Grouting system and grouting control method and equipment

Abstract

The invention provides a grouting system and a grouting control method and device, and relates to the technical field of engineering vehicles. The system comprises a drill rod, a slurry pipe, a controller, and a pressure sensor, a flow meter and a pressurizing winch which are respectively connected with the controller, wherein the pressure sensor is mounted on a slurry pipe and is used for detecting the grouting pressure value of slurry; the flow meter is mounted on the slurry pipe and used for detecting the grouting flow value of slurry; the controller is used for driving the pressurizing winch according to the pouring pressure value and the pouring flow value and controlling the lifting speed of the drill rod so that the drill rod can inject slurry conveyed by the slurry pipe into the grouting hole. The system is used for automatic control of grouting construction, the lifting speed of the drill rod is dynamically regulated and controlled by collecting grouting pressure and flow data in real time, accurate matching of the lifting speed and the slurry filling progress is achieved, it is guaranteed that slurry filling in a grouting hole is even and dense, errors caused by manual experience operation are avoided, and therefore the pile forming quality is effectively improved.

Description

Technical Field

[0001] This application relates to the field of engineering vehicle technology, and in particular to a grouting system, grouting control method and equipment. Background Technology

[0002] Grouting is a core process in pile foundation engineering, and its quality directly affects the stability, bearing capacity, and long-term durability of the pile structure. The purpose of this step is to precisely inject grout into the borehole (i.e., the grouting hole), utilizing the cementing effect, filling effect, and compaction properties of the grout after solidification to form a uniform, continuous, and high-strength pile body, thereby meeting the engineering requirements for bearing capacity and deformation control.

[0003] In existing grouting techniques, the current method relies on operator experience and manual control to adjust the drill rod lifting speed to ensure uniform filling of the grouting hole and the formation of a dense pile. However, manual control requires a high level of operator skill, and prolonged operation can lead to fatigue or misjudgment, causing a mismatch between the drill rod lifting speed and the grout filling progress in the grouting hole, resulting in poor pile quality. Summary of the Invention

[0004] This application provides a grouting system, grouting control method, and equipment to achieve precise matching between the drill rod lifting speed and the mud filling progress in the grouting hole, thereby improving the quality of pile formation.

[0005] In a first aspect, this application provides a grouting system, including: a drill pipe, a mud pipe, a controller, and a pressure sensor, a flow meter, and a pressurized winch respectively connected to the controller;

[0006] The pressure sensor is installed on the mud pipe to detect the injection pressure of the mud.

[0007] The flow meter is installed on the mud pipe and is used to detect the injection flow rate of the mud.

[0008] The controller is used to drive the pressurized winch according to the injection pressure value and the injection flow rate value, and control the lifting speed of the drill rod so that the drill rod injects the mud transported by the mud pipe into the grouting hole.

[0009] In one possible implementation, driving the pressure winch and controlling the lifting speed of the drill pipe based on the injection pressure value and the injection flow rate value includes:

[0010] If the injection pressure value is greater than the preset pressure threshold, the real-time filling rate is calculated based on the injection flow rate value and the hole parameters of the grouting hole.

[0011] Based on the real-time filling rate and the preset filling rate, the pressure winch is driven to control the lifting speed of the drill rod.

[0012] In one possible implementation, driving the pressure winch and controlling the lifting speed of the drill rod based on the real-time filling rate and the preset filling rate includes:

[0013] If the real-time filling rate is greater than the preset filling rate, then the pressure winch is driven to increase the lifting speed of the drill rod;

[0014] If the real-time filling rate is equal to the preset filling rate, then drive the pressure winch to maintain the lifting speed of the drill rod;

[0015] If the real-time filling rate is less than the preset filling rate, the pressure winch is driven to reduce the lifting speed of the drill rod.

[0016] In one possible implementation, the step of driving the pressure winch to increase the lifting speed of the drill rod if the real-time filling rate is greater than the preset filling rate includes:

[0017] Determine the initial lifting speed of the drill pipe;

[0018] The speed adjustment coefficient is determined based on the difference between the real-time filling rate and the preset filling rate;

[0019] The product of the initial lifting speed and the speed adjustment coefficient is determined as the speed adjustment amount;

[0020] Based on the speed adjustment amount, the pressure winch is driven to increase the initial lifting speed of the drill rod to the target lifting speed, which is obtained by adding the speed adjustment amount to the initial lifting speed.

[0021] In one possible implementation, if the injection pressure value is less than or equal to the preset pressure threshold, the pressurized winch is driven to control the lifting speed of the drill rod to zero.

[0022] In one possible implementation, before driving the pressurized winch and controlling the lifting speed of the drill pipe based on the injection pressure value and the injection flow rate value,

[0023] Based on the injection pressure value and the injection flow rate value, it is determined whether there are any abnormalities in the grouting process. The abnormalities include blockage of the mud pipe, leakage of the mud pipe, or the presence of cavities in the grouting hole.

[0024] If any abnormalities occur during the grouting process, grouting should be stopped.

[0025] If there are no abnormalities in the grouting process, the pressurized winch is driven according to the grouting pressure value and the grouting flow rate value to control the lifting speed of the drill rod.

[0026] In one possible implementation, the system further includes: a power head disposed on the drill pipe;

[0027] The power head is used to provide rotational power to the drill rod according to the rotation command sent by the controller, so as to reduce the frictional resistance between the drill rod and the mud in the grouting hole.

[0028] Secondly, this application provides a grouting control method, applied to a controller in the grouting system described in any one of the first aspects, the method comprising:

[0029] It receives the infusion pressure value detected by the pressure sensor and the infusion flow rate value detected by the flow meter;

[0030] Based on the injection pressure value and the injection flow rate value, the pressurized winch is driven to control the lifting speed of the drill rod, so that the drill rod injects the mud transported by the mud pipe into the grouting hole.

