Automatic continuous measurement method for filling material fluidity

Abstract

This application provides an automatic continuous measurement method for the flowability of filler materials, comprising the following steps: Step S1, connecting the continuous measurement equipment, including: a first branch and a second branch connected in parallel; a third branch simultaneously connected to the ends of the first and second branches; Step S2, powder preparation; Step S3, automatic batching and slurry preparation, including adjusting the pipeline status, the pipeline status including: slurry preparation mode; water addition mode; and slurry discharge mode; Step S4, leveling work using the automatic flowability measurement device; Step S5, automatic sampling using the automatic flowability measurement device; Step S6, automatic flowability measurement; Step S7, cleaning and resetting the test plate; Step S8, cleaning the pipeline and the continuous measurement equipment. The automatic continuous flowability measurement method involved in this application can achieve high-frequency and accurate monitoring of flowability under long-distance, high-temperature conditions, and its slurry pipeline design can significantly improve the efficiency of multi-ratio tests, meeting the needs of large-scale laboratory testing.

Description

Technical Field

[0001] This application relates to the field of performance testing technology for mine filling materials, and in particular to an automatic continuous measurement method for the flowability of filling materials. Background Technology

[0002] Flowability testing of filler materials is a core step in evaluating their workability and applicability for construction. Flowability directly determines whether the filler material can smoothly fill target voids (such as concrete cracks, steel structure grouting layers, and roadbed pores). If the flowability is too low, the material is prone to segregation, blockage, or failure to fill gaps, creating voids and weak areas. If the flowability is too high, it may lead to stratification and bleeding, reducing the material's density. Determining a reasonable flowability range through testing ensures smooth construction and avoids rework. Flowability testing can also guide mix design optimization, balancing workability and mechanical properties to ensure long-term stability of the filler. Omitting flowability testing and using substandard materials can easily lead to problems such as incomplete filling, cracking, and detachment, resulting in extremely high repair costs later. Early testing can mitigate these risks from the outset, reduce project quality accidents, and avoid economic losses due to material waste and project delays.

[0003] Currently, most flowability testing methods used in the industry, such as flowability tests, rely on manual operation. These traditional methods have several drawbacks: 1. Low testing efficiency: Manual operation is cumbersome and time-consuming, failing to meet the real-time quality monitoring needs of large-scale, continuous production. 2. Significant human error: Test results are easily affected by subjective factors such as operator skill level, mold lifting speed, and reading accuracy, leading to poor data repeatability and low reliability. 3. Inability to simulate real-world conditions: When slurry is transported in long-distance pipelines, its internal temperature and flow rate change due to friction, sedimentation, and hydration reactions. These changes significantly affect the viscosity and flowability of the slurry. Traditional testing methods are conducted in a static laboratory environment, completely ignoring these dynamic effects during pipeline transport, making it difficult to accurately reflect the performance of the slurry in actual applications.

[0004] Therefore, in order to overcome the shortcomings of existing technologies, there is an urgent need to develop a system that can simulate the pipeline transportation process and achieve fully automated and intelligent measurement. Summary of the Invention

[0005] To achieve the above objectives, this application provides the following technical solution: An automatic continuous measurement method for the flowability of filler materials, the measurement method comprising the following steps: Step S1, Connect the continuous measuring equipment; the continuous measuring equipment includes: an automatic pulping device and an automatic flowability measuring device; The automatic pulping device includes: Mixing tank; the mixing tank is connected to a vertical variable frequency motor via a water supply pipe; A vertical variable frequency motor is connected to the first and second branches in parallel. The first branch 1-8 is equipped with a first electrically controlled ball valve 1-1 and a second electrically controlled ball valve 1-2; the second branch 1-9 is equipped with a third electrically controlled ball valve 1-3, a fourth electrically controlled ball valve 1-4 and a sixth electrically controlled ball valve 1-6.

[0006] The third branch 1-10 is connected to the ends of the first branch 1-8 and the second branch 1-9; a fifth electrically controlled ball valve 1-5 is also installed on the third branch. A first manual ball valve 1-11 is installed at the end of the first branch that connects to the slurry pipeline interface of the automatic measuring machine; A second manual ball valve 1-12 is installed at one end of the second branch that connects to the clean water interface of the automatic measuring mechanism, and connects to the clean water pipeline; at the same time, a water supply pipeline is also installed on the second branch, and a seventh electrically controlled ball valve 1-7 is installed on the water supply pipeline; Step S2, Powder preparation; The automatic pulping device includes four independent hoppers, and the corresponding powder is added to each hopper; Step S3, automatic batching and pulping, includes adjusting the pipeline status, which includes: pulping mode; water adding mode and pulp discharging mode; Step S4: Leveling is performed using an automatic flowability measuring device; Step S5: Automatic sampling is performed using an automatic flowability measuring device; Step S6: Automatic flowability measurement; Step S7: Test board cleaning and reset; Step S8: Cleaning of pipelines and continuous measurement equipment.

[0007] Preferably, in step S3, adjusting the pipeline status to the pulping mode includes: Open the seventh electrically controlled ball valve 1-7 to inject clean water into the mixing tank; start the vertical variable frequency motor, and only open the second electrically controlled ball valve 1-2 and the third electrically controlled ball valve 1-3. The vertical variable frequency motor drives the centrifugal pump to prepare the slurry. The slurry is drawn out from the mixing tank and enters the second branch. After the temperature is detected by the thermometer, it flows through the third electrically controlled ball valve 1-3, through the centrifugal pump, and into the first branch. It then flows back to the mixing tank through the second electrically controlled ball valve 1-2 and the electromagnetic flow meter to be fully mixed evenly.

[0008] Preferably, in step S3, adjusting the pipeline status to the water filling mode includes: The main control mechanism controls the opening of the seventh electrically controlled ball valve 1-7, allowing clean water to enter the mixing tank pipeline through the second branch via the second manual ball valve 1-12 and the seventh electrically controlled ball valve 1-7, automatically adding clean water to the mixing tank. Based on the feedback from the weighing sensor, when the preset water addition amount is reached, the seventh electrically controlled ball valve 1-7 is closed to stop adding water.

