Dry-mixed mortar long-distance conveying control system

Abstract

The invention discloses a dry-mixed mortar long-distance conveying control system, and relates to the technical field of dry-mixed mortar conveying equipment control, the dry-mixed mortar long-distance conveying control system comprises a monitoring layer, a control layer, a sensing layer, an execution layer and a controlled object, each layer realizes communication through a signal line, and a collection, decision-making, execution and feedback closed loop is formed. According to the system, through hierarchical architecture and collaborative algorithm design, the stability and reliability of medium and long distance conveying are remarkably improved, the system depends on full-link parameter collection of the sensing layer and precise algorithm operation of the control layer, collaborative management and control of pressurization, segregation prevention, blocking prevention and moisture prevention are achieved, and the system reliability is improved. Core pain points such as material layering, pipeline blockage and damp deterioration in traditional conveying are effectively solved, uniformity and quality consistency of materials at the discharging end are ensured, material loss and reworking risks are greatly reduced, meanwhile, manual intervention is reduced through automatic initialization collection and real-time closed-loop regulation, and conveying efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of dry-mixed mortar conveying control technology, specifically a long-distance conveying control system for dry-mixed mortar. Background Technology

[0002] Dry-mixed mortar is a building cementitious material made by pre-mixing cement, sand, mineral admixtures and additives in a dry state. It can be used after adding water and stirring on the construction site. In actual construction, when there are site restrictions, large-scale projects and scattered construction points, strict environmental protection requirements, or the need to ensure the continuity of mortar supply, it is necessary to achieve remote transportation and pouring through special conveying equipment. The efficiency, material uniformity, operational stability and environmental compliance of long-distance transportation of dry-mixed mortar depend on the supporting long-distance transportation control system.

[0003] However, in the existing technology, the supporting long-distance conveying control system is not fully adapted to the multi-component material characteristics of dry-mixed mortar, the dynamic fluctuation of rheological parameters during the conveying process, and the interference of environmental temperature and humidity. It adopts rigid fixed parameter control logic and lacks full-link automated perception and closed-loop control capabilities, which leads to parameter coordination imbalance during long-distance conveying. This results in multiple performance shortcomings in conveying efficiency, material uniformity, and equipment stability. It is difficult to meet the requirements of engineering quality control and environmental compliance, and it cannot meet the core requirements of long-distance conveying for large-scale projects. Summary of the Invention

[0004] The purpose of this invention is to provide a long-distance conveying control system for dry-mixed mortar to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a long-distance conveying control system for dry-mixed mortar, comprising a monitoring layer, a control layer, a sensing layer, an execution layer, and a controlled object, wherein each layer communicates through signal lines to form a closed loop of data acquisition, decision-making, execution, and feedback; The monitoring layer includes local monitoring terminals and a remote monitoring platform; The control layer includes a core control unit, an initialization automated acquisition submodule, and a discharge port linkage control logic module. The core control unit has built-in adaptive multi-stage pressurization algorithm, variable pitch frequency modulation coupling anti-segregation algorithm, predictive graded anti-blocking algorithm, and inert gas closed-loop moisture-proof and anti-segregation algorithm. The sensing layer includes a basic sensor cluster, initialization automated data acquisition hardware, and a discharge port monitoring sensor cluster. The execution layer includes conventional actuators and dedicated components for the discharge port; The controlled object is a dry-mixed mortar conveying device, which is linked with the execution layer to realize long-distance material conveying; The various levels communicate through signal lines to form a closed loop of data acquisition, decision-making, execution, and feedback, specifically including the following steps: S1. Initialize automated data acquisition: Automatically acquire and verify the material characteristics, engineering layout, and environmental parameters of dry-mixed mortar through the sensing layer, and generate initial control parameters. S2. Real-time acquisition of parameters across the entire chain: Through the basic sensor cluster and the discharge port monitoring sensor cluster, material rheological parameters, pipeline operating status, environmental conditions and multi-dimensional parameters at the discharge end are continuously acquired during the conveying process. S3, core algorithm collaborative control, based on the collected parameters, performs dynamic calculations through four major algorithms: multi-stage pressurization, anti-segregation, anti-blockage, and anti-moisture, to generate adaptive control commands; S4. The actuator responds in a coordinated manner, executing control commands through conventional actuators and special components at the discharge port to perform pre-treatment of feed, pressurized conveying, anti-segregation and anti-blocking, and discharge regulation. S5. Monitoring feedback closed-loop optimization: Through local monitoring terminals and remote monitoring platforms, parameter display, abnormal alarms and remote operation and maintenance are realized, and control strategies are dynamically adjusted based on feedback data.

[0006] Preferably, the proportion of coarse aggregate, initial viscosity, and yield stress of the material are collected by an online particle size analyzer and an initial rheology analyzer; engineering parameters such as conveying distance and pipeline layout are obtained by a QR code scanner and a parameter storage module; basic environmental parameters are collected by an environmental temperature and humidity sensor; and after the data range and consistency are verified by the FPGA data verification processor, the data is automatically entered into the core control unit.

