Centrifugal forming and curing collaborative optimization method and equipment for concrete pipe pile

Abstract

The invention relates to the technical field of concrete pipe pile production, and discloses a concrete pipe pile centrifugal forming and curing collaborative optimization method and device.The concrete pipe pile centrifugal forming and curing collaborative optimization method comprises the following steps that conductivity modification is conducted on a concrete raw material, initial parameters are obtained, and internal density distribution of a pipe pile is sensed in real time through an integrated ultrasonic transducer phased array; and carrying out closed-loop compensation and compaction on the weak density area through the partitioned electric field on the basis of the distribution information, recording a final density distribution diagram and total applied electric energy, continuously applying the weak electric field in the transfer process to maintain early hydration, dynamically generating an optimal maintenance system according to the final density distribution diagram and the total applied electric energy, and carrying out closed-loop control. According to the method, online sensing, active regulation and control and data-driven maintenance strategies are deeply fused, the problem of splitting in the forming stage and the maintenance stage in a traditional technology is solved, closed-loop control over the internal quality of the pipe pile is achieved, the uniformity and reliability of the product quality are improved, and the production energy consumption and period are reduced.

Description

Technical Field

[0001] This invention relates to the field of concrete pipe pile production technology, and in particular to a method and equipment for the coordinated optimization of centrifugal molding and curing of concrete pipe piles. Background Technology

[0002] Prestressed high-strength concrete pipe piles are widely used foundation components in building construction. Their production process mainly includes two core stages: centrifugal molding and high-temperature curing. In traditional production processes, the centrifugal molding step relies on preset centrifuge speed and duration to compact the concrete mixture through centrifugal force. However, this molding process is essentially an open-loop process lacking real-time feedback. Because the density distribution inside the pipe pile cannot be known during the process, fixed centrifugal parameters are insufficient to cope with fluctuations in the physical properties of the concrete raw materials, potentially leading to uneven density defects inside the molded pipe pile, affecting its final performance.

[0003] After centrifugal molding, the pipe piles are sent to a curing kiln for steam curing to accelerate strength development. Existing curing processes generally employ experience-based, standardized temperature and humidity profiles. This universal curing system does not consider the actual internal structural state and early hydration level of each pipe pile after molding. It cannot employ energy-efficient curing schemes for pipe piles with superior internal structures, nor can it compensate for pipe piles with potential defects. This non-personalized approach not only results in energy waste and excessively long production cycles, but the drastic temperature rise process may also introduce harmful temperature stresses within the pipe pile.

[0004] The fundamental flaw in existing technology lies in the complete separation between the molding and curing stages. Key information about the internal quality of the pipe pile generated during the molding process is entirely lost, and the curing system is completely unaware of the initial state of the received pipe pile. Therefore, the entire production chain lacks a means to link and control the centrifugal molding and curing processes through data, thereby fundamentally improving product quality uniformity and optimizing production efficiency. Summary of the Invention

[0005] The purpose of this invention is to provide a method and equipment for the coordinated optimization of centrifugal molding and curing of concrete pipe piles. This invention solves the problems in the existing concrete pipe pile production process, such as the inability to sense the internal texture state online during the molding process, the lack of active control methods, and the fact that the curing process can only adopt a fixed and non-optimized curing system due to the disconnect between the data and the molding stage. This results in poor uniformity of final product quality, long production cycle and high energy consumption.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] This invention provides a method for the coordinated optimization of centrifugal molding and curing of concrete pipe piles, aiming to transform the production process of concrete pipe piles into a data-driven closed-loop control process. The method includes the following steps:

[0008] S100. In the centrifugal molding preparation stage, the concrete raw materials are modified to improve their conductivity, providing a physical basis for subsequent electric field control. Simultaneously, initial parameters such as the slump and moisture content of the modified concrete are measured online, and the molding equipment and control model are initialized based on these parameters.

[0009] S200, in the multi-physics coupled plastic forming stage, combines centrifugal force, acoustic field, and electric field to reshape the concrete texture online. The core innovation of this stage lies in:

[0010] Real-time perception of internal texture: By using an ultrasonic transducer phased array integrated inside the pipe mold and ultrasonic tomography technology, the density distribution map of the pipe pile cross section can be obtained in real time and non-invasively.

[0011] Sensing-based closed-loop control: The system compares the real-time density distribution map with a preset target to identify and quantify areas of weak density. Then, a vectorized, zoned electric field corresponding to the density deviation is applied through a zoned electrode system. This electric field utilizes electroosmotic and other electrodynamic effects to actively guide material migration within the slurry, precisely compensating for and compacting the weak areas. This sensing, analysis, and control process is repeated cyclically until the density inside the pipe pile reaches a highly uniform state. During this process, the system records the final density distribution map of the pipe pile and calculates the total applied electrical energy during compensation and compaction by integrating the applied voltage and current. The formula for calculating the total applied electrical energy is:

[0012] ;

[0013] in:

[0014] To apply electrical energy in total;

[0015] For the segment index of the partitioned electrode system;

[0016] and They flow through the first Real-time voltage and current of the section, The total molding time is given by this formula. This formula first integrates the instantaneous power of each section over time, and then sums the total energy consumption of all sections in space, thereby accurately quantifying the overall promoting effect of the electric field on the early hydration reaction.

