Self-adapting speed-adjusting centrifugal forming device and method for preparing concrete pole with uniform wall thickness

Abstract

The application discloses a self-adaptive speed-regulating centrifugal forming device and a concrete electric pole wall thickness uniform preparation method, relates to the technical field of cement products, and comprises a rack, a supporting wheel assembly, an electric pole steel mold driving motor, a sensing system and a self-adaptive controller; the supporting wheel assembly is fixedly installed on the rack, the rack is fixedly installed on a plane below a foundation pit and is used for supporting the electric pole steel mold; the driving motor is in transmission connection with the supporting wheel assembly and is used for outputting rotary power; the sensing system comprises a vibration sensor and a rotating speed sensor. The vibration signal of the electric pole steel mold during rotation is collected in real time through the sensing system, the axial and circumferential distribution uniformity of the concrete is analyzed by using a mapping relationship model built in the self-adaptive controller, and then the rotating speed and the output torque of the driving motor are dynamically adjusted, so that the self-adaptive speed regulation of the centrifugal process is realized, the problem that a traditional fixed rotating speed curve cannot compensate the uneven distribution of the concrete in real time is effectively solved, the uniformity of the wall thickness of the concrete electric pole is greatly improved, and the waste rate is reduced.

Description

Technical Field

[0001] This invention relates to the field of cement product technology, specifically to an adaptive speed-regulating centrifugal molding device and a method for preparing uniform wall thickness of concrete poles. Background Technology

[0002] Concrete poles (referred to as concrete poles) are widely used support structures in industries such as power and communications. In their production process, centrifugal molding is a key step. A motor drives the mold to rotate at high speed, and centrifugal force is used to evenly distribute concrete on the inner wall of the mold, forming a hollow annular cross-section pole.

[0003] Currently, traditional centrifugal molding processes mostly employ a fixed speed curve of low-speed fabric feeding, medium-speed transition, and high-speed compaction, that is, step-by-step or linear speed regulation according to a preset time-tachometer.

[0004] However, this process suffers from uneven concrete distribution within the mold or fluctuations in slump, making it impossible to compensate for the fixed rotation speed in real time. During centrifugation, the concrete undergoes axial flow due to its own weight and centrifugal force, resulting in thinner walls at both ends and thicker walls in the middle of the pole, or localized honeycomb and pitted surfaces. Manual operation relies on experience, making it difficult to guarantee consistent centrifugation quality for each pole, leading to a high scrap rate. To address these issues, we propose an adaptive speed-regulating centrifugal molding device and a method for preparing concrete poles with uniform wall thickness. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an adaptive speed-regulating centrifugal molding device and a method for preparing concrete poles with uniform wall thickness, thus solving the problems mentioned in the background section.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: an adaptive speed-regulating centrifugal molding device, comprising a frame, a roller assembly, a pole steel mold drive motor, a sensing system, and an adaptive controller;

[0007] The roller assembly is fixedly installed on the frame, which is fixedly installed on the plane below the foundation pit. It is used to support the steel formwork of the utility pole and drive the steel formwork of the utility pole to rotate around its axis.

[0008] The drive motor is connected to the roller assembly for outputting rotational power;

[0009] The sensing system includes a vibration sensor and a speed sensor. The vibration sensor is used to collect vibration signals when the pole steel mold rotates in real time, and the speed sensor is used to detect the real-time speed of the drive motor or roller assembly.

[0010] The adaptive controller is electrically connected to the drive motor and the sensing system. It has a pre-stored mapping model between vibration signals and concrete distribution. The mapping model is the correspondence between vibration characteristic parameters and concrete distribution, which are stored in the adaptive controller after centrifugal calibration tests on calibration samples with known eccentricity and known axial packing distribution. The axial distribution uniformity is the degree of uniformity of concrete distribution along the axis, and the circumferential distribution uniformity is the degree of uniformity of concrete distribution around the axis. The axial distribution uniformity is determined based on the differences in vibration characteristic parameters of multiple sets of vibration sensors arranged along the axis, and the circumferential distribution uniformity is determined based on the amplitude change of the rotational frequency component in the vibration signal. The adaptive controller is used to analyze the axial and circumferential distribution uniformity of concrete in the steel formwork of the pole according to the real-time vibration signal, and output speed adjustment commands to the drive motor to dynamically adjust the speed and / or output torque.

[0011] As a preferred embodiment of the present invention, the vibration sensor is a triaxial acceleration sensor, velocity sensor or displacement sensor, which is installed on the bearing seat of the roller assembly or the rigid support part of the frame, and at least two sets are distributed along the axial direction of the electric pole steel mold, for collecting vibration signals from both ends and the middle of the mold respectively.