[0009] Preferably, in step S3, adjusting the pipeline status to the slurry discharge mode includes: Open the first electrically controlled ball valve 1-1 and the third electrically controlled ball valve 1-3. The slurry flows from the mixing tank into the second branch. The temperature is measured by a thermometer. The slurry flows through the third electrically controlled ball valve 1-3 and enters the centrifugal pump. After flowing out of the centrifugal pump, it enters the first branch and flows through the first electrically controlled ball valve 1-1 and the first manual ball valve 1-11. It is then delivered to the automatic flowability measuring device.

[0010] Preferably, the automatic flowability measuring device includes: an automatic leveling mechanism; Step S4 includes: S4-1, Signal Acquisition, including adjusting the level of the test board, and sending the tilt angle data of the test board to the main control mechanism through the digital level measurement module of the automatic leveling mechanism; Step S4-2, levelness closed-loop adjustment, includes: the main control mechanism performs calculations based on the received tilt angle data; if tilt is detected, it calculates the height difference that needs to be adjusted and sends an adjustment command to the corresponding servo electric push rod of the automatic leveling mechanism. Step S4-3: Repeat steps S4-1 and S4-2 until the reading of the digital level measurement module shows that the test board is in a completely level state.

[0011] Preferably, the automatic leveling mechanism includes: an electric push rod in contact with the test plate and a ball bearing; the test plate is supported and leveled by four electric push rods, and the output end of each electric push rod is connected to the test plate through a ball bearing; The ball bearing includes a ball head seat and a ball head bolt; one end of the ball head seat is fixedly connected to the telescopic end of the electric push rod, and the connecting end of the ball head seat is provided with an internal thread structure, which is matched and connected with the end of the output shaft of the electric push rod, so that the ball head seat can move synchronously with the axial extension and retraction of the electric push rod. One end of the ball head bolt is provided with a ball head, which is installed in the hemispherical cavity of the ball head seat and can rotate in multiple directions within the cavity inside the ball head seat.

[0012] Preferably, the automatic flowability measurement device further includes: an automatic sampling and testing mechanism and an automatic vision measurement mechanism; Automatic sampling and testing organizations include: The upright frame is installed perpendicular to the ground and placed on one side of the leveling mechanism frame. A robotic arm is set perpendicular to the upright frame, with one end of the robotic arm connected to the upright frame and the other end equipped with a screw jack; The test mold includes a conical section mold; the largest section of the test mold is positioned opposite to the horizontal test panel and connected below the screw jack. The slurry pipeline has one end connected to the upper end of the test mold and the other end connected to the first manual ball valve 1-11 of the automatic slurry preparation device. A laser rangefinder is positioned above the test mold; the laser spot emitted by the laser rangefinder is aligned with the inside of the test mold.

[0013] Preferably, step S5, automatic flowability measurement and automatic sampling, includes: Step S5-1: Place the test mold stably on the test plate. Step S5-2 Automatic grouting: Grout is injected into the test mold through the grout pipeline. When the laser rangefinder detects that the height of the grout level in the mold has reached the standard height, a signal is sent and the main control mechanism stops the grout supply. Step S5-3: Mold lifting: The servo motor drives the screw jack to lift the mold vertically and at a constant speed until the mold is completely separated from the slurry.

[0014] Preferably, step S6, automatic flowability measurement includes: Step S6-1, Image capture: After the slurry stops flowing on the test plate, the visual measurement device (3-13) acquires a top view containing the complete diffusion pattern of the slurry; Step S6-2, Data Processing: The top view is transmitted to the embedded PC of the main control unit. The image processing algorithm automatically identifies the edge contour of the slurry and calculates the maximum diameter, average diameter or area flowability parameter of the slurry after diffusion by the calibration relationship between pixels and actual size.

[0015] Compared with the closest prior art, the technical solution of this application has the following beneficial effects: 1. Achieve high-frequency and accurate monitoring of flowability under long-distance and high-temperature conditions: For special working conditions such as underground filling and transportation at depths of thousands of meters, non-vertical pipeline layout, long transportation distance, and significant heat generation from material reaction, the system can automatically and continuously collect flowability data for the same proportion of material at high frequency, replacing the intermittent manual measurement every 10 to 15 minutes. This allows for real-time monitoring of the flowability variation with time and temperature, providing a reliable basis for proportion optimization and transportation parameter control.

[0016] 2. Reduce pipe blockage risk from the source and minimize pipeline replacement and downtime losses: Through automatic continuous monitoring, abnormal fluctuations in flowability can be warned in a timely manner, allowing for advance adjustments to the mixing ratio or delivery process, effectively preventing pipeline blockage caused by uncontrolled flowability. Replacing pipes after blockage is a complex, time-consuming, and labor-intensive process that impacts production. This device can significantly reduce the probability of blockage, ensuring continuous and stable operation of downhole filling and delivery.

[0017] 3. The slurry pipeline design involved in this application can significantly improve the efficiency of multi-ratio tests and meet the needs of large-scale laboratory testing: a single laboratory project needs to complete 40 to 50 sets of different ratio tests, and manual testing is time-consuming, labor-intensive, and inconsistent. This device realizes automated and programmed continuous measurement, eliminating the need for manual supervision and repetitive operations, significantly shortening the test cycle, freeing up manpower, and improving the efficiency and reliability of parallel and comparative tests of multiple ratios.

[0018] 4. Adaptable to non-standard slurries for mine backfilling, unlike conventional cement slurry testing: In view of the complex composition of mine backfilling materials, which are different from ordinary pure cement standardized slurry, the special measurement structure can be adapted to high solids content, multi-component, and exothermic reactive backfilling materials. The measurement is more in line with the actual working conditions on site, and the data is more meaningful for engineering guidance, making up for the shortcomings of traditional manual measurement in terms of specificity.

