An intelligent integrated construction system and method for rockfill concrete dam

Abstract

The application provides a kind of rockfill concrete dam intelligent integrated construction system and method, related dam equipment technical field includes: lightweight intelligent operation platform, for executing intelligent deployment step and whole-process collaborative control step;Stone pretreatment and transfer system, for executing digital material preparation step, complete stone cleaning air drying, three-dimensional information acquisition and vertical-horizontal seamless transfer;Horizontal intelligent transport system, for executing stacking step, realize stone global coverage type distribution.The beneficial effects of the application are: by adopting double camera linkage snapshot cooperation SAM image large model, realize the automatic gradation detection of 30-100cm large particle size rockfill;Aided by unmanned aerial vehicle aerial photography and laser scanning fusion verification, form the quality closed loop of prediction-implementation-verification-optimization;Bridge type travelling crane hoist cooperates dynamic scheduling algorithm to realize global accurate distribution, landing point error ±5mm, concrete distribution system is based on rockfill gap data to implement differential pouring, uniformity error is controlled within 5%.

Description

Technical Field

[0001] This invention relates to the field of dam construction equipment technology, and in particular to an intelligent integrated construction system and method for rockfill concrete dams. Background Technology

[0002] Rockfill concrete dams are widely used in water conservancy projects due to their advantages such as structural stability, controllable cost, and convenient construction. However, traditional rockfill concrete dam construction has many drawbacks: First, the processes are fragmented, with a lack of effective coordination in stone processing, transportation, stacking, and pouring, resulting in low construction efficiency. Second, quality control is difficult, as key indicators such as rock particle size, stacking density, and concrete pouring uniformity rely on manual monitoring, leading to significant errors. Third, safety risks are high, as dam construction often involves high-altitude, water-adjacent, and overlapping operations, with prominent safety hazards such as falls from heights and falling objects. Fourth, resource waste is serious, with issues such as direct discharge of wastewater from stone washing and excessive concrete pouring increasing environmental pressure and costs.

[0003] While existing technologies include some single-function construction equipment (such as stone transport vehicles and concrete placing booms), they lack integrated solutions for global coordination. The independent operation of each piece of equipment leads to disjointed construction processes, making it difficult to meet the demands of large-scale, high-quality dam construction. Therefore, developing a dam-building equipment that integrates multiple processes, is intelligent, and highly collaborative is crucial to solving the pain points of traditional construction methods. Summary of the Invention

[0004] In view of this, embodiments of the present invention provide an intelligent integrated construction system and method for rockfill concrete dams, which solves the technical problem that existing construction equipment cannot meet the requirements of large-scale collaborative construction processes when operating independently.

[0005] Embodiments of the present invention provide an intelligent integrated construction system for rockfill concrete dams, comprising: A lightweight intelligent operation platform for executing intelligent deployment steps and full-process collaborative management steps; The stone pretreatment and transfer system is used to perform digital material preparation steps, complete stone cleaning and drying, three-dimensional information acquisition and seamless vertical-horizontal transfer. A horizontal intelligent transportation system is used to perform stacking steps, enabling full-area coverage delivery of stone materials. The intelligent concrete placement system is used to execute intelligent pouring steps and complete concrete filling and pouring based on the gap data of the riprap. Safety protection device system is used to perform safety monitoring functions in the whole process collaborative control steps; The rockfill image recognition system is used to perform the stacking, cleaning and intelligent pouring steps, and to complete the digital modeling of the rockfill body and the calculation of the rockfill ratio. The steel formwork turnover system is used to perform formwork support and cyclic turnover steps, and to complete the transfer, installation and dismantling of steel formwork. The working face washing and slag removal system is used to perform cleaning treatment steps, complete the working face washing, automatic slag removal and wastewater recycling; The intelligent operation monitoring system is used to execute intelligent deployment steps and full-process collaborative management and control steps, integrating multi-source data collection, intelligent analysis, collaborative scheduling and security management functions.

[0006] Furthermore, the three-dimensional information acquisition module of the stone pretreatment and transfer system integrates an industrial camera and a laser three-dimensional scanner, and the vertical transportation system and the horizontal transfer trolley form a vertical-horizontal transfer channel.

[0007] Furthermore, the intelligent concrete placing system includes an independent placing frame, wear-resistant conveying pipes, a dual metering and monitoring module, and a laser level control module, with a coverage radius adapted to the width of the working surface.

[0008] Furthermore, the riprap image recognition system includes a laser 3D scanner, an industrial camera, and an edge computing node, and achieves real-time data exchange with the transportation and fabric laying systems through industrial Ethernet and 5G dual-mode communication.

[0009] Furthermore, the steel formwork turnover system includes a steel formwork body, a frequency conversion drive unit, a hydraulic lifting and tilting mechanism, and a double fixing device, and is equipped with an emergency manual operation device.