[0031] Thirdly, this application provides a controller, including: a memory and a processor;

[0032] The memory stores computer-executed instructions;

[0033] The processor executes computer execution instructions stored in the memory, causing the processor to perform the method as described in the second aspect.

[0034] Fourthly, this application provides an engineering vehicle, comprising: an engineering vehicle body; and a grouting system as described in any of the first aspects, or a controller as described in the third aspect.

[0035] Fifthly, this application provides a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, are used to implement the method described in the second aspect above.

[0036] In a sixth aspect, this application provides a computer program product, including a computer program that, when executed by a processor, implements the method described in the second aspect above.

[0037] This application provides a grouting system, grouting control method, and equipment. The grouting system includes a drill rod, a mud pipe, a controller, and a pressure sensor, a flow meter, and a pressurized winch connected to the controller. The pressure sensor is installed on the mud pipe to detect the mud injection pressure. The flow meter is installed on the mud pipe to detect the mud injection flow rate. The controller drives the pressurized winch based on the injection pressure and flow rates to control the lifting speed of the drill rod, so that the drill rod injects the mud delivered by the mud pipe into the grouting hole. In this grouting system, the controller can dynamically adjust the operating status of the pressurized winch based on real-time data collected by the pressure sensor and flow meter, achieving precise matching between the drill rod lifting speed and the mud injection status. This replaces the traditional manual adjustment based on experience, ensuring the uniformity and compactness of the mud filling in the grouting hole and improving the pile formation quality. Attached Figure Description

[0038] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0039] Figure 1 A schematic diagram illustrating the application scenarios provided in the embodiments of this application;

[0040] Figure 2 This is a schematic diagram of the structure of Embodiment 1 of the grouting system provided in this application;

[0041] Figure 3 This is a schematic diagram of the structure of Embodiment 2 of the grouting system provided in this application;

[0042] Figure 4 A schematic diagram of the hardware structure for executing the grouting system provided in this application;

[0043] Figure 5 Electrical topology diagram of the hardware for performing grouting system operations provided in this application;

[0044] Figure 6 A schematic flowchart of Embodiment 1 of the grouting control method provided in this application;

[0045] Figure 7 A schematic flowchart of Embodiment 2 of the grouting control method provided in this application;

[0046] Figure 8 A flowchart illustrating an example of the grouting control method provided in this application embodiment;

[0047] Figure 9 This is a schematic diagram of the controller provided in an embodiment of this application.

[0048] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0049] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0050] As modern engineering construction becomes larger and more complex, higher requirements are placed on the construction quality and efficiency of key processes such as foundation treatment and pile foundation forming. As a core link in ensuring the safety of engineering structures, the need for technological upgrading of grouting construction is becoming increasingly urgent.

[0051] The core purpose of grouting construction is to accurately inject mud into the grouting hole (hole formation), and to utilize the cementing, filling and compacting properties of the mud after solidification to achieve engineering goals such as foundation reinforcement, seepage prevention and pile foundation formation. In pile foundation engineering, the grouting quality directly determines the stability, bearing capacity and long-term durability of the pile structure, and thus affects the safety level and service life of the entire project.

[0052] In related technologies, existing grouting construction largely relies on traditional manual control. During construction, operators must directly control the drill rod lifting speed using handles or knobs based on the real-time grouting volume and their experience, to ensure that the grout fills the grouting hole evenly and compacts. However, this traditional manual control mode has significant drawbacks: on the one hand, relying solely on experience to adjust the drill rod lifting speed demands extremely high skill levels from the operators; on the other hand, prolonged operation can easily lead to operator fatigue or misjudgment, causing a mismatch between the drill rod lifting speed and the grout filling progress in the hole, resulting in uneven grout filling, local voids, and other problems that directly affect the quality of the pile.

[0053] To address the aforementioned problems, the inventors have proposed a grouting system, comprising a drill rod, a mud pipe, a controller, and a pressure sensor, a flow meter, and a pressurized winch connected to the controller. Specifically, a pressure sensor and a flow meter can be installed on the mud pipe of the grouting system to detect the injection pressure and flow rate of the mud, respectively. These detected values ​​are fed back to the controller, which can accurately generate control signals based on the injection pressure and flow rate values ​​provided by the pressure sensor and flow meter to drive the pressurized winch. This precisely controls the lifting speed of the drill rod, ensuring that the drill rod injects the mud transported by the mud pipe into the grouting hole. This guarantees uniform filling and compaction of the mud within the grouting hole, improving the quality of the grouting pile.

[0054] Figure 1 This is a schematic diagram illustrating an application scenario provided in an embodiment of this application. Please refer to [link / reference]. Figure 1 The system includes a mud tank 10, a mud tank 11, a drill pipe 12, and a mud hole. The mud tank 10 is used to store the mud to be injected. One end of the mud pipe 11 is connected to the mud tank 10, and the other end is connected to the drill pipe 12. The mud pipe 11 is responsible for transporting the mud in the mud tank 10 to the drill pipe 12. The drill pipe 12 extends into the mud hole and, through its own lifting action in conjunction with the mud pipe 11, injects the mud into the mud hole to complete the grouting and filling operation.

[0055] The technical solution of this application and how it solves the above-mentioned technical problems will be described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will be described below with reference to the accompanying drawings.

