Whole-process intelligent cement grouting system

Abstract

The invention relates to the technical field of cement grouting, and discloses a whole-process intelligent cement grouting system which comprises a field execution layer, a function enhancement layer and a remote decision-making layer. The field execution layer is a core execution carrier of the system and comprises various grouting operation execution devices and a local control unit; the function enhancement layer is a performance improvement module of the system and comprises a slurry storage blending device, a stratum monitoring device and an energy consumption optimization related device; the remote decision-making layer is a central management and control platform of the system and comprises a data processing server and a multi-role management platform; and the field execution layer is connected with the function enhancement layer through a pipeline and a signal line. Through a three-level architecture, data intercommunication and instruction collaboration of the whole links of slurrying, slurry conveying, slurry storage, slurry preparation and grouting are achieved, the traditional'information isolated island 'is broken through, the response efficiency of each module is improved, slurry temperature control and dynamic concentration adjustment are achieved through the intelligent slurry storage and preparation module, real-time parameter collection is combined with an intelligent grouting station, slurry adaptability is improved, and construction errors are reduced.

Description

Technical Field

[0001] This invention relates to the field of cement grouting technology, specifically to a fully intelligent cement grouting system. Background Technology

[0002] Cement grouting is an engineering method that involves injecting cement grout into rock fissures, concrete cracks, or cavities through drilling or pipe laying. It is primarily used to enhance the compactness, impermeability, and bearing capacity of surrounding rock or structures. Traditional grouting methods face several technical bottlenecks in engineering practice, specifically: The process is severely fragmented, with equipment operating independently in stages such as slurry preparation, slurry delivery, and grouting, and data cannot be shared, resulting in poor coordination between stages. There is a high reliance on manual labor, with slurry mixing and parameter adjustments largely dependent on manual operation, easily leading to mixing errors and operational mistakes, affecting construction quality. Parameter control is lagging, as it is impossible to monitor grouting pressure, flow rate, and formation changes in real time, making it difficult to dynamically adjust operating parameters according to site conditions. Risk warnings are lacking, making it difficult to detect sudden changes in formation stress and abnormal slurry diffusion in a timely manner, posing construction safety hazards. Furthermore, there is a lack of energy consumption control; equipment operation lacks energy consumption monitoring and optimization mechanisms, resulting in energy waste. These problems seriously restrict the efficiency, quality, and safety of grouting projects and urgently need improvement. Summary of the Invention

[0003] This invention provides a fully intelligent cement grouting system to solve the problems mentioned in the background section.

[0004] This invention provides the following technical solution: The fully intelligent cement grouting system includes an on-site execution layer, a function enhancement layer, and a remote decision-making layer; The field execution layer is the core execution carrier of the system, which includes various grouting operation execution equipment and local control units; The functional enhancement layer is a performance improvement module of the system, including devices related to slurry preparation, formation monitoring and energy consumption optimization; The remote decision-making layer is the central control platform of the system, which includes a data processing server and a multi-role management platform; The field execution layer and the function enhancement layer are connected through pipelines and signal lines, and the function enhancement layer communicates with the remote decision-making layer through a wireless network. The three form a closed-loop control architecture of "command-execution-feedback-adjustment" throughout the entire process.

[0005] Furthermore, the field execution layer includes an intelligent pulping station, an intelligent transfer station, an intelligent grouting station, a field coordination center, and a mobile application terminal; the field coordination center uses a single-chip microcomputer integrated PLC as the control core and realizes bidirectional signal interaction with the intelligent pulping station, intelligent transfer station, intelligent grouting station, and mobile application terminal respectively.

[0006] Furthermore, the functional enhancement layer includes an intelligent slurry storage and distribution module, a formation perception and early warning subsystem, and an energy consumption optimization unit; the intelligent slurry storage and distribution module connects the intelligent slurry preparation station and the intelligent transfer station, and the formation perception and early warning subsystem and the energy consumption optimization unit are respectively connected to the intelligent grouting station via signals.