[0017] S300. During the continuous hydration and transfer transition stage, a low-intensity, stable, weak electric field is continuously applied through the transfer device while the formed pipe pile is being transferred to the curing station. This maintains the continuity of the early hydration process and prevents a sudden drop in hydration rate due to process transitions. Simultaneously, the surface temperature and humidity of the pipe pile are monitored and compensated to prevent the formation of shrinkage microcracks.

[0018] S400. During the low-temperature integrated curing stage, a fixed curing schedule is abandoned. Based on the final density distribution map and total applied electrical energy obtained in the previous steps, the system dynamically calculates the optimal curing temperature and time for the pipe pile using a preset curing schedule generation function model. The basic principle of this model can be expressed as follows:

[0019] ;

[0020] The underlying logic is that pipe piles with more uniform internal structure and higher early hydration levels require less heat input for subsequent curing. This generates a medium- or low-temperature curing scheme with significantly reduced energy consumption, and the curing end point is ultimately determined based on real-time feedback from strength sensors, achieving dual optimization of performance and energy efficiency.

[0021] This invention provides a device for the coordinated optimization of centrifugal forming and curing of concrete pipe piles. This device provides hardware support for realizing the above method. It generally includes a dynamic centrifugal unit, a heat preservation and transfer unit, a linkage curing unit, and a coordinated control unit. Each unit is connected through a data bus to form a closed-loop coordinated control system.

[0022] The dynamic centrifugal unit is the core component for achieving plastic forming and texture reshaping. It includes a specially designed mold assembly with an integrated ultrasonic transducer phased array integrated into its inner wall for applying the sound field and performing ultrasonic tomography. The mold assembly also includes a partitioned electrode system, consisting of a mold inner wall divided into multiple electrically insulating sections serving as the cathode, and a similarly segmented, movable central anode rod. The unit is also equipped with a multi-channel high-voltage DC / pulse power supply for independently driving each electrode section to create a vectorized electric field.

[0023] The heat-insulating transfer unit is used for seamless connection between processes. It is equipped with a continuous hydration and state maintenance module, which includes a flexible electrode for applying a weak electric field and a low-voltage DC power supply, as well as a temperature and humidity sensor, a heating component and an atomizing spray component for stabilizing boundary conditions.

[0024] The linked curing unit is mainly an intelligent curing kiln, which is equipped with multi-dimensional monitoring and control components, including temperature and humidity control components and intensity sensors for real-time monitoring of intensity development.

[0025] The collaborative control unit is the control core of the entire device. Its hardware platform runs core software modules, including:

[0026] Ultrasonic Tomography Reconstruction Module: Used to receive ultrasonic signals and invert and reconstruct the density distribution map.

[0027] Density field analysis and decision module: used to interpret density distribution maps, identify weak areas, and calculate density deviation. .

[0028] The zoned electric field vector control module is the core logic for active regulation. This module receives the real-time average density deviation of each electrode segment. Based on the PID control law, the target control voltage is dynamically calculated for each segment. The mathematical expression for its control law is:

[0029] ;

[0030] in, In order to target the The target control voltage for the section;

[0031] Based on the driving voltage;

[0032] For the first Real-time average density deviation of the section;

[0033] For the first The integral of the real-time average density deviation of the section;

[0034] , , This is the preset gain coefficient;

[0035] Real-time average density deviation The rate of change;

[0036] For time.

[0037] This control law comprehensively considers current deviations, historical cumulative deviations, and future trends, thereby achieving precise, stable, and error-free compensation compaction of weak areas.

[0038] In summary, the present invention has at least one of the following beneficial technical effects:

[0039] 1. This invention utilizes an integrated ultrasonic transducer phased array to sense the internal density distribution of the pipe pile during the centrifugal molding process. Based on this data, a zoned electrode system and PID control law are used to actively and in a closed loop compensate and compact areas with weak density. This enables online real-time diagnosis and repair of the internal structure of the concrete pipe pile, significantly improving the density and structural uniformity of the final product.

[0040] 2. This invention records the final density distribution map and total applied electrical energy of the pipe pile during the forming stage, and dynamically generates a personalized maintenance system based on this. At the same time, it uses pre-embedded strength sensors to monitor the strength development in real time, thereby realizing the customization and closed-loop control of the maintenance system, which reduces maintenance energy consumption and shortens unnecessary maintenance cycles.