[0010] Furthermore, the working face flushing and slag removal system includes a high-pressure flushing unit, a mechanical slag removal unit, and a multi-stage wastewater filtration unit to achieve wastewater recycling.

[0011] Furthermore, the intelligent operation monitoring system includes a full-dimensional data acquisition unit, edge computing nodes, a cloud data center, and a three-dimensional visualization monitoring interface, supporting remote monitoring and manual intervention.

[0012] A smart integrated construction method for rockfill concrete dams, employing the aforementioned construction system, includes the following steps: S1: Deploy a lightweight operation platform on the dam working face, integrating a stone pretreatment and transfer system, a horizontal intelligent transportation system, a concrete intelligent placement system, a safety protection device system, a rockfill image recognition system, a steel formwork turnover system, a working face washing and slag removal system, and an intelligent operation monitoring system, and establish a data communication and collaborative control link between multiple systems; S2: After pretreatment, the stone is digitally archived through three-dimensional information acquisition and then transported to the work surface via a vertical and horizontal transfer system. S3: Based on the rock pile distribution data fed back by the rock pile image recognition system, the horizontal intelligent transportation system accurately delivers the stones to the designated location for stacking; S4: The working face flushing and slag removal system automatically plans the working path based on the rock pile distribution data, flushes and removes slag from the rock pile surface, and sends a ready signal after the cleaning standard is met. S5: The steel formwork turnover system receives the ready signal, transfers the steel formwork to the pouring area and fixes it, and sends the pouring ready signal after acceptance. S6: The intelligent concrete placement system receives the pouring ready signal and implements a differentiated pouring strategy based on the distribution data of the gaps between the riprap to achieve precise concrete filling. S7: The intelligent operation monitoring system collects real-time operation data and construction quality parameters of each system, and performs intelligent analysis and dynamic scheduling through edge computing to achieve process connection optimization, load balance control and safety risk early warning; S8: After the concrete strength reaches the standard, the steel formwork turnover system completes the dismantling and storage of the formwork and enters the next construction cycle.

[0013] Furthermore, in step S2, the stone pretreatment includes washing and air drying processes, and the three-dimensional information acquisition includes the extraction of particle size, shape and volume parameters.

[0014] Furthermore, in step S5, the steel formwork turnover system adapts to the changes in the slope angle of the dam surface through a hydraulic lifting and pitch adjustment mechanism, and achieves formwork fixation through a combination of mechanical clamping and bolt reinforcement.

[0015] The beneficial effects of the technical solutions provided by the embodiments of the present invention are as follows: The intelligent integrated construction system and method for rockfill concrete dams of the present invention achieves automated gradation detection of 30-100cm large-particle-size rockfill by using dual-camera linkage capture combined with SAM image large model; supplemented by drone aerial photography and laser scanning fusion verification, a quality closed loop of prediction-implementation-verification-optimization is formed; the bridge crane combined with dynamic scheduling algorithm achieves precise delivery across the entire area with a landing point error of ±5mm; the concrete placement system implements differentiated pouring based on rockfill gap data, and the uniformity error is controlled within 5%; UWB precise positioning and graded early warning mechanism build a zero-accident protection network; the flushing and slag removal system achieves high cleanliness and wastewater recycling rate; the formwork turnover system achieves ±3mm installation accuracy and 40-minute full-process efficiency; the load leveling and process optimization functions of the intelligent monitoring system ensure maximum resource utilization. In summary, this invention achieves significant results in improving construction efficiency, increasing rockfill ratio, and eliminating safety accidents, providing a systematic solution for the large-scale intelligent construction of rockfill concrete dams. Attached Figure Description

[0016] Figure 1 This is a side view schematic diagram of the intelligent integrated construction system and method for rockfill concrete dams of the present invention; Figure 2This is a frontal view schematic diagram of the intelligent integrated construction system and method for rockfill concrete dams of the present invention; Figure 3 This is a schematic diagram of the construction state a of the intelligent integrated construction system and method for rockfill concrete dams of the present invention; Figure 4 This is a schematic diagram of the construction state b of the intelligent integrated construction system and method for rockfill concrete dams of the present invention; Figure 5 This is a schematic diagram of the construction state c of the intelligent integrated construction system and method for rockfill concrete dams of the present invention.

[0017] In the diagram: 1. Lightweight intelligent operation platform; 2. Stone pretreatment and transfer system; 21. Cleaning module; 211. Nozzle; 22. Standardized loading module; 3. Horizontal intelligent transportation system; 4. Rockfill image recognition system; 5. Intelligent concrete placing system; 51. Independent placing frame; 52. Conveying pipeline; 6. Steel formwork turnover system; 61. Steel formwork body; 62. Turnover drive unit; 63. Fixing unit; 7. Working surface flushing and slag removal system. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be further described below with reference to the accompanying drawings. The following description presents a preferred embodiment of the various possible embodiments of the present invention, intended to provide a basic understanding of the invention, but not intended to identify key or decisive elements of the invention or to limit the scope of protection sought.