[0007] Furthermore, the remote decision-making layer includes a central server and a cloud management platform. The central server is equipped with data storage, algorithm calculation, and instruction issuance modules, while the cloud management platform is configured with multi-role access interfaces and a data visualization module.

[0008] Furthermore, the intelligent slurry storage and preparation module includes a slurry storage tank with an intelligent temperature control device, a concentration sensor, and an automatic slurry preparation device; the concentration sensor collects slurry concentration data and transmits it to a central server, and the central server issues slurry preparation instructions to the automatic slurry preparation device to realize dynamic adjustment of slurry concentration.

[0009] Furthermore, the formation sensing and early warning subsystem includes a formation stress sensor and a slurry diffusion monitoring device; when a sudden change in formation stress or an abnormality in slurry diffusion is detected, an early warning signal is automatically sent to the central server, and the parameter adjustment plan of the intelligent grouting station is triggered.

[0010] Furthermore, the energy consumption optimization unit includes an energy consumption monitoring sensor and a power adjustment module; the energy consumption monitoring sensor collects energy consumption data from each device, and the central server analyzes the data through an algorithm and sends a power adjustment command to the power adjustment module to dynamically optimize the operating power of the devices.

[0011] Furthermore, the intelligent grouting station integrates pressure sensors and flow sensors to collect grouting pressure and flow data in real time and upload them to the central server, while also receiving grouting parameter adjustment instructions from the central server.

[0012] Furthermore, the central server receives construction data from the field execution layer, geological data from the functional enhancement layer, and energy consumption data. After algorithm calculation, it issues dynamic control commands for slurry preparation, slurry mixing, and grouting to the intelligent slurry preparation station, intelligent slurry storage and mixing module, and intelligent grouting station, respectively.

[0013] Furthermore, the cloud management platform synchronizes data with the central server, allowing owners, supervisors, and construction units to remotely monitor, view early warnings, trace data, generate reports, and approve processes through role-based access control.

[0014] Beneficial effects: The intelligent cement grouting system described in this invention achieves data exchange and command coordination across the entire process of grout preparation, transportation, storage, mixing, and grouting through a three-level architecture, breaking down traditional "information silos" and improving the response efficiency of each module.

[0015] This invention achieves temperature control and dynamic adjustment of grout concentration through an intelligent grout storage and mixing module. Combined with real-time parameter acquisition from an intelligent grouting station, it improves grout adaptability and reduces construction errors.

[0016] This invention identifies geological anomalies in advance through a geological sensing and early warning subsystem, automatically triggers parameter adjustment commands and pushes early warning information, thereby reducing construction safety risks.

[0017] This invention reduces the overall energy consumption of equipment by dynamically adjusting the operating power of the equipment through an energy consumption optimization unit and combining it with energy consumption data analysis. In the long run, this can save a lot of energy costs.

[0018] This invention supports remote collaboration among multiple roles through a cloud management platform, automating data traceability, report generation, and process approval, thereby shortening management process time and reducing manual management costs.

[0019] This invention utilizes PLC integrated control through a field coordination center, enabling stable operation in harsh construction environments such as high temperature, high humidity, and dust, thereby increasing trouble-free operating time. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall cement grouting process of the present invention; Figure 2 This is a schematic diagram of the internal process of the field execution layer of the present invention; Figure 3 This is a schematic diagram of the internal process of the functional enhancement layer of the present invention; Figure 4 This is a schematic diagram of the internal process of the remote decision-making layer of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1 - Figure 4 The intelligent cement grouting system for the entire process includes an on-site execution layer, a function enhancement layer, and a remote decision-making layer; The on-site execution layer is the core execution carrier of the system, which includes various grouting operation execution equipment and local control units; The functional enhancement layer is a performance improvement module for the system, including devices related to slurry preparation, formation monitoring, and energy consumption optimization. The remote decision-making layer serves as the central control platform for the system, including a data processing server and a multi-role management platform. The on-site execution layer and the function enhancement layer are connected through pipelines and signal lines, while the function enhancement layer and the remote decision-making layer communicate through a wireless network. The three form a closed-loop control architecture for the entire process of "command-execution-feedback-adjustment". This three-layer architecture breaks through the limitations of the traditional grouting system of "dispersed equipment and disconnected management". Through deep linkage between layers, it achieves seamless connection of the entire chain from remote command issuance to on-site execution feedback, providing core architectural support for the intelligent and integrated management and control of grouting operations. At the same time, each layer can flexibly expand or reduce modules according to the scale of the project, and has strong scenario adaptability.