[0056] Figure 2 This is a schematic diagram of the structure of an embodiment of the grouting system provided in this application. Please refer to [link / reference]. Figure 2 The grouting system includes: drill rod 21, mud pipe 22, controller 23, and pressure sensor 24, flow meter 25 and pressurized winch 26 respectively connected to controller 23;

[0057] Pressure sensor 24 is installed on mud pipe 22 to detect the injection pressure value of mud;

[0058] The flow meter 25 is installed on the mud pipe 22 to detect the injection flow rate of the mud.

[0059] The controller 23 is used to drive the pressurized winch 26 according to the injection pressure value and injection flow rate value, and control the lifting speed of the drill rod 21 so that the drill rod 21 injects the mud conveyed by the mud pipe 22 into the grouting hole.

[0060] In one optional implementation, the pressure sensor 24 and the flow meter 25 are both electrically connected to the controller 23 via cables, transmitting the real-time collected injection pressure and injection flow values ​​to the controller 23 in the form of electrical signals. The controller 23 is also electrically connected to the pressurized winch 26 via cables, generating control electrical signals based on the injection pressure and injection flow values, directly driving the motor speed of the pressurized winch 26, thereby precisely adjusting the lifting speed of the drill rod 21.

[0061] In one specific implementation, the pressurized winch 26 is driven to control the lifting speed of the drill rod 21 based on the injection pressure value and injection flow rate value, which may include the following steps ① and ②.

[0062] Step ①: If the injection pressure value is greater than the preset pressure threshold, calculate the real-time filling rate based on the injection flow rate value and the grouting hole parameters.

[0063] Optionally, if the injection pressure is less than or equal to a preset pressure threshold, the pressurized winch 26 is driven to control the lifting speed of the drill rod 21 to zero.

[0064] Step 2: Based on the real-time filling rate and the preset filling rate, drive the pressure winch 26 to control the lifting speed of the drill rod 21.

[0065] Optionally, if the real-time filling rate is greater than the preset filling rate, the pressure winch 26 can be driven to increase the lifting speed of the drill rod 21; if the real-time filling rate is equal to the preset filling rate, the pressure winch 26 can be driven to maintain the lifting speed of the drill rod 21; if the real-time filling rate is less than the preset filling rate, the pressure winch 26 can be driven to reduce the lifting speed of the drill rod 21.

[0066] Specifically, based on the real-time filling rate being greater than a preset filling rate, driving the pressure winch 26 to increase the lifting speed of the drill rod 21 can include: determining the initial lifting speed of the drill rod 21; determining a speed adjustment coefficient based on the difference between the real-time filling rate and the preset filling rate; determining the speed adjustment amount as the product of the initial lifting speed and the speed adjustment coefficient; and driving the pressure winch 26 based on the speed adjustment amount to increase the initial lifting speed of the drill rod 21 to the target lifting speed. The target lifting speed is obtained by adding the speed adjustment amount to the initial lifting speed.

[0067] In addition, before driving the pressurized winch 26 to control the lifting speed of the drill rod 21 based on the injection pressure and injection flow rate, the injection pressure and injection flow rate can be used to determine whether there are any abnormalities in the grouting process, such as blockage of the mud pipe 22 or the presence of karst caves in the grouting hole. If there are any abnormalities in the grouting process, the grouting is stopped; if there are no abnormalities in the grouting process, the pressurized winch 26 is driven to control the lifting speed of the drill rod 21 based on the injection pressure and injection flow rate.

[0068] The grouting system provided in this application includes a drill pipe, a mud pipe, a controller, and a pressure sensor, a flow meter, and a pressurized winch connected to the controller. The mud pipe is used to transport mud into the grouting hole, and the drill pipe works in conjunction with the mud pipe to complete the mud injection operation. The pressure sensor is installed on the mud pipe to detect the mud injection pressure value. The flow meter is installed on the mud pipe to detect the mud injection flow rate value. The controller drives the pressurized winch according to the injection pressure value and the injection flow rate value, controlling the lifting speed of the drill pipe so that the drill pipe injects the mud transported by the mud pipe into the grouting hole. By real-time acquisition of the mud injection pressure value and the injection flow rate value by the pressure sensor and the flow meter, and the automatic drive control of the pressurized winch by the controller, the traditional operation mode of manually adjusting the drilling speed based on experience can be replaced, ensuring that the drill pipe lifting speed is accurately matched with the mud injection state, thereby improving the pile quality.

[0069] Figure 3 This is a schematic diagram of the structure of Embodiment 2 of the grouting system provided in this application. Please refer to [link / reference]. Figure 3 ,exist Figure 2 Based on the embodiment shown, the grouting system 20 further includes: a power head 27 disposed on the drill pipe 21;

[0070] The power head 27 is used to provide rotational power to the drill rod 21 according to the rotation command sent by the controller 23, so as to reduce the frictional resistance between the drill rod 21 and the mud in the grouting hole.

[0071] Similarly, the power head 27 can establish an electrical connection with the controller 23 via a cable and receive rotation commands output by the controller 23. The drill pipe 21 rotates under the drive of the power head 27, which can break the viscous adsorption layer formed between the mud and the surface of the drill pipe 21, thereby further reducing frictional resistance and making the lifting of the drill pipe 21 smoother and less strenuous.

[0072] Optionally, the controller 23 can also be connected to a separate display or have a display function integrated directly to show operational status information such as injection pressure, injection flow rate, drill pipe rotation speed, and lifting speed.