[0019] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0020] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0021] It should be noted that similar labels and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be discussed further in subsequent figures. Also, it should be understood that, for ease of description, the dimensions of the various parts shown in the figures are not drawn to actual scale.

[0022] In the description of this invention, it should be noted that the circuits, electronic components and modules involved in this invention are all prior art, which can be fully implemented by those skilled in the art, and need not be elaborated upon. The content protected by this invention does not involve improvements to the internal structure and method.

[0023] It should be further noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] Please refer to Figures 1-2 The present invention provides an intelligent integrated construction system for rockfill concrete dams, comprising nine parts: a lightweight intelligent operation platform 1, a stone pretreatment and transfer system 2, a horizontal intelligent transportation system 3, a rockfill image recognition system 4, an intelligent concrete placement system 5, a steel formwork turnover system 6, a working face washing and slag removal system 7, a safety protection device system, and an intelligent operation monitoring system.

[0025] The lightweight intelligent operation platform 1 serves as the core support carrier, employing a steel frame design with a width of 23-40 meters and an overall load-bearing capacity of ≥500t. Key stress-bearing components are reinforced with ribs and load-bearing pads. Equipped with a triple positioning system combining laser displacement sensors, encoders, and satellite positioning, it achieves horizontal positioning accuracy ≤±5mm and vertical positioning accuracy ≤±2mm. Through distributed pressure sensors and intelligent leveling algorithms, it ensures static and dynamic load distribution deviations ≤8% and horizontal deviations ≤±0.3° under all working conditions. The platform has reserved standardized interfaces, with water and electricity interfaces achieving IP67 protection. It features a dual-drive system for horizontal movement and vertical climbing, allowing for flexible coverage of different dam sections. High-strength anchor bolts and pre-embedded components in the dam ensure stable operation under all working conditions.

[0026] The stone pretreatment and transfer system 2 includes a cleaning module 21, a three-dimensional information acquisition module, a stone stockpile ratio prediction module, and a standardized loading module 22. It adopts a 15-20MPa high-pressure spray device and multiple sets of adjustable angle nozzles 211 to achieve all-round washing, remove floating dust, mud and other impurities. The cleaning wastewater is treated by a water collection tank and a filtration system and then recycled. After cleaning, the moisture content of the stone is controlled to within 5% by hot air circulation and natural ventilation drying.

[0027] The 3D information acquisition module adopts a dual-camera linkage capture system. The ground camera performs vehicle recognition, and when the transport vehicle enters the weighbridge area, the overhead camera is automatically controlled to capture images of stones inside the transport vehicle. High-precision automatic image correction is performed through geometric control points of the vehicle to eliminate perspective distortion. The SAM image large model is used to achieve accurate recognition and rapid block segmentation of the piled stone images. Cloud GPU accelerated computing improves the efficiency compared to traditional CPU processing. Parameters such as the number of stones, maximum and minimum particle size, and oversize and undersize content are extracted in real time to generate particle size distribution curves and establish digital archives for individual stones.

[0028] The rockfill ratio prediction module is based on the actual measured statistical data of rockfill size on site. It combines PFC3D discrete element simulation and machine learning random forest algorithm to build a large-scale rockfill ratio prediction model. It accurately correlates the gradation distribution with the rockfill ratio. Combined with the particle size analysis results of a single truck or multiple pouring bins, it predicts the theoretical rockfill ratio of the batch of stone, providing core support for the optimization of stacking strategy.

[0029] The standardized loading module 22 uses a steel cage to load stones, which is suitable for stones with a particle size of 50-1000mm. The vertical transfer unit runs along the track on the dam slope to transport the stones from the ground to the working platform. The horizontal transfer unit realizes left-right through transportation through the transfer trolley and is seamlessly linked with the horizontal intelligent transportation system.

[0030] The Horizontal Intelligent Transportation System 3 adopts a bridge-type overhead crane structure with a clear span of 10 meters and a rated lifting capacity of 5 tons. The main body is welded from high-strength steel, and the track system is made of national standard I-beams with surface wear-resistant treatment and a hardness of ≥HRC35. It is double-fixed by flanges and positioning pins and equipped with a positioning system that coordinates laser displacement sensors, encoders and satellite positioning. The landing point positioning error is ≤±5mm. The lifting mechanism has dual protection functions of overload and limit. The built-in dynamic scheduling algorithm receives the stacking demand, stacking ratio prediction results and platform load data from the rockfill image recognition system in real time, automatically allocates transportation routes and capacity, and prioritizes the delivery of high-potential rockfill materials to key areas. When multiple overhead cranes have track conflicts, they are adjusted according to the principle of prioritizing key areas and delivering nearby to avoid the accumulation or shortage of materials and achieve precise delivery with full coverage.

