Anti-cracking concrete watering maintenance equipment and using method thereof

Abstract

The invention relates to anti-cracking concrete watering maintenance equipment. The anti-cracking concrete watering maintenance equipment comprises a movable bearing platform, an intelligent temperature sensing system, a central controller, a partitioned spraying and recycling system, a water supply circulating system and a water cooling unit. And the zoning system is provided with a top spraying module, a height-adjustable reflux tank and a controllable micro-seepage module. The core of the method is based on the temperature difference of the upper end and the lower end of the wall body monitored in real time, the spraying strength, the height of the height-adjustable backflow groove and the seepage flow are intelligently adjusted, when the temperature difference is large, upper spraying cooling is strengthened, the height of the height-adjustable backflow groove is reduced, the cooling range is expanded, and lower seepage is reduced to protect the temperature; when the temperature difference is small, switching to a balanced moisturizing mode. And the integrated water cooling unit ensures that circulating water temperature is stable and efficient. According to the method, the span from uniform moisture preservation to precise temperature adjustment and crack prevention is achieved, cracks, caused by the sunlight temperature difference, of structures such as super-long basement outer walls can be effectively prevented, and the method has the advantages of being water-saving, intelligent and efficient.

Description

Technical Field

[0001] This invention relates to the field of concrete curing technology, and in particular to a crack-resistant concrete water curing device and its usage method. Background Technology

[0002] With the expansion of urban underground space development, underground structures with excessively long plan dimensions are becoming increasingly common. The exterior walls of such basements are often integrally cast with the roof slab, and their length frequently exceeds the maximum spacing of expansion joints specified in regulations. During summer construction or use, the exposed roof slab of the basement experiences a rapid increase in temperature due to solar radiation, causing thermal expansion and resulting in displacement of the top of the rigidly connected exterior walls. However, the bottom of the exterior walls is constrained by the soil, resulting in minimal temperature changes. This leads to a significant temperature difference between the top and bottom of the wall, generating substantial thermal stress that easily triggers through-cracks, severely impacting the structure's durability, waterproofing performance, and safety.

[0003] Traditional concrete curing methods primarily target plastic shrinkage and drying shrinkage in the early stages of concrete hardening, with the core objective of moisture retention. Common methods include manual watering, covering with plastic film or geotextile, and fixed sprinkler systems. These methods have significant drawbacks: 1) Poor uniformity: Manual watering cannot guarantee the continuity and uniformity of curing, easily causing alternating wet and dry conditions, which may induce shrinkage cracks; 2) Single objective: Focusing only on moisture retention, it cannot address the structural temperature stress caused by drastic changes in ambient temperature (especially the temperature rise of the roof slab due to sunlight); 3) Waste of water resources: Continuous flooding or timed spraying results in significant evaporation losses in open-air environments, which is not environmentally friendly; 4) Lack of specificity: It cannot provide targeted reinforcement intervention for key areas with concentrated temperature stress (such as the top of exterior walls).

[0004] While some automated maintenance equipment has emerged in the existing technology, its functions are mostly limited to timed and quantitative uniform water spraying. Although it saves manpower, it does not fundamentally solve the cracking problem caused by uneven temperature distribution in different parts of the structure. For wall cracking caused primarily by thermal expansion of the upper part, there is a lack of specialized maintenance equipment and methods that can actively and intelligently adjust the structural temperature field, especially reducing temperature differences in key areas.

[0005] Therefore, developing a water curing equipment and method that can intelligently regulate the temperature gradient of concrete structures (especially basement exterior walls) and actively intervene to suppress thermal stress, thereby achieving effective crack prevention, is of urgent engineering demand and significant technical value. Summary of the Invention

[0006] This invention provides a water curing device for preventing cracking of concrete and its usage method, which can solve the problem in the prior art that cannot fundamentally solve the problem of concrete cracking caused by uneven temperature field distribution in different parts of the structure.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a crack-resistant concrete watering and curing equipment and its usage method, wherein the crack-resistant concrete watering and curing equipment of the present invention includes: a mobile bearing platform, a water supply and circulation system, a zoned spraying and recycling system, an intelligent temperature sensing system, and a central controller.