[0041] 3. By using a transfer device with electric field application function to continuously apply a weak electric field during the transfer of the pipe pile from the centrifugal station to the curing station, the present invention achieves the continuity of the early hydration process of concrete, avoids the sudden drop in hydration rate caused by process change, and further improves the overall efficiency of the production process. Attached Figure Description

[0042] Figure 1 This is a structural block diagram of a concrete pipe pile centrifugal molding and curing synergistic optimization device according to an embodiment of the present invention;

[0043] Figure 2 This is a flowchart of a method for coordinating and optimizing the centrifugal molding and curing of concrete pipe piles according to an embodiment of the present invention.

[0044] Among them, 10. Dynamic centrifugation unit; 11. Integrated ultrasonic transducer phased array; 12. Zoned electrode system; 13. Multi-channel high-voltage DC / pulse power supply; 20. Insulated transfer unit; 21. Continuous hydration and state maintenance module; 211. Flexible electrode; 212. Low-voltage DC power supply; 30. Linked curing unit; 31. Intelligent curing kiln; 32. Multi-dimensional monitoring and control components; 40. Collaborative control unit; 41. Hardware platform; 42. Core software module; 421. Ultrasonic tomography reconstruction module; 422. Density field analysis and decision module; 423. Zoned electric field vector control module. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0046] Examples 1-2:

[0047] Example 1:

[0048] See attached document Figure 1 The present invention provides a device for the coordinated optimization of centrifugal molding and curing of concrete pipe piles. This device is designed to realize online sensing and active control of the internal texture of concrete pipe piles.

[0049] The centrifugal forming and curing collaborative optimization equipment for concrete pipe piles generally includes a dynamic centrifugal unit 10, a thermal insulation and transfer unit 20, a linkage curing unit 30, and a collaborative control unit 40 as the control core. Each unit achieves high real-time data interaction and command transmission through data buses such as industrial Ethernet, forming a closed-loop collaborative control system.

[0050] The dynamic centrifuge unit 10 is used for plastic shaping and textural remodeling of concrete. It is not a traditional centrifuge; its core lies in a specially designed tubular mold assembly. An integrated ultrasonic transducer phased array 11 is integrally integrated along its circumference and axis on the inner wall of this assembly. This phased array 11, made of materials such as piezoelectric ceramics, possesses dual functions of signal transmission and reception, serving as both a source of acoustic wave field application and a sensor for ultrasonic tomography.

[0051] To achieve vectorized application of the electric field, the mold assembly also includes a partitioned electrode system 12. Specifically, the inner wall of the mold body serves as the cathode of the system and is divided into multiple electrically insulated cathode sections along its axial direction. Simultaneously, an anode rod that can be inserted and removed along the central axis of the mold is also correspondingly designed as multiple electrically insulated anode sections. This structure allows multiple axially independent and controllable electric field regions to be formed within the mold.

[0052] To drive the aforementioned partitioned electrode system 12, the dynamic centrifugation unit 10 is equipped with a multi-channel high-voltage DC / pulse power supply 13. This power supply 13 has multiple independent output channels, each connected to a pair of cathode and anode sections. The coordination control unit 40 can control this power supply 13 to independently apply DC electric fields of different voltage values, or pulsed electric fields of specific waveforms, to any one or more sections.

[0053] The insulated transfer unit 20 is used to transfer concrete pipe piles between the centrifugation and curing processes, maintaining the continuity of their hydration process. The main body of this unit is a transfer trolley with a good insulation layer. Inside, there is a continuous hydration and condition maintenance module 21, which includes flexible electrodes 211 laid along the inner wall of the trolley and a dedicated low-voltage DC power supply 212. During transfer, the flexible electrodes 211 apply a weak, stable electric field to the concrete pipe pile. Furthermore, the continuous hydration and condition maintenance module 21 also includes temperature and humidity sensors and linked heating and spray actuators.

[0054] The integrated curing unit 30 is used for the final curing of concrete pipe piles. This unit mainly consists of an intelligent curing kiln 31, which can be divided into multiple independent curing areas. Each area is equipped with multi-dimensional monitoring and control components 32, including temperature and humidity control components for precise environmental control, and strength sensors that can be pre-embedded inside the concrete pipe pile for real-time monitoring of strength development.

[0055] The collaborative control unit 40, as the central processing core of the entire device, is responsible for data acquisition, processing, decision-making, and instruction issuance. Its hardware platform 41 includes an industrial computer (IPC) for high-speed computing and a programmable logic controller (PLC) for device logic control. Its internal core software module 42 contains multiple highly collaborative functional modules.

[0056] The ultrasonic tomography reconstruction module 421 is crucial for realizing the perception of the internal structure. This module receives ultrasonic propagation time signals from each path acquired by the integrated ultrasonic transducer phased array 11 in scanning mode, and, based on a preset algebraic reconstruction algorithm (ART) or filtered back projection (FBP) algorithm, reconstructs the density distribution map of the concrete pipe pile cross-section in real time. .