[0007] Preferably, the adaptive multi-stage boosting algorithm, the variable pitch frequency modulation coupling anti-segregation algorithm, the predictive grading anti-blocking algorithm, and the inert gas closed-loop moisture-proof and anti-segregation algorithm are applied to the core control unit of the dry-mixed mortar long-distance conveying control system. The adaptive multi-stage boosting algorithm is used to dynamically adjust the output pressure of the stepper booster pump group, including: inputting the real-time viscosity, yield stress, flow rate, cumulative conveying distance, and ambient temperature and humidity parameters of the material. The booster compensation is calculated based on a multi-parameter coupling model. The working conditions are adapted to changes through distance correction coefficients and environmental correction functions. The segmented step booster pump group is controlled to form a dynamic pressure gradient. Combined with pipeline pressure feedback closed-loop correction, the material flow rate is kept stable. The variable pitch frequency-modulated coupling anti-segregation algorithm is used to coordinate the control of the variable pitch agitator and the electromagnetic frequency-modulated vibrator, including: inputting the real-time flow rate of the material and the coarse aggregate ratio parameters; dynamically calculating the target speed of the agitator, matching the frequency and phase of the vibrator, and suppressing segregation through the coordinated use of axial thrust and radial vibration; and optimizing parameters based on the coarse aggregate ratio feedback at the discharge end. The predictive and graded anti-blockage algorithm is used to identify and handle pipeline blockage risks, including: inputting the thickness of material accumulation in the pipeline and pipe wall stress parameters; setting three levels of blockage standards (mild, moderate, and severe) according to the combination of dual-parameter thresholds and outputting differentiated handling instructions; and switching to normal transportation mode in a closed loop based on parameter feedback after handling.

[0008] The inert gas closed-loop moisture-proof and anti-segregation algorithm is used to achieve moisture-proof and anti-segregation in a coordinated manner. It includes: inputting the material moisture content, gas dew point and pressure parameters in the pipeline; adjusting the opening of the nitrogen flow regulating valve and the parameters of the dehumidification device with the goals of material drying, gas dew point compliance and slight positive pressure in the pipeline; achieving coordinated moisture-proof and anti-segregation through micro-airflow of inert gas, and optimizing the control accuracy through multi-parameter closed-loop optimization.

[0009] Preferably, the core algorithm collaborative control in step 3 specifically includes: The pressure compensation is dynamically calculated, and the step-by-step booster pump is used to achieve staged pressure increase. The speed of the variable pitch agitator is adjusted, and the electromagnetic frequency-modulated vibrator is used in sequence for coordinated operation. The dynamic calculation is based on the following formula: ; In the formula: This is the pressure compensation amount, in MPa; This is the distance correction factor, which is 0.002 + 0.0002 × L / 100; The yield stress weighting coefficient is 0.05. The environmental impact weighting coefficient is 0.08. The basic compensation amount is 0.1 MPa; The real-time viscosity of the material is expressed in Pa·s. The real-time yield stress of the material is expressed in Pa; L is the cumulative conveying distance in meters; and v is the real-time flow velocity of the material in meters per second. Ambient temperature, unit: °C; Relative humidity, unit: %RH; Environment correction function hour , hour ,otherwise ; The speed of a variable pitch agitator is adjusted based on the following formula: ; In the formula: n is the rotational speed of the variable pitch agitator, in rpm; This represents the percentage of coarse aggregate in the material, expressed as a decimal (unit: %, expressed as a decimal).

[0010] Preferably, the identification and handling of pipeline blockage risks specifically include: Real-time monitoring of the material accumulation thickness (h) and the pipe wall stress (σ) through an ultrasonic accumulation thickness detector and a pipe wall stress sensor, and determining the blockage level and implementing corresponding measures according to the following conditions Minor blockage (h ≤ 5 mm and σ < 1 MPa): The variable pitch agitator rotates in the reverse direction, the pipeline speed is increased, and the pressure of the front-stage step-type booster pump is reduced; Moderate blockage (5 mm < h ≤ 10 mm and 1 MPa ≤ σ < 2 MPa): Superimposed high-pressure reverse blowing system with low-pressure pulse reverse blowing, and coordinated adjustment of the pressures of the front and rear stages; Severe blockage (h > 10 mm and σ ≥ 2 MPa): Superimposed high-pressure reverse blowing system with high-pressure directional reverse blowing, the variable pitch agitator rotates in the reverse direction at high speed, and the front-stage step-type booster pump stops to maintain pressure; h is the material accumulation thickness in the pipeline (unit: mm), and σ is the pipe wall stress (unit: MPa).

[0011] Preferably, the optimization of parameters based on the feedback of the proportion of coarse aggregates at the discharge end specifically includes: Collecting four-dimensional parameters through an on-line particle size analyzer at the discharge port, a discharge flow rate sensor, a material humidity sensor at the discharge port, and a dust concentration sensor, and implementing the following after comparing with the preset target values: When the deviation between the proportion of coarse aggregates at the discharge end and the proportion of coarse aggregates at the feed end is greater than 0.5%, start the micro agitator in the discharge bin to adjust the homogenizing rotation speed; When the material humidity at the discharge end is greater than 0.6%, increase the flow rate of the inert gas and reduce the feeding speed of the double-shaft spiral disperser through the nitrogen flow regulating valve; When the dust concentration at the discharge port is greater than 10 mg / m³, increase the dust removal power in stages or deploy a pneumatic windshield; When the level sensor in the discharge bin detects an abnormal level in the discharge bin, adjust the feeding speed accordingly or stop the machine emergently.

[0012] Preferably, the collaborative implementation of moisture-proof and segregation-proof specifically includes: The opening of the nitrogen flow regulating valve and the parameters of the dehumidification device are adjusted in real time through the core control unit, and the functions of moisture-proof and segregation-proof are integrated through the micro air flow cushion on the pipe wall.

