Monitoring system for deformation and settlement of supporting mold caused by concrete pouring
The monitoring system, which uses multi-level signal conversion and segmented data indexing, solves the problems of signal interference and data visualization in mold deformation monitoring, and realizes dynamic quantification and visual tracking of mold deformation, thereby improving the accuracy and efficiency of monitoring.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-19
- Publication Date
- 2026-04-03
AI Technical Summary
Existing monitoring technologies are susceptible to interference and distortion of weak signals in complex environments, cannot dynamically quantify and track the deformation trajectory throughout the entire pouring process, and discrete monitoring data cannot intuitively reflect the overall deformation distribution.
It adopts a multi-level signal conversion architecture to convert analog signals to optical signals, combines segmented data indexing and differential calculation, utilizes fiber optic transmission to resist electromagnetic interference, and combines an inverse distance weighting algorithm to reconstruct the deformation field to achieve three-dimensional imaging and warning output.
Ensuring the accuracy of monitoring data enables dynamic quantitative tracking of mold deformation throughout the entire process, improving the visualization of monitoring data and the efficiency of risk assessment.
Smart Images
Figure CN121782972A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of industrial monitoring technology, specifically to a monitoring system for the deformation and settlement of concrete support molds caused by concrete pouring. Background Technology
[0002] In large-scale civil engineering construction, steel formwork serves as a temporary support structure for concrete pouring, and its stability directly affects the forming accuracy of components and construction safety. As the height of the poured concrete increases, the lateral pressure on the formwork sidewalls increases significantly. Excessive deformation or settlement of the formwork can lead to concrete component displacement, grout leakage, or even formwork collapse. Therefore, real-time monitoring of the formwork morphology during the pouring process is a crucial aspect of construction control.
[0003] Current mold monitoring technologies mostly employ resistive or capacitive displacement sensors, directly transmitting monitoring data via analog electrical signals. However, the concrete pouring site environment is complex, with numerous high-power frequency converters, vibrators, and pumps that generate strong electromagnetic fields during operation. Traditional analog signal transmission methods have weak anti-interference capabilities, and long-distance transmission cables are prone to coupling with electromagnetic noise from the site. This causes the weak deformation signals reaching the terminal to become distorted or drowned out by noise, making it difficult to accurately reflect the micron-level displacement changes of the mold and affecting the reliability of the monitoring data.
[0004] Furthermore, existing monitoring methods typically focus on threshold judgments of deformation at a single moment or in the final state, lacking the ability to continuously track dynamic stress changes throughout the entire pouring process. In actual construction, the stress state of the mold changes non-linearly with the increase of pouring height, and focusing only on the final deformation often lags behind the moment when risks occur. Existing technologies lack effective data indexing and differential calculation mechanisms, making it difficult to compare and analyze intermediate state data during the pouring process with the no-load baseline. This results in the inability to detect abnormal trends in deformation rate in a timely manner, limiting the timeliness of process parameter adjustments.
[0005] On the other hand, traditional monitoring systems have a relatively simple data output format, typically presenting the displacement of each measuring point in a discrete numerical table. Since the monitoring points are spatially discrete, this numerical display method cannot intuitively reflect the overall deformation field distribution on the mold surface. Technicians find it difficult to quickly visualize the overall torsion or settlement pattern of the mold based solely on discrete data points, easily overlooking potential risks in monitoring blind spots, leading to low efficiency in assessing potential hazards. Summary of the Invention
[0006] To address the shortcomings of existing technologies, this invention provides a monitoring system for the deformation and settlement of concrete support molds caused by concrete pouring. This system solves the problems of existing monitoring technologies, such as the susceptibility of weak signals to interference and distortion in complex environments, the inability to dynamically quantify and track the deformation trajectory throughout the pouring process, and the difficulty in intuitively reflecting the overall deformation distribution using discrete monitoring data.
[0007] To achieve the above objectives, the present invention provides the following technical solution: a monitoring system for deformation and settlement of concrete pouring-induced support formwork, comprising a displacement sensing device, a signal transmission device, and a monitoring digital display terminal. The displacement sensing device is positioned at monitoring points on the outer surface of the steel formwork, and establishes a linear mapping relationship between physical displacement and analog electrical signals using an internal linear displacement detection unit. When a spatial change occurs on the surface of the steel formwork, the displacement sensing device outputs a weak electrical analog signal reflecting the displacement change based on the electromechanical conversion sensitivity coefficient and the zero-point bias voltage.