[0008] 1. Mobile support platform: Provides support and mobility for all other components of the equipment. It typically uses a tracked or all-terrain wheeled chassis and integrates navigation modules (such as RTK-GPS and LiDAR) to enable the equipment to automatically cruise along a preset path or along concrete walls according to instructions.

[0009] 2. Water Supply and Circulation System: This includes a water storage tank, main water supply pump, return water pump, piping, and valves. Its innovation lies in the integration of an integrated water cooling unit. This unit comprises an aluminum plate-fin radiator and an axial flow fan. The heated recycled water enters the aluminum plate-fin radiator, where the axial flow fan drives forced air convection, carrying away the heat from the water. The cooled water then flows back to the water storage tank, ensuring that the spray water remains within a highly efficient cooling temperature range.

[0010] 3. Zonal Sprinkler and Recycling System: This is the core actuator for achieving differentiated maintenance, installed on a mobile platform. The system comprises, from top to bottom: The top spray module consists of several high-pressure atomizing nozzles, which are responsible for spraying the upper part of the wall. It utilizes the principle of water evaporation absorbing a large amount of heat to actively and effectively cool the upper part of the wall.

[0011] Adjustable height return channel: Located directly below the spray module, its inner bottom wall is a sloping flow-guiding structure. It has two main functions: first, to collect and recycle water flowing down from the wall; second, to dynamically control the length of the cooling water film's path on the wall by adjusting its height relative to the wall surface. Lowering the return channel extends the cooling range and enhances overall cooling of the upper part; raising the return channel shortens the cooling range and prevents over-cooling of the lower and middle parts.

[0012] The controllable micro-seepage module's core is a linear gate valve regulating mechanism, comprising holes in the return channel, a telescopic device, and a gate that can be driven by the telescopic device. By controlling the gate opening, the amount of water seeping from the return channel to the lower wall can be precisely and steplessly adjusted. This water volume is extremely small, used only to maintain the moisture of the lower concrete and prevent drying shrinkage. Because of its small volume and slow evaporation, it produces almost no cooling effect, thus protecting the lower temperature from disturbance.

[0013] 4. Intelligent Temperature Sensing System: This system includes a fixed array of wireless temperature sensors deployed on the surface of the concrete wall (covering at least the key points at the top, middle, and bottom) and an infrared thermal imager mounted on a mobile support platform. This system is responsible for real-time, continuous acquisition of two-dimensional temperature field data of the wall surface and calculating key indicators such as the average temperature at the top, the average temperature at the bottom, and the real-time temperature difference (ΔT) between the two.

[0014] 5. Central Controller: The "brain" of the equipment, typically an industrial computer or a high-performance embedded controller. It receives data from the intelligent temperature sensing system, runs the core control algorithm, and outputs control commands to: The drive motor of the mobile carrier platform.

[0015] Return channel lifting drive.

[0016] Main water supply pump and valves are used to regulate the flow rate of the top spray.

[0017] The telescopic device of the linear gate valve regulating mechanism is used to adjust the opening size of the orifice.

[0018] Axial flow fan of water cooling unit.

[0019] A method for water curing concrete to prevent cracking is disclosed. The control logic of this method is entirely based on the core feedback variable of the temperature difference (ΔT) between the upper and lower ends of the wall, achieving closed-loop control. The specific steps are as follows: S1: System Initialization and Path Planning: Input the digital model or parameters of the target concrete wall (such as the exterior wall of a basement) to plan the automatic inspection and operation path of the equipment. The system presets the target temperature difference safety threshold ΔT_target (e.g., 10℃) and the circulating water temperature threshold T_water_target.

[0020] S2: Temperature Field Scanning and Diagnosis: The device moves to the starting operating point. Using a fixed wireless temperature sensor and an infrared thermal imager, it acquires the current complete temperature field distribution of the wall and calculates the real-time temperature difference ΔT_current.