[0013] Compared with the prior art, the beneficial effects of the present invention are: 1. In this invention, the stability and reliability of medium- and long-distance conveying are significantly improved through hierarchical architecture and collaborative algorithm design. The system relies on the full-link parameter acquisition of the perception layer and the precise algorithm calculation of the control layer to achieve collaborative control of pressurization, anti-segregation, anti-blocking, and moisture prevention. It effectively solves the core pain points of material stratification, pipeline blockage, and moisture-induced deterioration in traditional conveying, ensuring the uniformity and quality consistency of materials at the discharge end, and greatly reducing material loss and rework risk. At the same time, automated initialization acquisition and real-time closed-loop control reduce manual intervention, improve conveying efficiency, and enhance the system's practicality and adaptability by flexibly adjusting to different project scales and mortar types. 2. In this invention, the pneumatic windshield and dust removal device work together to suppress dust diffusion, thus meeting environmental protection requirements. The local and remote dual monitoring system, fault self-diagnosis function, and perfect redundancy design simplify the operation and maintenance process, reduce the cost of fault diagnosis and repair, and ensure the long-term stable operation of the system. Safety protection measures and regular calibration mechanism further improve operational safety and equipment lifespan. This invention not only provides technical support for long-distance transportation of dry-mixed mortar, but also achieves a unity of economic, environmental and safety benefits. Attached Figure Description

[0014] Figure 1 This is a system block diagram of a long-distance conveying control system for dry-mixed mortar according to the present invention; Figure 2 This is a flowchart illustrating the workflow of a long-distance conveying control system for dry-mixed mortar according to the present invention.

[0015] In the picture: 100. Controlled object; 200. Basic sensor cluster; 210. Initialize automated data acquisition hardware; 220. Discharge port monitoring sensor cluster; 300. Core control unit; 310. Initialize automated data acquisition submodule; 320. Discharge port linkage control logic module; 400. Conventional actuator; 410. Discharge port dedicated component; 500. Local monitoring terminal; 510. Remote monitoring platform. Detailed Implementation

[0016] 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.

[0017] Reference Figures 1-2As shown: A long-distance conveying control system for dry-mixed mortar includes a monitoring layer, a control layer, a sensing layer, an execution layer, and a controlled object 100. Each layer communicates through signal lines to form a closed loop of data acquisition, decision-making, execution, and feedback. The monitoring layer includes a local monitoring terminal 500 and a remote monitoring platform 510; The control layer includes a core control unit 300, an initialization automation acquisition submodule 310, and a discharge port linkage control logic module 320. The core control unit 300 has built-in adaptive multi-level pressurization algorithm, variable pitch frequency modulation coupling anti-segregation algorithm, predictive grading anti-blocking algorithm, and inert gas closed-loop moisture-proof and anti-segregation algorithm. The sensing layer includes a basic sensor cluster 200, an initialization automated data acquisition hardware 210, and a discharge port monitoring sensor cluster 220. The execution layer includes a conventional actuator 400 and a special component for the discharge port 410; The controlled object 100 is a dry-mixed mortar conveying device, which is linked with the execution layer to realize long-distance material conveying; Communication between different levels is achieved through signal lines, forming a closed loop of data collection, decision-making, execution, and feedback. This includes the following steps: Step 1: Initialize automated data acquisition. The sensing layer automatically acquires and verifies the material characteristics, engineering layout, and environmental parameters of dry-mixed mortar, generating initial control parameters. Step 2: Real-time acquisition of parameters across the entire supply chain. The basic sensor cluster 200 and the discharge port monitoring sensor cluster 220 continuously acquire material rheological parameters, pipeline operating status, environmental conditions, and multi-dimensional parameters at the discharge end during the conveying process. Step 3: Core algorithm collaborative control. Based on the collected parameters, dynamic calculations are performed using four algorithms: multi-stage pressurization, anti-segregation, anti-blocking, and anti-moisture, to generate adaptive control commands. The adaptive multi-stage boosting algorithm is applied to the core control unit 300 of the dry-mixed mortar long-distance conveying control system. It is used to dynamically adjust the output pressure of the stepping booster pump group. The algorithm input parameters include the real-time viscosity of the material, real-time yield stress, real-time flow rate of the material, cumulative conveying distance and environmental temperature and humidity parameters collected by the sensing layer. The environmental temperature and humidity parameters include the ambient temperature and the ambient relative humidity. The algorithm calculates the pressure compensation amount based on a preset multi-parameter coupling model, adapts the pressure loss of different conveying distances through the distance correction coefficient, dynamically offsets the influence of ambient temperature and humidity on material flowability through the environmental correction function, and ensures the stability of pressure regulation through the yield stress weighting coefficient and the basic compensation amount. The control commands output by the algorithm target the stepper booster pump group configured in segments according to the conveying distance, realize the coordinated pressure regulation of each stage of booster pump, form a dynamic pressure gradient along the conveying pipeline, ensure stable material flow rate and compensate for pressure loss as needed. It has a pressure feedback closed-loop regulation function, which receives monitoring data from pipeline pressure sensors in real time and dynamically corrects the pressure compensation amount to avoid material flow imbalance caused by sudden pressure changes.

