Self-mixing intelligent control crack repair grouting device and method

Abstract

The invention discloses a self-mixing intelligent control crack repair grouting device and method, and relates to the technical field of building engineering crack repair. The interior of a barrel of the grouting device is divided into a material cavity A and a material cavity B which are parallel, outlets are converged and then connected with a static mixer, a pressure sensor and an intelligent control unit are integrated, and the control unit automatically controls a driving mechanism to stop according to real-time pressure signals when the pressure continuously exceeds a set threshold value and reaches preset stable time. The method is based on the device, and the whole process from parameter setting, bi-component synchronous propulsion and online mixing to automatic judgment of the grouting end point according to the pressure condition and stopping is achieved. The technical problems of uneven mixing, serious material waste and inaccurate grouting end point judgment caused by the fact that traditional epoxy resin grouting depends on artificial experience are solved, and the epoxy resin grouting device has the advantages of being uniform and stable in mixing quality, high in material utilization rate, good in repair plumpness, intelligent and standardized in operation and safe and efficient in construction.

Description

Technical Field

[0001] This invention relates to the field of building engineering crack repair technology, specifically to a self-mixing intelligent control crack repair grouting device and method. Background Technology

[0002] In the chemical grouting repair of concrete cracks, manual grouting guns or simple mechanical grouting equipment are currently commonly used. These traditional devices have several core problems that urgently need to be addressed:

[0003] 1. Uneven mixing: Two-component epoxy resins need to be mixed manually beforehand, which is not only inefficient, but also very easy to cause incomplete curing due to insufficient mixing, which seriously affects the repair strength and durability.

[0004] 2. Misjudgment of grouting endpoint: When to stop the grouting process depends entirely on the worker's subjective experience, which often results in insufficient grouting (incomplete repair) or excessive grouting (grout overflows from unnecessary pores, causing up to 15-30% material waste).

[0005] 3. Inadequate pressure control: Grouting pressure is often controlled by feel. Insufficient pressure prevents the grout from fully penetrating tiny cracks, while excessive pressure can cause secondary damage to the concrete structure, such as splitting. Therefore, developing intelligent equipment that can ensure mixing quality and achieve precise quantitative grouting is crucial for improving the quality, efficiency, and economic benefits of repair projects. Summary of the Invention

[0006] The purpose of this invention is to provide a self-mixing intelligent control crack repair grouting device and method, which has the beneficial effects of uniform and stable mixing quality, high material utilization rate, good repair fullness, intelligent and standardized operation, and safe and efficient construction, thus solving the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A self-mixing intelligent control crack repair grouting device, comprising:

[0009] The dual-cavity cylinder is divided into two parallel material cavities, A and B, which are used to contain the A and B components of epoxy resin, respectively. The A and B material cavities merge at the end near the discharge port to form a common outlet.

[0010] A static mixer, which is fixedly connected to the common outlet, has multiple continuous spiral units twisted at 180 degrees inside, used to cut and overlap the flowing A and B component slurries to achieve uniform mixing;

[0011] The pressure sensing system includes a pressure sensor installed on the flow channel near the discharge port to detect the system pressure in real time during the grouting process;

[0012] The intelligent control system includes a control unit and a motor driver. The control unit is connected to the pressure sensor and the encoder signal of the drive motor. The control unit is used to receive the signal from the pressure sensor. When the pressure value is detected to continuously exceed the preset threshold Pset for a set stabilization time Tset, the control unit sends a command to the motor driver to control the motor to stop running.

[0013] Preferably, the driving mechanism is a screw drive mechanism, including a servo motor, a lead screw connected to the output shaft of the servo motor, and a nut that cooperates with the lead screw. The nut is connected to a piston plate through a connecting plate. The piston plate includes an A-cavity piston plate and a B-cavity piston plate, which are used to propel the slurry in the A-cavity and B-cavity respectively.

[0014] Preferably, the volume ratio of the A material chamber to the B material chamber is 2:1.

[0015] Preferably, the control unit further includes an OLED display module for setting and displaying the pressure threshold Pset and the settling time Tset.

[0016] Preferably, the stabilization time Tset can be set between 2 and 5 seconds.

[0017] Preferably, the static mixer adopts a Kenics-type design, with a length of approximately 15 cm, and contains 24 spiral units inside.

[0018] A self-mixing intelligent control crack repair grouting method, based on a self-mixing intelligent control crack repair grouting device, includes the following steps:

[0019] Step 1, Parameter Setting: Using the OLED display module, set the grouting pressure threshold Pset and stabilization time Tset according to the crack size and grout characteristics;

[0020] Step 2, Equipment Ready: Inject the corresponding slurry components into material chambers A and B respectively, and install the static mixer;

[0021] Step 3: Start grouting: Start the device, the servo motor drives the piston plate to move forward at a constant speed, and pushes the A and B components of grout into the static mixer synchronously and at the same pressure. The mixed grout is then injected into the cracks.

[0022] Step 4, Intelligent Judgment and Stop: The control unit monitors the pressure in real time. Once the conditions of "pressure > Pset" and "duration > Tset" are met, it is determined that the crack is full, and the servo motor is immediately controlled to stop running, and the grouting process is automatically terminated.