[0057] The density field analysis and decision module 422 is used to interpret the reconstructed density distribution map in real time. This module compares the real-time density map with the preset target density function at the pixel level or region level, automatically identifies and quantifies weak areas where the density does not meet the standard, and calculates the real-time average density deviation corresponding to each electrode segment. .

[0058] The zoned electric field vector control module 423 is the core execution logic for achieving active control. This module receives the real-time average density deviation of each electrode segment output by the analysis and decision module 422. Based on the following PID control law, an independent control voltage signal is generated for each electrode segment.

[0059] The voltage signal command output by this module is sent to the multi-channel high-voltage DC / pulse power supply 13, thereby realizing precise, closed-loop, and vectorized electric field strengthening of the weak area inside the concrete pipe pile until the density distribution is uniform.

[0060] Example 2:

[0061] See attached document Figure 2 This invention provides a method for the coordinated optimization of centrifugal molding and curing of concrete pipe piles. This method, implemented based on the aforementioned coordinated optimization equipment, aims to transform the production process of concrete pipe piles into an intelligent process that can be sensed in real time, actively controlled, and deeply coordinated. The method may include the following steps:

[0062] S100, Perform centrifugal molding collaborative preparation. This step includes obtaining the initial parameters of the concrete raw materials and initializing the specially designed tube mold assembly and the partitioned electrode system 12 within the dynamic centrifugal unit 10.

[0063] S200 performs multi-physics coupled plastic forming. This step reshapes the concrete texture online through the synergistic effect of centrifugal force, acoustic field, and electric field. Specifically, it involves using ultrasonic tomography to perceive the internal density distribution of the concrete pipe pile in real time, and based on this distribution information, actively and in a closed loop, compensating and compacting weak density areas through zoned electric field vector guidance, ultimately achieving high uniformity and compaction of the concrete pipe pile and early strength growth.

[0064] S300, continuous hydration and transfer connection is performed. During the process of transferring the formed concrete pipe pile from the dynamic centrifugal unit 10 to the linkage curing unit 30, a weak electric field is continuously applied through the heat-insulating transfer unit 20 to maintain the continuity of the early hydration process and ensure the stability of the surface temperature and humidity of the concrete pipe pile.

[0065] S400, execute low-temperature linkage curing. The coordination control unit 40 dynamically generates the optimal curing regime based on the final density distribution map and total applied electrical energy collected and generated in step S200, and controls the linkage curing unit 30 to complete the low-temperature curing process.

[0066] To further illustrate the method disclosed in the embodiments of the present invention, the specific implementation process of the method will be described in detail below.

[0067] See attached document Figure 2 The specific implementation of step S100 will be described below. This centrifugal molding collaborative preparation stage aims to provide a precise material basis and controllable initial system conditions for the subsequent multiphysics coupled plastic molding process. The implementation of this stage may include the following sub-steps:

[0068] During the concrete mixing process, a predetermined proportion of conductive functional admixture is uniformly incorporated into the mixture. This admixture is a combination of one or more carbon-based conductive materials, such as carbon nanotubes, graphene, or conductive carbon black. Its function is to form a three-dimensional, interconnected microscopic conductive network within the cement-based hydration products. This network provides the necessary low-resistance pathway for the subsequent directional migration of charges in the pore liquid phase of the slurry, which is a technical prerequisite for realizing electroosmotic drainage and electro-hydration functions.

[0069] Before the concrete is pumped to the dynamic centrifugal unit 10, key rheological and compositional parameters of the concrete are collected in real time and non-contactly using online monitoring equipment connected to the delivery pipeline. Specifically, the slump of the concrete is measured using an online slump meter. The moisture content of the aggregate was determined using a microwave moisture content meter. The collected data is transmitted to the collaborative control unit 40 in real time.

[0070] After receiving the collected key rheological and component parameters, the collaborative control unit 40 prepares the equipment and control model. At the physical level, the automatic spraying device on the inner wall of the mold assembly sprays the release agent. Simultaneously, according to the preset measurement point layout, one or more wireless passive strength sensors are temporarily fixed at specific positions on the inner wall of the mold. The heating element integrated with the outer wall of the mold is activated to raise the mold temperature. Preheating and maintaining at a preset stable state. At the control level, the collaborative control unit 40 will collect the slump data. With moisture content As input variables, a pre-defined multiphysics coupling model is loaded and associated to generate a set of multiphysics collaborative control parameters for the upcoming molding process. These parameters include, but are not limited to: the initial centrifugal speed curve, the initial power and frequency of the applied acoustic field, and the base voltage in the partitioned electric field vector control law. With Proportional-Integral-Derivative (PID) gain coefficient , , The initial settings.

