Anti-interference material level detection method for construction equipment of stone column

Abstract

The application provides an anti-interference material level detection method for gravel pile construction equipment, and belongs to the technical field of material level detection.The method comprises the following steps: step 1, constructing a dust protection module for material level detection of the gravel pile construction equipment and performing corresponding control; step 2, constructing a vibration isolation and compensation module for material level detection of the gravel pile construction equipment; step 3, constructing a multi-source data fusion detection module for material level detection of the gravel pile construction equipment; and step 4, constructing a system control and feedback module for material level detection of the gravel pile construction equipment. Through integration of the dust protection module, the vibration isolation and compensation module and the multi-source data fusion detection module, the gravel pile construction equipment can be precisely detected in a pile pipe environment full of dust and strong vibration, and the defects of traditional material level detection, such as easy interference, false positives and false negatives, can be overcome.

Description

Technical Field

[0001] This invention belongs to the field of material level detection technology, specifically relating to a material level detection method for an anti-interference crushed stone pile construction equipment. Background Technology

[0002] In the prior art disclosed in patent publication number "CN118148127A" for crushed stone pile construction equipment, a level gauge is used to detect the accumulation height of crushed stone inside the pile pipe to control the amount of crushed stone entering the stratum and ensure the quality of pile formation. However, traditional level gauges face two major problems in practical applications: First, the process of crushed stone being placed and falling inside the pile pipe generates a large amount of dust, which adheres to the detection components of the level gauge (such as the probe and sensor surface), obstructing the detection signal and causing a decrease in measurement accuracy. Second, the vibratory hammer generates strong vibrations when it is working. These vibrations are transmitted to the level gauge, which may not only damage the precision structure inside the level gauge but also interfere with the stability of the detection signal, causing false alarms (such as misjudging the signal fluctuations caused by vibration as changes in material level) or missed alarms (such as failing to detect actual changes in material level due to vibration interference), seriously affecting construction efficiency and pile formation quality.

[0003] In existing technologies, dust interference is often addressed through periodic manual cleaning, but this cannot be done in real time during construction, and manual cleaning increases construction costs and safety risks. Vibration interference is often addressed with simple vibration damping brackets, but the damping effect is limited and cannot fundamentally eliminate the impact of vibration on the detection signal. Therefore, there is an urgent need for a technical solution that can effectively resist both dust and vibration interference while ensuring the accuracy of material level detection. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an anti-interference material level detection method for crushed stone pile construction equipment. It integrates a dust protection module, a vibration isolation and compensation module, and a multi-source data fusion detection module. This method is suitable for accurately detecting crushed stone material levels in the pile pipe environment of crushed stone pile construction equipment filled with dust and experiencing strong vibrations. It overcomes the shortcomings of traditional material level gauges, such as easy interference with measurement accuracy and false alarms or missed alarms.

[0005] The present invention employs the following technical solution.

[0006] A method for detecting material level in an anti-interference crushed stone pile construction equipment, comprising:

[0007] Step 1: Construct a dust protection module for the material level detection of the crushed stone pile construction equipment and implement corresponding controls;

[0008] Step 2: Construct a vibration isolation and compensation module for the material level detection of the crushed stone pile construction equipment;

[0009] Step 3: Construct a multi-source data fusion detection module for material level detection of crushed stone pile construction equipment;

[0010] Step 4: Design a control and feedback module for the material level detection system of the crushed stone pile construction equipment.

[0011] Furthermore, in step 1, the dust protection module includes:

[0012] A double-layer protective structure is installed on the outside of the detection probe of the level gauge. The double-layer protective structure includes an inner layer and an outer layer. The inner layer is a dustproof sleeve made of polytetrafluoroethylene, and the surface of the sleeve is covered with a nano-level anti-stick coating. The outer layer is a high-pressure airflow purging device, including an annular airflow nozzle and a high-pressure air source. The annular airflow nozzle is arranged around the dustproof sleeve, and the air outlet direction of the annular airflow nozzle is at an angle of 30° to 45° with the surface of the dustproof sleeve. The high-pressure air source is connected to the annular airflow nozzle through an air pipe, and a solenoid valve and a flow regulating valve connected to the controller are installed on the air pipe.

