concrete quality detection, and particularly relates to a concrete quality determination system and method. BACKGROUND

[0002] Concrete is one of the most core materials in construction engineering, and its delivery quality directly determines the overall quality and construction progress of the project. In actual engineering application, during the whole process from production completion of concrete at the mixing station to use at the construction site, quality problems such as segregation and bleeding are prone to occur due to the influence of factors such as transportation environment and working conditions. If these problems cannot be found and handled in time, it will leave serious quality hidden dangers for the project and cause unnecessary economic losses, so it is necessary to detect the quality of the concrete.

[0003] The existing concrete quality detection method has the following problems:

[0004] 1. Insufficient detection timeliness: the existing concrete quality detection is generally based on a one-time detection of the pressure sensor when the concrete is delivered, which cannot monitor the dynamic quality change in the transportation process in real time, so that the quality problems occurring in the transportation process cannot be detected in time;

[0005] 2. Poor judgment accuracy: the method of implementing detection in the transportation process mostly uses a fixed threshold to judge the quality, without fully considering the characteristic differences of different grade concretes and the influence of different climate conditions, so that the quality determination result is not accurate enough and it is difficult to meet the detection needs of complex scenes in actual engineering. SUMMARY

[0006] To solve the problems in the background art, the present application provides a concrete quality determination system and method to solve the problems of insufficient detection timeliness and poor judgment accuracy of the existing concrete quality detection method.

[0007] To achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0008] The concrete quality determination system comprises:

[0009] A communication terminal, which is arranged on the mixer truck;

[0010] A collection system, which comprises a real-time torque value collection device, a temperature sensor, a humidity sensor, a rotation speed sensor and a vibration sensor, wherein the real-time torque value collection device is arranged on the mixer truck, the temperature sensor and the humidity sensor are arranged on the inner side of the feeding port of the mixer truck for collecting concrete state data, the rotation speed sensor is arranged on the driving shaft of the drum of the mixer truck, and the vibration sensor is arranged in the middle part of the frame of the mixer truck, and the rotation speed sensor and the vibration sensor are used to collect working condition data of the current transportation task;

[0011] The communication terminal and the acquisition system are connected with the data cloud platform of the mixing station, the data cloud platform of the mixing station is provided with a database, all data collected by the acquisition system is uploaded to the database of the data cloud platform of the mixing station, the database also stores production correlation data, concrete grade and transportation distance data of the current transportation task and historical data samples, the historical data samples include concrete grade, concrete state data, working condition data, torque data, production correlation data and quality result information of each historical transportation task.

[0012] Preferably, the real-time torque value acquisition device is a motor controller or a drum torque sensor, when the current transportation task adopts an electric mixer truck, the motor controller of the electric mixer truck is used as the real-time torque value acquisition device, when the current transportation task adopts an oil-driven mixer truck, the drum torque sensor is used as the real-time torque value acquisition device, and the drum torque sensor is arranged on a drum driving transmission shaft of the oil-driven mixer truck.

[0013] The concrete quality determination method comprises the following steps:

[0014] S1: multi-dimensional data acquisition; torque data, concrete state data and working condition data of the mixer truck are collected through the acquisition system, and production correlation data, concrete grade, transportation distance data and historical data samples of the current transportation task are obtained through the data cloud platform of the mixing station;

[0015] S2: pre-processing of the collected multi-dimensional data;

[0016] S3: dynamic quality determination; according to the concrete grade, production correlation data, concrete state data, working condition data and transportation distance data of the current transportation task, the torque data of the historical data sample with positive evaluation in the same scene is matched from the historical database quality result information, and then the historical data sample quantity is adaptively adjusted according to the transportation distance, and then the torque average value of the matched historical data sample is calculated 历史 , and then the final dynamic reference value T 基准 is obtained by introducing a multi-environment factor correction.

[0017] The current real-time torque value T 当前 is calculated, and the relative deviation Δ of T 基准 is calculated, the torque values collected in a continuous preset group are taken as an analysis unit, the deviation change rate R is calculated, if the R of the continuous x analysis units is greater than a preset percentage, a warning is triggered and a corresponding warning scheme is executed.

