Foam concrete filling degree monitoring device with pressure sensing array

Abstract

The invention discloses a foam concrete filling degree monitoring device with a pressure sensing array. The foam concrete filling degree monitoring device comprises a flexible substrate, the pressure sensing array, a signal acquisition module, a data processing unit, a display and early warning module and a power supply communication unit. The pressure sensing arrays are distributed on the flexible substrate in a matrix mode and collect foam concrete pressure signals in real time. And the data processing unit judges a filling state through a threshold value, generates a visual cloud picture, positions a cavity and an underfilled area and performs early warning. The method can achieve global, real-time and accurate monitoring, is suitable for foam concrete construction scenes such as pipe galleries, foundation pits and roofs, remarkably improves the construction quality, and reduces the rework cost.

Description

Technical Field

[0001] This invention belongs to the field of building engineering monitoring technology, specifically relating to a device based on a pressure sensing array to realize real-time monitoring of the fullness, void location and early warning during the pouring of foamed concrete. Background Technology

[0002] Foamed concrete is widely used in projects such as foundation pit backfilling, underground pipe gallery filling, roof slope finding, and road and bridge subgrade due to its lightweight, heat insulation, and self-leveling properties. However, in actual construction, due to the high viscosity and uneven fluidity of foamed concrete, complex pouring paths, and obstruction by reinforcing bars and pipelines, quality defects such as local voids, underfilling, and insufficient compaction are very likely to occur.

[0003] Traditional testing methods mainly rely on manual tapping, subsequent core drilling, and visual inspection, which have significant shortcomings: 1. Delayed detection means problems are discovered after the product has already been manufactured, resulting in high rework costs; 2. The pouring process cannot be monitored in real time and across the entire area; 3. Single-point detection has low accuracy and is difficult to identify tiny holes and blind spots; 4. Human judgment is highly subjective and the data is not traceable. Existing technologies employ pressure or level sensors to a limited extent, but these are mostly single-point monitoring devices, unable to form a planar monitoring network, and have poor ability to identify the filling state of complex cavities. Therefore, developing a foamed concrete filling degree monitoring device that provides full coverage, real-time accuracy, and visualization has significant engineering value. Summary of the Invention

[0004] 1. Purpose of the invention To address the shortcomings of existing technologies, this invention provides a foamed concrete filling degree monitoring device with a pressure sensing array, enabling full-area, real-time, and visual monitoring of the pouring process, accurately locating voids and underfilled areas, guiding timely adjustments during construction, improving pouring quality, and reducing rework costs. 2. Technical Solution A foamed concrete filling degree monitoring device with a pressure sensing array includes a flexible substrate, a pressure sensing array, a signal acquisition module, a data processing unit, a display and early warning module, and a power supply and communication unit. (1) Flexible substrate Waterproof, corrosion-resistant, and flexible film materials, such as TPU, PVC, or silicone film, with a thickness of 0.5–2mm, are used. These films are flexible, cut to size, and can be applied to irregularly shaped structures such as foundation pits, pipe racks, and roofs, facilitating installation and recycling. Sealed interfaces are provided at the base edges to prevent grout from seeping in and damaging the circuitry. (2) Pressure sensing array Several miniature thin-film pressure sensors are evenly distributed in a matrix on a flexible substrate. Sensor parameters: - Monitoring area: 1–5 cm²; - Measuring range 0–100 kPa; - Accuracy ≥ ±0.5 kPa; - Response time ≤ 10ms; - Sensor spacing 5–10cm. Each sensor has a unique number for location. When foamed concrete covers and compacts the sensor, the pressure rises and exceeds a threshold, indicating that the sensor is full. (3) Signal acquisition module Connecting to a pressure sensor array, it performs signal amplification, filtering, and A / D conversion, transforming analog pressure signals into digital signals. It supports wired shielded cable or wireless Bluetooth / ZigBee transmission. (4) Data processing unit Built-in processor and storage module, execute: - Compare pressure thresholds to determine fullness / underfilling / void; - Generate a thermal cloud map of fullness based on sensor locations; - Locate the coordinates and extent of the defect area; - Store all process data and generate test reports. (5) Display and early warning module This includes industrial touch screens, sound and light alarms, and wireless communication modules. - The screen displays real-time abundance cloud map, pressure data, and early warning information; - Automatic audible and visual alarm when large areas of underfilling or voids are found; - Remotely upload data to the management platform via 4G / 5G / Wi-Fi. (6) Power supply and communication unit Powered by lithium batteries or an external power supply, the modules communicate stably via a bus to ensure uninterrupted pouring operations over long periods. 3. Working Principle A pressure-sensing array is pre-laid in the area to be poured. When the foamed concrete flows and covers the sensors, the pressure increases; in uncovered or uncompacted areas, the pressure is below the threshold. The system uses the array to form a planar monitoring network, judges the filling status of each point in real time, generates a cloud map, and issues an early warning. 4. Beneficial effects 1. Full-area surface monitoring with no blind spots, capable of identifying minute voids; 2. Real-time monitoring of the pouring process provides early warnings and reduces rework; 3. Visual cloud maps intuitively display the location of defects, guiding construction; 4. The flexible substrate adapts to complex irregular cavities, allowing for flexible layout; 5. The data is storable and traceable, meeting the requirements for project acceptance; 6. The device is detachable and reusable, making it economical. Detailed Implementation Example 1: Monitoring of Foamed Concrete Filling in Underground Utility Tunnels 1. Cut a flexible base according to the dimensions of the utility tunnel and deploy a matrix-type pressure sensing array; 2. Calibrate the filling pressure threshold and complete system wiring and debugging; 3. Apply the flexible substrate to the bottom and side walls of the pipe gallery and secure it firmly; 4. Start pouring; the device collects pressure data in real time and generates a filling cloud map. 5. When local underfilling of the sidewall is detected, the system will automatically alarm, and construction personnel will promptly fill the gaps. 6. After pouring is completed, a fullness test report will be generated for acceptance testing; 7. After the concrete has initially set, remove the device, clean it, and reuse it. Example 2: Monitoring of Roof Slope Finding Layer Pouring 1. Arrange the induction array according to the roof area to increase the threshold and adapt to the roof load; 2. Lay the flexible substrate on the template; 3. Real-time monitoring of the pouring process, detecting voids in the upper right corner and issuing an early warning; 4. Construction workers poured and vibrated the concrete to eliminate defects; 5. Archive the monitoring data and cloud map upon completion. Figure 1 This is a block diagram of the overall structure of the device of the present invention; Figure 2 This is a schematic diagram of the planar arrangement of the pressure sensing array of the present invention; Figure 3 This is a flowchart of the foamed concrete filling degree monitoring method of the present invention.