[0018] The variable pitch frequency modulation coupling anti-segregation algorithm is applied to the core control unit 300 of the dry-mixed mortar long-distance conveying control system. It is used to coordinate the control of the variable pitch agitator and the electromagnetic frequency modulation vibrator. The algorithm input parameters include the real-time flow rate of the material and the proportion of coarse aggregate in the material collected by the sensing layer. The proportion of coarse aggregate in the material is obtained by collecting the data through an online particle size analyzer and after data verification. The algorithm dynamically calculates the target rotation speed of the variable pitch agitator based on the material flow characteristics and particle size distribution. At the same time, it matches the vibration frequency and phase of the electromagnetic frequency-modulated vibrator according to the correlation model between the agitator rotation speed and the risk of material segregation. The speed regulation of the variable pitch agitator and the frequency regulation of the electromagnetic frequency-modulated vibrator are coupled to form a control. Through the synergistic effect of the axial thrust of the variable pitch structure and the radial vibration of the vibrator, the gravitational stratification tendency of the material particles is destroyed, and the segregation of aggregate and cementitious materials is inhibited. It has a real-time feedback adjustment function. By collecting the coarse aggregate ratio data at the discharge end through the online particle size analyzer at the discharge port, it reversely optimizes the stirring speed and vibration frequency parameters to ensure the material uniformity throughout the entire conveying chain.

[0019] The predictive hierarchical anti-blockage algorithm is applied to the core control unit 300 of the dry-mixed mortar long-distance conveying control system to identify and handle pipeline blockage risks. The algorithm input parameters include material accumulation thickness data in the pipeline collected by the ultrasonic accumulation thickness detector of the sensing layer and pipe wall stress data collected by the pipe wall stress sensor. The blockage status is determined by the fusion of the two parameters. The algorithm has three preset levels of blockage judgment criteria, corresponding to mild blockage, moderate blockage and severe blockage respectively. Each level of judgment criteria is set by a combination of the accumulation thickness threshold and the pipe wall stress threshold to achieve accurate classification of blockage risk. Differentiated handling instructions are output for different levels of blockage: for mild blockage, the variable pitch agitator is controlled to rotate in reverse and the pressure difference between the front and rear booster pumps is adjusted; for moderate blockage, the low-pressure pulse backflushing action of the high-pressure backflushing system is superimposed; for severe blockage, the high-pressure backflushing system is switched to high-pressure directional backflushing mode, in conjunction with the agitator's high-speed reverse rotation and the front booster pump's shutdown and pressure maintenance strategy. It has a function to verify the effect of blockage treatment, monitors the accumulation thickness and pipe wall stress data in real time, and automatically switches to normal conveying mode when the parameters recover to the safe threshold, forming a closed-loop anti-blockage logic of "prediction-graded treatment-effect verification".

[0020] The inert gas closed-loop moisture-proof and segregation-proof algorithm is applied to the core control unit 300 of the dry-mixed mortar long-distance conveying control system to achieve material moisture-proof and segregation-proof. The algorithm input parameters include the material moisture content, inert gas dew point in the pipeline and pressure data in the pipeline collected by the sensing layer. The material moisture content is collected collaboratively by the material humidity sensors in the feed hopper and the discharge hopper. The algorithm takes the material moisture content ≤ preset humidity threshold, inert gas dew point ≤ preset dew point threshold, and maintaining a slight positive pressure in the pipeline as control objectives, and dynamically adjusts the opening of the nitrogen flow regulating valve and the working parameters of the dehumidification device. By precisely controlling the flow rate of inert gas, a stable micro-positive pressure environment is formed in the pipeline, which isolates the intrusion of external humid air. At the same time, the airflow disturbance is used to help destroy the stratification tendency of material particles, so as to achieve the synergy of moisture-proof function and anti-segregation function. It has a multi-parameter closed-loop adjustment function, which compares the collected parameters with the preset target values ​​in real time, and optimizes the inert gas flow and dehumidification intensity through proportional adjustment logic to ensure that the material is in a dry and uniform state throughout the entire conveying process.

[0021] The core algorithm for collaborative control specifically includes: The pressure compensation is dynamically calculated, and the step-by-step booster pump is used to achieve staged pressure increase. The speed of the variable pitch agitator is adjusted, and the electromagnetic frequency-modulated vibrator is used in sequence for coordinated operation. The dynamic calculation is based on the following formula: ; In the formula: This is the pressure compensation amount, in MPa; This is the distance correction factor, which is 0.002 + 0.0002 × L / 100; The yield stress weighting coefficient is 0.05. The environmental impact weighting coefficient is 0.08. The basic compensation amount is 0.1 MPa; The real-time viscosity of the material is expressed in Pa·s. The real-time yield stress of the material is expressed in Pa; L is the cumulative conveying distance in meters; and v is the real-time flow velocity of the material in meters per second. Ambient temperature, unit: °C; Relative humidity, unit: %RH; Environment correction function hour , hour ,otherwise ; The speed of a variable pitch agitator is adjusted based on the following formula: ; Where: n is the rotational speed of the variable pitch agitator, unit: rpm; is the proportion of coarse aggregate in the material, substituted in decimals (unit: %, substituted in decimals).

[0022] Identifying and handling pipeline blockage risks specifically includes: Real-time monitoring of the material accumulation thickness (h) and the pipe wall stress (σ) through an ultrasonic accumulation thickness detector and a pipe wall stress sensor, and determining the blockage level and implementing corresponding measures according to the following conditions Minor blockage (h ≤ 5mm and σ < 1MPa): The variable pitch agitator rotates in the reverse direction, the pipeline speed increases, and the pressure of the pre-stage step-type booster pump decreases; Moderate blockage (5mm < h ≤ 10mm and 1MPa ≤ σ < 2MPa): Superimposed high-pressure reverse blowing system with low-pressure pulse reverse blowing, coordinated adjustment of the pressures of the front and rear stages; Severe blockage (h > 10mm and σ ≥ 2MPa): Superimposed high-pressure reverse blowing system with high-pressure directional reverse blowing, the variable pitch agitator rotates in the reverse direction at high speed, and the pre-stage step-type booster pump stops to maintain pressure; h is the material accumulation thickness in the pipeline (unit: mm), and σ is the pipe wall stress (unit: MPa).