[0031] The rockfill image recognition system 4 includes a data acquisition unit, which realizes digital modeling of the rockfill, calculation of the rockfill ratio, and elevation verification. The data acquisition unit includes a vehicle-mounted dual-camera linkage system deployed in the weighbridge area to automatically capture images of stones inside the transport vehicle for rapid detection of incoming stone gradation; a drone aerial photography system to capture images of the rockfill site on the dam body, which are then imported into the system software for analysis of the actual rockfill ratio; a laser 3D scanner with a scanning accuracy of ≤±0.1mm and a scanning speed of ≥1 million points / second, deployed around the work surface to form a no-dead-angle acquisition network; and a 20-megapixel industrial camera with an adaptive lighting system and an automatic lens cleaning device to adapt to strong light and dusty environments.

[0032] The data processing unit includes an edge server with a computing speed of ≥300 GFLOPS to achieve real-time data processing with a latency of ≤10 seconds; a large SAM image model to achieve accurate segmentation and particle size statistics of boulders; PFC3D discrete element simulation to simulate the boulder accumulation process and predict the boulder ratio; a machine learning random forest model to continuously optimize the prediction accuracy of gradation and boulder ratio; and a boulder body modeling algorithm to generate 3D models of individual stones and the boulder body, achieving a boulder ratio calculation error of ≤3% and an elevation verification accuracy of ≤±5mm. The data interaction unit adopts industrial Ethernet and 5G dual-mode communication with a data transmission latency of ≤1 second, supports the OPC UA standardized protocol, and pushes decision data, including boulder gap distribution maps, priority filling area identifiers, and stone delivery priority lists, to the transportation and material placement systems.

[0033] The core execution unit of the intelligent concrete placing system 5 consists of an independent placing frame 51, a conveying pipe 52, and a monitoring and control unit, integrated into a lightweight working platform 1. It has a coverage radius of 19 meters, an adjustable placing flow rate of 0-50 m³ / h, and a 360° horizontal rotation angle for full coverage of the working surface. The conveying pipe 52 is made of wear-resistant alloy material with a smooth inner wall to prevent segregation. It is equipped with shock-absorbing supports and sealing quick connectors. A flow guide device is installed at the placing head outlet to prevent segregation. An internal anti-clogging sensor in the pipe activates a backwashing function in case of malfunction. The intelligent concrete placing system 5 receives rockfill gap distribution data from a rockfill image recognition system, automatically generates differentiated pouring plans, identifies large gap areas as priority filling targets, and adjusts the placing flow rate to prevent segregation in densely packed rockfill areas, achieving on-demand placing.

[0034] The monitoring and control unit includes a dual pouring volume monitoring system with electromagnetic flowmeter and weighing meter working together, with an error ≤3%, and a laser liquid level sensor installed under the independent material placing frame 51 to monitor the pouring surface height and compare it with the design elevation in real time. When the deviation exceeds ±3mm, it will automatically adjust or stop the machine with an accuracy ≤±5mm.

[0035] The steel formwork turnover system 6 includes a steel formwork body 61, a turnover drive unit 62, and a fixing unit 63. The steel formwork 61 is made of high-strength steel plate with a thickness of ≥12mm, with horizontal and vertical reinforcing ribs on the back. The splice is designed with a tongue and groove joint with a gap of ≤1mm. The panel is treated with shot blasting to remove rust and anti-corrosion coating, and a release agent spraying interface is reserved.

[0036] The turnover drive unit 62 is integrated into the platform's horizontal track support frame. It features a dual-track parallel design, equipped with a variable frequency drive motor and a gear and rack transmission mechanism. The moving speed is 0.2-0.8m / s. The hydraulic lifting system has a rated lifting force of ≥10t and a lifting stroke of 0-15m. The electric pitch device has an adjustable angle of -5° to 5° to adapt to changes in the dam slope.

[0037] The template fixing unit 63 adopts a dual method of mechanical clamping and bolt reinforcement, with a firmness coefficient ≥1.5. The disassembly unit achieves smooth demolding by using a hydraulic jacking device to push at multiple points synchronously, avoiding damage to the dam body. The entire process of transporting, installing, disassembling, and storing a single set of templates takes ≤40 minutes. It is equipped with a backup hydraulic pump and a manual operation device for emergency handling in case of sudden failure.

[0038] The working face flushing and slag removal system 7 consists of a high-pressure flushing unit, an automatic slag removal unit, and a wastewater treatment unit. The high-pressure flushing unit adopts a multi-head bow-shaped flushing frame with a span of ≥3 meters. Each frame is equipped with 5-6 high-pressure nozzles with an adjustable spray pressure of 15-25MPa and a flow rate of 2-4m³ / h per nozzle. The flushing frame moves laterally along the platform, and the nozzles support 360° rotation and -15°~90° pitch adjustment. The working face flushing and slag removal system 7 has a built-in intelligent control module that presets the flushing path and strengthens the flushing of areas with concentrated gaps and areas with floating slag accumulation based on the rock pile distribution data fed back by the rock pile image recognition system 4.