[0073] The grouting system provided in this application embodiment also includes a power head mounted on the drill rod. This power head, based on the controlled drill rod lifting speed, drives the drill rod to rotate, breaking down the viscous adsorption layer between the mud and the drill rod surface, further reducing frictional resistance and making drill rod lifting smoother and less strenuous. This further enhances the stability and reliability of grouting operations under complex working conditions. Furthermore, the controller can be connected to an independent display or integrate display functionality. Based on the controlled drill rod lifting speed and rotation state, it can provide real-time visualization of grouting operation data (grouting pressure value, grouting flow rate value) and key equipment operating indicators (drill rod rotation speed, lifting speed), helping operators to intuitively and accurately grasp the entire working condition and promptly detect potential faults such as sudden pressure changes and abnormal flow rates.

[0074] Figure 4 A schematic diagram of the hardware structure for executing the grouting system provided in this application. Please refer to [link / reference]. Figure 4 It includes: drill pipe, mud pipe, controller, first pressure sensor (i.e., the aforementioned pressure sensor), flow meter, pressurized winch, power head, mud tank, luffing mechanism, mast, and second pressure sensor, wherein:

[0075] The drill pipe is connected to the power head, with one end connected to the mud pipe for conveying mud, and the other end injecting the mud into the pre-drilled grouting hole. The mud pipe serves as a mud conveying channel, with one end connected to the mud tank and the other end extending to the drill pipe to convey the mud to the grouting operation end. The controller, as the control core, can be integrated into the main unit of the engineering vehicle and is electrically connected to components such as the first pressure sensor, the second pressure sensor, the flow meter, the power head, and the pressurized winch to receive grouting operation data and output control commands.

[0076] The first pressure sensor is installed at the end of the mud pipe near the drill pipe to detect the mud injection pressure. The flow meter is installed at the end of the mud pipe (next to the first pressure sensor) to detect the mud injection flow rate. The pressurized winch is installed at the bottom of the mast and can be connected to the power head via a wire rope passing over the pulley at the top of the mast to drive the power head (and drill pipe) to move up and down along the mast. The power head is engaged in the guide groove of the mast and connected to the drill pipe, which can drive the drill pipe to rotate and move up and down along the mast.

[0077] The second pressure sensor can be installed at the beginning of the mud pipe near the mud tank to monitor the mud pressure at the beginning of the pipe, enabling pipe blockage warning and blockage location; the mud tank, as a mud storage unit, can be connected to the beginning of the mud pipe through a pipeline to provide material supply for grouting operations; the luffing mechanism can be connected to the main unit where the controller is located and the mast through mechanical connecting parts (such as hinge shafts, hydraulic / pneumatic actuators) to adjust the working angle of the mast; the mast, as a support carrier for operation, integrates a guide rail structure to limit the movement direction of the power head.

[0078] In one optional implementation, the pressurizing function of the pressurizing winch can be achieved through a steel wire rope in conjunction with other pulleys installed on the mast. Specifically, the pressurizing winch is installed at the bottom of the mast, one end of the steel wire rope is fixed to a drum, and the other end passes sequentially around a pre-set guide pulley and a reversing pulley on the mast, and is connected in the opposite direction to the top force point of the power head. When pressurizing during drilling, the winch generates tension by winding the rope in the forward direction. With the guidance and reversing action of the pulley group, the tension is converted into vertical downward pressure and transmitted to the power head, driving the power head (and drill rod) to apply downward pressure along the mast guide rail groove. The rotation of the power head completes the pressurized drilling.

[0079] Figure 5 The electrical topology diagram of the hardware executing the grouting system provided in this application is shown. Please refer to [link / reference needed]. Figure 5 The topology uses the controller as the core interaction unit: the first pressure sensor, the second pressure sensor, and the flow meter serve as monitoring components, which can transmit the collected grouting operation data to the controller; after receiving the grouting operation data, the controller can output control commands to the power head and the pressurized winch to regulate the rotation speed and lifting speed of the drill rod; at the same time, the controller will synchronize the operation status information to the display, so that the operator can view the grouting status in real time.

[0080] Figure 6 This is a schematic flowchart illustrating an embodiment of the grouting control method provided in this application. Please refer to... Figure 6 The method is used in the controller of the above-mentioned grouting system, including:

[0081] S601 receives the infusion pressure value detected by the pressure sensor and the infusion flow rate value detected by the flow meter.

[0082] In this step, the controller can receive the mud injection pressure value detected by the pressure sensor installed on the mud pipe, and the mud injection flow rate value detected by the flow meter in the same pipeline.

[0083] Specifically, the pressure sensor and flow meter can be electrically connected to the controller via cable, converting the real-time collected grouting operation data into standard electrical signals and transmitting them to the controller. After receiving the signals, the controller performs demodulation processing to obtain the grouting pressure and flow rate values.

[0084] S602. Based on the injection pressure and injection flow rate, drive the pressurized winch to control the lifting speed of the drill rod so that the drill rod injects the mud transported by the mud pipe into the grouting hole.

[0085] In this step, the controller can perform logical operations and decisions based on the received injection pressure and injection flow values ​​through the built-in control algorithm, generate corresponding control commands and send them to the pressurized winch, and achieve precise control of the drill pipe lifting speed by adjusting the operating status of the pressurized winch, so that the drill pipe can inject the mud transported by the mud pipe into the grouting hole.

[0086] In one optional implementation, the filling status of the bottom of the hole can be determined by the injection pressure value. If the injection pressure value is greater than the preset pressure threshold, it indicates that mud has initially formed at the bottom of the hole, and the real-time filling rate needs to be calculated in conjunction with the injection flow rate value. If the injection pressure value is less than or equal to the preset pressure threshold, it indicates that the bottom of the hole has not yet completed the basic filling, and the drill rod needs to be stopped from lifting (lifting speed is zero). Subsequent control can be started after the pressure reaches the standard.

