A device and method for curing concrete surfaces on highway bridges

Abstract

This invention discloses a device and method for curing concrete surfaces on highway bridges, which achieves integrated automated operation of watering, film placement, and film pressing, reducing the labor intensity of workers, improving the problem of insufficient or excessive local humidity caused by manual watering, and enhancing the quality of maintenance. The device includes a mobile module that can move on the ground; a spraying module fixed to the mobile module, including a spraying pipe connected to a water source; a film placement module fixed to the mobile module, including a third power unit and a film placement roller, the third power unit driving the film placement roller to rotate, the film placement roller being fitted with a concrete pavement curing film; and a film pressing module fixed to the rear end of the mobile module, including a film pressing roller that can rotate circumferentially and contacts the pavement to be covered.

Description

Technical Field

[0001] This invention relates to the field of highway bridge pavement construction engineering technology, and in particular to a highway bridge surface concrete curing device and method. Background Technology

[0002] Currently, the industry typically maintains concrete pavement by first removing residue from the pavement, then ensuring the pavement remains moist, and finally laying an insulation and moisture-retaining layer to maintain its moisture retention. In existing technologies, the core operations of this maintenance process largely rely on manual labor. Specifically, after the concrete has reached initial set and expansion joints have been cut, the pavement is first cleaned manually, then water is sprayed onto the concrete pavement using a handheld water sprayer. After watering, geotextile fabric is laid manually to achieve the maintenance of the concrete pavement.

[0003] However, the existing manual-based concrete pavement maintenance method has technical drawbacks. On the one hand, manually spraying water makes it difficult to ensure uniform watering, which may lead to insufficient or excessive humidity in some areas, thus affecting the consistency of the concrete hydration reaction and reducing the quality of maintenance. On the other hand, manually laying insulation and moisture-retaining layers such as burlap and geotextile is not only labor-intensive but also inefficient. Especially for large-area concrete pavement maintenance, it requires a large investment of manpower and time, making it difficult to meet the efficiency requirements of large-scale construction. Summary of the Invention

[0004] Therefore, in order to overcome the above-mentioned shortcomings, the present invention provides a concrete curing device and method for highway bridge surfaces, so as to realize the integrated automated operation of watering, film laying and film pressing, reduce the labor intensity of operators, improve the problem of insufficient or excessive local humidity caused by manual watering, and improve the quality of curing.

[0005] On one hand, the present invention provides a concrete curing device for highway bridge surfaces, comprising: A mobile module that can move on the ground; A spraying module, which is fixed on a mobile module, includes a spraying pipe connected to a water source; A film-laying module is fixed on a mobile module. The film-laying module includes a third power device and a film-laying roller. The third power device drives the film-laying roller to rotate. A covering film for concrete pavement maintenance is fitted on the film-laying roller. A film pressing module is fixed at the tail end of a mobile module. The film pressing module includes a film pressing roller that can rotate around its own circumference and contacts the road surface to be covered.

[0006] Furthermore, the spraying module also includes a first power unit, which drives the spraying pipe to move vertically up and down.

[0007] Furthermore, the spraying module also includes: A second power unit is installed on the spray pipe; An extension pipe is provided at both ends of the spray pipe. The extension pipe is connected to a second power device, which drives the extension pipe to move linearly along the axis of the spray pipe.

[0008] Furthermore, the spraying module also includes: A fixed water baffle is fixed to the spray pipe, and the nozzle of the spray pipe is located inside the fixed water baffle. A movable water barrier is fixed to an extension pipe, and the nozzle of the extension pipe is located inside the movable water barrier.

[0009] Furthermore, the film-laying module also includes a tensioning mechanism, which includes a fifth power unit and tensioning rollers. The tensioning rollers are provided in multiple sets, which are arranged linearly and parallel to each other. The fifth power unit drives the multiple sets of tensioning rollers to swing.

[0010] Furthermore, the film-dispensing module also includes: A fixed base is fixedly mounted on the mobile module; The slide is mounted on the third power unit, the film feeding roller and the tensioning mechanism, and the slide is slidably mounted on the fixed base. The fourth power unit drives the carriage to slide linearly in a direction perpendicular to the movement of the moving part.

[0011] Furthermore, the pressing module also includes a sixth power device, which drives the pressing roller to slide vertically.

[0012] Furthermore, the maintenance device also includes a control module, which is integrally mounted on the moving module and is communicatively connected to the spraying module, the film pressing module, and the film releasing module. The control module acquires road width data and makes an extension judgment based on the road width data. If the road width is greater than the spraying width of the spraying pipe, it calculates the extension length of the extension pipe and generates an extension pipe extension control signal based on the extension pipe extension length calculation result, which is then sent to the spraying module so that the spraying module can perform the corresponding action according to the extension pipe extension control signal. The system acquires real-time road surface humidity data and uses an incremental PID algorithm to control the spraying module to adjust the water volume based on the deviation between the real-time humidity data and the target humidity. The speed of the moving part is obtained, the rotation speed of the film feeding roller is calculated based on the speed of the moving part, and a film feeding roller rotation speed control signal is generated based on the film feeding roller rotation speed and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the film feeding roller rotation speed control signal. The real-time tension of the film is obtained. Based on the deviation between the real-time tension and the ideal tension of the film, the target angle that the tensioning roller needs to swing is calculated using the PI algorithm. Based on the target angle that the tensioning roller needs to swing, a tensioning roller adjustment control signal is generated and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the tensioning roller adjustment control signal. The lateral offset of the film edge is obtained, the correction distance of the carriage lateral movement is calculated based on the lateral offset of the film edge, and a correction control signal is generated based on the correction distance of the carriage lateral movement and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the correction control signal. The road surface slope angle is obtained, and the pressure of the pressing roller is calculated based on the road surface slope angle and the real-time tension of the film. Based on the pressure calculation result, a pressing roller pressing control signal is generated and sent to the pressing module so that the pressing module can perform corresponding actions according to the pressing roller pressing control signal.