[0008] To ensure the accuracy and interference resistance of signal transmission in industrial settings, this invention employs a specific multi-stage signal conversion architecture. The signal transmission device comprises a position sensor, a position transmitter, and a signal converter connected in sequence. The position sensor receives a weak analog signal and performs sampling and threshold discrimination processing. By introducing an analog-to-digital conversion gain coefficient and a background noise filtering threshold, the analog signal is converted into a discrete digital pulse signal that characterizes a specific displacement, thereby filtering out high-frequency noise interference at the source. The position transmitter receives and identifies this discrete digital pulse signal, employing a linear amplification model and converting it into a low-voltage electrical signal that conforms to industrial safety standards based on a voltage conversion coefficient. The signal converter connects the position transmitter and the monitoring digital display terminal, utilizing a laser diode to perform electro-optic signal modulation, modulating the low-voltage electrical signal into a light intensity signal based on the electro-optic conversion efficiency coefficient. This light intensity signal is transmitted to the monitoring digital display terminal via optical fiber, utilizing the immunity of optical signals to electromagnetic interference to ensure the integrity of the data link.
[0009] The monitoring digital display terminal communicates with the signal converter, receives light intensity signals, performs reverse demodulation, reconstructs displacement data, and then performs data integration analysis, 3D model imaging, tolerance comparison, and warning output. The monitoring digital display terminal integrates a data processing module, a 3D imaging module, and an warning module. The data processing module is responsible for storing raw and process monitoring data and performing numerical tolerance calculations. The 3D imaging module constructs a virtual 3D model of the steel mold based on the spatial coordinate encoding of the displacement sensing device and dynamically updates the model's shape according to real-time displacement data. The warning module compares the real-time calculated deformation with a preset tolerance threshold and generates a warning signal if the value exceeds the limit.
[0010] In terms of data processing logic, the data processing module establishes a data indexing and association mechanism. The system establishes time axis indices with the first data collected under no-load and zero-load conditions, based on the second data collected when the concrete pouring height reaches one-third, the third data collected when the pouring height reaches two-thirds, and the fourth data collected when the pouring is completed and the system is at full load. The data processing module executes a differential calculation program to calculate the relative displacement vector value of each stage data relative to the first data used as a reference, generating a deformation data set. The positive or negative sign of this relative displacement vector value is used to characterize the direction of displacement, thereby realizing the quantitative tracking of stress release and structural deformation trajectory of the mold throughout the entire process from no-load to full-load.
[0011] In terms of 3D imaging logic, the 3D imaging module reconstructs a continuous deformation field on the mold surface using discrete monitoring point data. This module employs an inverse distance weighted algorithm, constructing a weight function based on the Euclidean distance between the point to be calculated and its neighboring effective monitoring points. This weight function characterizes the influence of effective monitoring points on the deformation of the point to be calculated, and typically uses power-law constraints to ensure a smooth transition of the deformation field in space. Based on this, the system calculates the estimated deformation value of the point to be calculated and superimposes this value onto the initial geometric model of the steel mold for rendering and display, achieving intuitive visualization of the deformation data.
[0012] Regarding the warning logic, the monitoring digital display terminal receives control tolerance parameters, including the upper and lower limits of allowable deformation tolerance, through a human-machine interface. The warning module compares the effective deformation of each monitoring point with the control tolerance parameters. If the effective deformation exceeds the set tolerance range, the system generates a trigger signal and marks the corresponding monitoring point and its surrounding area in red on the 3D imaging interface, while simultaneously outputting an audible and visual alarm to allow technicians to take timely reinforcement measures.
[0013] Furthermore, to adapt to the on-site environment, the displacement sensing device includes multiple independent sensor connectors distributed in critical stress areas of the steel mold. The displacement sensing device is externally protected by a hemispherical or trapezoidal protective cover made of polycarbonate or stainless steel, forming a sealed cavity with rubber gaskets. Combined with waterproof connectors on the sides, this achieves physical isolation from the concrete slurry. For power supply and wiring, the system uses an independent DC regulated power supply module or a high-capacity lithium battery pack. If wired power is used, the power cable employs a double-shielded structure and is laid separately from the fiber optic cable to further cut off electromagnetic coupling interference paths.