[0087] When the injection pressure exceeds a preset pressure threshold, the direction of drill pipe lifting speed adjustment can be determined based on the comparison between the real-time filling rate and the preset filling rate. This is then used to drive the pressure winch to perform the corresponding action via control commands. The pressure winch is electrically connected to the controller via cable, allowing for precise response to speed adjustment commands issued by the controller. The direction of drill pipe lifting speed adjustment can be to increase, maintain, or decrease.

[0088] In this embodiment, the controller receives the injection pressure value detected by the pressure sensor and the injection flow rate value detected by the flow meter. Based on the injection pressure and flow rates, it drives the pressurized winch to control the lifting speed of the drill rod, so that the drill rod injects the mud transported by the mud pipe into the grouting hole. During this process, the controller can perform quantitative calculations based on the real-time collected injection pressure and flow rates, dynamically generating appropriate control commands for the pressurized winch. This achieves precise matching of the drilling speed to the injection status, replacing manual experience-based operation and improving the quality of pile formation.

[0089] Figure 7 This is a schematic flowchart illustrating Embodiment 2 of the grouting control method provided in this application. Please refer to... Figure 7 ,exist Figure 6 Based on the illustrated embodiment, the method includes:

[0090] S701 receives the infusion pressure value detected by the pressure sensor and the infusion flow rate value detected by the flow meter.

[0091] For example, in the construction scenario of grouting holes corresponding to bridge pile foundations, the pressure sensor installed on the grout pipe monitors the grouting pressure value A in real time, with the unit being megapascals (MPa), while the flow meter in the same pipeline monitors the grouting flow rate value B, with the unit being liters per minute (L / min). The two sensors can transmit the corresponding pressure and flow signals to the controller, respectively. After receiving the signals, the controller performs demodulation processing and can obtain the grouting pressure value A and the grouting flow rate value B.

[0092] S702. Based on the injection pressure and injection flow rate, determine whether there are any abnormalities in the grouting process.

[0093] In this step, the controller can determine whether there are any abnormalities in the grouting process based on the acquired injection pressure and flow rates. These abnormalities include blockage of the mud pipe, leakage of the mud pipe, or the presence of cavities in the grouting hole.

[0094] Optionally, if a partial blockage occurs in the pipeline, the mud delivery channel will be restricted, and the corresponding grouting operation data will exhibit the typical characteristics of pressure rise and flow drop. Specifically, the grouting pressure will rise sharply, while the grouting flow rate will drop significantly at the same time.

[0095] For example, if the injection pressure value A suddenly rises to more than twice the preset pressure threshold, and the injection flow rate value B suddenly drops to less than 50% of the preset flow rate threshold, it can be determined that there is a blockage in the mud pipe.

[0096] Optionally, a second pressure sensor can be installed at the beginning of the mud pipe near the mud tank. By monitoring the mud pressure data at the beginning of the pipe, not only can early warning of pipe blockage be achieved, but the location of the blockage can also be accurately located by combining the pressure difference between the second pressure sensor and the first pressure sensor.

[0097] Optionally, if the pipeline is damaged and leaks, the grout will seep out from the damaged area, and the corresponding grouting operation data will show typical characteristics of pressure drop and flow deviation, specifically, the grouting pressure will be continuously low and the actual grouting flow rate will deviate significantly from the output flow rate of the grout pump.

[0098] For example, if the injection pressure A remains below 60% of the preset pressure threshold, and the difference between the injection flow rate B and the mud pump output flow rate exceeds 20%, it can be determined that there is a leak in the mud pipe. The mud pump can be installed on the mud outlet side of the mud tank. Its output flow rate can be obtained through a flow meter installed at the mud pump's outlet pipe, or by reading the real-time operating parameters of the mud pump (such as motor speed and inverter output frequency) from the controller and calculating it using the rated flow rate-speed curve of the mud pump.

[0099] Optionally, if there are karst caves in the grouting holes, the slurry will continuously fill the karst cave cavities, and the corresponding grouting operation data will show typical characteristics of pressure drop and flow rise. Specifically, the grouting pressure will remain at a low level, while the grouting flow rate will be significantly higher than the preset standard value.

[0100] For example, if the injection pressure value A is continuously lower than 50% of the preset pressure threshold for 30 consecutive seconds, and the injection flow rate value B is continuously higher than twice the preset flow rate threshold for the same period of time, it can be determined that there is a karst cave in the grouting hole.

[0101] S703. If any abnormalities occur during the grouting process, grouting shall be stopped.

[0102] In this step, when the controller determines that there is any abnormality in the grouting process, such as pipe blockage, leakage, or karst caves in the grouting hole, it can immediately generate a shutdown control command and send it to the actuators such as the pressurized winch, the power head, and the mud pump, controlling the pressurized winch to stop driving the drill rod to rise and fall, the power head to stop driving the drill rod to rotate, and the mud pump to stop delivering mud.

[0103] Optionally, the controller can also synchronize the anomaly type and trigger parameters to the display for alarm purposes, so that operators can troubleshoot and handle the fault in a timely manner.

[0104] For example, in the construction scenario of grouting holes for bridge pile foundations, the preset pressure threshold is 1.0 MPa, the preset flow rate threshold is 50 L / min, and the mud pump output flow rate is 60 L / min. If the controller determines that the current grouting pressure value A suddenly rises to 2.1 MPa (exceeding twice the preset pressure threshold) and the grouting flow rate value B suddenly drops to 22 L / min (below 50% of the preset flow rate threshold), it is determined that there is an abnormality of mud pipe blockage. At this time, the controller can immediately generate a shutdown control command and send it to the pressurizing winch, the power head, and the mud pump respectively, controlling the pressurizing winch to stop the drill rod lifting and lowering action, the power head to stop the drill rod rotation, and the mud pump to stop mud delivery; at the same time, the abnormality type of "mud pipe blockage" and the trigger parameters of "pressure 2.1 MPa, flow rate 22 L / min" are synchronized to the display, and the display reminds the operator to check for pipeline blockage problems in the form of a red pop-up window and / or audible and visual alarms.