[0023] Preferably, for step four, after the grouting process automatically terminates, the process moves to the next grouting nozzle and repeats steps one through four until the entire crack is repaired.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. This invention employs a dual-cavity cylinder to separately store the A and B components of the slurry, and connects to a static mixer via a common outlet, achieving synchronous delivery and immediate mixing of the slurry. This integrated design avoids the traditional manual pre-mixing step, fundamentally ensuring uniform mixing and consistent quality, resulting in uniform and reliable curing performance for each grouting injection, and significantly improving the durability of the repair.

[0026] 2. This invention achieves uniform speed advancement of the piston plate through a servo motor and precision lead screw, ensuring the stability and consistency of the grouting process. The spiral unit inside the static mixer performs low-resistance and efficient cutting and overlapping of the grout, further enhancing the mixing effect. This not only improves construction efficiency but also reduces operational difficulty, making complex technology simple and standardized.

[0027] 3. This invention uses a pressure sensor to monitor grouting pressure in real time, and combines this with a microprocessor-preset threshold and stabilization time to automatically determine and stop the grouting endpoint. This closed-loop control mechanism accurately identifies the saturated state of cracks, reduces material waste, and avoids secondary damage caused by excessive pressure, demonstrating the safety and reliability of controllable pressure. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the control method of the present invention;

[0029] Figure 2 This is a schematic diagram of the overall structure of the control device of the present invention;

[0030] Figure 3 This is a schematic diagram of the control device part of the present invention.

[0031] In the diagram: 1. Dual-cavity cylinder; 1a. A material cavity; 1b. B material cavity; 2. Servo motor; 3. Precision lead screw; 4. Nut; 5. Connecting plate; 6. Piston plate; 6a. A cavity piston plate; 6b. B cavity piston plate; 7. Static mixer; 8. Pressure sensor; 9. Control unit; 10. OLED display module; 11. Discharge port; 12. Flow channel. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] To address the issues of low automation and poor quality control in existing grouting equipment, please refer to [link / reference needed]. Figure 1-3 This embodiment provides the following technical solution:

[0034] The main body of the device adopts a double-cavity cylinder 1, which is made of high-strength engineering plastic or aluminum alloy. The interior is divided into two parallel material cavities, A material cavity 1a and B material cavity 1b. The volume ratio of the two cavities is preferably 2:1 to match the ratio of commonly used epoxy resin.

[0035] The front end of the cylinder has a common outlet 11, which is connected to the static mixer 7 through the flow channel 12. The drive part adopts a screw drive mechanism, including a servo motor 2, a precision lead screw 3, a nut 4 and a connecting plate 5. The nut 4 is fixedly connected to the piston plate 6a of chamber A and the piston plate 6b of chamber B to realize the synchronous propulsion of components A and B.

[0036] The static mixer 7 adopts a Kenics-type design, is about 15cm long, and contains 24 spiral units twisted at 180 degrees to ensure that the A and B component slurries are continuously cut and overlapped under low resistance, achieving uniform mixing.

[0037] The pressure sensing system includes a piezoresistive pressure sensor 8 with a range of 0-5 MPa and an accuracy of ±0.1%FS. It is installed on the flow channel 12 before the outlet of the static mixer and is used to monitor the grouting pressure in real time.

[0038] The intelligent control system includes a control unit 9, which is based on an STM32F103 microcontroller and integrates a motor drive circuit, a power management module, and an OLED display module 10 to form a human-machine interface that allows users to set the pressure threshold Pset and the stabilization time Tset.

[0039] During implementation, the workflow begins with parameter setting: Pset and Tset are set via the human-machine interface. Then, the corresponding grout components are injected into material chambers A (1a) and B (1b), and the static mixer 7 is installed and connected to the grouting nozzle. Upon startup, the servo motor 2 drives the piston plates 6a and 6b of chambers A and B to advance at a constant speed, pushing the grout into the cracks. The control unit 9 receives signals from the pressure sensor 8 in real time. When the pressure continuously exceeds Pset for a duration equal to Tset (e.g., the pressure jumps to 1.1 MPa and remains there for 3 seconds), the microcontroller immediately commands the motor to stop, automatically terminating the grouting process. This closed-loop control mechanism ensures accurate determination of the grouting endpoint, avoiding the problems associated with traditional methods relying on manual experience.

[0040] To verify the effectiveness of the implementation, a comparative test was conducted with traditional manual grouting. Multiple identical cracks, 0.5 mm wide and 5 cm deep, were precast on the same concrete slab using the same epoxy resin. Under the same crack conditions, the device of this invention was used with Pset=0.8 MPa and Tset=3 seconds.

[0041] The results showed that the standard deviation of the curing degree of the experimental group was < 2%, while that of the control group was > 8%; the average waste rate of the experimental group was 3.5%, while that of the control group was 22%; the fullness of the experimental group was 100%, while that of the control group was 91% on average; the total time for repairing 10 cracks was 15 minutes for the experimental group and 23 minutes for the control group, demonstrating the advantages of this invention in standardized operations and highlighting the necessity of intelligent endpoint judgment.