[0039] The automatic slag removal unit adopts an integrated design of scraper collection, screw conveyor and waste storage box. The scraper is made of wear-resistant rubber and has a ≥90% fit with the working surface and moves synchronously with the washing frame. The screw conveyor has a conveying capacity of ≥5m³ / h, the storage box volume is ≥10m³, the material level sensor will issue an early warning when the storage volume reaches 80%, and the waste collection rate is ≥95%.

[0040] The wastewater treatment unit collects wastewater through a diversion channel and a collection channel. After three stages of treatment—grid filtration, sedimentation tank, and precision filter—it is recycled. The recycling rate is ≥80%, the operating efficiency for a single area of ​​100m² is ≤30 minutes, and the cleanliness of the working surface is ≥98%.

[0041] The safety protection system constructs a three-dimensional safety system encompassing fully enclosed boundary protection, precise personnel early warning, equipment safety protection, and emergency response. The boundary protection unit includes a lower protective frame (≥2.5 meters high) constructed with a steel structure frame and high-strength protective netting (mesh size ≤100×100mm, tensile strength ≥5kN), doubly fixed to the platform, with a wind load resistance ≥0.55kN / m². The upper protective canopy uses a steel structure frame and flame-retardant waterproof tarpaulin (flame retardant B1 grade, waterproof IPX5), with a roof slope ≥15°. It also includes a double-layered suspended protective netting: an inner layer of dense safety netting (mesh size ≤20×20mm) and an outer layer of fall protection netting (tensile strength ≥10kN), with a built-in tension sensor monitoring the stress state. The personnel safety protection unit integrates a UWB positioning system. Construction workers wear positioning wristbands with a battery life of ≥72 hours, IP67 waterproof rating, and positioning accuracy of ≤±30cm. When personnel approach a danger zone within ≤2m, the wristband and platform warning lights issue a synchronized warning; when approaching within ≤1m, the relevant equipment is automatically locked. The wristband also features a one-button alarm function. The equipment and area protection unit includes displacement monitoring sensors at the bottom of the platform support columns, triggering locking when the horizontal deviation is ≥±0.5°, dual limit switches at both ends of the track, and protective fences and infrared sensor alarms for danger zones. The emergency protection unit includes an emergency refuge chamber with a capacity of ≥6 people, an impact-resistant steel structure, built-in emergency power supply, a first-aid kit, and an escape slide with a slope of ≤60° to guide personnel to safety in case of emergencies.

[0042] The intelligent operation monitoring system includes a data acquisition unit, a processing unit, and a control and scheduling unit. The data acquisition unit includes: an equipment status acquisition module that installs sensors for pressure, displacement, vibration, etc., with a key parameter acquisition frequency of 100ms / time; a platform attitude and load acquisition module that uses dual-axis tilt sensors and laser displacement sensors, with a data synchronization deviation ≤0.1ms; a module that receives gradation data, rockfill ratio prediction results, and rockfill quality data from a 3D model of the rockfill image recognition system; a personnel and safety data acquisition module that uses a UWB positioning system and safety device status sensors; and an environmental and operational data acquisition module that monitors environmental parameters such as temperature, humidity, and wind speed, as well as operational data from various systems.

[0043] The data processing unit includes edge computing nodes with a computing speed of ≥300GFLOPS and a processing latency of ≤0.1 seconds. The core algorithm engine includes a load distribution calculation algorithm, a collaborative scheduling algorithm based on rockfill ratio prediction, a fault diagnosis algorithm with an accuracy of ≥90%, a security risk assessment algorithm, and a cloud data center with a storage capacity of ≥50TB that supports 5 years of data traceability and multi-dimensional retrieval.

[0044] The control and scheduling unit includes a global collaborative scheduling module that optimizes stone delivery priority based on riprap ratio prediction results and adjusts the pouring sequence according to the riprap gap distribution to achieve seamless connection between pretreatment, transfer, stacking, washing, and pouring; a platform stability control module that dynamically adjusts support stress to avoid local overload; and a safety risk management module with real-time graded early warning in blue, yellow, and red colors, automatically suspending operations and initiating emergency measures when a red warning is issued. The visualization and interaction unit includes a 3D visualization monitoring interface, a digital twin model that displays the riprap body model, riprap ratio distribution, pouring progress, and personnel location in real time, supporting remote monitoring and manual intervention.

[0045] Please refer to Figure 3-5 This is a schematic diagram of the construction state ac. As construction progresses and the road surface continues to descend, the horizontal span of the standardized transport module 22 gradually increases.

[0046] The embodiments of the present invention will be described in detail below with reference to specific examples.