[0019] 5. Improve measurement consistency and data reliability to support scientific optimization of proportions: Eliminate errors such as human reading, timing of operation, and uniformity of stirring in manual measurement, realize full automation of sampling, testing, and recording, and ensure continuous traceability and exportable analysis of data. Provide objective and accurate data support for the performance screening of 40 to 50 proportions and improve the scientific nature of filling material formulation design.

[0020] 6. Reduce labor intensity in experiments and improve laboratory working conditions: Replace a large number of repetitive manual measurement, recording and cleaning tasks, reduce the labor intensity of test personnel, reduce manual operations in high temperature and high humidity test environments, and improve the intelligence and standardization of laboratory testing work. Attached Figure Description

[0021] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. Wherein: Figure 1 This is a top view of the automatic pulping apparatus involved in this application; Figure 2 This is a left view of the automatic pulping apparatus involved in this application; Figure 3 This is a front view of the automatic measuring mechanism involved in this application; Figure 4 This is a left view of the automatic measuring mechanism involved in this application; Figure 5 This is a top view of the automatic measuring mechanism involved in this application;

[0022] Explanation of reference numerals in the attached figures: 1-1. First electrically controlled ball valve; 1-2. Second electrically controlled ball valve; 1-3. Third electrically controlled ball valve; 1-4. Fourth electrically controlled ball valve; 1-5. Fifth electrically controlled ball valve; 1-6. Sixth electrically controlled ball valve; 1-7. Seventh electrically controlled ball valve; 1-8. First branch; 1-9. Second branch; 1-10. Third branch; 1-11. First manual ball valve; 1-12. Second manual ball valve; 2-1. First storage silo; 2-2. Second storage silo; 2-3. Third storage silo; 2-4. Fourth storage silo; 2-5. Mixing tank; 2-6. Vertical variable frequency motor; 2-7. Electromagnetic flowmeter; 2-8. Thermometer; 3-1. Primary base; 3-2. Secondary base; 3-3. Leveling knob; 3- 4-1 Digital level measurement module; 3-4-2 Mechanical level; 3-5 Servo electric actuator; 3-6 Ball bearing; 3-7 Stand; 3-8 Robotic arm; 3-9 Screw jack; 3-10 Test mold; 3-11 Slurry pipeline; 3-12 Laser rangefinder; 3-13 Visual measurement device; 3-14 Test plate; 3-15-1 First screw guide rail; 3-15-2 Second screw guide rail; 3-16-1 First guide rail slide; 3-16-2 Second guide rail slide; 3-17 Flushing device; 3-18 Clean water pipeline interface; 3-20 Slurry pipeline interface; 3-21 Waste liquid collection tank; 3-22 Waste liquid collection port. Detailed Implementation

[0023] The present application will now be described in detail with reference to the accompanying drawings and embodiments. Various examples are provided by way of explanation and not by way of limitation. In fact, those skilled in the art will recognize that modifications and variations can be made to the present application without departing from the scope or spirit thereof. For example, a feature shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, it is desirable that the present application encompass such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0024] In the following description, the terms "first / second / third" are used merely to distinguish similar objects and do not represent a specific order of objects. It is understood that "first / second / third" may be interchanged in a specific order or sequence where permitted, so that the embodiments of this application described herein can be implemented in an order other than that illustrated or described herein.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terminology used herein is for the purpose of describing embodiments of this disclosure only and is not intended to limit this disclosure.

[0026] In the description of this application, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and do not require that this application be constructed and operated in a specific orientation, and therefore should not be construed as limiting this application. The terms "connected," "linked," and "set up" used in this application should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; direct connections or indirect connections through intermediate components; wired connections, radio connections, or wireless communication signal connections. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0027] Before providing a further detailed description of the embodiments of this disclosure, the nouns and terms involved in the embodiments of this disclosure will be explained, and the nouns and terms involved in the embodiments of this invention shall be interpreted as follows.

[0028] An automatic continuous measurement method for the flowability of filler materials, the measurement method comprising the following steps: Step S1, Connect the continuous measuring equipment; the continuous measuring equipment includes: an automatic pulping device and an automatic measuring device; like Figure 1 and Figure 2 As shown, the automatic pulping device includes: Mixing tank; The mixing tank is connected to a vertical variable frequency motor via a water supply pipe; The vertical variable frequency motor is also connected to the first branch 1-8 and the second branch 1-9 in parallel; The first branch 1-8 is equipped with a first electrically controlled ball valve 1-1 and a second electrically controlled ball valve 1-2; the second branch 1-9 is equipped with a third electrically controlled ball valve 1-3, a fourth electrically controlled ball valve 1-4 and a sixth electrically controlled ball valve 1-6.

[0029] The third branch 1-10 is connected to both the first branch 1-8 and the second branch 1-9; and a fifth electrically controlled ball valve 1-5 is installed on the third branch 1-10.

[0030] A first manual ball valve 1-11 is installed at the end of the first branch 1-8 that is connected to the slurry pipeline interface of the automatic measuring machine; A second manual ball valve 1-12 is installed at one end of the second branch 1-9 that is connected to the clean water pipeline interface of the automatic measuring mechanism, and is connected to the clean water pipeline. The automatic pulping device also includes: a water source addition component, a second manual ball valve 1-12 connected to an external water source, and a water supply pipeline connected to the second branch 1-9, and a seventh electrically controlled ball valve 1-7 installed on the water supply pipeline.

[0031] The automatic pulping device also includes: an electric control panel, an air compressor, and electromagnetic flow meters 2-7, etc.

[0032] Continuous measurement equipment connections include piping connections, including: Pipeline connections: such as Figure 1 , Figure 5 As shown, the water pipeline interface 3-18 of the automatic measuring mechanism is connected to the water pipeline through the second manual ball valve 1-12 of the automatic pulping device, and the first manual ball valve 1-11 of the automatic pulping device is connected to the slurry pipeline interface 3-20 of the automatic measuring mechanism.