[0023] The on-site execution layer includes an intelligent pulping station, an intelligent transfer station, an intelligent grouting station, an on-site coordination center, and a mobile application terminal. The on-site coordination center uses a microcontroller-integrated PLC as its control core, enabling bidirectional signal interaction with the intelligent pulping station, intelligent transfer station, intelligent grouting station, and mobile application terminal. The PLC control core has high reliability and anti-interference capabilities, and can adapt to the complex electromagnetic environment and temperature and humidity conditions at the construction site. The bidirectional signal interaction design ensures the accurate issuance of remote commands and synchronously feeds back the real-time operating status of each device, pulping progress, transfer tank level, and grouting pressure to the control center. The mobile application terminal provides on-site operators with a portable monitoring and emergency adjustment portal, avoiding operational delays caused by the limitations of fixed monitoring points.

[0024] The functional enhancement layer includes an intelligent slurry storage and preparation module, a formation sensing and early warning subsystem, and an energy consumption optimization unit. The intelligent slurry storage and preparation module connects the intelligent slurry preparation station and the intelligent transfer station. The formation sensing and early warning subsystem and the energy consumption optimization unit are respectively connected to the intelligent grouting station. As a "bridge" between on-site execution and remote decision-making, the functional enhancement layer not only realizes the refined upgrade of slurry treatment, but also expands the functional boundaries of the system through formation monitoring and energy consumption control. The signal connection between modules adopts a redundant design to ensure the stability of data transmission. Even if one module is temporarily offline, other modules can still maintain basic functional operation, improving the overall fault tolerance of the system.

[0025] The remote decision-making layer includes a central server and a cloud management platform. The central server is equipped with modules for data storage, algorithm computation, and command issuance. The cloud management platform is configured with multi-role access interfaces and a data visualization module. The central server adopts a distributed storage and computing architecture, which can process massive amounts of data from multiple construction sites simultaneously. The algorithm module has a built-in machine learning-based grouting parameter optimization model that can autonomously iterate and optimize strategies based on historical construction data and real-time working conditions. The multi-role permission design of the cloud management platform realizes a collaborative management model of "construction party operation, supervision party monitoring, and owner party control". The data visualization module presents key indicators intuitively through charts, curves, and other forms, reducing the data analysis threshold for non-professionals.

[0026] The intelligent slurry storage and mixing module includes a slurry storage tank with an intelligent temperature control device, a concentration sensor, and an automatic slurry mixing device. The concentration sensor collects slurry concentration data and transmits it to a central server. The central server then issues slurry mixing instructions to the automatic slurry mixing device to achieve dynamic adjustment of the slurry concentration. The intelligent temperature control device can keep the slurry temperature within the optimal construction range, avoiding initial setting of the slurry due to excessively high temperature or affecting the fluidity due to excessively low temperature. The concentration sensor adopts high-precision laser detection technology to reduce measurement errors. Combined with the servo motor control of the automatic slurry mixing device, it can achieve real-time fine adjustment of the slurry concentration, ensuring that the performance of the slurry injected into the formation always meets the design requirements and reducing grouting defects caused by improper mixing ratios.

[0027] The formation sensing and early warning subsystem includes a formation stress sensor and a grout diffusion monitoring device. When a sudden change in formation stress or abnormal grout diffusion is detected, an early warning signal is automatically sent to the central server, triggering the parameter adjustment plan of the intelligent grouting station. The formation stress sensor is embedded and can monitor the stress change curve of the formation in real time during the grouting process. The grout diffusion monitoring device uses radar wave detection technology to achieve non-contact detection of the grout diffusion range. After the early warning signal is triggered, the system can automatically adjust the grouting pressure or flow rate according to the preset plan. If the abnormality exceeds the threshold, construction is suspended to avoid engineering accidents caused by formation collapse or grout leakage, providing double protection for construction safety.