[0013] Furthermore, in step 1, the corresponding control method is executed, including:

[0014] Based on the dust concentration signal inside the pile pipe of the crushed stone pile construction equipment and the set material level detection cycle, the controller automatically controls the opening and closing of the solenoid valve and the opening of the flow regulating valve. That is, when the dust concentration exceeds the preset threshold or 10 seconds before the material level detection, the solenoid valve and the flow regulating valve are opened to spray high-pressure airflow for purging. The purging time lasts for 5 to 8 seconds, and the airflow speed is controlled at 8 to 12 m / s by the opening of the flow regulating valve.

[0015] Furthermore, in step 2, the vibration isolation and compensation module includes:

[0016] The vibration isolation structure, namely the level gauge, is connected to the inner wall of the pile pipe of the crushed stone pile construction equipment through a three-stage vibration damping support. The first-stage vibration damping sub-support of the three-stage vibration damping support is a metal spring vibration damper, the second-stage vibration damping sub-support is a rubber vibration damping pad, and the third-stage vibration damping sub-support is an air spring vibration damper. The first-stage, second-stage, and third-stage vibration damping sub-supports are connected in series from top to bottom, and mass blocks are set between adjacent sub-supports.

[0017] Furthermore, in step 2, the vibration isolation and compensation module also includes:

[0018] Vibration compensation algorithm: A three-axis accelerometer connected to the controller is integrated inside the level gauge to collect the vibration acceleration signal of the level gauge in real time and transmit it to the controller. The controller compensates the original level detection signal through the vibration compensation formula to obtain the corrected level value.

[0019] Furthermore, in step 2, the vibration compensation formula is:

[0020] L = L0 - kx·ax - ky·ay - kz·az;

[0021] In the formula:

[0022] L represents the corrected height of the crushed stone material;

[0023] L0 is the original material level height signal detected by the level gauge;

[0024] ax, ay, and az represent the vibration accelerations in the x, y, and z directions, respectively, collected by the triaxial accelerometer.

[0025] kx, ky, and kz are the vibration compensation coefficients in the x, y, and z directions, respectively.

[0026] Furthermore, in step 3, the multi-source data fusion detection module includes:

[0027] The multi-source detection component includes both laser level gauges and capacitive level gauges, with both types of level gauges having integrated dust protection and vibration isolation modules in their detection probes. Three temperature sensors are axially spaced on the inner wall of the pile tube of the crushed stone pile construction equipment to collect the temperature inside the pile tube in real time and transmit it to the controller, which is used to correct the influence of temperature on the laser and capacitive detection signals.

[0028] Furthermore, in step 3, the multi-source data fusion detection module also includes:

[0029] The data fusion algorithm is executed, which uses a weighted fusion algorithm to fuse the detection values ​​of the laser level gauge and the capacitive level gauge, while introducing a temperature correction coefficient.

[0030] Furthermore, in step 3, the calculation formula for the data fusion algorithm is as follows:

[0031] L_final=ω1·(L1+α·(T-T0))+ω2·(L2+α·(T-T0));

[0032] In the formula:

[0033] L_final represents the final, precise material level value;

[0034] ω1 and ω2 are the weighting coefficients of the laser level gauge and the capacitive level gauge, respectively, satisfying ω1+ω2=1. They are dynamically adjusted according to the detection accuracy of the two types of level gauges. When there is no dust obstruction to the laser level gauge, ω1=0.7 and ω2=0.3; when the dust concentration is high and the laser signal is obstructed, ω1=0.5 and ω2=0.5.

[0035] T represents the real-time temperature collected by the temperature sensor;

[0036] T0 is the standard temperature;

[0037] α is the temperature correction factor.

[0038] Furthermore, in step 4, the system control and feedback module includes...

[0039] The controller communicates with the main control system of the crushed stone pile construction equipment and feeds back the final accurate material level value to the main control system. If the material level value exceeds the preset range, the main control system will issue an alarm signal.