[0033] Circuit connection: Connect the main power supply of the electric control console, and also connect the power line and control line between the electric control console and the automatic measuring mechanism and automatic pulping device.

[0034] Step S2, Powder preparation; The automatic pulping device also includes: storage silos, with four independent storage silos connected to the mixing tank respectively; including the first storage silo 2-1, the second storage silo 2-2, the third storage silo 2-3, and the fourth storage silo 2-4, used for classifying and storing different dry powder materials. The storage silos are fixed to the base of the automatic pulping device by bolts.

[0035] Precision weighing unit: includes a weighing base fixed below the mixing tank. A bolted load cell is mounted on the weighing base for precise weighing.

[0036] Powder conveying unit: Each storage bin outlet is connected to a pneumatic conveying device. The power source of the pneumatic conveying device is an air compressor, which conveys the powder to the mixer. The air source is purified and pressure regulated by the air source triple unit and controlled by the solenoid valve group.

[0037] Liquid addition unit: It consists of a second manual ball valve 1-12 connected to an external water source, a water supply pipeline, and a seventh electrically controlled ball valve 1-7 installed on the water supply pipeline.

[0038] Step S3: Automatic ingredient batching and pulping; S3-1, Powder Preparation: The powder in each storage bin needs to be manually replenished. Sufficient powder must be manually added to the bins before the experiment begins. The automatic pulping device uses a "weight reduction method" for metering, calculating the powder usage in real time by weighing the mixing tank. Before adding material, the weighing sensor first acquires and records the initial total weight of all storage bins.

[0039] S3-2, Powder Conveying: The main control PC starts, checks the system status, and outputs the current formula to be executed according to the preset formula sequence in the test plan. Based on the current preset formula, the system controls the pneumatic conveying device to work. Compressed air, after being pressurized by the air source triplet, vacuum-conveys the powder (cement, fly ash, etc.) from the four storage silos to the mixing tank.

[0040] Specifically, when the main control unit issues a feeding command (e.g., adding material from one of the storage bins), the solenoid valve opens, and the corresponding pneumatic conveying device starts, using compressed air to transport the powder through the feeding pipeline to the mixing tank. During this process, the main control unit reads the data from the weighing sensor at a high frequency in real time. When the weight increase in the mixing tank reaches the formula setting value, the main control unit immediately shuts off the pneumatic conveying device, completing the precise addition of one material. This process is executed sequentially for each powder that needs to be added.

[0041] S3-3, Powder Injection and Mixing: Adjust the pipeline to mixing mode. Open the seventh electrically controlled ball valve 1-7 to inject clean water into the mixing tank. Start the vertical variable frequency motor, opening only the second and third electrically controlled ball valves 1-2 and 1-3. The vertical variable frequency motor drives the centrifugal pump to prepare the slurry. The slurry is drawn from the mixing tank and enters the second branch 1-9. The temperature is detected by a thermometer. After passing through the third electrically controlled ball valve 1-3 and the centrifugal pump, it enters the first branch 1-8. The flow rate is monitored by the second electrically controlled ball valve 1-2 and the electromagnetic flowmeter, and the slurry is returned to the mixing tank for thorough mixing. The thermometer serves as the data acquisition component in the experiment. As the slurry is continuously simulated and transported, the temperature of the slurry at different times is collected, thus obtaining the temperature change trend of the slurry during transport.

[0042] Specifically, S3-3, powder water injection and mixing: Open the seventh electrically controlled ball valve 1-7 (e.g. Figure 1 and Figure 2As shown in the diagram, clean water is injected into the mixing tank through the water supply pipeline; that is, clean water flows into the mixing tank through the water supply pipeline via the second manual ball valve 1-12 and the seventh electrically controlled ball valve 1-7. At the same time, the vertical variable frequency motor 2-6 starts, controlling the first electrically controlled ball valve 1-1 to close, the second electrically controlled ball valve 1-2 to open, the third electrically controlled ball valve 1-3 to open, the fourth electrically controlled ball valve 1-4 to close, the fifth electrically controlled ball valve 1-5 to close, and the sixth electrically controlled ball valve 1-6 to close. The vertical variable frequency motor drives the centrifugal pump, so that the slurry is fully mixed and homogeneous along the mixing tank-pipeline-thermometer-pipeline-third electrically controlled ball valve 1-3-centrifugal pump-second electrically controlled ball valve 1-2-electromagnetic flowmeter-mixing tank.

[0043] S3-4, Precise Weighing of Clean Water: The weighing sensor monitors the total weight of the mixing tank in real time. When the set value is reached, the seventh electrically controlled ball valve 1-7 is closed. Specifically, when water needs to be added, the pipeline is adjusted to the water adding mode: the main control mechanism precisely controls the opening of the seventh electrically controlled ball valve 1-7, allowing clean water to be automatically added to the mixing tank along the pipeline from the second manual ball valve 1-12 to the seventh electrically controlled ball valve 1-7 and then to the mixing tank. Based on the feedback from the weighing sensor, the system automatically stops adding the set amount of water.

[0044] S3-5, Precise Weighing of Powder: The weighing sensor in the mixing tank monitors the total weight of the mixing tank in real time. When the set value is reached, the corresponding pneumatic conveying device is shut off via a solenoid valve. Specifically, the empty weight of the mixing tank is set as m; the weight of water after addition is m0; the weights of the first, second, third, and fourth powders after addition are m1, m2, m3, and m4, respectively; the weight of water added is m0-m; the weights of the first, second, third, and fourth powders added are m1-m0, m2-m1, m3-m2, and m4-m3, respectively. Through the above method, the weighing of water and powders is achieved, thereby controlling the mixing ratio.

[0045] Adjusting the pipeline to the discharge mode includes: opening only the first electrically controlled ball valve 1-1 and the third electrically controlled ball valve 1-3, allowing the slurry to flow from the mixing tank into the second branch 1-9, where the temperature is measured by a thermometer, and then flowing through the third electrically controlled ball valve 1-3 into the centrifugal pump. After exiting the centrifugal pump, the slurry enters the first branch 1-8, flows through the first electrically controlled ball valve 1-1 and the first manual ball valve 1-11, and is then sent to the automatic flowability measuring device.