[0071] See attached document Figure 2 The specific implementation of step S200 will be described below. This multiphysics coupled plastic forming stage is the core link of the present invention for actively reshaping the concrete texture. The implementation of this stage may include the following sub-steps:

[0072] After the dynamic centrifugal unit 10 starts rotating at a preset low speed, the collaborative control unit 40 immediately drives the integrated ultrasonic transducer phased array 11 on the inner wall of the mold. The integrated ultrasonic transducer phased array 11 applies a low-frequency, high-energy acoustic wave field to the concrete slurry inside the mold. The acoustic flow effect and cavitation effect of the sound wave macroscopically manifest as a significant reduction in the apparent viscosity of the concrete, causing it to enter a fluidized state that facilitates flow, thereby rapidly and uniformly completing the initial distribution along the inner wall of the mold under a relatively low centrifugal force.

[0073] After the initial distribution is completed, the rotational speed of the tube mold is steadily increased from low speed to medium speed compaction range, and the system enters a continuous texture remodeling cycle that can be sensed, analyzed, decided and controlled in real time.

[0074] The first step in this cycle is the real-time sensing of the internal density field. The collaborative control unit 40 switches the operating mode of the integrated ultrasonic transducer phased array 11 to tomographic scanning mode. In this mode, the phased array unit is excited according to a predetermined program, emitting a focused ultrasonic beam and receiving the signal after penetrating the medium. The ultrasonic tomographic reconstruction module 421 acquires the ultrasonic propagation time between all transmit-receive path pairs. And based on the known geometric path length Calculate the average speed of sound along each path. Based on the physical model of the positive correlation between concrete density and sound velocity, this module uses algorithms such as Algebraic Reconstruction Technique (ART) to invert and reconstruct the discrete sound velocity data field into a continuous, high-resolution real-time density distribution map of the concrete pipe pile cross-section. .

[0075] The operating modes of the integrated ultrasonic transducer phased array 11 mainly include:

[0076] 1. Sound Field Application Mode: This mode aims to apply a uniform or specifically distributed energy field to the entire concrete within the formwork to alter its macroscopic physical properties. Its core focus is on energy output rather than information acquisition. In this mode, the co-control unit 40 controls the drive circuit to co-excite all or most of the transducer units in the phased array to vibrate synchronously in phase or with a specific phase relationship. This creates a non-focused, wide-area sound wave field. Depending on the application sub-steps, this mode can be further subdivided into:

[0077] Low-frequency fluidization sub-mode: In the initial distribution stage of S200, a low-frequency, high-energy acoustic wave field is applied to the system. Low-frequency acoustic waves have stronger penetrating power and more significant acoustic flow and cavitation effects in concrete slurry, which can effectively break the flocculation structure between cement particles, significantly reduce the apparent viscosity of the slurry, and enable the concrete slurry to enter the acoustic fluidization state.

[0078] High-frequency migration-assisted mode: During the electric field-guided compaction process, a high-frequency, low-energy acoustic field can be applied synergistically. The high-frequency vibration mainly acts on the contact interface between particles, which can effectively reduce the static frictional resistance between particles and assist the migration and filling process of materials under the action of electroosmotic force and centrifugal force.

[0079] Stress relief sub-mode: Near the end of the centrifugation process, the system applies a short, specific-frequency acoustic pulse. The energy and frequency of this pulse are specially designed to effectively release the internal micro-stress that may have accumulated in the material during rapid molding and hardening through instantaneous vibration, thereby improving the crack resistance of the finished product.

[0080] 2. Tomographic Scanning Mode: This mode is the core of internal texture sensing, aiming to accurately acquire internal structural information of the pipe pile cross-section. Essentially, it's a non-destructive testing operation. In this mode, the cooperative control unit 40 groups the transducer units of the phased array and executes a precise, programmed transmission and reception sequence. Its working principle is as follows: the cooperative control unit 40 excites only a small subset of the array at a time, and synthesizes a highly directional, focused ultrasonic beam by applying a microsecond-level precise phase delay to each unit within that subset. By dynamically changing the phase delay applied to each unit, the angle of this focused beam can be controlled, achieving rapid electronic scanning of the entire concrete cross-section without any mechanical rotation. After one beam is transmitted, all or another set of designated transducer units switch to receiving mode to capture the ultrasonic signal penetrating the concrete medium. The core acquisition parameter of this mode is the ultrasonic signal propagation time between each transmission and reception path pair. When the cooperative control unit 40 performs real-time sensing of the internal density field, it precisely switches the operating state of the phased array 11 from the sound field application mode or standby mode to this tomographic scanning mode to perform data acquisition tasks. After acquisition is completed, it can switch back to other modes.

[0081] By flexibly and rapidly switching between the two working modes and their sub-modes, the integrated ultrasonic transducer phased array 11 of this invention realizes the dual functions of macroscopic property control and microscopic structural imaging of concrete on a single hardware platform, which is the key technical foundation for building the entire closed-loop collaborative optimization system.