[0023] Optimizing parameters based on the feedback of the proportion of coarse aggregate at the discharge end specifically includes: Collecting four-dimensional parameters through an on-line particle size analyzer at the discharge port, a discharge flow rate sensor, a material humidity sensor at the discharge port, and a dust concentration sensor, and implementing after comparing with the preset target values: When the deviation between the proportion of coarse aggregate at the discharge end and that at the feed end is greater than 0.5%, start the micro agitator in the discharge bin to adjust the uniforming speed; When the material humidity at the discharge end is greater than 0.6%, increase the flow rate of the inert gas through the nitrogen flow regulating valve and reduce the feeding speed of the double-shaft spiral disperser; When the dust concentration at the discharge port is greater than 10mg / m³, increase the dust removal power in stages or deploy a pneumatic windshield; When the level sensor in the discharge bin detects an abnormal level in the discharge bin, adjust the feeding speed accordingly or stop the machine emergently.

[0024] Coordinating to achieve moisture-proof and segregation-proof specifically includes: Real-time adjusting the opening of the nitrogen flow regulating valve and the parameters of the dehumidifying device through the core control unit 300, and integrating the moisture-proof and segregation-proof functions through the micro air flow cushion on the pipe wall.

[0025] Step Four, the actuator makes a linkage response, and executes the control instructions through the conventional actuator 400 and the special component 410 at the discharge port to perform feed pretreatment, pressure boosting and conveying, segregation-proof and blockage-proof, and discharge regulation; Step 5: Optimize the closed-loop monitoring feedback. Parameter display, anomaly alarms, and remote operation and maintenance are achieved through the local monitoring terminal 500 and the remote monitoring platform 510. Control strategies are dynamically adjusted based on feedback data.

[0026] The material coarse aggregate ratio, initial viscosity, and yield stress are collected by an online particle size analyzer and an initial rheology analyzer; engineering parameters such as conveying distance and pipeline layout are obtained by a QR code scanner and a parameter storage module; basic environmental parameters are collected by an environmental temperature and humidity sensor; and after the data range and consistency are verified by the FPGA data verification processor, the data is automatically entered into the core control unit 300.

[0027] The detailed implementation process of this invention is described below to ensure that those skilled in the art can reproduce this method based on this embodiment: The controlled object 100, serving as the physical carrier for long-distance material transportation, mainly consists of a conveying pipeline, a feed hopper, a discharge hopper, and a discharge valve. The conveying pipeline is lined with wear-resistant ceramic material, possessing high hardness and wear resistance. A reasonable slope is controlled during pipeline laying along the construction path, and elbows are designed with large curvature radii to reduce the risk of material accumulation. The feed hopper and discharge hopper are made of carbon steel and treated with anti-corrosion measures to ensure long-term stability. The feed hopper is located close to the raw material storage area, and the discharge hopper is adjacent to the work point, shortening the material transfer path. All pipeline connection flanges employ a high-level sealing design to prevent material leakage and external moisture intrusion.