[0046] Specifically, when the slurry completes simulated circulation in the pipeline and needs to be delivered to the automatic flowability measuring device, the main control mechanism adjusts the electrically controlled ball valve combination to change the pipeline state, and the slurry passes through the slurry pipeline interface ( Figure 1The slurry is diverted and injected into the test mold: the first electrically controlled ball valve 1-1 is open, the second electrically controlled ball valve 1-2 is closed, the third electrically controlled ball valve 1-3 is open, the fourth electrically controlled ball valve 1-4 is closed, the fifth electrically controlled ball valve 1-5 is closed, and the sixth electrically controlled ball valve 1-6 is closed. At this time, the centrifugal pump continues to work, but the flow direction of the slurry is changed. It no longer returns to the mixing tank, but is discharged through the designated mixing tank-pipeline-thermometer-pipeline-third electrically controlled ball valve 1-3-centrifugal pump-first electrically controlled ball valve 1-1-first manual ball valve 1-11 pipeline.

[0047] Simultaneously, a laser rangefinder sensor monitors the liquid level. When the liquid is full, slurry discharge ends, and the main control mechanism changes the pipeline status: the first electrically controlled ball valve 1-1 closes, the second electrically controlled ball valve 1-2 opens, the third electrically controlled ball valve 1-3 closes, the fourth electrically controlled ball valve 1-4 opens, the fifth electrically controlled ball valve 1-5 opens, and the sixth electrically controlled ball valve 1-6 closes. This stops slurry injection and draws the slurry back into the mixing tank via the pipeline: first manual ball valve 1-11—fifth electrically controlled ball valve 1-5—fourth electrically controlled ball valve 1-4—centrifugal pump—second electrically controlled ball valve 1-2—electromagnetic flowmeter—mixing tank. After completion, the pipeline mode is switched to automatic mixing, pipeline slurry preparation, and slurry discharge mode to continue slurry preparation and simulate pipeline transportation along the pipeline. By adjusting the pump speed with a variable frequency motor and using feedback from the electromagnetic flowmeter, different transportation flow rates can be simulated.

[0048] The automatic flowability measurement device involved in this application includes: an automatic leveling mechanism, an automatic sampling and testing mechanism, and an automatic vision measurement mechanism.

[0049] Automatic leveling mechanisms include: Level the frame structure and set test plates 3-14 on the surface of the frame structure. The test plates are made of flat and uniformly colored boards.

[0050] The base, a flat structure, is located at the bottom of the frame; it includes a primary base 3-1 and a secondary base 3-2. The primary base contacts the ground via four leveling knobs 3-3 for initial coarse leveling of the equipment. The secondary base is parallel and coaxially arranged above the primary base and connected by a square steel column.

[0051] Sensor unit: such as Figure 3 and Figure 4 As shown, it includes a digital level measurement module 3-4-1 set at the bottom of the test board and a mechanical level 3-4-2 set at the top of the primary base instrument. The digital level monitoring is the core sensor for automatic leveling, which can monitor the tilt angle of the test board in real time and output an electrical signal.

[0052] Execution unit: such as Figure 3As shown, four servo-driven electric actuators 3-5 are evenly distributed above the secondary base 3-2. The top of each actuator is connected to a ball bearing (e.g., ...). Figure 4 The ball bearings (3-6) shown are flexibly connected to the support structure of the test board. Specifically, the servo electric actuator consists of key components such as a servo motor and a lead screw. It achieves displacement output by converting the axial rotation of the motor into the linear motion of the lead screw. The main control system of the equipment sends rotation commands to the motor through the servo controller, causing the motor to rotate slightly, thereby realizing the fine-tuning and extension operation of the lead screw.

[0053] Among them, such as Figure 3 , Figure 4 and Figure 5 The automatic sampling and testing mechanism shown includes: Frames 3-7 are installed perpendicular to the ground and placed on one side of the leveling mechanism frame; The robotic arm 3-8 is set vertically to the upright frame, with one end of the robotic arm connected to the upright frame 3-7 and the other end equipped with a screw jack 3-9; Test molds 3-10 include conical cross-section molds; the largest cross-section of the test mold is positioned opposite to the horizontal test panel and connected below the screw jack. Slurry pipeline 3-11, one end of the slurry pipeline is connected to the upper end of the test mold; the other end of the slurry pipeline is connected to the first manual ball valve 1-11 of the automatic slurry preparation device; The laser rangefinder 3-12 is positioned above the test mold; the light spot emitted by the laser rangefinder is aligned with the inside of the test mold.

[0054] Specifically, the automated sampling and testing mechanism includes a motion assembly consisting of a screw jack 3-9 capable of vertical lifting and a two-degree-of-freedom robotic arm 3-8 (rotation and extension). This robotic arm is responsible for precisely positioning the entire lifting unit on a horizontal plane when grouting is required, and for rotating it to the right to provide space for visual measurement. The screw jack is responsible for lifting and releasing the test mold. The end effector, mounted at the lower end of the screw jack, includes a gripper for grasping and releasing the test mold (standard conical mold). The grout supply system consists of a grout pipeline whose interface connects to the "automatic grouting and pipeline simulation section," located directly above the test mold. Auxiliary sensors include: Figure 3 and 4 As shown, a laser rangefinder sensor 3-12 is installed, with its light spot aligned with the inside of the test mold to measure the liquid level in the mold.

[0055] The automated vision measurement mechanism includes: Image acquisition unit: such as Figure 3 and Figure 4As shown, a vision measurement device 3-13 is fixedly installed high above the test board. It is typically a high-resolution industrial camera equipped with a uniformly illuminated shadowless light source. The test board serves as the measurement reference.

[0056] The automatic flowability measurement device ensures that the flowability test is carried out on an absolutely level reference surface, eliminating measurement errors caused by uneven ground.