[0021] S3: Control Decision Generation: The central controller compares ΔT_current with ΔT_target, and based on the magnitude and sign of the difference, calculates the optimal set of control parameters using a preset control strategy table or a PID / fuzzy control algorithm, including: The spray intensity (flow rate Q and start / stop duty cycle) of the top spray module. Target height (H) of the adjustable height return channel; Gate opening degree (K, 0%-100%) of the controllable micro-percolation module; Start-up status of the water cooling unit and fan power (P_cool).

[0022] The core principle of the control strategy is: the greater the temperature difference, the stronger the cooling intervention on the upper part and the stricter the "protective isolation" on the lower part.

[0023] When ΔT_current is much greater than ΔT_target (high temperature difference condition): the decision is to "enhance the cooling of the upper part and isolate the lower part".

[0024] Increase the spray flow rate Q and increase the spray frequency.

[0025] Lower the height H of the adjustable height reflux tank to expand the upper cooling area.

[0026] Reduce or even close the gate opening K (e.g., K=0%-5%) to strictly limit the water flow to the lower part.

[0027] Start the water cooling unit at high power to ensure effective spray water temperature.

[0028] The equipment slows down or operates repeatedly in this section.

[0029] When ΔT_current is close to ΔT_target (normal operating condition): the decision is "maintenance maintenance".

[0030] Use appropriate spray parameters.

[0031] Raise the adjustable height reflux tank to a medium height.

[0032] Adjust the gate opening K to the reference value (e.g., 10%-15%) and perform routine lower-level moisturizing.

[0033] Whether to activate the water cooling unit depends on the water temperature.

[0034] When the ambient temperature is low or ΔT_current is very small (low temperature / nighttime operation): the decision is "antifreeze and basic moisturization".

[0035] Significantly reduce or stop spraying.

[0036] Close the gate.

[0037] The equipment primarily performs monitoring tasks.

[0038] S4: Collaborative Execution and Dynamic Adjustment: Each actuator in the equipment operates collaboratively based on the decision results from S3. During execution, the intelligent temperature sensing system continuously monitors the temperature and feeds back new temperature data to the central controller. The central controller fine-tunes the control parameters based on temperature change trends (such as whether the cooling rate meets expectations), achieving adaptive control.

[0039] S5: Cyclic Operation and Data Recording: After completing the processing of one work section, the equipment moves to the next section and repeats steps S2-S4. Throughout the process, the system automatically records all control parameters, temperature data, equipment location, and other information, forming a complete construction and maintenance database for quality traceability and process optimization.

[0040] Compared with the prior art, the present invention has the following significant advantages: 1. Advanced crack prevention mechanism, targeting the root cause: This invention breaks through the limitations of traditional curing methods that only focus on "moisturizing," and pioneers a proactive control concept targeting the "temperature gradient" of concrete structures. By strengthening the cooling of the upper part and protecting and isolating the lower part, it directly addresses the core driving force leading to cracks—the temperature difference between the upper and lower parts—preventing temperature stress cracks from the root, and is especially suitable for solving the problem of summer cracking in the exterior walls of ultra-long basements.

[0041] 2. High level of intelligence and strong adaptability: The equipment uses closed-loop control based on real-time temperature field data, and can automatically adjust the maintenance strategy according to different working conditions (such as different times, different solar radiation intensities, and different wall sections), realizing a leap from "uniform maintenance" to "differentiated and precise temperature control".

[0042] 3. High efficiency in resource utilization and environmental protection: Water resources are recycled through an adjustable height return tank, and the circulating water is cooled and reused after being combined with a high-efficiency water cooling unit, which greatly reduces the consumption of maintenance water and meets the requirements of green construction. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the main cross-sectional view of the adjustable height return channel of the present invention; Figure 3 This is a schematic diagram of the workflow of the present invention; Figure 4 This is a schematic diagram of the control system of the present invention.