[0105] S704. If there are no abnormalities in the grouting process, determine whether the grouting pressure value is greater than the preset pressure threshold.

[0106] In this step, after confirming that there are no abnormalities in the grouting process, the controller can compare the grouting pressure value with the pre-configured preset pressure threshold to determine the basic filling status of the mud in the grouting hole.

[0107] S705. If the injection pressure value is less than or equal to the preset pressure threshold, the pressurized winch is driven to control the lifting speed of the drill rod to zero.

[0108] In this step, if the controller determines that the injection pressure value is less than or equal to the preset pressure threshold, it indicates that a mud accumulation layer that meets the requirements has not yet been formed at the bottom of the grouting hole. At this time, the controller can generate a control command of "lifting speed is zero" to drive the pressurized winch to stop running and keep the drill rod stationary in the lifting direction. After the mud injection pressure value rises above the preset pressure threshold, the subsequent control process will be started.

[0109] S706. If the injection pressure value is greater than the preset pressure threshold, the real-time filling rate is calculated based on the injection flow rate value and the grouting hole parameters.

[0110] In this step, when the injection pressure exceeds a preset pressure threshold, the controller calculates the real-time filling rate of the grouting hole using a filling rate calculation formula, based on the pre-acquired injection flow rate and the hole parameters. The hole parameters include the hole diameter and the current grouting depth.

[0111] Specifically, the formula for calculating the filling rate is shown in formula (1):

[0112] Formula (1)

[0113] Where η represents the real-time filling rate, ranging from 0 to 1, with a value closer to 1 indicating fuller filling; Q represents the injection flow rate; t represents the unit time; and V represents the theoretical volume of the grouting hole at the corresponding depth.

[0114] Specifically, the formula for calculating the theoretical volume of the grouting hole is shown in formula (2):

[0115] Formula (2)

[0116] Where d represents the diameter of the grouting hole; h represents the current grouting depth.

[0117] In one alternative implementation, the current grouting depth h can be obtained by collecting drill rod displacement data through an encoder linked to the power head, ensuring that it matches the real-time grouting conditions.

[0118] S707. Based on the real-time filling rate and the preset filling rate, drive the pressure winch to control the lifting speed of the drill rod so that the drill rod injects the mud transported by the grout pipe into the grouting hole.

[0119] In this step, the controller can compare the calculated real-time filling rate with the pre-configured preset filling rate, generate a targeted speed control command based on the comparison result, and send it to the pressurized winch for execution to control the lifting speed of the drill rod so that the drill rod can inject the mud transported by the grout pipe into the grouting hole.

[0120] Optionally, the preset filling rate can be set in conjunction with construction specifications and geological conditions, and the typical value range is (0.95, 1). For example, the preset filling rate is 0.98.

[0121] In one specific implementation, if the real-time filling rate is greater than the preset filling rate, the pressure winch is driven to increase the lifting speed of the drill pipe; if the real-time filling rate is equal to the preset filling rate, the pressure winch is driven to maintain the lifting speed of the drill pipe; if the real-time filling rate is less than the preset filling rate, the pressure winch is driven to reduce the lifting speed of the drill pipe.

[0122] In one specific implementation, if the real-time filling rate is greater than the preset filling rate, the pressure winch is driven to increase the lifting speed of the drill rod, which may include the following steps ①②③④.

[0123] Step 1: Determine the initial lifting speed of the drill pipe.

[0124] In one alternative implementation, the controller can directly read the real-time operating parameters of the pressure winch (such as motor speed, wire rope winding and unwinding speed, etc.) after starting the grouting process and determining that there are no abnormalities in the grouting process, and obtain the initial lifting speed of the drill rod.

[0125] In another alternative implementation, the initial lifting speed can be preset. Specifically, it can be preset and stored in the controller in advance based on the borehole diameter parameters, geological conditions, mud performance parameters, etc.

[0126] Step 2: Determine the speed adjustment coefficient based on the difference between the real-time filling rate and the preset filling rate.

[0127] Specifically, the controller can first calculate the difference between the real-time filling rate and the preset filling rate, and then determine the speed adjustment coefficient based on the preset difference-adjustment coefficient mapping relationship.

[0128] Specifically, the formula for calculating the difference between the real-time filling rate and the preset filling rate is shown in formula (3):

[0129] Formula (3)

[0130] in, This indicates the preset filling rate.

[0131] For example, if the preset filling rate The value is 0.98. When the difference Δη∈(0, 0.02], the speed adjustment coefficient can be determined to be 0.1 according to the preset difference-adjustment coefficient mapping relationship; when Δη∈(0.02, 0.05], the speed adjustment coefficient can be determined to be 0.2 according to the preset difference-adjustment coefficient mapping relationship.

[0132] Step 3: The product of the initial lifting speed and the speed adjustment coefficient is determined as the speed adjustment amount.

[0133] Specifically, you can first retrieve the initial drill pipe lifting speed determined in step ①, then extract the speed adjustment coefficient calculated in step ②, multiply these two parameters, and the result is the speed adjustment amount that needs to be adjusted.

[0134] Step 4: Based on the speed adjustment, drive the pressure winch to increase the initial lifting speed of the drill pipe to the target lifting speed. The target lifting speed is obtained by increasing the speed adjustment amount based on the initial lifting speed.