[0028] The energy consumption optimization unit includes energy consumption monitoring sensors and a power regulation module. The energy consumption monitoring sensors collect energy consumption data from each device. After analysis by the central server through algorithms, the central server issues power adjustment commands to the power regulation module to dynamically optimize the operating power of the devices. The energy consumption monitoring sensors can perform sub-item energy consumption metering for high-power devices such as the slurry mixing plant mixer and grouting pump. The energy consumption optimization algorithm of the central server combines the equipment load rate and construction progress to automatically reduce the operating power of the devices under non-full load conditions, thereby achieving a balance between energy saving and construction efficiency.

[0029] The intelligent grouting station integrates pressure and flow sensors to collect grouting pressure and flow data in real time and upload them to a central server. It also receives grouting parameter adjustment commands from the central server. The pressure sensor uses a high-precision strain gauge design with a measurement range of 0-10 MPa and an accuracy class of 0.1. The flow sensor uses an electromagnetic flowmeter with a range ratio of 1:100, adapting to flow changes at different grouting stages. Parameter adjustment commands are transmitted via industrial Ethernet, ensuring timely and accurate adjustment of pressure and flow during grouting to meet the dynamic requirements of different geological formations for grouting parameters.

[0030] The central server receives construction data from the field execution layer, geological data from the functional enhancement layer, and energy consumption data. After algorithmic calculation, it issues dynamic control commands for slurry preparation, mixing, and grouting to the intelligent slurry preparation station, intelligent slurry storage and mixing module, and intelligent grouting station, respectively. The central server's computing module adopts multi-threaded parallel processing technology, which can simultaneously analyze dozens of types of data from different levels. The dynamic control commands are generated based on a multi-dimensional coupled model of "geological demand - slurry performance - equipment status". When the geological stress increases, the grouting pressure is reduced and the slurry concentration is increased simultaneously to achieve coordinated optimization of parameters in each link and avoid system imbalance caused by adjustment of a single parameter.

[0031] The cloud management platform synchronizes data with the central server, supporting owners, supervisors, and construction units to remotely monitor, view early warnings, trace data, generate reports, and approve processes through role-based access control. The cloud management platform adopts a B / S architecture, so users do not need to install special software and can access it through a browser. The low data synchronization latency ensures the real-time nature of remote monitoring. The report generation module supports custom report templates and can automatically generate documents such as daily grouting construction reports and quality inspection reports. The approval process is realized online through electronic signatures, improving approval efficiency and significantly shortening the management cycle.

[0032] The practical application of this invention includes the following stages: In the instruction issuance phase: The central server of the remote decision-making layer generates basic instructions such as slurry preparation and grouting based on engineering requirements and preset algorithms, and transmits them to the field coordination center of the field execution layer, which is controlled by a PLC, via a wireless network. On-site execution phase: The on-site coordination center distributes instructions to equipment such as intelligent pulp preparation station and intelligent grouting station. After the intelligent pulp preparation station completes the slurry preparation, it is transported to the intelligent slurry storage and mixing module of the functional enhancement layer. After slurry storage, temperature control and concentration adjustment, it is transported to the intelligent grouting station through the intelligent transfer station to perform grouting operation. Data acquisition phase: The intelligent grouting station in the field execution layer collects construction data such as pressure and flow rate; the ground perception and early warning subsystem in the function enhancement layer collects ground stress and grout diffusion data; the energy consumption optimization unit collects equipment energy consumption data; and the data from each module is uploaded to the central server in real time. Dynamic control phase: The central server integrates and analyzes the uploaded data, generates dynamic adjustment instructions based on preset algorithms, and sends them to the field execution layer and function enhancement layer respectively to achieve real-time optimization of slurry ratio, grouting parameters, and equipment energy consumption; Remote management phase: The central server will aggregate data and synchronize it to the cloud management platform, supporting remote monitoring, early warning viewing, report generation, and process approval for multiple roles such as owners, supervisors, and construction units, forming a closed loop of the entire process of "instruction-execution-feedback-adjustment".