[0040] The beneficial effects of the present invention are as follows, compared with the prior art:

[0041] Dust interference elimination effect: Through a double-layer dustproof structure (PTFE dustproof sleeve + nano anti-stick coating) and adaptive high-pressure airflow purging, the adhesion of dust to the level gauge detection probe is effectively reduced. Experimental data shows that in an environment with a dust concentration ≤120mg / m³, the level detection error can be controlled within ±0.05m, which is more than 75% more accurate than traditional level gauges (error above ±0.2m); at the same time, adaptive purging avoids the energy waste caused by continuous purging, reducing purging energy consumption by 40%.

[0042] Vibration interference suppression effect: The vibration attenuation rate of the three-stage vibration damping bracket can reach more than 90%, which can reduce the vibration acceleration transmitted from the vibrating hammer to the level gauge from 10m / s² to less than 1m / s². Combined with the vibration compensation algorithm, the interference of residual vibration on the detection signal can be further eliminated. The detection error caused by vibration is reduced from ±0.15m to within ±0.03m, the false alarm rate is reduced from more than 20% to less than 1%, and the missed alarm rate is reduced from more than 15% to less than 0.5%.

[0043] Temperature and Multi-Source Fusion Optimization Effects: The introduction of a temperature correction coefficient eliminates the impact of temperature changes on material level detection. Within the temperature range of 10-40℃, the detection error caused by temperature is reduced from ±0.08m to within ±0.02m. Multi-source data fusion (laser + capacitance) combined with dynamic weight adjustment fully leverages the advantages of both material level gauges. In complex environments with fluctuating dust concentration and varying vibration intensity, the overall error of the final material level detection is stabilized within ±0.05m, ensuring precise control of the amount of crushed stone fed. The pass rate of pile construction quality has increased from the traditional 85% to over 98%, and construction efficiency has improved by 15%-20% (reducing rework and waiting time caused by material level misjudgment).

[0044] Practicality and economic benefits: Each module of this invention uses mature industrial-grade components, making the cost controllable and easy to install. It can be adapted to different models of existing crushed stone pile construction equipment. The system has a high degree of automation, requiring no manual intervention, which reduces manual maintenance costs and safety risks. At the same time, the system's anti-interference ability extends the service life of the level gauge from the traditional 6 months to more than 2 years, reducing equipment replacement costs. Attached Figure Description

[0045] Figure 1 This is a flowchart of the material level detection method for the anti-interference crushed stone pile construction equipment in this invention. Detailed Implementation

[0046] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this invention. The embodiments described in this application are merely some embodiments of this invention, and not all embodiments. Based on the spirit of this invention, other embodiments obtained by those skilled in the art without creative effort are all within the protection scope of this invention.

[0047] like Figure 1 As shown, a material level detection method for interference-resistant crushed stone pile construction equipment includes:

[0048] Step 1: Construct a dust protection module for the material level detection of the crushed stone pile construction equipment and implement corresponding controls;

[0049] In a preferred but non-limiting embodiment of the present invention, in step 1, the dust protection module includes:

[0050] A double-layer protective structure is installed on the outside of the level gauge's detection probe. This structure consists of an inner and an outer layer. The inner layer is a dustproof sleeve made of polytetrafluoroethylene (PTFE) with a nano-level anti-stick coating (such as a PTFE nano-coating) to reduce dust adhesion. The outer layer is a high-pressure airflow purging device, including an annular airflow nozzle and a high-pressure air source. The annular airflow nozzle surrounds the dustproof sleeve, with its outlet direction forming a 30°~45° angle with the surface of the dustproof sleeve. The high-pressure air source is connected to the annular airflow nozzle via an air pipe, which is equipped with a solenoid valve and a flow regulating valve connected to a controller. The controller can be an industrial computer or a PLC.

[0051] In a preferred but non-limiting embodiment of the present invention, step 1 includes a method for performing corresponding control, comprising:

[0052] Based on the dust concentration signal inside the pile pipe of the crushed stone pile construction equipment disclosed in the technical solution of patent publication number "CN118148127A" (which is collected in real time by a dust concentration sensor connected to the controller and transmitted to the controller) and the set material level detection cycle, the controller automatically controls the opening and closing of the solenoid valve and the opening of the flow regulating valve. That is, when the dust concentration exceeds the preset threshold (such as 50mg / m³) or 10 seconds before the material level detection, the solenoid valve and the flow regulating valve are opened to spray high-pressure airflow for purging. The purging time lasts for 5 to 8 seconds, and the airflow speed is controlled at 8 to 12 m / s by the opening of the flow regulating valve to ensure that the dust on the surface of the dustproof sleeve is removed without disturbing the crushed stone accumulation state.