[0013] On the other hand, the present invention also provides a method for controlling the above-mentioned concrete curing device for highway bridge surfaces, the method comprising: The control module acquires road width data and makes an extension judgment based on the road width data. If the road width is greater than the spraying width of the spraying pipe, it calculates the extension length of the extension pipe and generates an extension pipe extension control signal based on the extension pipe extension length calculation result. The extension pipe extension control signal is then sent to the spraying module so that the spraying module can perform the corresponding action according to the extension pipe extension control signal. The system acquires real-time road surface humidity data and uses an incremental PID algorithm to control the spraying module to adjust the water volume based on the deviation between the real-time humidity data and the target humidity. The speed of the moving part is obtained, the rotation speed of the film feeding roller is calculated based on the speed of the moving part, and a film feeding roller rotation speed control signal is generated based on the film feeding roller rotation speed and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the film feeding roller rotation speed control signal. The real-time tension of the film is obtained. Based on the deviation between the real-time tension and the ideal tension of the film, the target angle that the tensioning roller needs to swing is calculated using the PI algorithm. Based on the target angle that the tensioning roller needs to swing, a tensioning roller adjustment control signal is generated and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the tensioning roller adjustment control signal. The lateral offset of the film edge is obtained, the correction distance of the carriage lateral movement is calculated based on the lateral offset of the film edge, and a correction control signal is generated based on the correction distance of the carriage lateral movement and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the correction control signal. The road surface slope angle is obtained, and the pressure of the pressing roller is calculated based on the road surface slope angle and the real-time tension of the film. Based on the pressure calculation result, a pressing roller pressing control signal is generated and sent to the pressing module so that the pressing module can perform corresponding actions according to the pressing roller pressing control signal.

[0014] The present invention has the following advantages: This invention utilizes a mobile module to drive the spraying module, enabling water spraying of concrete pavements and addressing the issues of insufficient or excessive humidity caused by manual watering, thus improving maintenance quality. Through the coordination of the film-laying and film-pressing modules, a third power unit drives the film-laying roller to automatically release the maintenance covering film, and the film-pressing roller then applies the film, reducing the labor intensity of operators. Simultaneously, the mobile module allows for continuous operation of all modules, improving maintenance efficiency compared to manual segmented operations, making it suitable for large-area concrete pavement maintenance scenarios. This invention achieves integrated automated operation of watering, film-laying, and film-pressing, reducing labor costs.

[0015] The control module enables intelligent, adaptive, and coordinated control of spraying, film spreading, and film pressing, improving the quality, efficiency, and reliability of maintenance operations.

[0016] Specifically, the control module periodically samples and acquires real-time road surface humidity data through a road surface humidity detection unit located behind the spraying area. The system has a target humidity value set for concrete curing. The control module calculates the current humidity deviation. An incremental PID algorithm is used to calculate this deviation to determine the required water volume adjustment for the current cycle. The specific calculation method can be found in Example 1, which uses an incremental approach. The control module converts the calculated water volume adjustment into a specific water volume adjustment control signal and sends it to the water pump drive unit or flow proportional valve of the spraying module, so that the water pump drive unit or flow proportional valve adjusts the water flow according to the signal.

[0017] Specifically, the control module acquires real-time film tension data via a tension sensor mounted on the tensioning mechanism. An ideal film tension value is preset within the system. The control module calculates the tension deviation. A PI algorithm is used to process this deviation to calculate the target angle at which the tensioning rollers need to swing. The specific calculation method can be found in Example 1, which describes the method for calculating the target angle. The control module generates a tensioning roller adjustment control signal based on the target angle and sends it to the fifth power unit of the film feeding module. The fifth power unit drives all tensioning rollers in the tensioning mechanism to swing synchronously to the target angle, thereby changing the wrap angle and length of the film path.