[0014] Regarding the communication protocol, the optical signal data stream generated by the signal converter follows a specific serial communication frame structure, including a synchronization frame header for identifying the start of data packets, an address code segment storing the physical location code, a data payload segment storing the quantized displacement value, and a check code segment for verifying transmission errors. Simultaneously, the system can be configured with a multi-channel data aggregation unit, employing time-division multiplexing technology to sort and merge multiple electrical signals into a single high-speed serial data stream according to time slots, thereby reducing wiring complexity.
[0015] This invention provides a monitoring system for the deformation and settlement of concrete support formwork caused by concrete pouring. It has the following beneficial effects:
[0016] 1. This invention adopts a multi-level signal conversion architecture from analog signals to optical signals, which improves the anti-interference capability of data acquisition. By sampling and threshold discrimination by the position sensor, the weak electrical analog signal is converted into a pulse signal, and high-frequency noise is filtered out at the source. Then, it is converted into an industrial safety low voltage by the position transmitter, and finally electro-optic modulation is performed by the signal converter. By utilizing the immunity of optical fiber transmission to electromagnetic interference, the electromagnetic coupling path generated by large equipment at the concrete pouring site is cut off. This solves the problem that weak deformation signals are easily distorted or overwhelmed by interference during long-distance transmission, and ensures the accuracy of monitoring data.
[0017] 2. This invention establishes a segmented data index and differential calculation mechanism based on the pouring height, realizing the dynamic quantification of the entire mold deformation process. It collects displacement data at different stages of the pouring process and calculates the relative displacement vector value based on the no-load zero state. It not only records the final deformation amount, but also completely restores the stress release and structural deformation trajectory of the steel mold from no-load to full-load process. It can detect abnormal deformation trends in the middle of pouring in a timely manner and provide accurate data support for real-time adjustment of process parameters.
[0018] 3. This invention utilizes an inverse distance weighted algorithm to reconstruct the continuous deformation field of the mold surface, improving the visualization of monitoring data. A weighting function is constructed based on the Euclidean distance between the effective monitoring point and the point to be calculated, mapping discrete single-point sensor data into a continuous three-dimensional model surface morphology. When the value exceeds the limit, specific areas are highlighted, enabling technicians to intuitively observe the deformation distribution of the entire mold surface, quickly locate the deformation peak area, and thus take reinforcement measures before the mold suffers substantial damage. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the overall architecture of the monitoring system of the present invention;
[0020] Figure 2 This is a flowchart of the monitoring method of the present invention.
[0021] Among them, 100 is the monitoring system; 200 is the steel mold; 10 is the displacement sensing device; 11 is the sensor connector; 12 is the position sensor; 13 is the position transmitter; 14 is the signal converter; 20 is the signal transmission device; 30 is the monitoring digital display terminal; 31 is the data processing module; 32 is the three-dimensional imaging module; and 33 is the warning module. Detailed Implementation
[0022] The technical solutions in 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.
[0023] See attached document Figure 1 The present invention provides a monitoring system 100 for the deformation and settlement of the support mold caused by concrete pouring. The monitoring system 100 is applied to the production and pouring process of steel mold 200 and is used to acquire deformation data of steel mold 200 under load in real time.
[0024] The monitoring system 100 mainly includes a displacement sensing device 10, a signal transmission device 20, and a monitoring digital display terminal 30. The displacement sensing device 10 is configured to be installed at monitoring points on the exterior of the steel mold 200, for physical contact and sensing of spatial position changes on the mold surface. The signal transmission device 20 is electrically connected to the displacement sensing device 10, for converting the physical displacement into a system-recognizable digital signal and completing the conversion and transmission from electrical signal to optical signal. The monitoring digital display terminal 30 is communicatively connected to the signal transmission device 20, for receiving and demodulating the optical signal, and then performing data integration analysis, three-dimensional model imaging, tolerance comparison, and warning output.