[0044] In the diagram: 1. Mobile support platform; 2. Water storage tank; 3. Main water supply pump; 4. Central controller; 5. Navigation module; 6. Spraying module; 7. Adjustable height return channel; 71. Screw slide module; 8. Linear gate valve adjustment mechanism; 81. Telescopic device; 82. Hole; 83. Gate; 84. Water outlet; 9. Return water pump; 10. Water cooling unit; 101. Axial flow fan; 102. Aluminum plate-fin radiator; 11. Infrared thermal imager; 12. Fixed wireless temperature sensor. Detailed Implementation

[0045] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the technical solution of this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0046] like Figure 1 As shown in Figures 2 and 4, a crack-resistant concrete water curing device includes: a mobile support platform 1, on which a water storage tank 2, a main water supply pump 3, a return water pump 9, a zoned spraying and recycling system, and a central controller 4 as the core are mounted.

[0047] The top of the zoned spraying and recycling system consists of a row of horizontally arranged high-pressure atomizing nozzles, forming the spraying module 6. An adjustable-height return trough 7 is located below the spraying module 6, and its vertical lifting relative to the spraying module 6 is achieved via a screw-slide module 71. The bottom of the adjustable-height return trough 7 is designed to slope to one end, with its lower end facing the movable support platform 1 and its upper end facing the wall. Multiple holes 82 are formed at the highest point. A water outlet 84, connected to the multiple holes 82, is formed on the side wall of the adjustable-height return trough 7, guiding the water flowing from the holes 82 towards the wall. A linear gate valve adjustment mechanism 8 is installed at each hole 82. A stainless steel gate 83, driven by a telescopic device 81, moves axially along the holes 82, thereby precisely controlling the opening area of ​​the multiple holes 82.

[0048] The water supply and circulation system piping connections are as follows: The main water supply pump 3 draws water from the water storage tank 2 and delivers it to the spray module 6 through pipelines. Water flowing down the wall and collected by the adjustable height return channel 7 enters the water cooling unit 10 through pipelines. In this embodiment, the water cooling unit 10 adopts a forced air-cooled plate-fin radiator scheme, including an aluminum plate-fin radiator 102 and an axial flow fan 101. The heat recovery water flows inside the aluminum plate-fin radiator 102, and the axial flow fan 101 blows air for forced cooling. The cooled water is pumped back into the water storage tank 2 by the return water pump 9, completing the circulation.

[0049] The intelligent temperature sensing system consists of two parts: first, multiple fixed wireless temperature sensors 12 pre-attached to key locations on the exterior wall surface of the basement, including the top, upper middle, lower middle, and bottom; and second, an infrared thermal imager 11 installed on the top of the mobile support platform 1, used to scan and obtain a two-dimensional temperature cloud map of the wall surface.

[0050] The central controller 4 receives data from the fixed wireless temperature sensor 12, the infrared thermal imager 11, and the navigation module 5, and runs the core control program. It controls the movement of the mobile carrier platform 1, the main water supply pump 3, the return water pump 9, the valves, the lead screw slide module 71, the telescopic device 81, and the start, stop, and speed regulation of the axial flow fan 101 via CAN bus or Ethernet.

[0051] See Figure 3 The control system operates as follows: The intelligent temperature sensing system collects wall temperature data (especially the top temperature T_top and bottom temperature T_bot) and sends it to the temperature difference calculation and decision-making module of the central controller 4. This module calculates ΔT = T_top - T_bot in real time and compares it with the preset ΔT_target. Based on the deviation value, it generates a corresponding set of control instructions by querying a pre-stored control strategy mapping table. These instructions are distributed to the actuator drive module, thereby controlling the spray flow rate, the height H of the adjustable height return channel 7, the opening degree K of the gate 83, the moving speed V of the mobile support platform 1, and the power P_cool of the water cooling unit 10.

[0052] See Figure 3 The complete workflow of the device of the present invention is as follows: Step 301: Start-up and Deployment. Deploy the device on the inside of the basement exterior wall, confirm that the fixed wireless temperature sensor 12 is working properly, and set the target wall parameters and ΔT_target (e.g., 12℃) in the central controller 4.

[0053] Step 302: Automatic cruise to the starting point. The equipment automatically moves to the starting point of the wall section to be cured according to the navigation path.

[0054] Step 303: Comprehensive Temperature Scan and Diagnosis. The infrared thermal imager 11 performs a comprehensive scan of the current wall segment and, in conjunction with data from the fixed wireless temperature sensor 12, calculates the precise ΔT_current.