Claims

1. A device for monitoring the filling degree of foamed concrete with a pressure sensing array, characterized in that, The system includes a flexible substrate, a pressure sensing array, a signal acquisition module, a data processing unit, and a display and early warning module. The pressure sensing array consists of several miniature pressure sensors arranged in a matrix on the flexible substrate to collect pressure signals from various measuring points during the pouring process. The signal acquisition module is connected to the pressure sensing array and performs signal amplification, filtering, and A / D conversion. The data processing unit performs threshold judgment on the pressure signals, generates a fullness cloud map, and locates defect areas. The display and early warning module provides visual display and abnormal alarms.

2. The apparatus according to claim 1, characterized in that, The flexible substrate is a waterproof and corrosion-resistant flexible film with a thickness of 0.5–2 mm. It can be bent, cut, and fitted to irregularly shaped casting surfaces and can be reused.

3. The apparatus according to claim 1, characterized in that, The miniature pressure sensor is a thin-film pressure sensor with a monitoring area of ​​1–5 cm², a range of 0–100 kPa, an accuracy of not less than ±0.5 kPa, and a response time of ≤10 ms; the sensor spacing is 5–10 cm, and each sensor has a unique location number.

4. The apparatus according to claim 1, characterized in that, The signal acquisition module supports wired shielded cable or wireless Bluetooth / ZigBee communication.

5. The apparatus according to claim 1, characterized in that, The data processing unit can perform: pressure threshold comparison, determination of full / underfilled / void status, generation of fullness thermal cloud map, defect location and data storage.

6. The apparatus according to claim 1, characterized in that, The display and early warning module includes a touch screen, an audible and visual alarm, and a 4G / 5G / Wi-Fi wireless communication unit, which can display monitoring data on-site and transmit it remotely.

7. The apparatus according to claim 1, characterized in that, It also includes a power supply and communication unit, which is powered by a lithium battery or an external power supply, and enables the modules to work together through a bus.

8. A method for monitoring the filling degree of foamed concrete based on the device according to any one of claims 1-7, characterized in that, Includes the following steps: (1) Cut the flexible base according to the size of the pouring area, set up the pressure sensing array, and complete the calibration and debugging; (2) Lay the device at the preset monitoring location and fix it in place; (3) Collect pressure signals in real time during the pouring process to determine the filling status of each point; (4) Generate a fullness cloud map to locate and issue warnings for underfilled and void areas; (5) Construction personnel adjust the pouring process based on the early warning; (6) After the pouring is completed, store the data and generate an inspection report; (7) After the construction is completed, the equipment shall be dismantled, cleaned and reused.

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