[0082] The second step of this cycle involves guiding the partitioned electric field vector based on density deviation. The density field analysis and decision module 422 receives the aforementioned density distribution map and compares it with a preset target density function. Real-time comparison is performed to identify weak areas where density does not meet standards. For the first [area] divided along the axial direction... For each pipe module segment, this module calculates the average density within its coverage area. And obtain the real-time average density deviation of this section. The partitioned electric field vector control module 423 then uses this deviation... As the core input, based on the PID control law, for the first... The target control voltage required to achieve closed-loop correction is dynamically calculated for each section. The calculation formula is as follows:

[0083] ;

[0084] in, In order to target the The target control voltage for the section;

[0085] Based on the driving voltage;

[0086] For the first Real-time average density deviation of the section;

[0087] For the first The integral of the real-time average density deviation of the section;

[0088] , , This is the preset gain coefficient;

[0089] Real-time average density deviation The rate of change;

[0090] For time.

[0091] The collaborative control unit 40 will calculate the target voltage for each segment. The command is sent to the multi-channel high-voltage DC / pulse power supply 13. This power supply 13 then independently adjusts each output channel, applying precise voltage to the corresponding anode and cathode sections of the partitioned electrode system 12. This creates a localized, enhanced electric field vector in the low-density, weak areas. This electric field vector generates a stronger electroosmotic driving force, actively and directionally discharging excess free water from the area, providing space and impetus for the surrounding denser slurry to migrate and fill the area under centrifugal force. The entire scanning, analysis, and correction process is cyclically executed at a high frequency until the real-time average density deviation of all sections is measured. The material converges to a preset threshold, thereby achieving precise repair and homogenization of the internal structure of the concrete pipe pile. During this process, the ultrasonic transducer phased array 11 can collaboratively apply high-frequency sound waves to reduce the frictional resistance between particles and assist in the material migration guided by the electric field.

[0092] After the density distribution of the concrete pipe pile reaches a uniform state, the central anode rod is removed, and the rotation speed of the pipe mold is increased to high speed for final compaction and surface leveling. At this time, the co-control unit 40 controls the multi-channel high-voltage DC / pulse power supply 13 to switch to pulse output mode, applying a high-frequency electrical pulse of a specific waveform to the concrete through the pipe mold body (cathode). This electrical pulse can effectively accelerate the ion exchange and hydration product generation rate on the surface of cement particles without causing a significant temperature rise, achieving electrocatalytic growth of early strength. Near the end of the centrifugation process, the co-control unit 40 drives the ultrasonic transducer phased array 11 to apply a short, specific frequency acoustic pulse to release the internal micro-stress that may have accumulated in the material during the rapid molding process.

[0093] See attached document Figure 2The specific implementation of step S300 will be described below. This continuous hydration transfer transition stage aims to ensure that the early hydration process, which has been accelerated by the electric field during the forming stage, continues uninterrupted during process transitions, and stabilizes the thermal / humid boundary conditions of the concrete pipe pile, laying a consistent initial state for subsequent low-temperature curing. The implementation of this stage may include the following sub-steps:

[0094] After step S200 is completed, the demolded concrete pipe piles are transferred to the thermal insulation transfer unit 20. At this time, the concrete pipe piles have undergone electro-hydration treatment and have high initial strength, which is sufficient to support their own transfer process.

[0095] After the concrete pipe pile enters the insulation transfer unit 20, its internal continuous hydration and state maintenance module 21 is activated. Flexible electrodes 211 laid on the inner wall of this module make contact with the outer surface of the concrete pipe pile and are powered by a matching low-voltage DC power supply 212. This power supply applies a low-intensity, stable DC electric field in the radial direction of the concrete pipe pile. The electric field does not dehydrate the concrete pipe pile, but rather maintains the migration activity of ions in the pore solution inside the concrete pipe pile, prolonging the catalytic effect of the electric field on the cement hydration reaction. This ensures the continuity of early strength development from the end of centrifugation to before entering the curing kiln, and avoids a sudden drop in hydration rate due to the disappearance of the electric field.

[0096] Throughout the entire transfer process, the temperature and humidity sensor in the continuous hydration and condition maintenance module 21 monitors the temperature of the concrete pipe pile surface in real time. relative humidity of the internal microenvironment of the transfer unit The collaborative control unit 40 compares the monitored values ​​with a preset stable range. If the surface temperature of the concrete pipe pile is detected... Due to a decrease in ambient temperature or relative humidity When the temperature drops below saturation, the co-control unit 40 immediately activates the heating and atomizing spray components within the drive module to provide compensatory heating and humidification. This effectively prevents shrinkage microcracks from forming on the concrete pipe pile due to excessively rapid evaporation of surface moisture and avoids thermal shock caused by sudden temperature drops.

[0097] After the thermal insulation transfer unit 20 transports the concrete pipe pile to the designated position in the linkage curing unit 30, the continuous hydration sustaining electric field is removed, and the transfer process ends. At this time, the internal hydration process of the concrete pipe pile is continuous, and the surface condition is stable, which prepares it for seamless entry into the low-temperature linkage curing step S400.