[0055] Step 304: Intelligent Decision Making. The central controller 4 determines the operating condition.

[0056] • If ΔT_current ≥ 20℃ (strong temperature difference condition), proceed to step 305a.

[0057] • If 10℃≤ΔT_current < 20℃ (medium temperature difference condition), proceed to step 305b.

[0058] If ΔT_current < 10℃ (low temperature difference / maintaining operating condition), proceed to step 305c.

[0059] Step 305a: Implement the strategy of "strong cooling of the upper part and strict isolation of the lower part".

[0060] • Control the nozzles to spray intermittently at maximum flow rate (Q=100%) (spray for 30 seconds, stop for 60 seconds).

[0061] • Control the adjustable height return channel 7 to descend to the lowest working height (H=H_min) so that the cooling water film covers approximately 40% of the upper part of the wall.

[0062] • Control the opening of gate 83 to close to K=2% (to maintain only a small amount of leakage to prevent blockage).

[0063] • Start the axial flow fan at speed 101 to the highest setting (P_cool=100%).

[0064] The equipment moves forward at a low speed (V=0.2m / s).

[0065] Step 305b: Implement the "moderate adjustment, balanced maintenance" strategy.

[0066] • Control the nozzles to spray at a medium flow rate (Q=70%) (spray for 20 seconds, stop for 180 seconds).

[0067] • Control the adjustable height return tank (7) to rise to the middle height (H=H_mid).

[0068] • Control the opening degree of gate 83 to close to K=10%.

[0069] • Axial flow fan 101 is operated at medium speed (P_cool=50%).

[0070] The equipment moves forward at a constant speed (V=0.5m / s).

[0071] Step 305c: Implement the "basic moisturizing, monitoring as the main focus" strategy.

[0072] • Control the nozzles to spray at a low flow rate (Q=30%) for low frequency (spray for 10 seconds, stop for 600 seconds) or decide whether to pause based on the absolute temperature.

[0073] • Control the adjustable height return channel 7 to rise to the high position (H=H_high) to reduce contact.

[0074] • Control the opening degree of gate 83 to close to K=5%.

[0075] • Axial flow fan 101 in standby mode.

[0076] • The equipment moves at an inspection speed (V=1.0m / s) and mainly performs monitoring.

[0077] Step 306: Dynamic Feedback and Adjustment. During strategy execution (e.g., every 2 minutes), the system recalculates ΔT_current. If the rate of temperature difference decrease is lower than expected, the parameters in step 305 are fine-tuned (e.g., slightly increasing Q or decreasing H).

[0078] Step 307: Segment Completion Judgment and Loop. Determine whether the current wall segment has been processed. If not, return to step 303 or 304 for the next round of scanning and decision-making; if completed, proceed to step 308.

[0079] Step 308: Move to the next wall segment. Based on the path plan, the equipment automatically moves to the next wall segment to be cured and jumps to step 303 to begin a new round of work. This continues until the curing tasks for all designated areas are completed.

[0080] Step 309: Data Archiving and Report Generation. Throughout the entire operation, all control commands, sensor data, and equipment location information are recorded. After the operation is completed, the system can automatically generate a maintenance report, including temperature change curves at each point, the implemented maintenance strategies, water consumption, etc., for project management and quality traceability.

[0081] Through the implementation of the above embodiments, the equipment of the present invention can automatically and intelligently complete the crack prevention and maintenance work of the exterior walls of ultra-long basements. It not only replaces inefficient and water-intensive manual maintenance, but more importantly, through precise temperature field control, it actively defends against structural cracks caused by solar temperature differences, thereby improving the quality and durability of underground engineering projects.