[0018] Specifically, the control module can obtain the road surface slope angle through an inclinometer. The control module first dynamically calculates the target pressure of the pressing roller based on the road conditions and the film's condition. The calculation method can be found in the specific method for calculating the pressing roller pressure described in Example 1. Simultaneously, the control module reads the measured value from the pressing roller pressure sensor. Based on the target pressure, the control module generates a pressing roller lowering control signal and sends it to the sixth power unit of the pressing module. The sixth power unit drives the pressing roller to rise and fall according to this signal. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the maintenance device; Figure 2 yes Figure 1 A schematic diagram of the back of the maintenance device shown; Figure 3 yes Figure 1 A schematic diagram of the spraying module in the maintenance device shown; Figure 4 yes Figure 1 A schematic diagram of the membrane placement module in the curing device shown; Figure 5 yes Figure 4 A front view of the membrane placement module shown; Figure 6 yes Figure 4 A cross-sectional schematic diagram of the membrane placement module shown; Figure 7 yes Figure 2 A schematic diagram of the membrane pressing module in the curing device shown; Figure 8 yes Figure 1 The control logic diagram of the maintenance device shown is as follows; In the picture: 100. Spraying module; 110. First power unit; 120. Spraying pipe; 130. Second power unit; 140. Extension pipe; 150. Fixed water barrier; 160. Movable water barrier; 200. Film feeding module; 210. Third power unit; 220. Film feeding roller; 230. Carriage; 240. Fixed base; 250. Fourth power unit; 260. Tensioning mechanism; 300. Mobile module; 400. Control module; 500. Film pressing module; 510. Sixth power unit; 520. Film pressing roller; 600. Sensing module. Detailed Implementation

[0021] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0022] In this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, without necessarily requiring or implying any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0023] As described in the background section, the existing manual-based concrete pavement maintenance method has technical defects. On the one hand, manual spraying of water is difficult to ensure uniformity, which may lead to insufficient or excessive humidity in some areas, thereby affecting the consistency of the concrete hydration reaction and reducing the quality of maintenance. On the other hand, manually laying insulation and moisture-retaining layers such as burlap and geotextile is not only labor-intensive but also inefficient. Especially for large-area concrete pavement maintenance, it requires a large investment of manpower and time, which is difficult to meet the efficiency requirements of large-scale construction.

[0024] Example 1: Therefore, in order to solve the above-mentioned technical problems existing in the prior art, this embodiment provides a concrete curing device for highway bridge surfaces, such as... Figure 1 , 2 As shown, the maintenance device includes: Mobile module 300, which can move on the ground; Spraying module 100, which is fixed on the mobile module, such as... Figure 3 As shown, the spraying module includes a spraying pipe 120, which is connected to a water source; Film-laying module 200, which is fixedly mounted on the moving module, such as... Figure 4 As shown, the film-laying module includes a third power unit 210 and a film-laying roller 220. The third power unit drives the film-laying roller to rotate, and a covering film for concrete pavement maintenance is fitted on the film-laying roller. Film pressing module 500, the film pressing module is fixed to the tail end of the movable module, such as Figure 7 As shown, the film pressing module includes a film pressing roller 520, which can rotate around its own circumference and is in contact with the road surface to be covered.

[0025] Specifically, the mobile module can be selected from wheeled, tracked, or rail-mounted mobile mechanisms, or other mechanisms capable of moving on the ground; the third power unit can be selected from commonly used three-phase asynchronous motors, servo motors, stepper motors, hydraulic motors, pneumatic motors, or other devices capable of rotating the film-laying roller; in addition, a water tank and a water pump can be installed on the mobile module. The water tank contains the water required for the spraying module, and the water pump pumps the water from the tank into the spraying pipe. The film-pressing roller can be installed on the output end of the sixth power unit or on the support of the film-pressing module via detachable connections such as quick-connect couplings, clips, or bolts. When the curing film is about to run out or needs to be replaced with a different type / specification of film, the operator can easily remove the entire film-pressing roller, then remove the used film-laying roller from the film-laying module, and install a new film-laying roller with film roll into the film-laying module. After replacement, the film-pressing roller is reinstalled in its original position.

[0026] In this embodiment, during operation, the moving module is activated and controlled to move along the preset direction of the concrete pavement to be cured. The moving module will drive the spraying module, film-laying module, and film-pressing module fixed on it to move synchronously. During the movement of the moving module, the spraying module is activated, and water is sprayed evenly onto the concrete pavement below through the spraying pipe. At the same time, the third power device drives the film-laying roller to rotate around its own axis, and the curing covering film mounted on the film-laying roller is released. The film-pressing roller fixed at its tail end contacts the surface of the newly laid covering film. Since the film-pressing roller can rotate around its own circumference, under the traction of the moving module, the film-pressing roller rolls along the road surface, applying uniform pressure to the covering film and compacting the film onto the concrete pavement, thereby covering the road surface with the film.

[0027] This embodiment utilizes a mobile module to drive the spraying module, enabling water spraying of concrete pavements and addressing the issues of insufficient or excessive humidity caused by manual watering, thus improving maintenance quality. Through the coordination of the film-laying and film-pressing modules, a third power unit drives the film-laying roller to automatically release the maintenance covering film, and the film-pressing roller then applies the film, reducing the labor intensity of operators. Simultaneously, the mobile module allows for continuous operation of all modules, improving maintenance efficiency compared to manual segmented operations, making it suitable for large-area concrete pavement maintenance scenarios. This invention achieves integrated automated operation of watering, film-laying, and film-pressing, reducing labor costs.

[0028] For example, such as Figure 3 As shown, the spraying module also includes a first power unit 110, which drives the spraying pipe to move vertically up and down.