[0018] S4: After the execution of the early warning scheme, a group of real-time torque values is collected every preset minute. When the relative deviation △ of a continuous preset group of real-time torque values is less than or equal to a preset percentage, the early warning is removed, and the relevant data of the current execution of the early warning scheme is archived to a historical database for subsequent sample updating and optimization of the dynamic reference value.

[0019] Preferably, in S1, if the mixer truck is an electric mixer truck, the current real-time torque value T 当前 = K × U × I, where K is a motor characteristic coefficient determined by the motor model of the electric mixer truck, and U and I are the voltage and current of the motor, respectively. If the mixer truck is an oil-driven mixer truck, the real-time torque value T 当前 is directly obtained through the drum torque sensor.

[0020] Preferably, the preprocessing in S2 includes digital filtering and outlier rejection.

[0021] Preferably, the transportation distance L in S1 is calculated by real-time path planning through navigation software.

[0022] Preferably, in S3, the transportation distance L is divided into three types: short distance <5km, medium distance 5km≤L≤15km, and long distance >15km. The historical data sample size is adaptively adjusted according to the transportation distance. For short distance, the latest 50 groups are taken, for medium distance, 80 groups are taken, and for long distance, 120 groups are taken.

[0023] Preferably, in S3, the multiple environmental factors include temperature correction coefficient K T , humidity correction coefficient K H , and jolt correction coefficient K A . The specific value rules are as follows:

[0024] ;

[0025] ;

[0026] ;

[0027] Where T env is the temperature data collected by the temperature sensor in the concrete state data, H is the humidity data collected by the humidity sensor, and A is the amplitude data collected by the vibration sensor.

[0028] T 基准 is specifically expressed as:

[0029] .

[0030] Preferably, in S3, the specific calculation method of the relative deviation △ is:

[0031] ;

[0032] The specific calculation method of the deviation change rate R is as follows:

[0033] ;

[0034] Wherein △ n is the relative deviation of the n-th group of real-time torque values, and △ n+1 is the relative deviation of the n+1-th group of real-time torque values.

[0035] Preferably, in S3, the early warning scheme includes first to third early warnings, and the specific triggering conditions are as follows:

[0036] When 10% < △ ≤ 20%, a first early warning is triggered, and the data cloud platform of the mixing station pushes a roller speed adjustment suggestion to the communication terminal;

[0037] When 20% < △ ≤ 30%, a second early warning is triggered, and the data cloud platform of the mixing station sends early warning information to the technical personnel of the mixing station, the technical personnel of the mixing station perform technical analysis, and the personnel of the mixing station send the analysis results and countermeasures to the communication terminal;

[0038] When △ > 30%, a third early warning is triggered, the current transportation task is suspended, and the slump of the concrete is detected on site, and whether to continue the current transportation task is determined according to the detection result.

[0039] Compared with the prior art, the beneficial effects of the present application are:

[0040] The present application introduces a dynamic reference value, matches historical qualified samples of the same scene, adjusts the sample size in combination with the transportation distance, introduces three types of environmental factors such as temperature, humidity and jolt to correct the reference value, fully considers the differences of different grade concretes, different environmental conditions and different transportation conditions, makes the determination result more in line with the actual quality state, and solves the problem of avoiding misjudgment of the fixed threshold. At the same time, the present application sets three levels of early warning according to the severity of the quality anomaly, realizes gradient control of risk, avoids cost waste caused by over-treatment of slight anomaly, and prevents engineering hidden dangers caused by failure to intervene in time in case of serious anomaly. Finally, the complete data of each transportation task is archived to the historical database, the historical sample library is continuously enriched and optimized, the calculation of the subsequent dynamic reference value is more accurate, a virtuous cycle of "data accumulation-determination optimization-precision improvement" is formed, and the misjudgment rate can be further reduced in long-term use. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 is the flowchart of the present application. DETAILED DESCRIPTION

[0042] For the skilled in the art to understand the technical content of the present application, the present application is further described in detail below in combination with the drawings and specific examples. It should be understood that the specific examples described herein are only used to explain the present application and do not limit the present application.