[0047] The lightweight intelligent operation platform 1 is fixed to the dam's pre-embedded components using high-strength anchors with a specification ≥ M36. These anchors have a pull-out force ≥ 500kN, ensuring a reliable connection between the platform and the dam structure. The installation and docking of the following systems are completed: stone pretreatment and transfer system 2, horizontal intelligent transportation system 3, intelligent concrete placement system 5, safety protection device system, rockfill image recognition system 4, steel formwork turnover system 6, work surface washing and slag removal system 7, and intelligent operation monitoring system. Construction parameters, including dam section length 80m, width 25m, target rockfill ratio 50%, pouring elevation EL.450m, safety warning threshold wind speed 20m / s, and horizontal deviation ±0.5°, are initialized through the intelligent operation monitoring system. A multi-system data communication link is established. The rockfill image recognition system is connected to the intelligent operation monitoring system via a 5G network to ensure image analysis latency ≤ 10 seconds. Each execution system is connected to the edge computing node via industrial Ethernet to ensure control command transmission latency ≤ 0.1 seconds.

[0048] Stone is transported from the stockpile to the pretreatment unit via conveyor belt. A 15-20MPa high-pressure spray system thoroughly washes away dust and dirt. The washing wastewater is treated by a collection tank and filtration system before being recycled. After washing, the stone is dried using hot air circulation and natural ventilation to control the moisture content to below 5%. Once the transport vehicle enters the weighbridge area, a dual-camera linkage system is activated. The ground camera identifies the vehicle's position and controls the overhead camera to capture images of the stones inside the truck bed. Image correction is performed using geometric control points at the four corners of the truck bed to eliminate perspective distortion. The images are uploaded to the cloud GPU server, where the SAM large model accurately segments the stones. Parameters such as the maximum particle size (85cm), minimum particle size (32cm), oversized content (8%), and undersized content (5%) are extracted to generate a particle size distribution curve. The PFC3D discrete element simulation module establishes a three-dimensional stacking model of the graded stone to simulate its stacking state in the casting silo. The random forest algorithm, combined with historical data, predicts a theoretical stacking rate of 52.3% for this batch of stone, providing data support for the stacking strategy. After being loaded with stones, the standardized cage is transported to the working platform at a speed of 0.5m / s along the dam slope track by a vertical circulation transport system. The horizontal transport trolley then transfers the stones to the lifting position of the overhead crane, with a landing point positioning accuracy of ≤±10mm, achieving seamless vertical and horizontal transfer.

[0049] Based on a predicted rockfill ratio of 52.3%, the intelligent operation monitoring system marked this batch of stones as high priority and sent it to the horizontal intelligent transportation system. A gantry crane, using a triple positioning system, precisely lifted the stones to the central area of ​​the storage area, where the designed rockfill ratio was high, with a landing error of ≤±5mm. The dynamic scheduling algorithm monitored the platform's load distribution in real time and found that the concentration on the east side was as high as 12%, leading to adjustments in subsequent stone delivery to the west side to achieve load balance control within 8%. Aerial images of the stacked area taken by a drone were imported into the rockfill image recognition system. Analysis showed an actual rockfill ratio of 51.8%, a deviation of 0.5% from the predicted value of 52.3%, within the allowable range. The system fed the actual data back to the machine learning module to optimize the prediction model parameters. A laser 3D scanner collected real-time 3D point cloud data of the rockfill body to generate a digital model. Comparing this model with the design parameters revealed that the rockfill ratio in a local area was 48%, lower than the target value. The system sent a replenishment command to the horizontal intelligent transportation system to schedule large-diameter stones to fill this area, achieving dynamic optimization of the rockfill density.

[0050] After the stacking is completed, the working face flushing and slag removal system 7 receives the rock distribution data and automatically plans the flushing path. It identifies three areas with concentrated gaps and two areas with scum accumulation, generating an optimized working route. The multi-head bow-shaped flushing frame is activated, with the nozzle pressure at 20MPa. The flushing time is extended by 30% for areas with concentrated gaps, and the nozzle pitch angle is increased to 60° to enhance the flushing force for areas with scum accumulation. The scraper collects the scum and transports it to the temporary storage tank via a screw conveyor. The flushing wastewater is collected through the diversion channel and then filtered through a grid to remove large particles. Fine particles settle in the sedimentation tank and are purified by a precision filter before being stored in the circulating water tank, achieving a recycling rate of 85%. After the operation is completed, the system detects that the cleanliness of the working face is 99% and sends a cleanliness compliance signal to the intelligent operation monitoring system.