[0012] As a preferred embodiment of the present invention, the drive motor is a variable frequency motor or servo motor with vector control function, and its speed regulation response time is no more than 100ms, so as to realize stepless speed regulation and differential speed control.

[0013] As a preferred embodiment of the present invention, the sensing system further includes a weighing sensor or strain gauge for monitoring the weight distribution of concrete inside the steel formwork of the utility pole. The sensor is installed on the support shaft of the roller assembly or at the bottom of the frame for real-time weighing after the steel formwork of the utility pole is installed, and transmits the weight signal to the adaptive controller to help determine the initial concrete placement state.

[0014] As a preferred embodiment of the present invention, the adaptive controller has a built-in signal discrimination module for filtering the vibration signal collected by the vibration sensor, and the adaptive controller has a built-in fuzzy PID control algorithm, neural network algorithm or adaptive sliding mode control algorithm.

[0015] The controller is configured to perform the following operations: extract time-domain feature parameters of the vibration signal, including amplitude, effective value, kurtosis index and / or waveform factor; compare the extracted feature parameters with a preset threshold determined by calibration test to identify areas of concrete accumulation or sparse distribution; and generate a PID adjustment amount based on the comparison result to dynamically change the operating frequency of the drive motor.

[0016] A method for preparing concrete poles with uniform wall thickness, using the adaptive speed-regulating centrifugal molding device as described above, includes the following steps:

[0017] S1. Injection and Formwork Closure: Inject concrete into the steel formwork of the utility pole and close the formwork, then hoist it onto the roller assembly;

[0018] S2. Start-up: Start the drive motor and rotate it at an initial low speed of 100-200r / min to initially distribute the concrete on the inner wall of the mold.

[0019] S3. Signal Acquisition: Vibration and speed signals are acquired through vibration and speed sensors and transmitted to the adaptive controller;

[0020] S4. Attitude Control: The adaptive controller filters and performs fast Fourier transform on the vibration signal to obtain the vibration spectrum;

[0021] The uniformity of concrete distribution in the axial and circumferential directions of the mold is determined based on the spectral characteristics.

[0022] If the distribution is determined to be uneven, dynamic adjustment is performed: the drive motor is accelerated or decelerated within a set time by differential control, generating a tangential acceleration fluctuation of 0.05g-0.2g, which breaks the equilibrium state of the concrete and promotes the concrete to flow towards the thin-walled area.

[0023] Once the effective value and kurtosis index of the vibration signal tend to stabilize, indicating uniform distribution, the rotation speed is gradually increased to medium speed (300-500 r / min) and then to high speed (600-900 r / min) according to the preset slope for centrifugal compaction.

[0024] S5. Shutdown: During the high-speed phase, the adaptive controller fine-tunes the rotation speed based on the vibration intensity feedback, controlling the vibration intensity within the set threshold range of 5-15 mm / s to ensure that the concrete is fully vented and compacted. After compaction is completed, the drive motor is controlled to slowly decelerate to a stop within 60-120 seconds to prevent sudden shutdown from causing damage to the concrete structure.

[0025] As a preferred embodiment of the present invention, the dynamic adjustment further includes: when the vibration sensor detects that the amplitude of a certain section of the mold continuously exceeds that of other sections by more than 20%, the adaptive controller controls the drive motor to instantaneously increase its speed by 50-100 r / min when passing the support roller assembly in that section, so as to perform local material replenishment.

[0026] As a preferred embodiment of the present invention, the execution time of differential control lasts for 10-30 seconds, and the frequency of acceleration fluctuation avoids the inherent frequency of the pole steel mold to prevent resonance.

[0027] As a preferred embodiment of the present invention, the initial low speed of the drive motor during rotation is 100-200 r / min, the medium speed is 300-500 r / min, and the high speed is 600-900 r / min.

[0028] As a preferred embodiment of the present invention, after step S1 and before step S2, the total weight of the concrete in the mold is obtained by a weighing sensor, and the adaptive controller automatically matches the initial low-speed running time and the target high-speed rotation speed value according to the weight.

[0029] It also includes a feature that during centrifugation, if the speed sensor detects a deviation of more than ±2% between the actual speed and the set speed, the adaptive controller will immediately trigger an alarm and adjust the output torque of the drive motor to maintain stable speed.