[0025] The displacement sensing device 10 includes multiple independently operating sensor connectors 11. These sensor connectors 11 are distributed and fixed in the key stress areas of the steel mold 200 according to a preset monitoring scheme. When the steel mold 200 settles or bulges laterally, the sensor connectors 11 generate displacement and output weak electrical analog signals. The signal transmission device 20 includes a position sensor 12, a position transmitter 13, and a signal converter 14. The position sensor 12 is connected to the sensor connectors 11 and is used to receive the weak electrical analog signals and convert them into pulse signals representing specific displacement amounts. The position transmitter 13 is connected to the position sensor 12 and is used to receive and identify the pulse signals, converting them into low-voltage electrical signals that meet industrial safety standards. The signal converter 14 is connected between the position transmitter 13 and the monitoring digital display terminal 30 and is used to modulate the low-voltage electrical signals into optical signals, which are then transmitted to the monitoring digital display terminal 30 via optical fiber to reduce interference from the electromagnetic environment at the concrete pouring site on data transmission.
[0026] The monitoring digital display terminal 30 integrates a data processing module 31, a 3D imaging module 32, and an alert module 33. The monitoring digital display terminal 30 receives data from sensors at different coded locations via a cable interface. The data processing module 31 is configured to store raw monitoring data and process monitoring data, and to perform numerical tolerance calculations. The 3D imaging module 32 constructs a virtual 3D model of the steel mold 200 based on the spatial coordinate encoding of each sensor connector 11, and dynamically updates the shape of this 3D model according to real-time displacement data. The alert module 33 compares the real-time calculated deformation with a preset tolerance threshold and generates an alert signal when the value exceeds the limit.
[0027] See attached document Figure 2 This invention provides a method for monitoring the deformation and settlement of concrete support molds caused by concrete pouring, the method comprising the following steps:
[0028] S10, according to the layout requirements of the monitoring design document, install the displacement sensing device 10 at the corresponding position on the exterior facade of the steel mold 200, and implement physical isolation protection for the displacement sensing device 10; when the steel mold 200 is in an unloaded and qualified state, configure the displacement sensing device 10 to the zero state.
[0029] S20, connect the displacement sensing device 10 to the monitoring digital display terminal 30, encode the distribution position of the displacement sensing device 10 on the steel mold 200, construct the initial imaging model of the steel mold 200 based on the encoded information, and collect the initial displacement information in the zero state, and mark it as the first data.
[0030] S30, during the concrete pouring process, one-third of the height of the steel mold 200 is used as the segment node. When the pouring height reaches one-third, two-thirds and when the pouring is completed, the displacement sensing device 10 collects the real-time displacement information of each node and marks it as the second data, the third data and the fourth data in sequence.
[0031] S40, input the preset control tolerance into the monitoring digital display terminal 30; calculate the displacement changes of the second, third and fourth data relative to the first data through the data processing module 31; map the displacement changes to the imaging model for visualization display, and trigger an alarm signal when the displacement changes exceed the control tolerance.
[0032] The monitoring system 100 provided by this invention adopts a multi-level signal conversion architecture at the hardware level. This architecture not only includes physical connections but also follows a signal transfer function model to ensure accurate data acquisition and transmission in the complex electromagnetic environment of a concrete pouring site. The subsystem mainly includes:
[0033] The sensor connector 11 in the displacement sensing device 10 is fixedly installed at a predetermined detection position on the outer surface of the steel mold 200. The sensor connector 11 contains a linear displacement detection unit configured to establish a linear mapping between physical displacement and analog electrical signals. Let x(t) be the physical displacement of the steel mold 200 at the monitoring point at time t, and let V be the weak electrical analog signal output by the sensor connector 11. weak (t) follows the following response formula:
[0034] V weak (t)=α·x(t)+V offset ;
[0035] Where α is the electromechanical conversion sensitivity coefficient of sensor connector 11, in mV / mm; V offset This is the zero-point bias voltage of the sensor. The weak current analog signal V... weak (t) Transmitted to the next level via shielded cable.
[0036] Position sensor 12 has its input terminal electrically connected to sensor connector 11. Position sensor 12 is equipped with signal conditioning and analog-to-digital conversion circuitry for receiving weak analog signals and converting them into discrete digital pulse signals. Position sensor 12 is sensitive to V... weak (t) Performs sampling and threshold discrimination, generating pulse count value N. pulse (t) satisfies the following quantization relation:
[0037]
[0038] Where β is the analog-to-digital conversion gain coefficient; V noiseThe preset background noise filtering threshold; This indicates a floor function (rounding down). The pulse count value N... pulse (t) can accurately characterize the amplitude change of displacement, and the high-frequency noise interference in the analog signal is initially filtered out through discretization.