[0028] The monitoring layer comprises a local monitoring terminal 500 and a remote monitoring platform 510, forming a dual local and remote control system. The local monitoring terminal 500 uses an industrial-grade touchscreen, is dustproof and waterproof, and is equipped with an emergency stop button and a working mode switch. It is embedded in the equipment room control cabinet or wall-mounted in a convenient operating area on the construction site. It establishes communication with the core control unit 300 via a shielded Ethernet cable to ensure real-time parameter transmission and command issuance. The remote monitoring platform 510 is deployed on a public cloud server, supports web and mobile app access, and interacts bidirectionally with the core control unit 300 via a wireless communication module to achieve parameter traceability, anomaly warning, and remote operation and maintenance functions. The control layer is the core decision-making unit of the system, including the core control unit 300, the initialization automation acquisition submodule 310, and the discharge port linkage control logic module 320. The core control unit 300 uses an industrial-grade PLC, equipped with a dedicated acquisition module and drive module, and is installed in the control cabinet of the equipment room with sufficient heat dissipation space. It is responsible for algorithm calculation, data processing, and control command generation. The initialization automation acquisition submodule 310 integrates a data acquisition interface board, an engineering parameter database, and an FPGA data verification processor. It communicates with the core control unit 300 at high speed through the backplane bus to complete the transfer, verification, and input of initialization parameters. The discharge port linkage control logic module 320 is deployed close to the discharge hopper to shorten the communication distance with the discharge end sensors, quickly process the discharge end parameters, and generate linkage control commands to ensure real-time control. The sensing layer consists of a basic sensor cluster 200, an initialization automated acquisition hardware 210, and a discharge port monitoring sensor cluster 220, achieving accurate acquisition of parameters across the entire process. The basic sensor cluster 200 includes various functional sensors, all powered by 24VDC and connected to the core control unit 300 via shielded analog cables. The wiring is routed away from power cables to avoid interference. Material humidity sensors are installed at the discharge port of the feed hopper and on the top of the discharge hopper, with probes penetrating deep into the material to collect moisture content. Rheological characteristic sensors are arranged in sections along the conveying pipeline to monitor material viscosity and yield stress in real time. Material flow rate sensors are installed in a one-to-one correspondence with the rheological characteristic sensors to ensure spatiotemporal consistency of parameter acquisition. Environmental temperature and humidity sensors are deployed in the equipment room and construction site to collect environmental climate parameters. Ultrasonic buildup thickness detectors and pipe wall stress sensors are installed at easily clogged sections of the pipeline to collaboratively monitor blockage risks. The initialization automated acquisition hardware 210 includes an online particle size analyzer, an initial rheological detector, a QR code scanner, and a parameter storage module. After obtaining the project ID, the QR code scanner triggers other devices to collect initial material characteristic parameters and preset project parameters, which are then verified and stored accordingly. The discharge port monitoring sensor cluster 220 is deployed at the bottom of the discharge hopper and around the discharge port. It communicates with the discharge port linkage control logic module 320 via industrial Ethernet to accurately collect parameters such as the proportion of coarse aggregate at the discharge end, discharge flow rate, material moisture, dust concentration and material level. The execution layer is responsible for responding to control commands and realizing various functions of material conveying, including the conventional actuator 400 and the special component 410 for the discharge port. In the conventional actuator 400, a dual-shaft spiral disperser is installed at the bottom of the feed hopper, and its horizontal arrangement ensures uniform material dispersion; a stepping booster pump is connected in series in sections along the conveying pipeline, equipped with a shock-absorbing base to reduce operating vibration and achieve graded pressurization as needed; a variable pitch agitator and an electromagnetic frequency-modulated vibrator work together, with the variable pitch agitator installed coaxially with the pipeline and the electromagnetic frequency-modulated vibrator fixed to the agitator housing, suppressing material segregation through the synergistic effect of agitation and vibration; a high-pressure backflushing system is deployed at easily clogged parts of the pipeline, clearing blockages by spraying airflow through nozzles; and a nitrogen flow regulating valve is installed between the nitrogen tank and the main pipeline to precisely control the inert gas flow rate. In the discharge port special component 410, a micro agitator is installed inside the discharge hopper to correct the uniformity of the material through agitation; a pneumatic windshield is deployed above the discharge port to quickly deploy and suppress dust diffusion; and a conical buffer plate tilt adjuster is installed above the discharge port to stabilize the discharge flow rate by adjusting the tilt angle. After the system is powered on, the operator switches to initialization mode via the local monitoring terminal 500, scans the project-specific QR code using a QR code scanner to obtain the project ID, and transmits it to the data acquisition interface board. The data acquisition interface board triggers the project parameter database to retrieve the preset parameters for that project, and simultaneously instructs the online particle size analyzer and initial rheology analyzer to collect the initial material characteristic parameters, while the environmental temperature and humidity sensor synchronously collects environmental parameters. All collected data is transmitted via the data acquisition interface board to the FPGA data verification processor for range and consistency checks. After removing abnormal data, the effective average value is taken, stored in the project parameter database, and automatically entered into the core control unit 300 to generate initial control parameters. After initialization, the system switches to operating mode. After the system enters the operating mode, each sensor in the sensing layer continuously collects parameters at a preset frequency. The basic sensor cluster 200 collects rheological characteristics, flow velocity, humidity, pipe buildup thickness, pipe wall stress, and environmental parameters in real time during the material conveying process. The data is transmitted via analog cable to the acquisition module of the core control unit 300, and after filtering, it is used for algorithm calculation. The discharge port monitoring sensor cluster 220 synchronously collects various parameters at the discharge end and transmits them to the discharge port linkage control logic module 320 via industrial Ethernet, providing data support for discharge end regulation. All collected parameters are synchronously uploaded to the local monitoring terminal 500 and the remote monitoring platform 510, realizing full-link status visualization. The core control unit 300 invokes built-in adaptive multi-stage pressurization algorithm, variable pitch frequency-coupled anti-segregation algorithm, predictive grading anti-blocking algorithm, and inert gas closed-loop moisture-proof and anti-segregation algorithm to generate control commands based on collected parameters. The multi-stage pressurization and anti-segregation collaborative algorithm calculates pressurization compensation based on real-time material rheological characteristics, flow rate, conveying distance, and environmental parameters, controlling