[0043] The concrete quality determination system is characterized in that it comprises:

[0044] The communication terminal is arranged on the oil-driven mixer truck, and the communication terminal adopts a mobile communication device, such as a smart phone with communication software, etc., and the oil-driven mixer truck is of the model Xugong XZJ5250GJBA2.

[0045] The acquisition system comprises a real-time torque value acquisition device, a temperature sensor, a humidity sensor, a rotation speed sensor and a vibration sensor, wherein the real-time torque value acquisition device is a drum torque sensor of the model HCNJ-101A, the drum torque sensor is arranged on a drum driving transmission shaft of the oil-driven mixer truck, the temperature sensor and the humidity sensor are both arranged inside a feeding port of the oil-driven mixer truck for acquiring concrete state data, the rotation speed sensor is arranged on a drum driving shaft of the oil-driven mixer truck, and the vibration sensor is arranged in a middle part of a frame of the oil-driven mixer truck, the rotation speed sensor and the vibration sensor being used for acquiring working condition data of a current transportation task.

[0046] The mixing station data cloud platform is of a distributed micro-service architecture, takes DDD as a core, comprises independent modules of each business split, such as commodity management, order processing, etc., and is connected with the communication terminal and the acquisition system through Kubernetes container arrangement, a hybrid database, and the acquisition system uploads all the data acquired by the acquisition system to a database of the mixing station data cloud platform, the database further stores production correlation data, concrete grade and transportation distance data of the current transportation task and historical data samples, the historical data samples comprising concrete grade, concrete state data, working condition data, torque data, production correlation data and quality result information of each historical transportation task.

[0047] Taking a transportation concrete of the model C35, a transportation distance L=18km, production correlation data of a water-cement ratio 0.42, mixing time 85 seconds and cement consumption 360kg / m³ as an example, the concrete quality determination method comprises the following steps:

[0048] S1: multi-dimensional data acquisition; acquiring torque data T 当前 =17200N·m, temperature T env= 32℃, humidity H = 82%, amplitude A = 1.1mm, roller speed 5r / min, through the stirring station data cloud platform to obtain the current production associated data of transportation task, concrete grade, transportation distance data and historical data samples, and the transportation distance L is calculated through real-time path planning by navigation software;

[0049] S2: preprocessing the collected multi-dimensional data; the preprocessing includes digital filtering and outlier rejection, and a sliding average filtering method (window size 5 groups of data) is adopted to remove random noise in torque, temperature and humidity data according to the following formula to improve data smoothness:

[0050] ;

[0051] Wherein, is the filtered data, X1-X5 is the original data of 5 groups in succession, such as torque, temperature and humidity data;

[0052] The outlier rejection is specifically:

[0053] When a group of data exceeds the reasonable range, such as torque T > 1.2 x T 设计值 , temperature T env > 60℃, humidity H < 20% and the like, it is marked as an outlier, and the average value of the previous 3 groups of valid data is replaced to avoid the interference of abnormal data on the determination result.

[0054] S3: dynamic quality determination; according to the current concrete grade of transportation task, production associated data, concrete state data, working condition data and transportation distance data, the quality result information of the same scene is matched from the historical database to be the torque data of the historical data sample of positive evaluation, such as matching 120 groups of historical samples of "C35 grade + water-cement ratio 0.42 + long-distance transportation + quality qualified", calculating the torque average value of the matched historical data sample 历史 = 16500N·m, introducing multi-environment factor correction to obtain the final dynamic reference value T 基准 , for example:

[0055] T env = 32℃, which is high temperature, K T = 0.05 x (T env - 25) = 0.35;

[0056] H = 82%, which is high humidity, K H = -0.03;

[0057] A = 1.1mm, which is light jolt, K A = 0;

[0058] Then T 基准 is:

[0059] T 基准 = 16500 x (1 + 0.35 - 0.03 + 0) = 16500 x 1.32 = 21780 N.m.