[0030] This invention provides an adaptive speed-regulating centrifugal molding device and a method for preparing uniform wall thickness of concrete poles, which has the following beneficial effects:

[0031] 1. The vibration signal of the steel formwork of the pole is collected in real time by the sensing system, and the axial and circumferential distribution uniformity of the concrete is analyzed by the mapping relationship model built into the adaptive controller. Then, the speed and output torque of the drive motor are dynamically adjusted to realize the adaptive speed regulation of the centrifugal process. This effectively solves the problem that the traditional fixed speed curve cannot compensate for the uneven distribution of concrete in real time, greatly improves the uniformity of the concrete pole wall thickness, and reduces the scrap rate.

[0032] 2. By generating tangential acceleration fluctuations through differential speed control and combining them with a localized material replenishment strategy that instantaneously increases the rotational speed, the equilibrium state of the concrete within the mold can be precisely disrupted, causing the concrete to flow towards the thin-walled area. This further ensures the consistency of the pole's axial and circumferential wall thickness, while avoiding quality fluctuations caused by manual operation relying on experience, thus achieving the digitization and standardization of process parameters.

[0033] 3. By using weighing sensors to assist in determining the initial fabric feeding state, the system automatically matches the running time and rotation speed, and monitors rotation speed deviation in real time during centrifugation, triggering alarms and torque adjustments, thus forming a complete closed-loop control system. This not only improves the automation level and energy efficiency of the equipment but also ensures the safety and stability of the centrifugal forming process, extending the equipment's service life. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the installation state of the adaptive speed-regulating centrifugal molding device and the method for preparing uniform wall thickness of concrete poles according to the present invention inside the foundation pit.

[0035] Figure 2 This is a schematic diagram of the structure of an adaptive speed-regulating centrifugal molding device and a method for preparing uniform wall thickness of concrete poles according to the present invention;

[0036] Figure 3 This is a schematic diagram of the uninstalled steel mold structure of the adaptive speed-regulating centrifugal molding device and the method for preparing uniform wall thickness of concrete poles according to the present invention. Figure 1 ;

[0037] Figure 4 This is a schematic diagram of the uninstalled steel mold structure of the adaptive speed-regulating centrifugal molding device and the method for preparing uniform wall thickness of concrete poles according to the present invention. Figure 2 ;

[0038] Figure 5 This is a schematic diagram of the steel mold structure for an adaptive speed-regulating centrifugal molding device and a method for preparing uniform wall thickness of concrete poles according to the present invention.

[0039] Figure 6 For the present invention Figure 4 Enlarged structural diagram at point A in the middle;

[0040] Figure 7 This is a flowchart of an adaptive speed-regulating centrifugal molding device and a method for preparing uniform wall thickness of concrete poles according to the present invention.

[0041] 1. Frame; 2. Roller assembly; 3. Drive motor; 4. Vibration sensor; 5. Speed ​​sensor; 6. Adaptive controller; 7. Pole steel formwork. Detailed Implementation

[0042] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0043] like Figures 1-7As shown, the present invention provides a technical solution: an adaptive speed-regulating centrifugal molding device, including a frame 1, a roller assembly 2, a drive motor 3 for a utility pole steel mold 7, a sensing system, and an adaptive controller 6; the roller assembly 2 is fixedly installed on the frame 1, and the frame 1 is fixedly installed on a plane below the foundation pit, used to support the utility pole steel mold 7 and drive the utility pole steel mold 7 to rotate around its axis; the drive motor 3 is connected to the roller assembly 2 for outputting rotational power; the sensing system includes a vibration sensor 4 and a speed sensor 5, the vibration sensor 4 is used to collect the vibration signal when the utility pole steel mold 7 rotates in real time, and the speed sensor 5 is used to detect the real-time speed of the drive motor 3 or the roller assembly 2; the adaptive controller 6 is electrically connected to the drive motor 3 and the sensing system respectively, and its internal storage contains a mapping relationship between the vibration signal and the concrete distribution state. The system model and mapping relationship model are the correspondence between the vibration characteristic parameters and the concrete distribution state of the calibration sample with known eccentricity and known axial stacking distribution state, which are pre-tested by centrifugation and stored in the adaptive controller 6. The axial distribution uniformity is the degree of uniformity of concrete distribution along the axial axis, and the circumferential distribution uniformity is the degree of uniformity of concrete distribution around the circumferential axis. The axial distribution uniformity is judged based on the difference of vibration characteristic parameters of multiple sets of vibration sensors 4 arranged along the axial axis, and the circumferential distribution uniformity is judged based on the amplitude change of the rotational frequency component in the vibration signal. The adaptive controller 6 is used to analyze the axial and circumferential distribution uniformity of concrete in the pole steel mold 7 according to the real-time vibration signal, and output speed adjustment command to drive motor 3 to dynamically adjust the speed and / or output torque.