[0057] Step S4, leveling is performed using an automatic flowability measuring device, including: S4-1, Signal Acquisition: Before each test begins, the device is basically leveled by adjusting the leveling knob 3-3 on the primary base of the automatic measuring mechanism. At the same time, the digital level measurement module installed on the secondary device base will accurately measure the levelness of the current test board and send the tilt angle data to the main control mechanism.

[0058] S4-2, Levelness Closed-Loop Adjustment: The main control mechanism performs calculations based on the received tilt angle data. If tilt is detected, it will accurately calculate the height difference that needs adjustment and send a command to the corresponding servo electric actuator. For example, if a certain apex angle of the test board is detected to be too low, the main control mechanism will drive the servo electric actuator to extend upwards for a slight adjustment, while continuously monitoring the readings of the digital level measurement module.

[0059] S4-3, Precise Leveling: Repeat steps S4-1 and S4-2 until the digital leveling module displays the test plate as perfectly level (tilt angle less than the preset threshold), at which point all linear motors stop operating. The ball bearing connection ensures that the push rod does not generate lateral stress during lifting and lowering, guaranteeing the smoothness and accuracy of leveling.

[0060] Specifically, the experimenter uses a mechanical level to determine the equipment's levelness, identifies the higher and lower areas, and manually rotates the corresponding leveling knobs. This uses the threaded transmission to move the base plate of that area up or down, adjusting the distance between the base plate and the ground until the mechanical level displays a horizontal reading, thus achieving the equipment's level adjustment.

[0061] The ball bearing connection method is as follows: the test plate is supported and leveled by four electric push rods, and the output end of each electric push rod is connected to the test plate through a ball bearing, forming a flexible connection structure between the push rod and the test plate.

[0062] The ball bearing includes a ball head seat and a ball head bolt. One end of the ball head seat is fixedly connected to the telescopic end of the electric actuator. The connecting end of the ball head seat has an internal thread structure and mates with the output shaft end of the electric actuator. The threaded connection achieves a reliable connection, allowing the ball head seat to move synchronously with the axial extension and retraction of the electric actuator. The ball head seat has a hemispherical cavity inside for supporting and limiting the ball head portion.

[0063] One end of the ball-head bolt has a ball-head structure, which is installed in the hemispherical cavity of the ball-head seat and can rotate in multiple directions within the cavity. The other end of the ball-head bolt has a threaded structure for connecting to the test plate. Since the test plate body is relatively thin and not suitable for direct threading, a nut, preferably a welded nut, is fixedly installed on the lower surface of the test plate at the corresponding ball-head bolt mounting position. After the threaded end of the ball-head bolt passes through the mounting hole on the test plate, it forms a threaded engagement with the nut, thereby achieving a fixed connection between the ball-head bolt and the test plate.

[0064] The above structure enables the axial thrust generated by the electric actuator to be stably transmitted to the test plate via the ball bearing. At the same time, the universal rotation characteristic of the ball bearing allows for a certain angle of relative rotation between the actuator and the test plate. This allows for adaptive compensation for installation errors and attitude changes during the coordinated adjustment of the four electric actuators, preventing additional stress, jamming, or structural deformation caused by rigid connections, and improving the stability and reliability of the horizontal adjustment process.

[0065] Step S5: The automatic flowability measurement device, with highly standardized actions, simulates and outperforms the key test steps of manual slurry addition and mold lifting. Automatic flowability measurement and automatic sampling include: Step S5-1: Mold Placement: The two-degree-of-freedom robotic arm first moves to precisely position the screw jack and the test mold below it at the center of the test plate. Then, the screw jack descends, smoothly placing the test mold on the test plate.

[0066] Step S5-2 Automatic Grouting: The grout pipeline begins injecting grout into the test mold. During this process, a laser rangefinder sensor monitors the grout level in the mold in real time. When the grout level reaches the standard height, the laser rangefinder sensor sends a signal, and the main control mechanism immediately stops the grout supply, ensuring accurate and consistent grout volume for each injection.

[0067] Step S5-3 Standardized Mold Lifting: The servo motor drives the screw jack to lift the mold vertically upwards. The lifting speed is uniform vertically raised within 3-7 seconds. Specifically, after grouting is completed, the main control mechanism instructs the screw jack to lift the test mold vertically upwards at a constant speed that meets the test standards (e.g., uniform vertical lifting within 3-7 seconds), completely detaching it from the grout. The stability and repeatability of this process are unparalleled by manual operation, fundamentally eliminating errors introduced by different lifting speeds and methods.

[0068] Step S6, Automatic Flowability Measurement: This method uses non-contact, high-precision automatic measurement to determine the diffusion range of the slurry. Automatic flowability measurement includes the following steps: Step S6-1, Image Capture: After the slurry stops flowing on the test plate, the vision measurement device 3-13 acquires a top-view image containing the complete diffusion pattern of the slurry. Specifically, after the model is lifted, the robotic arm rotates 90 degrees to the right to provide space for vision measurement, and the slurry naturally collapses and diffuses on the test plate. Once the slurry flow has essentially stopped (which can be determined by time delay or image change rate), the vision measurement device captures a high-resolution top-view image containing the complete diffusion pattern of the slurry.

[0069] Step S6-2, Data Processing: The top view is transmitted to the embedded PC of the main control unit. The image processing algorithm automatically identifies the edge contour of the slurry and calculates the maximum diameter, average diameter or area flowability parameter of the slurry after diffusion by the calibration relationship between pixels and actual size.

[0070] Specifically, the embedded PC runs an image processing algorithm to identify the slurry edges and calculate the maximum diffusion diameter and coverage area. The diffusion value is then calculated. The image is transmitted to the embedded PC in the main control unit. The built-in image processing algorithm automatically identifies the slurry edge contours in the image and, through the calibration relationship between pixels and actual dimensions, accurately calculates the maximum diameter, average diameter, or area of ​​the slurry after diffusion, as well as other flowability parameters. The measurement results are directly displayed on the operating interface and stored, completely avoiding visual and estimation errors associated with manual readings.