[0060] Calculate the relative deviation Δ of the current real-time torque value Tcurrent and Treference:

[0061] ;

[0062] Take the torque values collected in 5 groups continuously as an analysis unit, with an interval of 10 seconds between each group, a unit duration of 50 seconds, and calculate the deviation change rate R. If the average deviation Δ1 of the first unit is -21.03%, the average deviation Δ2 of the second unit is -22.15%, and the average deviation Δ3 of the third unit is -21.87%, then:

[0063] ;

[0064] ;

[0065] Since Δ = -21.03%, it meets the condition of "20% < Δ ≤ 30%", triggering a secondary warning, and the warning scheme is as follows:

[0066] The warning scheme includes primary to tertiary warnings, and the specific triggering conditions are as follows:

[0067] When 10% < Δ ≤ 20%, trigger a primary warning, and the mixing station data cloud platform pushes the roller speed adjustment suggestion to the communication terminal;

[0068] When 20% < Δ ≤ 30%, trigger a secondary warning, and the mixing station data cloud platform sends warning information to the mixing station technical personnel, the mixing station technical personnel perform technical analysis, and the mixing station personnel send the analysis results and countermeasures to the communication terminal;

[0069] When Δ > 30%, trigger a tertiary warning, and stop the current transportation task, and detect the slump of the concrete on site, and decide whether to continue the current transportation task according to the detection results;

[0070] S4: The mixing station data cloud platform immediately sends warning information (including current torque value, temperature and humidity, amplitude, deviation rate, etc.) to the mixing station technical personnel, the technical personnel analyze and judge that "the deviation is caused by high temperature leading to change of concrete viscosity, and the roller speed needs to be maintained and closely monitored", and then send the analysis results and countermeasures to the mixer communication terminal through the cloud;

[0071] After the implementation of measures, every 5 minutes, 1 group of real-time torque values were collected, and the relative deviations of 3 groups of data were calculated as -19.8%, -18.5%, and -19.2% respectively, all of which were less than or equal to 20%, meeting the conditions for canceling the early warning, and the system automatically canceled the secondary early warning;

[0072] Data archiving: the complete data of this transportation (including the collected raw data, preprocessing records, benchmark value calculation process, early warning level and treatment measures, and the construction site test result of slump 158 mm (qualified) were archived to the historical database for subsequent dynamic benchmark value sample updating and optimization of C35 grade long-distance transportation tasks.

Claims

1. A concrete quality assessment system, characterized in that, include: Communication terminal; The communication terminal is installed on the mixer truck; Data acquisition system; The data acquisition system includes a real-time torque acquisition device, a temperature sensor, a humidity sensor, a speed sensor, and a vibration sensor. The real-time torque acquisition device is installed on the mixer truck. The temperature and humidity sensors are installed inside the feed inlet of the mixer truck to collect concrete condition data. The speed sensor is installed on the drum drive shaft of the mixer truck, and the vibration sensor is installed in the middle of the mixer truck frame. The speed sensor and vibration sensor are used to collect the working condition data of the current transportation task. The batching plant data cloud platform; the communication terminal and the acquisition system are all connected to the batching plant data cloud platform. The batching plant data cloud platform has a database. All data collected by the acquisition system is uploaded to the database of the batching plant data cloud platform. The database also stores production-related data of the current transportation task, concrete grade and transportation distance data, as well as historical data samples. The historical data samples include concrete grade, concrete condition data, working condition data, torque data, production-related data and quality result information for each historical transportation task.

2. The concrete quality assessment system according to claim 1, characterized in that, The real-time torque value acquisition device is either a motor controller or a drum torque sensor. When the current transportation task uses an electric mixer truck, the motor controller of the electric mixer truck is used as the real-time torque value acquisition device. When the current transportation task uses a hydraulic mixer truck, the drum torque sensor is used as the real-time torque value acquisition device. The drum torque sensor is installed on the drum drive shaft of the hydraulic mixer truck.