[0082] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A water curing device for crack-resistant concrete, characterized in that, include: A mobile carrier platform, wherein the mobile carrier platform is equipped with a navigation module; The intelligent temperature sensing system is used to acquire temperature distribution data on the surface of concrete walls and calculate the real-time temperature difference ΔT between the upper and lower ends of the wall. The central controller, connected to the intelligent temperature sensing system and navigation module, is used to generate control commands based on the real-time temperature difference ΔT. A zoned spraying and recycling system is installed on the mobile carrier platform and connected to the central controller; the zoned spraying and recycling system includes: The top sprinkler module is used to spray water onto the upper part of the wall. An adjustable height return channel, located below the spray module, is used to collect water flowing down from the wall, and its height can be adjusted relative to the wall to change the water film flow path. A controllable micro-seepage module is installed on the adjustable height return channel to guide a portion of the water in the adjustable height return channel to the lower part of the wall at a controllable flow rate. A water supply and circulation system, connected to the spray module and the adjustable height return tank, is used for water supply and recycling; and A water cooling unit, integrated into the water supply and circulation system, is used to cool the recycled water.

2. The anti-cracking concrete water curing equipment according to claim 1, characterized in that: The controllable micro-percolation module is a linear gate valve adjustment mechanism, including multiple holes opened on the adjustable height return channel and an outlet connected to the multiple holes, a gate that is movably set at the holes to adjust its opening degree, and a telescopic device that drives the gate to move. The telescopic device is electrically connected to the central controller.

3. The anti-cracking concrete water curing equipment according to claim 1, characterized in that: The water cooling unit is a forced air-cooled plate-fin radiator, including an aluminum plate-fin radiator and an axial flow fan that blows air towards the aluminum plate-fin radiator; the axial flow fan is electrically connected to the central controller.

4. The anti-cracking concrete water curing equipment according to claim 1, characterized in that: The intelligent temperature sensing system includes multiple fixed wireless temperature sensors arranged on the surface of the concrete wall and an infrared thermal imager installed on the mobile support platform.

5. The anti-cracking concrete water curing equipment according to claim 1, characterized in that: The central controller is configured to simultaneously adjust the spraying parameters of the spraying module, the height of the adjustable height return tank, and the flow rate of the controllable micro-percolation module based on the deviation between the real-time temperature difference ΔT and the preset target temperature difference ΔT_target.

6. The anti-cracking concrete water curing equipment according to claim 5, characterized in that: The central controller's regulation strategy includes: When ΔT is greater than the first threshold, the spray intensity of the spray module is increased, the height of the adjustable height return tank is reduced, and the flow rate of the controllable micro-percolation module is decreased. When ΔT is less than or equal to the first threshold and greater than the second threshold, a moderate spray intensity, an adjustable height return trough height, and a seepage flow rate are used. When ΔT is less than or equal to the second threshold, the spray intensity is maintained to keep the basic moisture level, the height of the adjustable height return tank is increased, and a low seepage flow rate or the seepage is turned off.

7. The anti-cracking concrete water curing equipment according to claim 1, characterized in that: The water supply and circulation system includes a water storage tank, a main water supply pump, and a return water pump. The main water supply pump supplies water from the water storage tank to the spray module. The return water pump transports the water collected by the adjustable height return channel to the water cooling unit for cooling, and the cooled water flows back to the water storage tank.

8. A method for water curing anti-cracking concrete, implemented using the anti-cracking concrete water curing equipment described in claim 7, characterized in that... Includes the following steps: S1: Obtain temperature data of the concrete wall surface and calculate the real-time temperature difference ΔT between the upper and lower ends of the wall; S2: Compare the real-time temperature difference ΔT with the preset target temperature difference; S3: Based on the comparison results, generate and execute control commands, which include at least a spray control command for the top spray module, a height adjustment command for the adjustable height return channel, and a flow rate adjustment command for the controllable micro-seepage module, so that when ΔT is large, the cooling of the upper part of the wall is enhanced and the water supply to the lower part of the wall is restricted, so as to reduce the real-time temperature difference ΔT.

9. The method for water curing crack-resistant concrete according to claim 8, characterized in that, The control strategy in step S3 is a closed-loop dynamic adjustment: after executing the control command, the temperature data is reacquired and a new ΔT is calculated. Based on the deviation between the new ΔT and the target temperature difference, the spray control command of the spray module, the height adjustment command of the adjustable height return tank, and the flow adjustment command of the controllable micro-percolation module are finely adjusted until the ΔT reaches or approaches the target temperature difference range.

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