[0039] A position transmitter 13 is connected to a position sensor 12. The position transmitter 13 is configured to receive and identify pulse signals output by the position sensor 12. To accommodate long-distance transmission in the field and comply with industrial safety regulations, the position transmitter 13 converts the pulse signals into a safe voltage electrical signal V at a specified voltage level. safe (t). This conversion process follows the following linear amplification model:
[0040] V safe (t)=k v ·N pulse (t);
[0041] Where, k v This is the voltage conversion factor, and its value ensures the output V safe (t) It is within the safe voltage range for the human body (e.g., below 24V or 36V) and has sufficient power to drive subsequent optoelectronic components.
[0042] Signal converter 14 is connected to the output of position transmitter 13. Signal converter 14 is configured to perform electro-optic signal modulation, using a built-in laser diode to modulate a safe voltage electrical signal into a light intensity signal I. opt (t). The photoelectric conversion equation for this modulation process is:
[0043] I opt (t)=η·V safe (t);
[0044] Where η is the electro-optical conversion efficiency coefficient. The light intensity signal I... opt (t) is transmitted to the monitoring digital display terminal 30 via an optical fiber line. Due to the optical signal I... opt (t) is immune to electromagnetic interference during transmission, so the system can ensure that the information characteristics of the original physical displacement x(t) are not distorted in the signal link from sensor connector 11 to monitoring digital display terminal 30.
[0045] Preferably, the position transmitter 13 or signal converter 14 is configured with a multi-channel data aggregation unit. Before the signal is electro-optically modulated, the aggregation unit uses time-division multiplexing (TDM) technology to queue and sort the electrical signals from different position sensors 12 according to a preset time slot, merging them into a single high-speed serial data stream. In this way, data from all monitoring points on the steel mold 200 can be transmitted through a single or a small number of optical fiber lines, reducing the complexity of on-site wiring and the cost of optical fibers.
[0046] In addition, considering the wiring limitations and electrical safety at the concrete pouring site, the displacement sensing device 10, position sensor 12, and position transmitter 13 are powered by independent DC regulated power supply modules, or by high-capacity lithium battery packs for local power supply. When wired power supply is used, the power cable adopts a double-shielded structure and is laid separately from the signal transmission optical fiber to cut off the electromagnetic coupling interference of power grid fluctuations on the front-end weak current signal acquisition.
[0047] The optical receiving port of the monitoring digital display terminal 30 is connected to the optical fiber output of the signal converter 14. The monitoring digital display terminal 30 receives the optical signal and performs reverse demodulation, based on the aforementioned conversion coefficients α, β, k. v The inverse operation of η accurately restores the received optical signal into digital displacement data. Furthermore, when modulating the optical signal, the signal converter 14 uses time-division multiplexing or frequency-division multiplexing technology to encapsulate the identification data containing position encoding information along with the displacement data, enabling the monitoring digital display terminal 30 to accurately identify the specific spatial coordinates of the received data source from the steel mold 200.
[0048] Specifically, in the signal converter 14 or the multi-channel data aggregation unit, the generated optical signal data stream follows a serial communication frame structure. This frame structure includes: a synchronization header, used to identify the start of the data packet; an address ID segment, occupying 4-8 binary bits, used to store the physical location code of the sensor connector 11; a data payload segment, storing the quantized displacement value; and a check coded message (CRC) segment, used to monitor whether bit errors occur during the transmission process in the digital display terminal 30.
[0049] Before the monitoring system 100 provided by this invention can be put into formal operation, it needs to be systematically installed, deployed, and its parameters initialized. This process mainly includes:
[0050] Based on the pre-established monitoring design documents, the key stress-deformation areas and settlement observation points on the exterior facade of the steel mold 200 are determined. Multiple displacement sensing devices 10 are fixedly installed at the corresponding detection positions on the exterior facade of the steel mold 200. The installation positions are selected to cover the midpoints, corners, and support stress points of the long side of the steel mold 200 to construct a complete deformation monitoring grid.