[0071] Step S7, Test board cleaning and reset: Use an automatic cleaning mechanism to clean and reset the test board, so as to automatically and thoroughly clean the test board after each test and restore it to the test state.

[0072] The automatic flowability measuring device also includes an automatic cleaning mechanism, comprising: The lead screw guide rails are provided on both sides of the test plate, with the first lead screw guide rail 3-15-1 and the second lead screw guide rail 3-15-2 respectively. The guide slide is provided with a first guide slide 3-16-1 mounted on a first lead screw guide 3-15-1 and a second guide slide 3-16-2 mounted on a second lead screw guide 3-15-2.

[0073] The rinsing device 3-17 includes a nozzle and a bucket brush connected as one piece. The rinsing device is set perpendicular to the lead screw guide rail and is connected to the first guide rail slide 3-16-1 and the second guide rail slide 3-16-2. Water supply and drainage system: The clean water pipe interface is used to connect to a clean water source; the test plate is surrounded by slots as waste liquid collection tanks 3-21, and a waste liquid collection port 3-22 is provided at the bottom of the test plate for discharging sewage.

[0074] The guide slide can slide on the lead screw guide rail, thereby driving the rinsing device to move and using a bucket brush to roll and scrub the test plate. Waste liquid flows into the waste liquid collection tank and is discharged into the waste liquid collection port. Preferably, servo motors are respectively installed on the lead screw guide rails 3-15-1 and 3-15-2 to provide sliding power for the guide rail slides 3-16-1 and 3-16-2.

[0075] Preferably, the bucket brush is driven to rotate by a DC motor. The cleaning head is covered by a bucket brush guard.

[0076] Step S7, test board cleaning and reset, includes: Step S7-1, Pre-rinsing: After the measurement is completed, the rinsing device sprays high-pressure water through the clean water pipeline to preliminarily rinse the residual slurry on the test plate.

[0077] Step S7-2, Mechanical Cleaning: Two servo motors start simultaneously, driving the guide rail slide to move the nozzle and roller brush across the entire surface of the test plate. During this process, the DC motor rotates at high speed, driving the barrel brush to mechanically scrub the test plate, while the rinsing device continuously sprays water to thoroughly remove stubborn slurry.

[0078] Step S7-3, Waste liquid treatment: All cleaning wastewater and slurry residue are flushed into the waste liquid collection tank at the edge of the test plate and finally discharged through the waste liquid collection interface, keeping the experimental environment clean.

[0079] Step S8, cleaning of pipelines and continuous measurement equipment, including: Step S8-1, Clean the test device pipeline: Open the second electrically controlled ball valve 1-2, the fourth electrically controlled ball valve 1-4, and the sixth electrically controlled ball valve 1-6; clean water flows into the second branch 1-9 through the second manual ball valve 1-12, and then into the centrifugal pump through the sixth electrically controlled ball valve 1-6 and the fourth electrically controlled ball valve 1-4. After flowing out of the centrifugal pump, it enters the first branch 1-8 and flushes the pipeline of the test device through the first electrically controlled ball valve 1-1 and the first manual ball valve 1-11.

[0080] Specifically, the testing device processes as follows: The robotic arm rotates 90 degrees to the left, moving the mold to the receiving position. The screw jack stops pressing down and remains suspended. The bucket brush and rinsing device move to the side of the mold and begin rinsing the test plate. The main control keeps the first electrically controlled ball valve 1-1 closed, the second electrically controlled ball valve 1-2 open, the third electrically controlled ball valve 1-3 closed, the fourth electrically controlled ball valve 1-4 open, the fifth electrically controlled ball valve 1-5 closed, the sixth electrically controlled ball valve 1-6 open, and the seventh electrically controlled ball valve 1-7 closed, allowing clean water to flow along the pipeline of the testing mechanism from the second manual ball valve 1-12 to the sixth electrically controlled ball valve 1-6, the fourth electrically controlled ball valve 1-4, the centrifugal pump, the first electrically controlled ball valve 1-1, and the first manual ball valve 1-11.

[0081] Step S8-2, Pulping device processing: Manually disconnect the connection between the first manual ball valve 1-11 and the slurry pipeline interface, connect the waste discharge pipeline to the first manual ball valve 1-11, and control the valve group of the main control mechanism to make the device cycle through the three modes of adding water (step 3-4), stirring (step 3-3), and discharging slurry (step S4) multiple times, so that the waste slurry is discharged from the first manual ball valve 1-11 through the waste discharge pipeline, so as to achieve the purpose of thoroughly cleaning the automatic pulping device.

[0082] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for automatic continuous measurement of the flowability of a filler material, characterized in that, The measurement method includes the following steps: Step S1, Connect the continuous measuring equipment; the continuous measuring equipment includes: an automatic pulping device and an automatic flowability measuring device; The automatic pulping device includes: Mixing tank; the mixing tank is connected to a vertical variable frequency motor via a water supply pipe; A vertical variable frequency motor is connected to the first and second branches in parallel. The first branch (1-8) is equipped with a first electrically controlled ball valve (1-1) and a second electrically controlled ball valve (1-2); the second branch (1-9) is equipped with a third electrically controlled ball valve (1-3), a fourth electrically controlled ball valve (1-4) and a sixth electrically controlled ball valve (1-6). The third branch (1-10) is connected to the ends of the first branch (1-8) and the second branch (1-9); a fifth electrically controlled ball valve (1-5) is installed on the third branch. A first manual ball valve (1-11) is installed at the end of the first branch that is connected to the slurry pipeline interface of the automatic measuring machine. A second manual ball valve (1-12) is installed at the end of the second branch that connects to the clean water interface of the automatic measuring mechanism, and connects to the clean water pipeline; at the same time, a water supply pipeline is also installed on the second branch, and a seventh electrically controlled ball valve (1-7) is installed on the water supply pipeline. Step S2, Powder preparation; The automatic pulping device includes four independent hoppers, and the corresponding powder is added to each hopper; Step S3, automatic batching and pulping, includes adjusting the pipeline status, which includes: pulping mode; water adding mode and pulp discharging mode; Step S4: Leveling is performed using an automatic flowability measuring device; Step S5: Automatic sampling is performed using an automatic flowability measuring device; Step S6: Automatic flowability measurement; Step S7: Test board cleaning and reset; Step S8: Cleaning of pipelines and continuous measurement equipment.