[0029] Specifically, the first power unit is installed on the mobile module, and its actuating end is connected to the spraying pipe to drive the spraying pipe to perform vertical lifting and lowering movements. The first power unit can be flexibly selected from one of the following, depending on the overall design of the device, control accuracy requirements, and power source configuration: electric push rod, hydraulic cylinder, servo electric cylinder, gear and rack mechanism, chain / synchronous belt lifting mechanism, or cylinder.

[0030] In this embodiment, the spraying pipe is driven to move vertically up and down by a first power device, and the height of the spraying pipe above the ground can be adjusted in real time according to the actual working conditions.

[0031] For example, the spraying module further includes: A second power unit 130 is installed on the spray pipe; An extension pipe 140 is provided at both ends of the spray pipe. The extension pipe is connected to a second power device, which drives the extension pipe to move linearly along the axial direction of the spray pipe.

[0032] Specifically, the second power unit can be flexibly selected from one of the following, depending on the overall design of the device, control precision requirements, and power source configuration: electric push rod, hydraulic cylinder, servo cylinder, gear and rack mechanism, chain / synchronous belt lifting mechanism, or pneumatic cylinder. The extension pipe and spraying pipe can be connected via a guide mechanism, which can be a sliding pair guide mechanism, a linear guide rail guide mechanism, a guide rod and linear bearing (bushing) combination mechanism, or a telescopic sleeve guide and sealing integrated mechanism. In this embodiment, the second power unit drives the linear extension pipes on both sides to extend and retract, allowing the total coverage width of the spraying operation to be dynamically adjusted according to the actual width of the road surface.

[0033] For example, the spraying module further includes: A fixed water baffle 150 is fixed to the spray pipe, and the nozzle of the spray pipe is located inside the fixed water baffle. A movable water-blocking cover 160 is fixed to an extension pipe, and the nozzle of the extension pipe is located inside the movable water-blocking cover.

[0034] This embodiment uses fixed and movable water-blocking covers to enclose the nozzles of the spray pipes and extension pipes, creating a localized confined space. When water is sprayed, the water-blocking covers significantly suppress the lateral diffusion and upward drift of water mist caused by wind, inertia, and other factors, allowing the water to fall vertically or nearly vertically onto the target road surface in a controlled manner. This improves the problems of blurred boundaries between dry and wet surfaces, localized over-wetting, or insufficient watering caused by water mist dispersion.

[0035] For example, such as Figure 6As shown, the film-laying module also includes a tensioning mechanism 260, which includes a fifth power unit and tensioning rollers. The tensioning rollers are provided in multiple sets, which are arranged linearly and parallel to each other. The fifth power unit drives the multiple sets of tensioning rollers to swing.

[0036] Specifically, multiple sets of tension rollers can be mounted on a swing shaft or connected to each other via a linkage mechanism to form an integral swing frame. One end of the fifth power device (e.g., an electric push rod, hydraulic cylinder, or servo cylinder) can be hinged to a fixed point (such as a slide or fixed base), while the other end is hinged to the swing shaft or the integral swing frame. When the fifth power device performs a linear telescopic movement, it drives the swing shaft or the integral swing frame to swing synchronously around its fulcrum, thereby causing all the tension rollers mounted on it to swing at the same angle.

[0037] After the film is drawn from the unwinding roller, it will pass through multiple sets of linearly arranged tension rollers in a serpentine path. The operation of the fifth power unit will change the overall wrap angle and length of this path, thereby adjusting the tension applied to the film.

[0038] For example, such as Figure 4 , 5 As shown, the membrane placement module further includes: Fixed base 240, which is fixedly installed on the mobile module; The slide 230 is on which the third power unit, the film feeding roller and the tensioning mechanism are all mounted, and the slide is slidably mounted on the fixed base. The fourth power unit 250 drives the carriage to slide linearly in a direction perpendicular to the movement of the moving part.

[0039] Specifically, the fixed base is rigidly connected to the frame of the moving module by bolts or welding. The carriage is slidably mounted on the fixed base via a linear guide rail, a slide rail and slider, or a guide rod and bushing, with its sliding direction (usually lateral) perpendicular to the normal travel direction of the moving module. The fourth power unit can be a servo electric cylinder, an electric push rod, a hydraulic cylinder, or a linear drive device such as a screw and nut mechanism driven by a motor. Its body is fixed to the fixed base or the moving module, and its output end (push rod, piston rod, or nut seat) is connected to the carriage. When the fourth power unit is working, its output end drives the carriage to slide on the fixed base to adjust the lateral position of the film-laying roller and the initial release point of the film. When the equipment is initialized or enters road sections of different widths, the lateral position of the carriage can be adjusted to change the starting laying point of the film relative to the road surface, improving the adaptability of the equipment.

[0040] For example, such as Figure 7As shown, the film pressing module also includes a sixth power device 510, which drives the film pressing roller to slide vertically.