[0098] See attached document Figure 2The specific implementation of step S400 is described below. The core of this low-temperature integrated curing stage lies in abandoning the traditional, experience-based fixed curing system and instead utilizing real-time, high-dimensional data generated during the forming stage to dynamically generate and execute an optimized low-temperature curing plan for each concrete pipe pile, thereby achieving a dual improvement in energy efficiency and product performance. The implementation of this stage may include the following sub-steps:

[0099] After the concrete pipe pile is moved from the insulation transfer unit 20 to the linkage curing unit 30, the collaborative control unit 40 immediately retrieves and integrates two core historical data generated by the concrete pipe pile throughout step S200: the final density distribution map. With total applied electrical energy The former, determined by ultrasonic tomography before centrifugation, accurately characterizes the internal structural uniformity and density of the finished concrete pipe pile; the latter is obtained by integrating and summing the real-time current and voltage of each section, and its calculation formula is as follows:

[0100] ;

[0101] in:

[0102] To apply electrical energy in total;

[0103] and They flow through the first Real-time voltage and current of the section;

[0104] Total molding time;

[0105] This represents the total electrical energy applied to all areas of the entire pipe pile;

[0106] To calculate the total electrical energy applied to a single electrode segment.

[0107] The overall promoting effect of the electric field on the early hydration reaction of concrete pipe piles was quantitatively characterized.

[0108] The collaborative control unit 40 will combine the above two high-dimensional data... and As input, a pre-defined maintenance regime generation function model is substituted. In this process, the optimal curing temperature is calculated in real time for the current concrete pipe piles. With maintenance time This relationship can be represented as:

[0109] ;

[0110] The underlying logic of this function model is: a model with higher uniformity (by...) Characterization) and higher early hydration levels (by The concrete pipe piles (characterized by this method) require less heat input for subsequent strength development. Therefore, this model can generate a medium-temperature constant-temperature curing system that eliminates the need for a high-temperature heating stage and significantly reduces energy consumption, fundamentally avoiding the risks of internal stress and cracking that may be caused by drastic temperature gradients in traditional high-temperature curing.

[0111] The collaborative control unit 40 will calculate the maintenance parameters The command is sent to the coordinated curing unit 30, where the multi-dimensional monitoring and control component 32 receives the command and precisely controls the ambient temperature and humidity inside the curing kiln to the target value. and maintain Duration. During this period, strength sensors embedded inside the concrete pipe piles monitor their strength development data in real time and feed this data back to the collaborative control unit 40, forming a closed-loop monitoring of the curing process.

[0112] Although maintenance time The preset control target is used, but the final basis for determining the end of curing is the real-time reading of the strength sensor. When the co-control unit 40 confirms that the measured strength of the concrete pipe pile has reached the design requirements, the curing process is immediately terminated, regardless of the preset time. Completion restrictions. This termination mechanism, based on the final product performance, ensures that each concrete pipe pile meets quality requirements while minimizing the curing period and further optimizing energy utilization.

[0113] 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, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for the coordinated optimization of centrifugal molding and curing of concrete pipe piles, characterized in that, Includes the following steps: S100, the conductivity of concrete raw materials is modified, the slump and moisture content of the modified concrete are measured as initial parameters, and the relevant parameters of the special tube mold assembly and the partitioned electrode system used for centrifugal molding are initialized according to the initial parameters. S200, during the centrifugal molding process, through the synergistic effect of centrifugal force field, sound field and electric field, the integrated ultrasonic transducer phased array senses the internal density distribution of the concrete pipe pile in real time, thereby generating a density distribution map. Based on the internal density distribution of the concrete pipe pile, through the guidance of the zoned electric field vector, active and closed-loop compensation and compaction are carried out in the density-weak areas to promote the early hydration process, and determine the final density distribution map of the concrete pipe pile and the total applied electrical energy in the compensation and compaction process, thus completing the uniform densification and early strength growth of the concrete pipe pile. S300, during the process of transferring the formed concrete pipe pile from the centrifugal forming station to the low-temperature curing station, a weak electric field is continuously applied through the transfer device to maintain the continuity of the early hydration process and ensure the stability of the surface temperature and humidity of the concrete pipe pile. S400: Based on the final density distribution map and the total applied electrical energy, an optimal curing regime is dynamically generated, and the low-temperature curing process is controlled according to the curing regime.

2. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, characterized in that, The conductivity modification specifically includes: One or more carbon-based conductive materials are uniformly incorporated into the concrete mixture to form a three-dimensional conductive network, giving the concrete mixture overall conductive properties. The determination of slump and moisture content specifically includes measuring the slump of concrete using an online slump meter and measuring the moisture content of aggregates using a microwave moisture content meter.

3. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, characterized in that, The initialization of the specially designed tube mold assembly and the partitioned electrode system specifically includes: The specially designed tube mold assembly is sprayed with a release agent, preheated to a preset stable mold temperature, and the collected slump and moisture content are used as input variables to generate initial multi-physics field collaborative control parameters, which are then used as initial control settings for subsequent collaborative effects.

4. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, characterized in that, The synergistic effect of centrifugal force field, sound field and electric field in the initial distribution stage specifically includes: After the specially designed tube mold assembly rotates at a preset low speed, it drives the integrated ultrasonic transducer phased array to apply a low-frequency, high-energy acoustic wave field. The acoustic wave field uses the acoustic flow effect and cavitation effect to reduce the apparent viscosity of the concrete, so that the concrete enters the acoustic fluidization state and completes the rapid and uniform initial distribution of the concrete paste.

5. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, characterized in that, The sensing of the internal density distribution of the concrete pipe pile specifically includes: The working mode of the integrated ultrasonic transducer phased array is switched to tomographic scanning mode. By collecting the ultrasonic propagation time and based on the physical model of the positive correlation between concrete density and sound velocity, the sound velocity data field is inverted and reconstructed into a continuous, high-resolution density distribution map of the cross-section of the concrete pipe pile.

6. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, characterized in that, The process of actively and in a closed loop compensating and compacting areas with low density by guiding the zoned electric field vector specifically includes: The density distribution map is received, and the density distribution map is compared with a preset target density function in real time to identify weak areas where the density does not meet the standard and to calculate the real-time average density deviation of each electrode segment in the partitioned electrode system. The average density deviation is used as the core input. Based on the PID control law, the target control voltage of each electrode section is dynamically calculated. The voltage is then independently applied to the partitioned electrode system by a multi-channel high-voltage DC / pulse power supply to generate a directional electric field corresponding to the average density deviation in each electrode section, thereby achieving active compensation compaction of the weak area.

7. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 6, characterized in that, In step S200, the step of completing the uniform densification and early strength growth of the concrete pipe pile specifically includes: After the density distribution of the concrete pipe pile reaches a uniform state and the central anode rod is removed, the rotation speed of the pipe mold is increased from low speed to high speed to perform final mechanical compaction and surface leveling of the concrete pipe pile, thereby completing the uniform densification. During the high-speed rotation phase, a high-frequency electrical pulse of a specific waveform is applied to the concrete through the tube mold body to accelerate the early hydration reaction rate and achieve the aforementioned early strength growth. As the centrifugation process is about to end, the integrated ultrasonic transducer phased array is driven to apply a short, specific frequency acoustic pulse to release internal micro-stress.

8. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, characterized in that, Step S300 specifically includes: The formed concrete pipe pile is transferred to the transfer device, and the flexible electrode on the transfer device contacts the outer surface of the concrete pipe pile. It is powered by a low-voltage DC power supply to apply the low-intensity, constant DC electric field. The temperature of the concrete pipe pile surface and the relative humidity of the transport microenvironment are monitored in real time, and compensatory heating and humidification are performed.

9. The method for synergistic optimization of centrifugal molding and curing of concrete pipe piles according to claim 1, wherein step 400 specifically includes: The final density distribution map and the total applied electrical energy are retrieved and integrated as inputs, and substituted into the preset curing regime generation function model to calculate the optimal curing temperature and curing time without the need for a high-temperature heating stage in real time. The low-temperature curing process includes precisely controlling the ambient temperature and humidity of the low-temperature curing station according to the calculated curing parameters, and monitoring the strength development data in real time through a strength sensor embedded in the concrete pipe pile. The low-temperature curing process is terminated immediately when the measured strength reaches the design requirements.

10. A device for the coordinated optimization of centrifugal molding and curing of concrete pipe piles, characterized in that, include: The dynamic centrifuge unit includes a drive motor for driving the rotation of the tube mold, an integrated ultrasonic transducer phased array integrated into the inner wall of a specially designed tube mold assembly, a movable central anode rod, and a partitioned electrode system for applying a vectorized electric field. The dynamic centrifuge unit also includes a multi-channel high-voltage DC / pulse power supply for driving the partitioned electrode system. The heat preservation and transfer unit includes a continuous hydration and state maintenance module, which is equipped with a flexible electrode, a low-voltage DC power supply, a temperature and humidity sensor, a heating component, and an atomizing spray component. The linkage maintenance unit includes an intelligent maintenance kiln and a multi-dimensional monitoring and control component, wherein the multi-dimensional monitoring and control component includes a temperature and humidity control component and an intensity sensor; The collaborative control unit includes a hardware platform, and an ultrasonic tomography reconstruction module, a density field analysis and decision module, and a zoned electric field vector control module running on the hardware platform. The collaborative control unit interacts with the dynamic centrifugal unit, the heat preservation and transfer unit, and the linkage maintenance unit through a data bus to form a closed-loop collaborative control.

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