3. A method for judging concrete quality, applied to the concrete quality judging system as described in claims 1-2, characterized in that, Includes the following steps: S1: Multidimensional data acquisition; The system collects torque data, concrete condition data, and operating data of the mixer truck, and obtains production-related data, concrete grade, transportation distance data, and historical data samples of the current transportation task through the mixing plant data cloud platform. S2: Preprocess the collected multidimensional data; S3: Perform dynamic quality assessment; based on the concrete grade, production-related data, concrete condition data, working condition data, and transportation distance data of the current transportation task, match the torque data of historical data samples with positive evaluations for the same scenario from the historical database. Simultaneously, adaptively adjust the historical data sample size according to the transportation distance, and then calculate the average torque of the matched historical data samples. 历史 Then, multiple environmental factors are introduced for correction to obtain the final dynamic baseline value T. 基准 ; Calculate the current real-time torque value T 当前 With T 基准 The relative deviation △ is calculated by taking the torque value collected in a continuous preset group as an analysis unit, and the deviation change rate R is calculated. If R of x consecutive analysis units is greater than the preset percentage, an early warning is triggered and the corresponding early warning plan is executed. S4: After the early warning plan is executed, a set of real-time torque values ​​is collected every preset minute. When the relative deviation Δ of the consecutive preset sets of real-time torque values ​​is less than or equal to the preset percentage, the early warning is lifted, and the relevant data of the early warning plan executed this time is archived to the historical database for subsequent sample updates and optimization of dynamic benchmark values.

4. The method for judging concrete quality according to claim 3, characterized in that, In S1, if the mixer truck is an electric mixer truck, then the current real-time torque value T is... 当前 =K×U×I, where K is the motor characteristic coefficient, determined by the motor model of the electric mixer truck, and U and I are the motor voltage and current, respectively. If the mixer truck is a hydraulic mixer truck, the real-time torque value T is obtained directly through the drum torque sensor. 当前 .

5. The method for judging concrete quality according to claim 3, characterized in that, Preprocessing in S2 includes digital filtering and outlier removal.

6. The method for determining the quality of concrete according to claim 3, characterized in that, The transport distance L in S1 is calculated using real-time route planning by navigation software.

7. The method for judging concrete quality according to claim 3, characterized in that, In S3, the transportation distance L is divided into three types: short distance < 5km, medium distance 5km≤L≤15km, and long distance > 15km. The historical data sample size is adaptively adjusted according to the transportation distance: the most recent 50 groups are taken for short distance, 80 groups for medium distance, and 120 groups for long distance.

8. The method for determining the quality of concrete according to claim 3, characterized in that, In S3, multiple environmental factors include the temperature correction factor K. T Humidity correction factor K H And bump correction factor K A The specific value selection rules are as follows: ； ； ； Among them, T env H represents the temperature data collected by the temperature sensor in the concrete condition data, H represents the humidity data collected by the humidity sensor, and A represents the amplitude data collected by the vibration sensor. T 基准 Specifically, it can be expressed as follows: 。 9. The method for judging the quality of concrete according to claim 8, characterized in that, In S3, the specific calculation method for the relative deviation △ is as follows: ； The specific calculation method for the deviation change rate R is as follows: ； Where △ n Δ represents the relative deviation of the nth group of real-time torque values. n+1 This represents the relative deviation of the real-time torque value in the (n+1)th group.

10. The method for determining the quality of concrete according to claim 3, characterized in that, In S3, the early warning scheme includes Level 1 to Level 3 early warnings, with the specific triggering conditions as follows: When 10% < △ ≤ 20%, a Level 1 warning is triggered, and the data cloud platform of the mixing plant pushes a drum speed adjustment suggestion to the communication terminal; When 20% < △ ≤ 30%, a level-two warning is triggered. The data cloud platform of the mixing plant sends the warning information to the technical personnel of the mixing plant. The technical personnel of the mixing plant conduct technical analysis and send the analysis results and countermeasures to the communication terminal. When △ > 30%, a Level 3 warning is triggered, the current transportation task is suspended, and the concrete slump is tested on-site. The decision on whether to continue the current transportation task is based on the test results.

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