[0053] Step 2: Construct a vibration isolation and compensation module for the material level detection of the crushed stone pile construction equipment;

[0054] In a preferred but non-limiting embodiment of the present invention, in step 2, the vibration isolation and compensation module includes:

[0055] The vibration isolation structure connects the level gauge to the inner wall of the pile pipe of the crushed stone pile construction equipment via a three-stage vibration damping support. The first-stage vibration damping sub-support is a metal spring vibration damper, the second-stage vibration damping sub-support is a rubber vibration damping pad (made of nitrile rubber with a hardness of 50-60 Shore A), and the third-stage vibration damping sub-support is an air spring vibration damper. The first-stage, second-stage, and third-stage vibration damping sub-supports are connected in series from top to bottom, and a mass block (0.5-1kg) is placed between adjacent sub-supports to form a damping vibration system, effectively attenuating the vibration energy transmitted from the vibrating hammer to the level gauge.

[0056] In a preferred but non-limiting embodiment of the present invention, in step 2, the vibration isolation and compensation module further includes:

[0057] Vibration compensation algorithm: A three-axis accelerometer connected to the controller is integrated inside the level gauge to collect the vibration acceleration signal (ax, ay, az) of the level gauge in real time and transmit it to the controller. The controller compensates the original level detection signal (L0) using the following vibration compensation formula to obtain the corrected level value (L).

[0058] In a preferred but non-limiting embodiment of the present invention, in step 2, the vibration compensation formula is:

[0059] L = L0 - kx·ax - ky·ay - kz·az;

[0060] In the formula:

[0061] L is the corrected height of the crushed stone material (unit: m);

[0062] L0 is the original material level height signal detected by the level gauge (unit: m);

[0063] ax, ay, and az are the vibration accelerations (unit: m / s²) in the x, y, and z directions collected by the triaxial accelerometer.

[0064] kx, ky, and kz are the vibration compensation coefficients (unit: m·s² / m) in the x, y, and z directions, respectively. Their values ​​are determined through experimental calibration. Specifically, in a dust-free environment with different vibration intensities (simulating the vibration frequency of a vibratory hammer at 10-50 Hz and amplitude at 0.5-5 mm), the deviation between the original detection value and the actual material level value of the level gauge is measured. Through linear regression calculation, kx = 0.02-0.05, ky = 0.01-0.03, and kz = 0.03-0.06 are obtained.

[0065] Step 3: Construct a multi-source data fusion detection module for material level detection of crushed stone pile construction equipment;

[0066] In a preferred but non-limiting embodiment of the present invention, in step 3, the multi-source data fusion detection module includes:

[0067] The multi-source detection component includes a laser level gauge (for high-precision detection of material level height) and a capacitive level gauge (for auxiliary detection, unaffected by dust color or transparency). The detection probes of both level gauges integrate the aforementioned dust protection module and vibration isolation module. Three temperature sensors are axially spaced on the inner wall of the pile tube of the crushed stone pile construction equipment to collect the temperature (T) inside the pile tube of the crushed stone pile construction equipment in real time and transmit it to the controller for the controller to correct the influence of temperature on the laser and capacitive detection signals.

[0068] In a preferred but non-limiting embodiment of the present invention, in step 3, the multi-source data fusion detection module further includes:

[0069] The data fusion algorithm is executed, that is, the weighted fusion algorithm is used to fuse the laser level gauge detection value (L1) and the capacitive level gauge detection value (L2), while introducing a temperature correction coefficient (α).