the stepper pressurization pump to achieve grading pressurization. Simultaneously, it calculates the target speed of the variable pitch agitator and coordinates the vibration frequency of the electromagnetic frequency-modulated vibrator to suppress material segregation. The predictive-grading anti-blocking algorithm determines the blockage level based on pipe buildup thickness and pipe wall stress data, generating corresponding control commands for light, moderate, and severe blockages. Combined with different operating modes such as agitator reverse rotation, pressure difference adjustment between upstream and downstream pressurization pumps, and high-pressure backflushing system, it achieves efficient blockage clearing. The discharge link... The dynamic control algorithm is executed by the discharge port linkage control logic module 320. It compares the parameters at the discharge end with the preset target value. When the deviation of the coarse aggregate ratio exceeds the standard, the speed of the micro agitator in the discharge hopper is adjusted. When the material moisture exceeds the standard, the nitrogen flow rate and feeding speed are adjusted in coordination. When the dust concentration exceeds the standard, the dust removal device and pneumatic windshield are controlled in stages. When the material level is abnormal, the feeding or unloading status is adjusted. The inert gas closed-loop moisture-proof and anti-segregation algorithm uses material moisture, gas dew point and pipeline positive pressure as control targets. It dynamically adjusts the opening of the nitrogen flow regulating valve and the parameters of the dehumidification device to isolate external moisture and assist in anti-segregation through airflow disturbance. Each device in the execution layer responds precisely to control commands, ensuring stable material conveying operation. The dual-shaft spiral disperser adjusts its speed according to commands, breaking up clumps and stabilizing the feed flow; the stepper booster pump adjusts its output pressure based on the booster compensation, offsetting pressure loss along the pipeline; the variable-pitch agitator and electromagnetic frequency-modulated vibrator work together to disrupt material stratification; the high-pressure backflushing system switches operating modes according to the blockage level, working in conjunction with differential pressure adjustment to clear blockages; and the nitrogen flow regulating valve precisely controls the inert gas injection volume, working in conjunction with the dehumidification device to ensure moisture protection. At the discharge end, the micro-agitator in the discharge hopper rotates according to commands to correct material uniformity, the pneumatic windshield unfolds as needed to suppress dust, and the conical buffer plate tilt adjuster adjusts the discharge flow rate, ensuring stable and environmentally friendly discharge. The local monitoring terminal 500 displays real-time parameters and device status across the entire supply chain, with abnormal parameters highlighted and triggering audible and visual alarms. The remote monitoring platform 510 updates data synchronously, supporting historical curve queries, data export, and anomaly information push notifications. The core control unit 300 periodically reviews control effectiveness, automatically fine-tuning algorithm parameters based on operational data to optimize control accuracy. Maintenance personnel can manage permissions, modify parameters, and perform remote operations through the remote monitoring platform 510. The system has a self-diagnostic function, capable of locating faulty components and providing troubleshooting suggestions to ensure stable and reliable system operation. To ensure long-term stable operation of the system, this invention incorporates comprehensive safeguards. Regarding calibration and standardization, all sensors undergo initial calibration after system installation, with subsequent periodic calibrations to ensure measurement accuracy. The control curves of the actuators are also periodically calibrated using the self-calibration function of the core control unit 300 to guarantee execution accuracy. In terms of redundancy design, critical sensors are equipped with backup devices that automatically switch in case of failure. The communication link employs a dual-link or dual-card redundancy design to avoid communication interruptions. The power supply system adopts a redundant configuration, with dual-circuit switching power supplies for the control and sensing layers, and dual-circuit power supply with backup power for the execution layer, ensuring uninterrupted power supply. For safety protection, rotating parts are equipped with protective devices and implement linked shutdown. The electrical system is equipped with leakage, overcurrent, and overvoltage protection. At the process level, pipeline pressure relief valves, material temperature monitoring, and nitrogen leak detection are implemented to promptly address abnormal situations. Regarding maintenance, daily cleaning, periodic inspections, and fault handling plans are established, clearly defining maintenance requirements such as sensor probe cleaning, actuator lubrication, and filter replacement, extending equipment lifespan and ensuring continuous and stable system operation. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A long-distance conveying control system for dry-mixed mortar, characterized in that, It includes a monitoring layer, a control layer, a perception layer, an execution layer, and a controlled object (100). Each layer communicates through signal lines to form a closed loop of data collection, decision-making, execution, and feedback. The monitoring layer includes a local monitoring terminal (500) and a remote monitoring platform (510). The control layer includes a core control unit (300), an initialization automated acquisition submodule (310), and a discharge port linkage control logic module (320). The core control unit (300) has built-in adaptive multi-stage pressurization algorithm, variable pitch frequency modulation coupling anti-segregation algorithm, predictive graded anti-blocking algorithm, and inert gas closed-loop moisture-proof and anti-segregation algorithm. The sensing layer includes a basic sensor cluster (200), an initialization automated acquisition hardware (210), and a discharge port monitoring sensor cluster (220). The execution layer includes a conventional actuator (400) and a special component for the discharge port (410). The controlled object (100) is a dry-mixed mortar conveying device, which is linked with the execution layer to carry out long-distance material conveying; The various levels communicate via signal lines, forming a closed loop of data acquisition, decision-making, execution, and feedback, specifically including the following steps: S1. Initialize automated data acquisition: Automatically acquire and verify the material characteristics, engineering layout, and environmental parameters of dry-mixed mortar through the sensing layer, and generate initial control parameters. S2. Real-time acquisition of parameters across the entire chain: The material rheological parameters, pipeline operating status, environmental conditions and multi-dimensional parameters at the discharge end are continuously acquired through the basic sensor cluster (200) and the discharge port monitoring sensor cluster (220) during the conveying process. S3, core algorithm collaborative control, based on the collected parameters, performs dynamic calculations through four major algorithms: multi-stage pressurization, anti-segregation, anti-blockage, and anti-moisture, to generate adaptive control commands; S4. The actuator responds in a coordinated manner, executing control commands through the conventional actuator (400) and the special component (410) at the discharge port to perform feed pretreatment, pressurized conveying, anti-segregation and anti-blocking, and discharge regulation. S5. Monitoring feedback closed-loop optimization: Parameter display, abnormal alarm and remote operation and maintenance are performed through local monitoring terminal (500) and remote monitoring platform (510), and control strategy is dynamically adjusted based on feedback data.