[0041] Specifically, the sixth power unit can be a linear drive device such as an electric push rod, hydraulic cylinder, or servo electric cylinder. Its cylinder body or main body can be fixedly mounted on the tail frame of the moving module or the fixed bracket of the film pressing module. Its output end (such as a push rod or piston rod) is connected to the bearing seat or mounting bracket of the film pressing roller. The film pressing roller is mounted on a sliding block or slide block that can slide vertically via bearings at both ends. This sliding block or slide block cooperates with a vertical guide rail or guide sleeve fixed on the moving module or film pressing module bracket to form a guide pair. Alternatively, the sixth power unit itself has sufficient bending rigidity and guiding accuracy, and can directly drive the film pressing roller to perform vertical movement. By controlling the vertical position of the film pressing roller and its pressure on the ground through the sixth power unit, the clamping force can be dynamically adjusted according to the slight undulations of the road surface, changes in slope, and the thickness and condition of the film. For example, the pressure can be increased on uphill sections to prevent the film from slipping backward, and the pressure can be reduced in uneven areas to avoid excessive stretching and breakage of the film.

[0042] In this embodiment, as Figure 8 As shown, the maintenance device also includes a control module 400, which is integrally mounted on the moving module and is communicatively connected to the spraying module, the film pressing module, and the film releasing module. The control module acquires road width data and makes an extension judgment based on the road width data. If the road width is greater than the spraying width of the spraying pipe, it calculates the extension length of the extension pipe and generates an extension pipe extension control signal based on the extension pipe extension length calculation result, which is then sent to the spraying module so that the spraying module can perform the corresponding action according to the extension pipe extension control signal. The system acquires real-time road surface humidity data and uses an incremental PID algorithm to control the spraying module to adjust the water volume based on the deviation between the real-time humidity data and the target humidity. The speed of the moving part is obtained, the rotation speed of the film feeding roller is calculated based on the speed of the moving part, and a film feeding roller rotation speed control signal is generated based on the film feeding roller rotation speed and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the film feeding roller rotation speed control signal. The real-time tension of the film is obtained. Based on the deviation between the real-time tension and the ideal tension of the film, the target angle that the tensioning roller needs to swing is calculated using the PI algorithm. Based on the target angle that the tensioning roller needs to swing, a tensioning roller adjustment control signal is generated and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the tensioning roller adjustment control signal. The lateral offset of the film edge is obtained, the correction distance of the carriage lateral movement is calculated based on the lateral offset of the film edge, and a correction control signal is generated based on the correction distance of the carriage lateral movement and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the correction control signal. The road surface slope angle is obtained, and the pressure of the pressing roller is calculated based on the road surface slope angle and the real-time tension of the film. Based on the pressure calculation result, a pressing roller pressing control signal is generated and sent to the pressing module so that the pressing module can perform corresponding actions according to the pressing roller pressing control signal.

[0043] Specifically, the method for calculating the extension length of the pipe is as follows: in, L s The target length that the single-sided extension pipe needs to extend; W The detected real-time effective width of the road surface; W 0 represents the spray width of the spray pipe; δ To allow for a safety margin, the spraying boundary can be slightly smaller than the road surface boundary to prevent water from spraying off the road surface.

[0044] The control module calculates the target length that the single-sided extension pipe needs to extend according to the above formula, generates an extension pipe extension control signal containing the length value, and sends it to the second power unit of the spraying module to drive the two-sided extension pipes to extend or retract synchronously to the target position.

[0045] The specific method for adjusting the water volume using the incremental PID algorithm to control the spraying module is as follows: ; in, u k For the first k The final control quantity of each control cycle is the frequency command to the water pump inverter or the opening command to the proportional valve. u k-1 For the first k -The final control quantity for one control cycle; ∆u k For the first k The increment of the control quantity for each control cycle.

[0046] The control module calculates u k Then, a corresponding water volume adjustment and control signal is generated and sent to the water pump or valve actuator of the spraying module to realize the control of the spraying flow rate.

[0047] The first k The calculation method for the control quantity increment per control cycle is as follows: ; in, ϵ k , ϵ k-1 , ϵ k-2 These are the humidity deviations for the current, previous, and two previous control cycles, respectively. K p , K i , K d These are the proportional, integral, and differential coefficients, respectively.

[0048] The specific method for calculating the film-dispensing roller rotation speed based on the moving part speed is as follows: ; in, ω k For the first k The target angular velocity of the film-dispensing roller in each control cycle; K s This refers to the speed synchronization coefficient; r The real-time radius of the thin film roll; v k For the first k The real-time travel speed of the movement module in each control cycle.

[0049] The control module calculates according to the above formula. ω k The system generates a control signal for the film feeding roller speed and sends it to the third power unit of the film feeding module to control the film feeding roller to rotate at the target angular velocity.

[0050] The specific calculation method for calculating the target angle of the tensioning roller to swing based on the deviation between the real-time tension of the film and the ideal tension of the film using the PI algorithm is as follows: ; in, α k For the first k The target swing angle that the tensioning roller assembly needs to achieve in each control cycle; F 0 represents the preset ideal tension value for the thin film; F k For the first k Real-time tension of the thin film in each control cycle; K pf , K if These are the proportional and integral coefficients for tension control, respectively. F j From the start of the control process to the... k Between the first control cycles j The actual tension value of the thin film measured in each control cycle.j =1, 2, ..., k -1.