[0070] In a preferred but non-limiting embodiment of the present invention, the calculation formula of the data fusion algorithm in step 3 is as follows:

[0071] L_final=ω1·(L1+α·(T-T0))+ω2·(L2+α·(T-T0));

[0072] In the formula:

[0073] L_final is the final accurate material level value (unit: m);

[0074] ω1 and ω2 are the weighting coefficients for the laser level gauge and the capacitive level gauge, respectively, satisfying ω1+ω2=1. They are dynamically adjusted according to the detection accuracy of the two types of level gauges. When there is no dust obstruction to the laser level gauge, ω1=0.7 and ω2=0.3; when the dust concentration is high (exceeding 100mg / m³) and the laser signal is slightly obstructed, ω1=0.5 and ω2=0.5.

[0075] T represents the real-time temperature (unit: °C) collected by the temperature sensor.

[0076] T0 is the standard temperature (taken as 25℃, which is the reference temperature for calibrating the level gauge).

[0077] α is the temperature correction coefficient (unit: m / ℃). Through experimental calibration, α1=0.0005-0.001m / ℃ for laser level gauge and α2=0.0003-0.0008m / ℃ for capacitive level gauge. In the formula, α is the average of α1 and α2, that is, α=(α1+α2) / 2.

[0078] Step 4: Design a control and feedback module for the material level detection system of the crushed stone pile construction equipment.

[0079] In a preferred but non-limiting embodiment of the present invention, in step 4, the system control and feedback module includes

[0080] The controller is set up to connect to the dust concentration sensor, the solenoid valve and flow control valve of the high-pressure air source, the triaxial accelerometer, the laser level gauge, the capacitive level gauge, and the temperature sensor respectively. It receives the detection data of each module in real time and performs the calculations of the above vibration compensation formula and multi-source data fusion formula.

[0081] The controller communicates with the main control system of the crushed stone pile construction equipment, feeding back the final precise material level value (L_final) to the main control system. If the material level value exceeds the preset range (e.g., below the minimum construction material level or above the maximum pile pipe capacity), the main control system will issue an alarm signal and simultaneously control the opening and closing status of the feed gate to adjust the amount of crushed stone fed. The main control system can be a computer or a server.

[0082] An example of the present invention is shown below:

[0083] The three-stage vibration damping bracket (sequentially consisting of a metal spring vibration damper, a mass block, a rubber vibration damping pad, a mass block, and an air spring vibration damper) is fixed to the pre-set bracket at the upper part of the inner cavity of the pile pipe with bolts;

[0084] Install the detection probes of the laser level gauge and the capacitive level gauge on the top of the three-stage vibration damping bracket, ensuring that the probes face the crushed stone accumulation area inside the pile pipe cavity;

[0085] A polytetrafluoroethylene dustproof sleeve is fitted over the outside of the level gauge detection probe. The surface of the sleeve is coated with a nano anti-stick coating. At the same time, an annular airflow nozzle is installed on the outside of the dustproof sleeve. The nozzle is connected to a high-pressure air source through an air pipe. A solenoid valve and a flow regulating valve are installed on the air pipe.

[0086] A dust concentration sensor is installed on the inner wall of the pile pipe at a distance of 50-100mm from the level gauge probe. A triaxial acceleration sensor is integrated inside the level gauge. Three temperature sensors are installed on the inner wall of the pile pipe at axial intervals of 300mm.

[0087] The controller is installed in an explosion-proof box outside the pile pipe, and is connected to the dust concentration sensor, solenoid valve, flow regulating valve, triaxial accelerometer, laser level gauge, capacitive level gauge, temperature sensor, and the main control system of the crushed stone pile construction equipment via cables.

[0088] In a vibration-free and dust-free environment, crushed stone of known height (e.g., 1m, 2m, 3m, 4m, 5m, 6m) is placed into the pile pipe. The original detection values ​​of the laser level gauge and the capacitive level gauge are recorded respectively. The detection error is calculated. If the error exceeds ±0.05m, the installation angle and detection parameters of the level gauge are adjusted until the error meets the requirements.

[0089] Turn on the vibratory hammer to simulate different vibration intensities (vibration frequencies of 10Hz, 20Hz, 30Hz, 40Hz, and 50Hz; amplitudes of 0.5mm, 1mm, 2mm, 3mm, 4mm, and 5mm). Collect ax, ay, and az values ​​using a triaxial accelerometer, and record the deviation between the original detection value of the level gauge and the actual level value under different vibration conditions. Calculate the specific values ​​of kx, ky, and kz using a linear regression method (e.g., kx=0.03, ky=0.02, kz=0.04).