2. The long-distance conveying control system for dry-mixed mortar according to claim 1, characterized in that, The initial automated data acquisition in S1 specifically includes: The material coarse aggregate ratio, initial viscosity and yield stress are collected by an online particle size analyzer and an initial rheology analyzer; engineering parameters such as conveying distance and pipeline layout are obtained by a QR code scanner and parameter storage module; basic environmental parameters are collected by an environmental temperature and humidity sensor; after the data range and consistency are verified by the FPGA data verification processor, the data is automatically entered into the core control unit (300).

3. The long-distance conveying control system for dry-mixed mortar according to claim 1, characterized in that, The adaptive multi-stage boosting algorithm, variable pitch frequency modulation coupling anti-segregation algorithm, predictive grading anti-blocking algorithm, and inert gas closed-loop moisture-proof and anti-segregation algorithm are applied to the core control unit (300) of the dry-mixed mortar long-distance conveying control system. The adaptive multi-stage boosting algorithm is used to dynamically adjust the output pressure of the stepper booster pump group, including: inputting the real-time viscosity, yield stress, flow rate, cumulative conveying distance, and ambient temperature and humidity parameters of the material. Calculate the boost compensation amount based on the multi-parameter coupling model, and adapt to the working condition changes through the distance correction coefficient and the environmental correction function. Control the step-by-step boost pump group arranged in segments to form a dynamic pressure gradient, and combine the pipeline pressure feedback closed-loop correction to ensure the stable material flow rate. The variable pitch frequency modulation coupling anti-segregation algorithm is used to synergistically control the variable pitch agitator and the electromagnetic frequency modulation vibrator, including: inputting the real-time material flow rate and the proportion parameter of coarse aggregate; dynamically calculating the target speed of the agitator, matching the frequency and phase of the vibrator, and synergistically suppressing segregation through the axial thrust and radial vibration; optimizing the parameters based on the feedback of the proportion of coarse aggregate at the discharge end. The pre-judgment grading anti-blocking algorithm is used to identify and handle the risk of pipeline blockage, including: inputting the material accumulation thickness and the pipe wall stress parameters in the pipeline; setting the mild, moderate, and severe three-level blockage standards according to the double-parameter threshold combination, and outputting differentiated handling instructions; based on the feedback of the parameters after handling, switching to the normal conveying mode in a closed loop. The inert gas closed-loop moisture-proof and anti-segregation algorithm is used to synergistically achieve moisture-proof and anti-segregation, including: inputting the material moisture content, the gas dew point and pressure parameters in the pipeline; aiming at material drying, gas dew point reaching the standard, and slightly positive pressure in the pipeline, adjusting the opening of the nitrogen flow regulating valve and the parameters of the dehumidification device; achieving the synergy of moisture-proof and anti-segregation through the micro-airflow of inert gas, and optimizing the control accuracy in a multi-parameter closed loop.

4. The long-distance conveying control system for dry-mixed mortar according to claim 3, characterized in that, The core algorithm synergy control of S3 specifically includes: Dynamically calculate the boost compensation amount, perform staged boosting through the step-by-step boost pump, adjust the speed of the variable pitch agitator, and coordinate the sequential operation of the electromagnetic frequency modulation vibrator. The dynamic calculation is based on the following formula: ； In the formula: This is the pressure compensation amount, in MPa; This is the distance correction factor, which is 0.002 + 0.0002 × L / 100; The yield stress weighting coefficient is 0.

05. The environmental impact weighting coefficient is 0.

08. The basic compensation amount is 0.1 MPa; The real-time viscosity of the material is expressed in Pa·s. The real-time yield stress of the material is expressed in Pa; L is the cumulative conveying distance in meters; and v is the real-time flow velocity of the material in meters per second. Ambient temperature, unit: °C; Relative humidity, unit: %RH; Environment correction function hour , hour ,otherwise ; Adjusting the speed of the variable pitch agitator is based on the following formula: ； In the formula: n is the rotational speed of the variable pitch agitator, in rpm; This represents the proportion of coarse aggregate in the material, substituted as a decimal.

5. The long-distance conveying control system for dry-mixed mortar according to claim 3, characterized in that, The identification and handling of the risk of pipeline blockage specifically includes: The material buildup thickness h and pipe wall stress are monitored in real time using an ultrasonic buildup thickness detector and a pipe wall stress sensor. The congestion level will be determined based on the following conditions, and corresponding measures will be implemented: Mild blockage: h ≤ 5mm and σ < 1MPa: The variable pitch agitator rotates in the reverse direction, the pipeline speed increases, and the previous-stage step-by-step boost pump reduces pressure. Moderate blockage: 5mm < h ≤ 10mm and 1MPa ≤ σ < 2MPa: Superimpose the low-pressure pulse backwashing of the high-pressure backwashing system, and coordinate the adjustment of the pressure of the front and rear stages. Severe blockage: h > 10mm and σ ≥ 2MPa: Superimpose the high-pressure directional backwashing of the high-pressure backwashing system, the variable pitch agitator rotates in the reverse direction at high speed, and the previous-stage step-by-step boost pump stops to maintain pressure. h is the material accumulation thickness in the pipeline, unit: mm; σ is the pipe wall stress, unit: MPa.

6. The long-distance conveying control system for dry-mixed mortar according to claim 3, characterized in that, The optimization of parameters based on the feedback of the proportion of coarse aggregate at the discharge end specifically includes: Collect four-dimensional parameters through the online particle size analyzer at the discharge port, the discharge flow rate sensor, the material humidity sensor at the discharge port, and the dust concentration sensor, and execute after comparing with the preset target value: When the deviation between the proportion of coarse aggregate at the discharge end and the proportion of coarse aggregate at the feed end is greater than 0.5%, start the micro-agitator in the discharge bin to adjust the uniforming speed. When the material humidity at the discharge end is greater than 0.6%, increase the inert gas flow rate through the nitrogen flow regulating valve and reduce the feeding speed of the double-shaft spiral disperser. When the dust concentration at the discharge port is greater than 10mg / m³, increase the dust removal power in stages or deploy the pneumatic windshield. When the material level sensor in the discharge bin detects abnormal material level, adjust the feeding speed accordingly or stop urgently.

7. The long-distance conveying control system for dry-mixed mortar according to claim 3, characterized in that, The synergistic realization of moisture-proof and anti-segregation specifically includes: The opening degree of the nitrogen flow regulating valve and the parameters of the dehumidification device are adjusted in real time by the core control unit (300), and the moisture-proof and anti-segregation functions are integrated by the micro-flow cushion layer on the pipe wall.

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