[0042] Working principle: First, two key parameters are set through the human-machine interface 10: grouting pressure threshold Pset and stabilization time Tset. Then, epoxy resin components A and B are injected into the A material cavity 1a and B material cavity 1b of the dual-cavity cylinder 1, respectively. The static mixer 7 is installed, and the outlet is connected to the grouting nozzle of the crack through a pipeline.

[0043] After startup, the drive mechanism begins to work. The servo motor 2 drives the precision lead screw 3 to rotate, which in turn drives the mating nut 4 and connecting plate 5 to move forward at a constant speed in a straight line, thereby pushing the piston plate 6 to move synchronously. During this process, the A and B component slurries are pushed out of the material chamber at equal pressure and in equal proportion, and enter the static mixer 7 through the common discharge port 11 and flow channel 12. A series of spiral units in the static mixer 7 continuously cut, divide, and recombine the slurry flow, thereby achieving online uniform mixing of components A and B before output.

[0044] Throughout the grouting process, pressure sensor 8, installed on flow channel 12, monitors the system pressure in real time and transmits the data to control unit 9. Control unit 9 continuously compares the detected real-time pressure with a preset threshold Pset. As the cracks are gradually filled with grout, the resistance within the flow channel increases, and the pressure rises accordingly. Once control unit 9 determines that the pressure value has exceeded Pset for a preset stabilization time Tset, it immediately determines that the grouting endpoint has been reached and sends a command to the motor driver to stop the servo motor 2, automatically terminating the grouting process. After completing the grouting at this point, the process can be repeated at the next grouting station.

[0045] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0046] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention.

Claims

1. A self-mixing intelligent control crack repair grouting device, characterized in that, include: The double-cavity cylinder (1) is divided into two parallel material cavities, A (1a) and B (1b), which are used to contain the A component and B component of epoxy resin, respectively. The A component (1a) and B component (1b) merge at the end near the discharge port (11) to form a common outlet. The static mixer (7) is fixedly connected to the common outlet and has multiple continuous spiral units twisted at 180 degrees inside, which are used to cut and overlap the A and B component slurries flowing through to achieve uniform mixing. The pressure sensing system includes a pressure sensor (8) installed on the flow channel (12) near the outlet, for real-time detection of system pressure during the grouting process; The intelligent control system includes a control unit (9) and a motor driver. The control unit (9) is connected to the pressure sensor (8) and the encoder signal of the drive motor. The control unit is used to receive the signal from the pressure sensor (8). When the pressure value is detected to exceed the preset threshold Pset for a set stabilization time Tset, the control unit sends a command to the motor driver to control the motor to stop running.

2. The self-mixing intelligent control crack repair grouting device according to claim 1, characterized in that, The driving mechanism is a screw drive mechanism, including a servo motor (2), a lead screw (3) connected to the output shaft of the servo motor (2), and a nut (4) that cooperates with the lead screw. The nut (4) is connected to the piston plate (6) through a connecting plate (5). The piston plate (6) includes an A-cavity piston plate (6a) and a B-cavity piston plate (6b), which are used to push the slurry in the A-cavity (1a) and B-cavity (1b) respectively.

3. The self-mixing intelligent control crack repair grouting device according to claim 2, characterized in that, The volume ratio of material chamber A (1a) to material chamber B (1b) is 2:

1.

4. The self-mixing intelligent control crack repair grouting device according to claim 3, characterized in that, The control unit (9) also includes an OLED display module (10) for setting and displaying the pressure threshold Pset and the stabilization time Tset.

5. The self-mixing intelligent control crack repair grouting device according to claim 4, characterized in that, The settling time Tset can be set between 2 and 5 seconds.

6. The self-mixing intelligent control crack repair grouting device according to claim 5, characterized in that, The static mixer (7) adopts a Kenics-type design and is approximately 15 cm long. The interior of the static mixer (7) contains 24 spiral units.

7. A self-mixing intelligent control crack repair grouting method, implemented based on the self-mixing intelligent control crack repair grouting device according to any one of claims 1-6, characterized in that, Includes the following steps: Step 1, Parameter Setting: Using the OLED display module (10), set the grouting pressure threshold Pset and stabilization time Tset according to the crack size and grout characteristics; Step 2, Equipment Ready: Inject the corresponding slurry components into material chamber A (1a) and material chamber B (1b) respectively, and install the static mixer (7); Step 3, Start grouting: Start the device, the servo motor (2) drives the piston plate (6) to move forward at a constant speed, and push the A and B components of grout into the static mixer (7) synchronously and at the same pressure. The grout after being mixed evenly is injected into the crack. Step 4, Intelligent Judgment and Stop: The control unit monitors the pressure in real time. Once the conditions of "pressure > Pset" and "duration > Tset" are met, it is determined that the crack is full and the servo motor (2) is immediately controlled to stop running, and the grouting process is automatically terminated.

8. The self-mixing intelligent control crack repair grouting method according to claim 7, characterized in that, For step four, after the grouting process automatically terminates, move to the next grouting nozzle and repeat steps one through four until the entire crack is repaired.

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