[0090] Different concentrations of dust (20mg / m³, 50mg / m³, 80mg / m³, 100mg / m³, 120mg / m³) are introduced into the pile pipe. The relationship between the detection value of the dust concentration sensor and the detection error of the level gauge is recorded. The threshold for dust purging (e.g., 50mg / m³) is set, and the speed of the high-pressure airflow (e.g., 10m / s) and the purging time (e.g., 6s) are adjusted to ensure that the detection error of the level gauge recovers to within ±0.05m after purging.

[0091] Adjust the temperature inside the pile pipe (10℃, 15℃, 20℃, 25℃, 30℃, 35℃, 40℃), record the deviation between the detection value of the laser level gauge and the capacitive level gauge and the actual level value at different temperatures, and calculate α1 and α2 (e.g., if α1=0.0007m / ℃, α2=0.0005m / ℃, then α=0.0006m / ℃).

[0092] The crushed stone pile construction equipment is started, and the vibratory hammer drives the pile pipe to vibrate and sink into the ground. The controller receives the detection data from the dust concentration sensor, the triaxial acceleration sensor, and the temperature sensor in real time.

[0093] When crushed stone is put into the pile pipe, if the dust concentration exceeds 50mg / m³, the controller controls the solenoid valve to open, and the high-pressure airflow blows through the annular airflow nozzle to sweep the surface of the dustproof sleeve for 6 seconds and then closes.

[0094] Laser level gauges and capacitive level gauges detect the crushed stone level, obtaining L1 and L2 respectively. The controller uses the ax, ay, and az values ​​collected by the triaxial accelerometer to initially correct L1 and L2 using vibration compensation formulas (e.g., L1 corrected to L1' = L1 - 0.03ax - 0.02ay - 0.04az, and L2 corrected to L2' = L2 - 0.03ax - 0.02ay - 0.04az).

[0095] The controller calculates the temperature correction term α·(T-T0) based on the real-time temperature T (e.g., when T=30℃, the correction term = 0.0006×(30-25)=0.003m), and adjusts ω1 and ω2 according to the dust concentration (e.g., when the dust concentration = 80mg / m³, ω1=0.6, ω2=0.4), and calculates L_final=0.6×(L1'+0.003)+0.4×(L2'+0.003) through the multi-source data fusion formula;

[0096] The controller feeds back L_final to the main control system. If L_final is lower than the minimum construction material level (e.g., 1m), it issues an "insufficient material level" alarm signal, controls the feed gate to open, and increases the amount of crushed stone fed. If L_final is higher than the maximum pile pipe capacity (e.g., 6m), it issues an "excessive material level" alarm signal, controls the feed gate to close, and stops the feeding of crushed stone.

[0097] Existing technologies only employ single dust protection measures (such as dust covers) to address dust interference and simple vibration reduction structures to address vibration interference. Furthermore, they fail to consider the impact of temperature on detection accuracy and do not organically combine dust protection, vibration compensation, temperature correction, and multi-source data fusion. This invention, through a dust protection module with "double-layer dust protection + adaptive purging," a vibration suppression module with "three-level vibration reduction + dynamic compensation algorithm," and a data processing module with "multi-source detection + dynamic weight fusion," forms a complete, multi-dimensional anti-interference solution, comprehensively revolutionizing traditional material level detection methods from hardware structure to software algorithm.

[0098] When faced with the dual interference of dust and vibration, those skilled in the art typically seek solutions to address either the dust or vibration problem separately. They rarely consider combining three-stage vibration reduction (metal spring + rubber + air spring) with vibration compensation algorithms, nor do they envision using multi-source data fusion with dynamic weight adjustments to further improve accuracy. Furthermore, they would not integrate dust protection, vibration suppression, and temperature correction into a cohesive system. The technical solution of this invention requires a deep understanding of mechanical structure design, sensor technology, and signal processing algorithms, as well as cross-disciplinary integration capabilities; it is not a conventional improvement easily conceived by those skilled in the art.