[0051] The control module calculates α k The system generates a tension roller adjustment control signal, which is sent to the fifth power unit of the film feeding module to drive multiple sets of tension rollers to swing synchronously to the target angle, thereby changing the wrap angle of the film path.

[0052] The specific method for calculating the correction distance of the carriage's lateral movement based on the lateral offset of the film edge is as follows: ; in, x k For the first k Each control cycle requires a lateral movement correction distance for the carriage; τ k For the first k The lateral offset of the thin film edge in each control cycle; K c This is the proportional coefficient for corrective control.

[0053] The control module calculates the correction distance according to the above formula, generates a correction control signal, and sends it to the fourth power unit of the film feeding module to drive the entire carriage and film feeding assembly to move in the opposite direction of the offset, thereby realizing real-time automatic correction of the film edge position.

[0054] The specific method for calculating the pressure of the film pressing roller based on the road surface slope angle and the real-time tension of the film is as follows: ; in, N k For the first k The target pressure of the pressure membrane in each control cycle; N 0 represents the base compaction force on a level, flat road surface; θ k For the first k Real-time road surface slope angle (positive for uphill and negative for downhill) for each control cycle. β This represents the slope compensation pressure value. F n This is a reference value for film tension. γ This is the tension feedforward compensation coefficient.

[0055] The control module first calculates according to the formula. N k Then, the measured value of the pressure sensor was read. F kThe system calculates the required vertical height adjustment for the pressure roller. Finally, it generates a pressure roller pressing control signal containing instructions and sends it to the sixth power unit of the pressure roller module to adjust the height / pressure of the pressure roller so that its actual pressure approaches the dynamically calculated target pressure.

[0056] This embodiment achieves intelligent, adaptive, and coordinated control of spraying, film placement, and film pressing through a control module, thereby improving the quality, efficiency, and reliability of maintenance operations.

[0057] In addition, the maintenance device in this embodiment may also include a sensing module 600. Specifically, the sensing module may include: The road width detection unit, which can be a laser scanner or millimeter-wave radar, is installed on the front crossbeam of the mobile module to measure the effective width of the road surface to be maintained.

[0058] The road surface humidity detection unit can use a non-contact infrared humidity sensor or a microwave humidity sensor, which is installed behind the spray pipe and in front of the pressure roller to measure the road surface humidity value.

[0059] The road slope sensing unit can be an inclinometer (IMU) installed at the center of the mobile module to measure the pitch angle of the equipment's travel direction, i.e., the longitudinal slope angle of the road surface. At the same time, it can be combined with an ultrasonic ranging sensor installed on the pressure roller bracket to assist in detecting the smoothness of the road surface.

[0060] The film tension detection unit can be a strain gauge tension sensor or a tension detection roller, which is installed in the bearing housing of the swing shaft or tension roller of the tensioning mechanism to measure the real-time tension value of the film during the tensioning process.

[0061] The film edge position detection unit can be a photoelectric sensor or a linear CCD sensor, symmetrically installed near the film outlet of the film feeding roller or on the support in front of the film pressing roller, to detect the lateral offset of the film relative to a preset baseline.

[0062] The film roll diameter detection unit can use an ultrasonic ranging sensor or an encoder of the film unwinding roller drive motor to measure the real-time radius of the film roll.

[0063] The speed and position detection unit can use an encoder (connected to the drive wheel of the mobile module) and / or a GNSS (Global Navigation Satellite System) receiver to provide real-time speed and geographical location information of the mobile module.

[0064] The spray pipe height detection unit can integrate a displacement sensor (such as a magnetostrictive displacement sensor) on the first power unit, or install an ultrasonic sensor on the spray pipe support to provide real-time feedback on the spray pipe's height above the ground.

[0065] The pressure detection unit for the film pressing roller can be installed with a pressure sensor on the force transmission path of the sixth power unit or in the bearing housing of the film pressing roller to measure the actual pressure of the film pressing roller on the ground.

[0066] An ambient temperature, humidity, and wind speed detection unit can be installed on the upper part of the mobile module to collect ambient temperature, humidity, and wind speed data.

[0067] Example 2: This embodiment provides a method for controlling a highway bridge surface concrete curing device described in Embodiment 1, the method comprising: The control module acquires road width data and makes an extension judgment based on the road width data. If the road width is greater than the spraying width of the spraying pipe, it calculates the extension length of the extension pipe and generates an extension pipe extension control signal based on the extension pipe extension length calculation result. The extension pipe extension control signal is then sent to the spraying module so that the spraying module can perform the corresponding action according to the extension pipe extension control signal. Specifically, the control module can acquire real-time road width data of the area to be maintained through a road width detection unit (such as a laser scanner) installed at the front end of the mobile module. The system internally stores the base spray width of the spray pipe when the extension pipe is fully retracted. The control module compares the road width data of the area to be maintained with the base spray width and performs an extension judgment. If the road width is less than the spray width of the spray pipe, it is determined that the extension pipe does not need to be extended; if the road width is greater than the spray width of the spray pipe, it is determined that the extension pipe needs to be extended. When it is determined that extension is necessary, the control module calculates the target extension length of the extension pipe on one side. The specific calculation method can be found in the specific method for calculating the extension length of the extension pipe described in Example 1. Based on the calculation result, the control module generates an extension pipe extension control signal and sends it to the second power unit of the spray module. The second power unit drives the extension pipes on both sides to move to the target position according to the signal.