[0135] Specifically, the controller can increase the speed adjustment amount to obtain the target lifting speed based on the initial lifting speed, and then generate a control command containing the target lifting speed and send it to the pressurized winch. After receiving the command, the pressurized winch can change the power output by adjusting the operating state of its own drive components to ensure that the drill rod can be lifted smoothly and accurately to the target lifting speed, thus achieving the adaptation between the mud filling state and the lifting speed.

[0136] Similarly, if the real-time filling rate is less than the preset filling rate, the pressure winch is driven to reduce the drill pipe's lifting speed. This can include: determining the initial lifting speed of the drill pipe; determining a speed adjustment coefficient based on the difference between the real-time filling rate and the preset filling rate; determining the speed adjustment amount as the product of the initial lifting speed and the speed adjustment coefficient; and driving the pressure winch based on the speed adjustment amount to reduce the initial lifting speed of the drill pipe to the target lifting speed. The target lifting speed is obtained by subtracting the speed adjustment amount from the initial lifting speed.

[0137] In this embodiment, the controller can first receive the injection pressure value detected by the pressure sensor and the injection flow rate value detected by the flow meter to determine whether there is an abnormality in the grouting process (if there is an abnormality, grouting is stopped). If there is no abnormality, the controller can drive the pressurized winch to control the lifting speed of the drill rod to zero to continue grouting, based on the injection pressure value being less than or equal to a preset pressure threshold. If the injection pressure value is greater than the preset pressure threshold, the controller can calculate the real-time filling rate through the injection flow rate value and the hole parameters of the grouting hole. Then, based on the real-time filling rate and the preset filling rate, the controller can drive the pressurized winch to regulate the lifting speed of the drill rod, so that the drill rod injects the mud transported by the mud pipe into the grouting hole. In the above process, the controller can achieve dynamic adaptation between the drill rod lifting speed and the mud injection state through an automated process of data acquisition, abnormality interception, pressure determination, and filling rate regulation, thereby improving the accuracy and stability of the grouting operation and effectively improving the quality of pile formation.

[0138] Figure 8 This is a flowchart illustrating an example of the grouting control method provided in this application. Please refer to... Figure 8 The method includes:

[0139] S801. Collect concrete pressure and volume information.

[0140] The operator can automatically lift the drill with a single button and collect information on concrete pressure and volume. The concrete pressure information is the mud injection pressure value detected by the pressure sensor installed on the mud pipe; the concrete volume information is the mud injection flow rate value detected by the flow meter installed on the mud pipe.

[0141] Optionally, one-click automatic drilling can be triggered by a function button integrated into the control console. After pressing the button, the controller can automatically start the data acquisition program and drill pipe lifting control process, completing parameter acquisition and equipment linkage without manual intervention.

[0142] S802. Determine if there is pipe blockage, leakage, or cavities.

[0143] The controller can analyze and determine based on the collected concrete pressure and volume information: if it is determined that there is a blockage or leakage in the mud pipe or a karst cave in the grouting hole, then step S803 is executed; if it is determined that there is no abnormal working condition, then step S804 is executed.

[0144] S803, End of grouting operation.

[0145] If it is determined that there is a blockage or leakage in the mud pipe or a karst cave in the grouting hole, the one-click automatic drilling function can be deactivated and the grouting operation can be terminated.

[0146] S804. Determine whether the concrete pressure is greater than the preset pressure threshold.

[0147] If the concrete pressure (i.e., the injection pressure value) is less than or equal to the preset pressure threshold, then step S805 is executed; conversely, if the concrete pressure is greater than the preset pressure threshold, then step S806 is executed.

[0148] S805, continue grouting and stop drilling.

[0149] The controller drives the pressure winch to control the lifting speed of the drill rod to zero, keeping the drill rod stationary in the lifting direction and continuously injecting mud until the concrete pressure value reaches the preset pressure threshold.

[0150] S806. Determine whether the real-time filling rate is less than the preset filling rate.

[0151] The real-time filling rate is calculated based on the concrete volume information and the hole parameters of the grouting holes. If the real-time filling rate is less than the preset filling rate, step S807 is executed. If the real-time filling rate is greater than or equal to the preset filling rate, step S808 is executed.

[0152] S807, Reduce drilling speed.

[0153] S808. Determine whether the real-time filling rate is equal to the preset filling rate.

[0154] If the real-time filling rate is equal to the preset filling rate, then step S809 is executed to keep the drilling speed unchanged; if the real-time filling rate is greater than the preset filling rate, then step S810 is executed to increase the drilling speed.

[0155] During the process of reducing, maintaining, or increasing the drilling speed, the power head installed on the drill pipe can provide rotational power to the drill pipe according to the rotation command sent by the controller, so as to reduce the frictional resistance between the drill pipe and the mud in the grouting hole.

[0156] The grouting control method provided in this application is an example. The specific execution process can be found in the technical solution shown in the above embodiments. The implementation principle and beneficial effects are similar, and will not be repeated here.

[0157] Figure 9 This is a schematic diagram of the controller provided in an embodiment of this application. Please refer to... Figure 9 The controller 90 provided in this embodiment includes at least one processor 91 and a memory 92. Optionally, the controller 90 further includes a communication component 93. The processor 91, the memory 92, and the communication component 93 are connected via a bus 94.

[0158] In a specific implementation, at least one processor 91 executes computer execution instructions stored in memory 92, causing at least one processor 91 to perform the above-described method.

[0159] The specific implementation process of processor 91 can be found in the above method embodiments, and its implementation principle and technical effect are similar. It will not be repeated here.

[0160] In the above embodiments, it should be understood that the processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), etc. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the method disclosed in this invention can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor.