[0099] The material level detection system of this invention maintains a stable detection error within ±0.05m under complex environments with dust concentration ≤120mg / m³, vibration acceleration ≤10m / s², and temperature 10-40℃. The false alarm rate is ≤1%, the missed alarm rate is ≤0.5%, the pile quality qualification rate is increased to over 98%, and the construction efficiency is increased by 15%-20%. It is significantly superior to existing technologies and solves the long-standing technical problems of poor material level detection accuracy and numerous interferences in the field. It has outstanding substantive features and significant progress, and meets the inventiveness requirements of the patent law.

[0100] The beneficial effects of the present invention are as follows, compared with the prior art:

[0101] Dust interference elimination effect: Through a double-layer dustproof structure (PTFE dustproof sleeve + nano anti-stick coating) and adaptive high-pressure airflow purging, the adhesion of dust to the level gauge detection probe is effectively reduced. Experimental data shows that in an environment with a dust concentration ≤120mg / m³, the level detection error can be controlled within ±0.05m, which is more than 75% more accurate than traditional level gauges (error above ±0.2m); at the same time, adaptive purging avoids the energy waste caused by continuous purging, reducing purging energy consumption by 40%.

[0102] Vibration interference suppression effect: The vibration attenuation rate of the three-stage vibration damping bracket can reach more than 90%, which can reduce the vibration acceleration transmitted from the vibrating hammer to the level gauge from 10m / s² to less than 1m / s². Combined with the vibration compensation algorithm, the interference of residual vibration on the detection signal can be further eliminated. The detection error caused by vibration is reduced from ±0.15m to within ±0.03m, the false alarm rate is reduced from more than 20% to less than 1%, and the missed alarm rate is reduced from more than 15% to less than 0.5%.

[0103] Temperature and Multi-Source Fusion Optimization Effects: The introduction of a temperature correction coefficient eliminates the impact of temperature changes on material level detection. Within the temperature range of 10-40℃, the detection error caused by temperature is reduced from ±0.08m to within ±0.02m. Multi-source data fusion (laser + capacitance) combined with dynamic weight adjustment fully leverages the advantages of both material level gauges. In complex environments with fluctuating dust concentration and varying vibration intensity, the overall error of the final material level detection is stabilized within ±0.05m, ensuring precise control of the amount of crushed stone fed. The pass rate of pile construction quality has increased from the traditional 85% to over 98%, and construction efficiency has improved by 15%-20% (reducing rework and waiting time caused by material level misjudgment).

[0104] Practicality and economic benefits: Each module of this invention uses mature industrial-grade components, making the cost controllable and easy to install. It can be adapted to different models of existing crushed stone pile construction equipment. The system has a high degree of automation, requiring no manual intervention, which reduces manual maintenance costs and safety risks. At the same time, the system's anti-interference ability extends the service life of the level gauge from the traditional 6 months to more than 2 years, reducing equipment replacement costs.

[0105] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention without departing from the spirit and scope of the present invention. Any modifications or equivalent substitutions should be covered within the scope of protection of the claims of the present invention.

Claims

1. A method for detecting material level in anti-interference crushed stone pile construction equipment, characterized in that, include: Step 1: Construct a dust protection module for the material level detection of the crushed stone pile construction equipment and implement corresponding controls; Step 2: Construct a vibration isolation and compensation module for the material level detection of the crushed stone pile construction equipment; Step 3: Construct a multi-source data fusion detection module for material level detection of crushed stone pile construction equipment; Step 4: Design a control and feedback module for the material level detection system of the crushed stone pile construction equipment.

2. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 1, characterized in that, In step 1, the dust protection module includes: A double-layer protective structure is installed on the outside of the detection probe of the level gauge. The double-layer protective structure includes an inner layer and an outer layer. The inner layer is a dustproof sleeve made of polytetrafluoroethylene, and the surface of the sleeve is covered with a nano-level anti-stick coating. The outer layer is a high-pressure airflow purging device, including an annular airflow nozzle and a high-pressure air source. The annular airflow nozzle is arranged around the dustproof sleeve, and the air outlet direction of the annular airflow nozzle is at an angle of 30° to 45° with the surface of the dustproof sleeve. The high-pressure air source is connected to the annular airflow nozzle through an air pipe, and a solenoid valve and a flow regulating valve connected to the controller are installed on the air pipe.

3. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 2, characterized in that, In step 1, the corresponding control method is executed, including: Based on the dust concentration signal inside the pile pipe of the crushed stone pile construction equipment and the set material level detection cycle, the controller automatically controls the opening and closing of the solenoid valve and the opening of the flow regulating valve. That is, when the dust concentration exceeds the preset threshold or 10 seconds before the material level detection, the solenoid valve and the flow regulating valve are opened to spray high-pressure airflow for purging. The purging time lasts for 5 to 8 seconds, and the airflow speed is controlled at 8 to 12 m / s by the opening of the flow regulating valve.

4. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 3, characterized in that, In step 2, the vibration isolation and compensation module includes: The vibration isolation structure, namely the level gauge, is connected to the inner wall of the pile pipe of the crushed stone pile construction equipment through a three-stage vibration damping support. The first-stage vibration damping sub-support of the three-stage vibration damping support is a metal spring vibration damper, the second-stage vibration damping sub-support is a rubber vibration damping pad, and the third-stage vibration damping sub-support is an air spring vibration damper. The first-stage, second-stage, and third-stage vibration damping sub-supports are connected in series from top to bottom, and mass blocks are set between adjacent sub-supports.

5. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 4, characterized in that, In step 2, the vibration isolation and compensation module also includes: Vibration compensation algorithm: A three-axis accelerometer connected to the controller is integrated inside the level gauge to collect the vibration acceleration signal of the level gauge in real time and transmit it to the controller. The controller compensates the original level detection signal through the vibration compensation formula to obtain the corrected level value.

6. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 5, characterized in that, In step 2, the vibration compensation formula is: L = L0 - kx·ax - ky·ay - kz·az; In the formula: L represents the corrected height of the crushed stone material; L0 is the original material level height signal detected by the level gauge; ax, ay, and az represent the vibration accelerations in the x, y, and z directions, respectively, collected by the triaxial accelerometer. kx, ky, and kz are the vibration compensation coefficients in the x, y, and z directions, respectively.

7. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 6, characterized in that, In step 3, the multi-source data fusion detection module includes: The multi-source detection component includes both laser level gauges and capacitive level gauges, with both types of level gauges having integrated dust protection and vibration isolation modules in their detection probes. Three temperature sensors are axially spaced on the inner wall of the pile tube of the crushed stone pile construction equipment to collect the temperature inside the pile tube in real time and transmit it to the controller, which is used to correct the influence of temperature on the laser and capacitive detection signals.

8. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 7, characterized in that, In step 3, the multi-source data fusion detection module also includes: The data fusion algorithm is executed, which uses a weighted fusion algorithm to fuse the detection values ​​of the laser level gauge and the capacitive level gauge, while introducing a temperature correction coefficient.

9. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 8, characterized in that, In step 3, the calculation formula for the data fusion algorithm is as follows: L_final=ω1·(L1+α·(T-T0))+ω2·(L2+α·(T-T0)); In the formula: L_final represents the final, precise material level value; ω1 and ω2 are the weighting coefficients of the laser level gauge and the capacitive level gauge, respectively, satisfying ω1+ω2=1. They are dynamically adjusted according to the detection accuracy of the two types of level gauges. When there is no dust obstruction to the laser level gauge, ω1=0.7 and ω2=0.3; when the dust concentration is high and the laser signal is obstructed, ω1=0.5 and ω2=0.

5. T represents the real-time temperature collected by the temperature sensor; T0 is the standard temperature; α is the temperature correction factor.

10. The material level detection method for the anti-interference crushed stone pile construction equipment according to claim 9, characterized in that, In step 4, the system control and feedback module includes The controller communicates with the main control system of the crushed stone pile construction equipment and feeds back the final accurate material level value to the main control system. If the material level value exceeds the preset range, the main control system will issue an alarm signal.

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