[0051] After receiving the cleanliness compliance signal, the steel formwork turnover system 6 starts the frequency converter drive motor to transfer the steel formwork from the storage area to the pouring area at a speed of 0.6m / s, a distance of 45m, in 75 seconds. The hydraulic lifting system lifts the formwork to the designed height EL.450m, and the electric tilt device adjusts the angle to -3° to adapt to the slope angle of the dam. The positioning pins work with the installation base to achieve precise positioning with an installation accuracy of ±2mm. The formwork joints are fixed with high-strength bolts to a joint gap of 0.8mm. The mechanical clamping claws automatically clamp the formwork frame with a firmness coefficient of 1.6. After the system detects and accepts the installation accuracy and firmness, it sends a pouring ready signal.

[0052] After receiving the pouring ready signal, the intelligent concrete placing system 5 retrieves the rockfill gap distribution data pushed by the rockfill image recognition system 4. It identifies five large gap areas with gaps greater than 15cm as priority filling targets and identifies two dense rockfill areas as flow-limiting areas. The placing frame rotates to the top of the first large gap area and adjusts the placing flow rate to 45m³ / h for rapid filling. As the gap decreases, the flow rate gradually decreases to 30m³ / h. Before entering the dense rockfill area, the flow rate is reduced to 20m³ / h to prevent segregation, thus realizing a differentiated pouring strategy.

[0053] The electromagnetic flowmeter monitors the cumulative pouring volume in real time, which is 125 m³, while the weighing display shows 123.8 m³. The double data verification error is 0.96%. The laser level sensor monitors the pouring surface elevation EL.449.2 m, which deviates from the design elevation EL.450 m by -8 mm. The PLC controller automatically adjusts the height of the concrete placing head to continue pouring until the elevation is reached. During the pouring process, the rockfill image recognition system updates the rockfill gap distribution every 30 seconds to dynamically adjust the pouring strategy. When the pouring volume in a certain area reaches 95% of the design value, an automatic warning is issued and preparations are made to move to the next area, achieving precise concrete filling.

[0054] Throughout the construction process, the intelligent operation monitoring system collects and analyzes data from various systems in real time to achieve full-process collaborative management. Regarding load balance control, the load ratio on the east side of the platform is 52% and on the west side is 48%. The scheduling algorithm optimizes subsequent processes, prioritizing concrete pouring on the east side to increase the load, and prioritizing formwork dismantling on the west side to reduce the load. After dynamic balancing, the load ratio on the east and west sides is adjusted to 50.5% to 49.5%. Regarding process connection optimization, based on the comparison between the current rockfill ratio of 51.5% and the target value of 50%, it is determined that the current rockfill ratio on the storage surface is too high, and instructions are sent to the stone pre-processing and transfer system. In the next batch of stone screening, the proportion of small-diameter particles will be increased to 60% to optimize the gradation. In terms of safety warnings, the UWB positioning system detected that three people entered within 2 meters of the overhead crane's operating track, triggering a yellow warning. The wristband vibrated, the platform warning light flashed, and the overhead crane slowed down by 50%. When one person entered within 1 meter, a red warning was triggered. The overhead crane automatically locked and was released after the personnel were evacuated. All data, including stone gradation, predicted and actual values ​​of rockfill ratio, pouring volume, and personnel location trajectory, are uploaded to the cloud in real time and stored in categories by timestamp, region, and process, supporting retrieval at any time within 5 years.

[0055] After 72 hours of concrete curing, the strength test met the standard. The actual measured strength of C15 was 18.5MPa. The steel formwork turnover system started the dismantling procedure. The hydraulic jacking device pushed the formwork synchronously from three points on the back, with a jacking force of 10kN at each point. The formwork was smoothly removed from the dam surface in 8 minutes. The frequency conversion drive transported the formwork to the storage area. The entire process took 35 minutes. The working surface washing and slag removal system 7 was restarted to wash and remove slag from the dam surface after pouring to prepare for the construction of subsequent dam sections and enter the next construction cycle.

[0056] Through the above implementation, the single-compartment rockfill rate increased from the initial 46.1% to a maximum of 54.9%, an increase of 8.8 percentage points compared with traditional construction. The single-compartment construction cycle was shortened from the traditional 5 days to 3.5 days, improving efficiency by 30%. No safety accidents occurred, the wastewater recycling rate was 85%, and the concrete material waste rate was less than 3%.

[0057] In this document, the directional terms such as front, back, top, and bottom are defined based on the position of the components in the accompanying drawings and their relative positions to each other, solely for the purpose of clarity and convenience in expressing the technical solution. It should be understood that these are relative concepts and can vary depending on different methods of use and placement; the use of these directional terms should not limit the scope of protection claimed in this application.

[0058] Where there is no conflict, the above embodiments and features described herein can be combined with each other.