[0161] The memory may include random access memory (RAM) and may also include non-volatile memory (NVM), such as at least one disk storage device.

[0162] The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized as address buses, data buses, control buses, etc. For ease of illustration, the buses shown in the accompanying drawings are not limited to a single bus or a single type of bus.

[0163] This application also provides an engineering vehicle, including an engineering vehicle body; and Figure 2 or Figure 3 The grouting system shown, or, Figure 9 The controller shown is used to implement the grouting control method described in the above method embodiment.

[0164] The engineering vehicles provided in this application include, but are not limited to, rotary drilling rigs, long spiral drilling rigs, and anchor drilling rigs, which are equipped with grouting operation functions. These engineering vehicles can integrate the aforementioned grouting system into the vehicle's working end, relying on the vehicle's own power system to support the grouting operation, and using a controller to achieve automated control of grouting operation data monitoring, drill rod lifting and rotation movements.

[0165] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the above-described method.

[0166] This application also provides a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, implement the above-described method.

[0167] The aforementioned readable storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk. The readable storage medium can be any available medium accessible to a general-purpose or special-purpose computer.

[0168] An exemplary readable storage medium is coupled to a processor, enabling the processor to read information from and write information to the readable storage medium. Of course, the readable storage medium can also be a component of the processor. The processor and the readable storage medium can reside in an Application Specific Integrated Circuit (ASIC). Alternatively, the processor and the readable storage medium can exist as discrete components in the device.

[0169] The division of units is merely a logical functional division; in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0170] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0171] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0172] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0173] Those skilled in the art will understand that all or part of the steps of the above-described method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When executed, the program performs the steps of the above-described method embodiments; and the aforementioned storage medium includes various media capable of storing program code, such as ROM, RAM, magnetic disks, or optical disks.

[0174] Finally, it should be noted that other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A grouting system, characterized in that, include: Drill pipe, mud pipe, controller, and pressure sensor, flow meter and pressurized winch respectively connected to the controller; The pressure sensor is installed on the mud pipe to detect the injection pressure of the mud. The flow meter is installed on the mud pipe and is used to detect the injection flow rate of the mud. The controller is used to drive the pressurized winch according to the injection pressure value and the injection flow rate value, and control the lifting speed of the drill rod so that the drill rod injects the mud transported by the mud pipe into the grouting hole.

2. The system according to claim 1, characterized in that, The step of driving the pressure winch and controlling the lifting speed of the drill pipe based on the injection pressure value and the injection flow rate value includes: If the injection pressure value is greater than the preset pressure threshold, the real-time filling rate is calculated based on the injection flow rate value and the hole parameters of the grouting hole. Based on the real-time filling rate and the preset filling rate, the pressure winch is driven to control the lifting speed of the drill rod.

3. The system according to claim 2, characterized in that, The step of driving the pressure winch and controlling the lifting speed of the drill rod based on the real-time filling rate and the preset filling rate includes: If the real-time filling rate is greater than the preset filling rate, then the pressure winch is driven to increase the lifting speed of the drill rod; If the real-time filling rate is equal to the preset filling rate, then drive the pressure winch to maintain the lifting speed of the drill rod; If the real-time filling rate is less than the preset filling rate, the pressure winch is driven to reduce the lifting speed of the drill rod.

4. The system according to claim 3, characterized in that, If the real-time filling rate is greater than the preset filling rate, then driving the pressure winch to increase the lifting speed of the drill rod includes: Determine the initial lifting speed of the drill pipe; The speed adjustment coefficient is determined based on the difference between the real-time filling rate and the preset filling rate; The product of the initial lifting speed and the speed adjustment coefficient is determined as the speed adjustment amount; Based on the speed adjustment amount, the pressure winch is driven to increase the initial lifting speed of the drill rod to the target lifting speed, which is obtained by adding the speed adjustment amount to the initial lifting speed.

5. The system according to any one of claims 2-4, characterized in that, If the injection pressure value is less than or equal to the preset pressure threshold, the pressurized winch is driven to control the lifting speed of the drill rod to zero.

6. The system according to any one of claims 2-4, characterized in that, Before driving the pressurized winch and controlling the lifting speed of the drill pipe based on the injection pressure and injection flow rates, Based on the injection pressure value and the injection flow rate value, it is determined whether there are any abnormalities in the grouting process. The abnormalities include blockage of the mud pipe, leakage of the mud pipe, or the presence of cavities in the grouting hole. If any abnormalities occur during the grouting process, grouting should be stopped. If there are no abnormalities in the grouting process, the pressurized winch is driven according to the grouting pressure value and the grouting flow rate value to control the lifting speed of the drill rod.

7. The system according to any one of claims 2-4, characterized in that, The system also includes: a power head mounted on the drill pipe; The power head is used to provide rotational power to the drill rod according to the rotation command sent by the controller, so as to reduce the frictional resistance between the drill rod and the mud in the grouting hole.

8. A grouting control method, characterized in that, The controller applied to the grouting system according to any one of claims 1-7, the method comprising: It receives the infusion pressure value detected by the pressure sensor and the infusion flow rate value detected by the flow meter; Based on the injection pressure value and the injection flow rate value, the pressurized winch is driven to control the lifting speed of the drill rod, so that the drill rod injects the mud transported by the mud pipe into the grouting hole.

9. A controller, characterized in that, include: Memory, processor; The memory stores computer-executed instructions; The processor executes computer execution instructions stored in the memory, causing the processor to perform the method as described in claim 8.

10. An engineering vehicle, characterized in that, include: Main body of the engineering vehicle; And, the grouting system as described in any one of claims 1-7, or the controller as described in claim 9.

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