[0051] After the displacement sensing device 10 is installed, each displacement sensing device 10 and its connecting lines are physically isolated and protected. A protective cover or isolation baffle is installed. Specifically, the protective cover is made of high-strength polycarbonate or stainless steel, and its shape is hemispherical or trapezoidal, fastened and fixed to the outside of the displacement sensing device 10. Rubber sealing gaskets are provided on the edges of the protective cover that contact the surface of the steel mold 200 to form a sealed cavity to prevent grout penetration. A waterproof connector is provided on the side of the protective cover for the connecting cable to pass through, physically isolating the displacement sensing device 10 from the concrete pouring area. This prevents concrete grout from splashing onto the surface of the displacement sensing device 10 during pouring, avoiding sensor sensitivity degradation or mechanical structure jamming due to contamination.
[0052] The signal output line of the displacement sensing device 10 is connected to the imaging port of the monitoring digital display terminal 30. Based on the geometry of the steel mold 200 and the actual physical distribution of the displacement sensing devices 10, the monitoring digital display terminal 30 assigns an address code to each connected displacement sensing device 10. This address code establishes a one-to-one mapping relationship with the three-dimensional spatial coordinates of the steel mold 200 surface, ensuring that the subsequently acquired displacement data can accurately correspond to specific parts of the mold.
[0053] The steel mold 200 is subjected to dimensional adjustments under no-load conditions. After the steel mold 200 has not been filled with concrete and its geometric dimensions have been confirmed to meet the design specifications, a zeroing command is sent to all connected displacement sensing devices 10 via the monitoring digital display terminal 30. The displacement sensing devices 10 respond to the zeroing command and set their currently detected position as the initial zero point.
[0054] The monitoring digital display terminal 30 reads the position and encoding information of all displacement sensing devices 10 in the zero-state state, and uses the built-in three-dimensional imaging algorithm to generate the initial undeformed model of the steel mold 200. The system saves the dataset of all position coordinates collected at this moment to the storage unit and marks this dataset as Data 1. This Data 1 serves as the sole reference data for calculating the relative deformation and settlement during subsequent concrete pouring.
[0055] The segmented casting data acquisition method provided by this invention mainly includes the following steps:
[0056] During concrete pouring operations, the displacement sensing device 10 and its connecting cables are physically shielded. During the pouring process, operators or automated pouring equipment must avoid direct mechanical impact to the displacement sensing device 10. At the same time, the connectivity of the signal transmission channel is monitored in real time by the digital display terminal 30 to ensure that the data acquisition link is in a stable closed-loop state consisting of the position sensor 12, the position transmitter 13, and the signal converter 14.
[0057] A segmented node acquisition strategy based on pouring height is implemented. The entire concrete pouring process is divided into three key observation nodes according to the vertical height of the steel mold 200. The first observation node is set when the concrete pouring height reaches one-third of the total height of the steel mold 200. When the pouring operation reaches this height, the monitoring digital display terminal 30 sends a synchronous reading command to all online displacement sensing devices 10 to obtain the instantaneous displacement coordinates of each monitoring point at this time. The system marks all displacement datasets collected at this moment as the second data and stores them in the storage unit.
[0058] The second observation node is set at the point where the concrete pouring height reaches two-thirds of the total height of the steel mold 200. When the pouring operation reaches this height, the monitoring digital display terminal 30 triggers the synchronous reading command again to obtain the displacement coordinates of each monitoring point under this load condition. The system marks all displacement datasets collected at this moment as the third data and stores them in the storage unit.
[0059] The third observation node is set at the point where the concrete pouring operation is completed and the steel mold 200 is under full load. After pouring stops, the monitoring digital display terminal 30 performs a final process acquisition to obtain the displacement coordinates under full load. The system marks all displacement datasets acquired at this moment as the fourth data set and stores them in the storage unit.
[0060] The data processing module 31 establishes a data indexing and association mechanism. The data processing module 31 establishes a timeline index by linking the collected second, third, and fourth data with the pre-stored first data, which serves as the zero-point reference. The second data is used to analyze the initial stress deformation trend at the bottom of the steel mold 200, the third data is used to analyze the transitional deformation in the middle of the mold, and the fourth data is used to evaluate the final deformation state of the mold as a whole under ultimate load. Through this segmented acquisition method, the system records the stress release and structural deformation trajectory of the steel mold 200 throughout the entire process from no-load to full-load.