[0068] The system acquires real-time road surface humidity data and uses an incremental PID algorithm to control the spraying module to adjust the water volume based on the deviation between the real-time humidity data and the target humidity. Specifically, the control module periodically samples and acquires real-time road surface humidity data through a road surface humidity detection unit located behind the spraying area. The system has a target humidity value set for concrete curing. The control module calculates the current humidity deviation. An incremental PID algorithm is used to calculate this deviation to determine the required water volume adjustment for the current cycle. The specific calculation method can be found in Example 1, which uses an incremental approach. The control module converts the calculated water volume adjustment into a specific water volume adjustment control signal and sends it to the water pump drive unit or flow proportional valve of the spraying module, so that the water pump drive unit or flow proportional valve adjusts the water flow according to the signal.

[0069] The speed of the moving part is obtained, the rotation speed of the film feeding roller is calculated based on the speed of the moving part, and a film feeding roller rotation speed control signal is generated based on the film feeding roller rotation speed and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the film feeding roller rotation speed control signal. Specifically, the control module can acquire the traveling speed of the moving module in real time via an encoder or GNSS module. Simultaneously, it measures the real-time radius of the film roll using sensors. The control module calculates the target angular velocity of the film-laying roller according to the specific method for calculating the film-laying roller rotation speed described in Example 1. The speed synchronization coefficient ensures that the film release linear velocity is slightly faster than the equipment's traveling speed, providing a margin for subsequent tensioning and preventing the film from being forcibly dragged. Based on the target angular velocity of the film-laying roller, the control module generates a film-laying roller rotation speed control signal (such as analog voltage, PWM wave, or bus command) and sends it to the third power unit of the film-laying module. The third power unit then controls the rotation speed of the film-laying roller accordingly.

[0070] The real-time tension of the film is obtained. Based on the deviation between the real-time tension and the ideal tension of the film, the target angle that the tensioning roller needs to swing is calculated using the PI algorithm. Based on the target angle that the tensioning roller needs to swing, a tensioning roller adjustment control signal is generated and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the tensioning roller adjustment control signal. Specifically, the control module acquires real-time film tension data via a tension sensor mounted on the tensioning mechanism. An ideal film tension value is preset within the system. The control module calculates the tension deviation. A PI algorithm is used to process this deviation to calculate the target angle at which the tensioning rollers need to swing. The specific calculation method can be found in Example 1, which describes the method for calculating the target angle. The control module generates a tensioning roller adjustment control signal based on the target angle and sends it to the fifth power unit of the film feeding module. The fifth power unit drives all tensioning rollers in the tensioning mechanism to swing synchronously to the target angle, thereby changing the wrap angle and length of the film path.

[0071] The lateral offset of the film edge is obtained, the correction distance of the carriage lateral movement is calculated based on the lateral offset of the film edge, and a correction control signal is generated based on the correction distance of the carriage lateral movement and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the correction control signal. Specifically, the control module can detect the lateral offset of the film edge relative to a preset baseline in real time using a film edge position sensor (such as a photoelectric sensor) installed near the film outlet. The control module calculates the required lateral correction distance for the carriage according to the specific method described in Example 1 for calculating the correction distance of the carriage's lateral movement. Based on the correction distance of the carriage's lateral movement, the control module generates a correction control signal and sends it to the fourth power unit of the film-laying module. The fourth power unit drives the entire carriage and all film-laying components on it to move in a direction perpendicular to the travel direction, correcting the film's laying position in real time.

[0072] The road surface slope angle is obtained, and the pressure of the pressing roller is calculated based on the road surface slope angle and the real-time tension of the film. Based on the pressure calculation result, a pressing roller pressing control signal is generated and sent to the pressing module so that the pressing module can perform corresponding actions according to the pressing roller pressing control signal.

[0073] Specifically, the control module can obtain the road surface slope angle through an inclinometer. The control module first dynamically calculates the target pressure of the pressing roller based on the road conditions and the film's condition. The calculation method can be found in the specific method for calculating the pressing roller pressure described in Example 1. Simultaneously, the control module reads the measured value from the pressing roller pressure sensor. Based on the target pressure, the control module generates a pressing roller lowering control signal and sends it to the sixth power unit of the pressing module. The sixth power unit drives the pressing roller to rise and fall according to this signal.

[0074] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A concrete curing device for highway bridge surfaces, characterized in that, include: A mobile module that can move on the ground; A spraying module, which is fixed on a mobile module, includes a spraying pipe connected to a water source; A film-laying module is fixed on a mobile module. The film-laying module includes a third power device and a film-laying roller. The third power device drives the film-laying roller to rotate. A covering film for concrete pavement maintenance is fitted on the film-laying roller. A film pressing module is fixed at the tail end of a mobile module. The film pressing module includes a film pressing roller that can rotate around its own circumference and contacts the road surface to be covered.