2. The automatic continuous measurement method for the flowability of filling materials as described in claim 1, characterized in that, In step S3, adjusting the pipeline status to the pulping mode includes: Open the seventh electrically controlled ball valve (1-7) to inject clean water into the mixing tank; start the vertical variable frequency motor, and only open the second electrically controlled ball valve (1-2) and the third electrically controlled ball valve (1-3). The vertical variable frequency motor drives the centrifugal pump to prepare the slurry. The slurry is drawn out from the mixing tank and enters the second branch. After the temperature is detected by the thermometer, it flows through the third electrically controlled ball valve (1-3), through the centrifugal pump, and enters the first branch. It then flows back to the mixing tank through the second electrically controlled ball valve (1-2) and the electromagnetic flow meter to be fully mixed evenly.

3. The automatic continuous measurement method for the flowability of filling materials as described in claim 1, characterized in that, In step S3, adjusting the pipeline status to water filling mode includes: The main control mechanism controls the opening of the seventh electric ball valve (1-7) to allow clean water to enter the mixing tank pipeline through the second manual ball valve (1-12) and the seventh electric ball valve (1-7) along the second branch, automatically adding clean water to the mixing tank. Based on the feedback from the weighing sensor, when the preset water addition amount is reached, the seventh electric ball valve (1-7) is closed to stop adding water.

4. The automatic continuous measurement method for the flowability of filling materials as described in claim 1, characterized in that, In step S3, adjusting the pipeline status to the slurry discharge mode includes: Open the first electrically controlled ball valve (1-1) and the third electrically controlled ball valve (1-3), and the slurry flows from the mixing tank into the second branch. After the temperature is measured by the thermometer, it flows through the third electrically controlled ball valve (1-3) into the centrifugal pump. After flowing out of the centrifugal pump, it enters the first branch, flows through the first electrically controlled ball valve (1-1) and the first manual ball valve (1-11), and is delivered to the automatic flowability measuring device.

5. The automatic continuous measurement method for the flowability of filling materials as described in claim 1, characterized in that, The automatic flowability measurement device includes: an automatic leveling mechanism; Step S4 includes: S4-1, Signal Acquisition, including adjusting the level of the test board, and sending the tilt angle data of the test board to the main control mechanism through the digital level measurement module of the automatic leveling mechanism; Step S4-2, levelness closed-loop adjustment, includes: the main control mechanism performs calculations based on the received tilt angle data; if tilt is detected, it calculates the height difference that needs to be adjusted and sends an adjustment command to the corresponding servo electric push rod of the automatic leveling mechanism. Step S4-3: Repeat steps S4-1 and S4-2 until the reading of the digital level measurement module shows that the test board is in a completely level state.

6. The automatic continuous measurement method for the flowability of filler materials as described in claim 5, characterized in that, The automatic leveling mechanism includes: electric push rods and ball bearings that contact the test plate; the test plate is supported and leveled by four electric push rods, and the output end of each electric push rod is connected to the test plate through a ball bearing. The ball bearing includes a ball head seat and a ball head bolt; one end of the ball head seat is fixedly connected to the telescopic end of the electric push rod, and the connecting end of the ball head seat is provided with an internal thread structure, which is matched and connected with the end of the output shaft of the electric push rod, so that the ball head seat can move synchronously with the axial extension and retraction of the electric push rod. One end of the ball head bolt is provided with a ball head, which is installed in the hemispherical cavity of the ball head seat and can rotate in multiple directions within the cavity inside the ball head seat.

7. The automatic continuous measurement method for the flowability of filler materials as described in claim 1, characterized in that, The automatic flowability measurement device also includes: an automatic sampling and testing mechanism and an automatic vision measurement mechanism; Automatic sampling and testing organizations include: The upright frame is installed perpendicular to the ground and placed on one side of the leveling mechanism frame. A robotic arm is set perpendicular to the upright frame, with one end of the robotic arm connected to the upright frame and the other end equipped with a screw jack; The test mold includes a conical section mold; the largest section of the test mold is positioned opposite to the horizontal test panel and connected below the screw jack. The slurry pipeline has one end connected to the upper end of the test mold and the other end connected to the first manual ball valve (1-11) of the automatic slurry preparation device. A laser rangefinder is positioned above the test mold; the laser spot emitted by the laser rangefinder is aligned with the inside of the test mold.

8. The automatic continuous measurement method for the flowability of filler materials as described in claim 7, characterized in that, Step S5, automatic flowability measurement and sampling includes: Step S5-1: Place the test mold stably on the test plate. Step S5-2 Automatic grouting: Grout is injected into the test mold through the grout pipeline. When the laser rangefinder detects that the height of the grout level in the mold has reached the standard height, a signal is sent and the main control mechanism stops the grout supply. Step S5-3: Mold lifting: The servo motor drives the screw jack to lift the mold vertically and at a constant speed until the mold is completely separated from the slurry.

9. The automatic continuous measurement method for the flowability of filler materials as described in claim 7, characterized in that, Step S6, automatic flowability measurement includes: Step S6-1, Image capture: After the slurry stops flowing on the test plate, the visual measurement device (3-13) acquires a top view containing the complete diffusion pattern of the slurry; Step S6-2, Data Processing: The top view is transmitted to the embedded PC of the main control unit. The image processing algorithm automatically identifies the edge contour of the slurry and calculates the maximum diameter, average diameter or area flowability parameter of the slurry after diffusion by the calibration relationship between pixels and actual size.

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