[0059] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A smart integrated construction system for rockfill concrete dams, characterized in that, include: A lightweight intelligent operation platform for executing intelligent deployment steps and full-process collaborative management steps; The stone pretreatment and transfer system is used to perform digital material preparation steps, complete stone cleaning and drying, three-dimensional information acquisition and seamless vertical-horizontal transfer. A horizontal intelligent transportation system is used to perform stacking steps, enabling full-area coverage delivery of stone materials. The intelligent concrete placement system is used to execute intelligent pouring steps and complete concrete filling and pouring based on the gap data of the riprap. Safety protection device system is used to perform safety monitoring functions in the whole process collaborative control steps; The rockfill image recognition system is used to perform the stacking, cleaning and intelligent pouring steps, and to complete the digital modeling of the rockfill body and the calculation of the rockfill ratio. The steel formwork turnover system is used to perform formwork support and cyclic turnover steps, and to complete the transfer, installation and dismantling of steel formwork. The working face washing and slag removal system is used to perform cleaning treatment steps, complete the washing of the working face, automatic slag removal and wastewater recycling; The intelligent operation monitoring system is used to execute intelligent deployment steps and full-process collaborative management and control steps, integrating multi-source data collection, intelligent analysis, collaborative scheduling and security management functions.

2. The intelligent integrated construction method for rockfill concrete dams as described in claim 1, characterized in that: The three-dimensional information acquisition module of the stone pretreatment and transfer system integrates an industrial camera and a laser three-dimensional scanner, and the vertical transportation system and the horizontal transfer trolley form a vertical-horizontal transfer channel.

3. The intelligent integrated construction method for rockfill concrete dams as described in claim 1, characterized in that: The intelligent concrete placing system includes an independent placing frame, wear-resistant conveying pipeline, dual metering and monitoring module, and laser liquid level control module, with a coverage radius adapted to the width of the working surface.

4. The intelligent integrated construction method for rockfill concrete dams as described in claim 1, characterized in that: The riprap image recognition system includes a laser 3D scanner, an industrial camera, and an edge computing node. It achieves real-time data exchange with the transportation and fabric laying systems through industrial Ethernet and 5G dual-mode communication.

5. The intelligent integrated construction method for rockfill concrete dams as described in claim 1, characterized in that: The steel formwork turnover system includes a steel formwork body, a frequency conversion drive unit, a hydraulic lifting and tilting mechanism, and a double fixing device, and is equipped with an emergency manual operation device.

6. The intelligent integrated construction method for rockfill concrete dams as described in claim 1, characterized in that: The working face flushing and slag removal system includes a high-pressure flushing unit, a mechanical slag removal unit, and a multi-stage wastewater filtration unit to achieve wastewater recycling.

7. The intelligent integrated construction method for rockfill concrete dams as described in claim 1, characterized in that: The intelligent operation monitoring system includes a full-dimensional data acquisition unit, edge computing nodes, a cloud data center, and a three-dimensional visualization monitoring interface, supporting remote monitoring and manual intervention.

8. A smart integrated construction method for rockfill concrete dams, employing the construction system described in any one of claims 1-7, characterized in that, Includes the following steps: S1: Deploy a lightweight operation platform on the dam working face, integrating a stone pretreatment and transfer system, a horizontal intelligent transportation system, a concrete intelligent placement system, a safety protection device system, a rockfill image recognition system, a steel formwork turnover system, a working face washing and slag removal system, and an intelligent operation monitoring system, and establish a data communication and collaborative control link between multiple systems; S2: After pretreatment, the stone is digitally archived through three-dimensional information acquisition and then transported to the work surface via a vertical and horizontal transfer system. S3: Based on the rock pile distribution data fed back by the rock pile image recognition system, the horizontal intelligent transportation system accurately delivers the stones to the designated location for stacking; S4: The working face flushing and slag removal system automatically plans the working path based on the rock pile distribution data, flushes and removes slag from the rock pile surface, and sends a ready signal after the cleaning standard is met. S5: The steel formwork turnover system receives the ready signal, transfers the steel formwork to the pouring area and fixes it, and sends the pouring ready signal after acceptance. S6: The intelligent concrete placement system receives the pouring ready signal and implements a differentiated pouring strategy based on the distribution data of the gaps between the riprap to achieve precise concrete filling. S7: The intelligent operation monitoring system collects real-time operation data and construction quality parameters of each system, and performs intelligent analysis and dynamic scheduling through edge computing to achieve process connection optimization, load balance control and safety risk early warning; S8: After the concrete strength reaches the standard, the steel formwork turnover system completes the dismantling and storage of the formwork and enters the next construction cycle.

9. The intelligent integrated construction method for rockfill concrete dams as described in claim 8, characterized in that: In step S2, the stone pretreatment includes washing and air drying processes, and the three-dimensional information acquisition includes the extraction of particle size, shape and volume parameters.

10. The intelligent integrated construction method for rockfill concrete dams as described in claim 8, characterized in that: In step S5, the steel formwork turnover system adapts to the changes in the slope angle of the dam surface through a hydraulic lifting and pitch adjustment mechanism, and achieves formwork fixation through a combination of mechanical clamping and bolt reinforcement.

Images