[0033] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A fully integrated intelligent cement grouting system, characterized in that, It comprises a field execution layer, a function enhancement layer and a remote decision-making layer; The field execution layer is the core execution carrier of the system, containing various grouting operation execution equipment and local control units; The function enhancement layer is the performance improvement module of the system, containing grout storage and deployment, stratum monitoring and energy consumption optimization related devices; The remote decision-making layer is the central management platform of the system, containing a data processing server and a multi-role management platform; The field execution layer and the function enhancement layer are connected through pipelines and signal lines, the function enhancement layer and the remote decision-making layer are connected through wireless network communication, and the three form a full-process closed-loop control architecture of "instruction-execution-feedback-adjustment".

2. The whole-process intelligent cement grouting system according to claim 1, characterized in that: The field execution layer comprises an intelligent grouting station, an intelligent transfer station, an intelligent grouting station, a field coordination center and a mobile application end; the field coordination center takes the PLC integrated with a single-chip microcomputer as a control core and realizes bidirectional signal interaction with the intelligent grouting station, the intelligent transfer station, the intelligent grouting station and the mobile application end.

3. The entire process intelligent cement grouting system according to claim 1, characterized in that: The function enhancement layer comprises an intelligent grout storage and deployment module, a stratum perception and early warning subsystem and an energy consumption optimization unit; the intelligent grout storage and deployment module is connected with the intelligent grouting station and the intelligent transfer station, and the stratum perception and early warning subsystem and the energy consumption optimization unit are respectively connected with the intelligent grouting station.

4. The entire process intelligent cement grouting system according to claim 1, characterized in that: The remote decision-making layer comprises a central server and a cloud management platform; the central server is provided with data storage, algorithm operation and instruction issuing modules, and the cloud management platform is configured with multi-role access interfaces and data visualization modules.

5. The entire process intelligent cement grouting system according to claim 3, characterized in that: The intelligent grout storage and deployment module comprises a grout storage tank with an intelligent temperature control device, a concentration sensor and an automatic grout mixing device; the concentration sensor collects grout concentration data and transmits them to the central server, and the central server issues grout mixing instructions to the automatic grout mixing device to realize dynamic adjustment of grout concentration.

6. The entire process intelligent cement grouting system according to claim 3, characterized in that: The stratum perception and early warning subsystem comprises a stratum stress sensor and a grout diffusion monitoring device; when stratum stress mutation or grout diffusion anomaly is monitored, an early warning signal is automatically sent to the central server, and a parameter adjustment plan of the intelligent grouting station is triggered.

7. The whole-process intelligent cement grouting system according to claim 3, characterized in that: The energy consumption optimization unit comprises an energy consumption monitoring sensor and a power adjustment module; the energy consumption monitoring sensor collects energy consumption data of each device, and the central server issues power adjustment instructions to the power adjustment module after algorithm analysis, to dynamically optimize device operating power.

8. The entire process intelligent cement grouting system according to claim 2, characterized in that: The intelligent grouting station integrates a pressure sensor and a flow sensor, collects grouting pressure and flow data in real time and uploads them to the central server, and receives grouting parameter adjustment instructions issued by the central server.

9. The entire process intelligent cement grouting system according to claim 4, characterized in that: The central server receives construction data of the field execution layer, stratum data and energy consumption data of the function enhancement layer, and issues dynamic control instructions of grouting, grout mixing and grouting to the intelligent grouting station, the intelligent grout storage and deployment module and the intelligent grouting station after algorithm operation.

10. The entire process intelligent cement grouting system according to claim 4, characterized in that: The cloud management platform is synchronized with the central server, supports role permission division of owners, supervisors and construction units, and realizes remote monitoring, early warning viewing, data tracing, report generation and process approval functions.

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