[0061] The data integration analysis, imaging, and alert logic provided by this invention mainly includes the following processing steps:
[0062] During the data integration and analysis phase, the monitoring digital display terminal 30 receives control tolerance parameters input by the operator through a human-machine interface. These control tolerance parameters include the upper limit of the allowable deformation tolerance L. max and the lower limit of allowable deformation tolerance L min The data processing module 31 retrieves the first data stored in the storage unit as the benchmark dataset, and retrieves the second, third, and fourth data as the test datasets respectively.
[0063] The data processing module 31 executes a differential calculation program to quantify the relative deformation of the steel mold 200 at different casting stages. Let i be the encoding index of the displacement sensing device 10. Let D... i (t0) is the initial displacement value of the i-th monitoring point in the first data, D i (t k ) represents the i-th monitoring point in the process data (second, third, or fourth data) at time t. k The measured displacement value.
[0064] Data processing module 31 calculates the effective deformation ΔE of the i-th monitoring point according to the following formula. i :
[0065] ΔE i =D i (t k )-D i (t0);
[0066] Where, ΔE i This represents the relative displacement vector value of the i-th monitoring point relative to the unloaded zero state, with its positive or negative sign indicating the direction of displacement (e.g., outward displacement is set as positive, and inward displacement as negative). The data processing module 31 performs the above calculation on all monitoring points to generate the deformation data set of the corresponding casting node.
[0067] The 3D imaging module 32 receives the deformation data set and updates the 3D visualization model of the steel mold 200 according to the spatial interpolation algorithm. The 3D imaging module 32 reconstructs the continuous deformation field of the mold surface using discrete monitoring point data. Let P(x,y,z) be the spatial coordinates of any point on the surface of the 3D model, and let V be the predicted deformation value at that point. def The following shape function formula is used to derive:
[0068]
[0069] Where m is the number of valid monitoring points participating in the calculation within the neighborhood; ω j (x,y,z) is a weighting function related to spatial distance, used to characterize the influence of the j-th monitoring point on the deformation of the target location; ΔE j Let V be the effective deformation at the j-th monitoring point. The three-dimensional imaging module 32 will calculate V... def It is superimposed on the initial geometric model of the steel mold 200 and rendered on the display screen as a virtual entity image with deformation characteristics.
[0070] Preferably, the weighting function ω j (x,y,z) is constructed using the Inverse Distance Weighting (IDW) algorithm, and its calculation formula is as follows:
[0071]
[0072] Where, d j is the Euclidean distance between the point P(x,y,z) to be calculated and the j-th monitoring point; p is the power exponent, usually taken as 2, to ensure a smooth transition of the deformation field in space.
[0073] The warning module 33 executes numerical discrimination logic to monitor whether the deformation state of the steel mold 200 is within the controllable range. The warning module 33 compares the effective deformation amount ΔE of each monitoring point one by one. i Control and tolerance parameters. Warning status indicator S alert The judgment logic is as follows:
[0074]
[0075] When the warning status indicator S alert When the value is 1, the warning module 33 generates a trigger signal. The monitoring digital display terminal 30 responds to the trigger signal, marks the corresponding i-th monitoring point and its neighboring area as red highlight in the three-dimensional imaging interface, and simultaneously outputs an audible and visual alarm signal.
[0076] The system generates independent analysis reports for all triggered alarm values and their corresponding monitoring point coordinates. These reports specify the exact locations and magnitudes of values exceeding tolerances, providing data support for structural optimization of the steel mold 200. Based on this data, technicians add reinforcing ribs or adjust the support structure in the corresponding deformation areas of the steel mold 200 to control the mold's load variables.
Claims
1. A monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring, characterized in that, The monitoring system is applied to the production and casting process of steel molds, and the monitoring system includes: A displacement sensing device is configured to be installed on a monitoring point on the outer facade of the steel mold. The displacement sensing device is equipped with a linear displacement detection unit, which is configured to establish a linear mapping between physical displacement and analog electrical signal and output a weak electrical analog signal. A signal transmission device electrically connected to the displacement sensing device, the signal transmission device comprising a position sensor, a position transmitter, and a signal converter connected in sequence; The position sensor is connected to the displacement sensing device and is configured to sample and threshold the weak current analog signal, and convert the weak current analog signal into a discrete digital pulse signal that characterizes the specific displacement. The position transmitter is connected to the position sensor and is configured to receive and identify the discrete digital pulse signal, and convert the discrete digital pulse signal into a low-voltage electrical signal that meets industrial safety standards through a linear amplification model. The signal converter is connected between the position transmitter and the monitoring digital display terminal, and is configured to use a laser diode to perform electro-optic signal modulation function, modulate the low voltage electrical signal into an optical intensity signal and transmit the optical intensity signal through an optical fiber; The monitoring digital display terminal is communicatively connected to the signal converter and is used to receive the light intensity signal and demodulate it, thereby performing data integration analysis, three-dimensional model imaging, tolerance comparison and warning output.
2. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 1, characterized in that, The displacement sensing device includes multiple independently operating sensor connectors, which are distributed and fixed in the critical stress areas of the steel mold. The displacement sensing device is externally fastened with a protective cover. The protective cover is hemispherical or trapezoidal in shape and is made of polycarbonate or stainless steel. The edge of the protective cover that contacts the surface of the steel mold is provided with a rubber sealing gasket. The rubber sealing gasket forms a sealed cavity, and a waterproof connector for the connecting cable to pass through is provided on the side of the protective cover.
3. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 1, characterized in that, The monitoring digital display terminal integrates a data processing module, a three-dimensional imaging module, and an alarm module. The data processing module is configured to store raw monitoring data and process monitoring data and perform numerical tolerance calculations. The three-dimensional imaging module is configured to construct a virtual three-dimensional model of the steel mold based on the spatial coordinate encoding of the displacement sensing device and update the shape of the virtual three-dimensional model according to real-time displacement data. The warning module is configured to compare the real-time calculated deformation with a preset tolerance threshold and generate a warning signal if the value exceeds the limit.
4. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 3, characterized in that, The data processing module has a data index association mechanism, which is configured to establish a time axis index with the first data collected when the concrete pouring height reaches one-third, the third data collected when the pouring height reaches two-thirds, and the fourth data collected when the pouring is completed and the full load state is reached, respectively.
5. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 4, characterized in that, The data processing module is configured to execute a differential calculation program to calculate the relative displacement vector values of the second data, the third data, and the fourth data relative to the first data, which serves as a reference dataset, and to generate a deformation data set, wherein the positive or negative sign of the relative displacement vector values represents the direction of the displacement.
6. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 5, characterized in that, The three-dimensional imaging module is configured to receive the deformation data set and reconstruct the continuous deformation field of the mold surface using discrete monitoring point data. The three-dimensional imaging module employs an inverse distance weighting algorithm, constructing a weighting function based on the Euclidean distance between the point to be calculated and the effective monitoring points in the neighborhood. The weighting function characterizes the degree of influence of the effective monitoring points on the deformation of the point to be calculated, calculates the estimated deformation value of the point to be calculated, and superimposes the estimated deformation value onto the initial geometric model of the steel mold for rendering and display.
7. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 3, characterized in that, The monitoring digital display terminal is equipped with a human-machine interface for receiving control annotation tolerance parameters, including the upper limit of allowable deformation tolerance and the lower limit of allowable deformation tolerance. The warning module is configured to compare the effective deformation of each monitoring point with the control annotation tolerance parameter one by one. If the effective deformation is greater than the upper limit of the deformation tolerance or less than the lower limit of the deformation tolerance, a trigger signal is generated and the corresponding monitoring point and the neighborhood area of the corresponding monitoring point are marked as red and highlighted in the three-dimensional imaging interface.
8. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 1, characterized in that, The optical signal data stream generated by the signal converter follows a serial communication frame structure, which includes: Synchronization frame header, which is used to identify the start of the data packet; The address code segment is used to store the physical location code of the displacement sensing device; The data payload section is used to store the quantized displacement values. The check segment is used to verify bit errors during transmission.
9. The monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 1, characterized in that, The location transmitter or the signal converter is equipped with a multi-channel data aggregation unit. The multi-channel data aggregation unit uses time-division multiplexing technology to queue and sort electrical signals from different location sensors according to preset time slots, and merge them into a single high-speed serial data stream.
10. A monitoring system for deformation and settlement of concrete support formwork caused by concrete pouring according to claim 1, characterized in that, The displacement sensing device, the position sensor, and the position transmitter are powered by an independent DC regulated power supply module or a high-capacity lithium battery pack. When wired power is used, the power cable adopts a double-shielded structure and is laid separately from the optical fiber used to transmit the light intensity signal.