2. The concrete curing device for highway bridge surfaces according to claim 1, characterized in that, The spraying module also includes a first power unit, which drives the spraying pipe to move vertically up and down.

3. The concrete curing device for highway bridge surfaces according to claim 2, characterized in that, The spraying module also includes: A second power unit is installed on the spray pipe; An extension pipe is provided at both ends of the spray pipe. The extension pipe is connected to a second power device, which drives the extension pipe to move linearly along the axis of the spray pipe.

4. A concrete curing device for highway bridge surfaces according to claim 3, characterized in that, The spraying module also includes: A fixed water baffle is fixed to the spray pipe, and the nozzle of the spray pipe is located inside the fixed water baffle. A movable water barrier is fixed to an extension pipe, and the nozzle of the extension pipe is located inside the movable water barrier.

5. A concrete curing device for highway bridge surfaces according to claim 1, characterized in that, The film-laying module also includes a tensioning mechanism, which includes a fifth power unit and tensioning rollers. The tensioning rollers are provided in multiple sets, which are arranged linearly and parallel to each other. The fifth power unit drives the multiple sets of tensioning rollers to swing.

6. A concrete curing device for highway bridge surfaces according to claim 5, characterized in that, The membrane dispensing module further includes: A fixed base is fixedly mounted on the mobile module; The slide is mounted on the third power unit, the film feeding roller and the tensioning mechanism, and the slide is slidably mounted on the fixed base. The fourth power unit drives the carriage to slide linearly in a direction perpendicular to the movement of the moving part.

7. A concrete curing device for highway bridge surfaces according to claim 1, characterized in that, The film pressing module also includes a sixth power device, which drives the film pressing roller to slide vertically.

8. A concrete curing device for highway bridge surfaces according to claim 1, characterized in that, The maintenance device also includes a control module, which is integrally mounted on the mobile module and is communicatively connected to the spraying module, the film pressing module, and the film releasing module. The control module acquires road width data and makes an extension judgment based on the road width data. If the road width is greater than the spraying width of the spraying pipe, it calculates the extension length of the extension pipe and generates an extension pipe extension control signal based on the extension pipe extension length calculation result, which is then sent to the spraying module so that the spraying module can perform the corresponding action according to the extension pipe extension control signal. The system acquires real-time road surface humidity data and uses an incremental PID algorithm to control the spraying module to adjust the water volume based on the deviation between the real-time humidity data and the target humidity. The speed of the moving part is obtained, the rotation speed of the film feeding roller is calculated based on the speed of the moving part, and a film feeding roller rotation speed control signal is generated based on the film feeding roller rotation speed and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the film feeding roller rotation speed control signal. The real-time tension of the film is obtained. Based on the deviation between the real-time tension and the ideal tension of the film, the target angle that the tensioning roller needs to swing is calculated using the PI algorithm. Based on the target angle that the tensioning roller needs to swing, a tensioning roller adjustment control signal is generated and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the tensioning roller adjustment control signal. The lateral offset of the film edge is obtained, the correction distance of the carriage lateral movement is calculated based on the lateral offset of the film edge, and a correction control signal is generated based on the correction distance of the carriage lateral movement and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the correction control signal. The road surface slope angle is obtained, and the pressure of the pressing roller is calculated based on the road surface slope angle and the real-time tension of the film. Based on the pressure calculation result, a pressing roller pressing control signal is generated and sent to the pressing module so that the pressing module can perform corresponding actions according to the pressing roller pressing control signal.

9. A method for controlling the surface concrete curing device for highway bridges as described in claim 8, characterized in that, The method includes: The control module acquires road width data and makes an extension judgment based on the road width data. If the road width is greater than the spraying width of the spraying pipe, it calculates the extension length of the extension pipe and generates an extension pipe extension control signal based on the extension pipe extension length calculation result. The extension pipe extension control signal is then sent to the spraying module so that the spraying module can perform the corresponding action according to the extension pipe extension control signal. The system acquires real-time road surface humidity data and uses an incremental PID algorithm to control the spraying module to adjust the water volume based on the deviation between the real-time humidity data and the target humidity. The speed of the moving part is obtained, the rotation speed of the film feeding roller is calculated based on the speed of the moving part, and a film feeding roller rotation speed control signal is generated based on the film feeding roller rotation speed and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the film feeding roller rotation speed control signal. The real-time tension of the film is obtained. Based on the deviation between the real-time tension and the ideal tension of the film, the target angle that the tensioning roller needs to swing is calculated using the PI algorithm. Based on the target angle that the tensioning roller needs to swing, a tensioning roller adjustment control signal is generated and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the tensioning roller adjustment control signal. The lateral offset of the film edge is obtained, the correction distance of the carriage lateral movement is calculated based on the lateral offset of the film edge, and a correction control signal is generated based on the correction distance of the carriage lateral movement and sent to the film feeding module so that the film feeding module can perform corresponding actions according to the correction control signal. The road surface slope angle is obtained, and the pressure of the pressing roller is calculated based on the road surface slope angle and the real-time tension of the film. Based on the pressure calculation result, a pressing roller pressing control signal is generated and sent to the pressing module so that the pressing module can perform corresponding actions according to the pressing roller pressing control signal.

Images