[0044] like Figure 1 and 2 As shown, the roller assembly 2 is fixedly installed on the frame 1, and the frame 1 is fixedly installed on the plane below the foundation pit to support the steel formwork 7 of the utility pole; the drive motor 3 is connected to the roller assembly 2 for outputting rotational power.

[0045] In this embodiment, the frame 1 is welded from high-strength steel to ensure the overall structure is stable; the roller assembly 2 includes symmetrically arranged active rollers and driven rollers. The drive motor 3 is connected to the active rollers through belt drive or chain drive. When the drive motor 3 starts, the active rollers drive the electric pole steel mold 7 to rotate through friction, and the driven rollers play a supporting role to ensure that the mold rotates smoothly.

[0046] like Figure 3 and 4As shown, the sensing system includes a vibration sensor 4 and a speed sensor 5. The vibration sensor 4 is used to collect vibration signals when the pole steel mold 7 rotates in real time, and the speed sensor 5 is used to detect the real-time speed of the drive motor 3 or the roller assembly 2. The vibration sensor 4 is a triaxial acceleration sensor, speed sensor or displacement sensor, which is installed on the bearing seat of the roller assembly 2 or the rigid support part of the frame 1, and at least two sets are distributed along the axial direction of the pole steel mold 7, which are used to collect vibration signals at both ends and the middle of the mold respectively.

[0047] In this embodiment, the triaxial accelerometer can simultaneously collect the vibration acceleration of the mold in the X, Y, and Z directions, comprehensively reflecting the vibration state of the mold; at least two sets of sensors are respectively arranged on the bearing seats near the two ends and the middle of the mold. By comparing the signals of sensors at different positions, the accumulation or sparse area of ​​concrete in the axial direction can be accurately determined, providing a reliable data basis for the adaptive controller 6.

[0048] like Figure 3 and 4 As shown, the sensing system also includes a weighing sensor or strain gauge for monitoring the weight distribution of concrete inside the pole formwork 7. It is installed on the support shaft of the roller assembly 2 or at the bottom of the frame 1 for real-time weighing after the pole formwork 7 is installed, and transmits the weight signal to the adaptive controller 6 to help determine the initial concrete placement state.

[0049] In this embodiment, the weighing sensor monitors the total weight of the mold and the concrete inside in real time. When the weight deviates from the preset process requirements, the adaptive controller 6 can issue an alarm or adjust the subsequent centrifugation parameters in a timely manner. The strain gauge indirectly calculates the weight by monitoring the small deformation of the support shaft. Its installation method is simple and does not affect the normal operation of the roller assembly 2, thus improving the adaptability of the system.

[0050] like Figure 4 As shown, the adaptive controller 6 is electrically connected to the drive motor 3 and the sensing system. It has a pre-stored mapping model between vibration signals and concrete distribution, used to analyze the axial and circumferential uniformity of the concrete distribution within the pole's steel formwork 7 based on real-time vibration signals, and outputs speed control commands to the drive motor 3 to dynamically adjust the speed and / or output torque. The drive motor 3 is a variable frequency motor or servo motor with vector control function, and its speed control response time is no more than 100ms to achieve stepless speed regulation and differential control.

[0051] In this embodiment, the adaptive controller 6 can be an industrial PLC or an embedded computer. The built-in data processing module can quickly filter and perform fast Fourier transform on the vibration signal. The drive motor 3 is a variable frequency motor with vector control function, used in conjunction with a dedicated frequency converter to ensure that it can complete the response within 100ms after receiving the speed adjustment command, realize precise stepless speed adjustment and differential speed control, and meet the high requirements of the process for dynamic response.

[0052] like Figure 4 As shown, the adaptive controller 6 has a built-in signal discrimination module for filtering the vibration signal collected by the vibration sensor 4. The adaptive controller 6 has a built-in fuzzy PID control algorithm, neural network algorithm, or adaptive sliding mode control algorithm. The controller is configured to perform the following operations: extract the time-domain feature parameters of the vibration signal, including amplitude, effective value, kurtosis index, and / or waveform factor; compare the extracted feature parameters with a preset threshold determined by calibration test to identify areas of concrete accumulation or sparse distribution; and generate a PID adjustment amount based on the comparison result to dynamically change the operating frequency of the drive motor 3.

[0053] In this embodiment, the fuzzy PID control algorithm can automatically adjust the proportional, integral, and derivative parameters according to the real-time changes of the vibration signal, overcoming the shortcomings of traditional PID control in nonlinear systems with poor adaptability. The controller compares the extracted time-domain characteristic parameters such as amplitude and effective value with the preset threshold in real time. Once the concrete accumulation area is identified, the PID adjustment is immediately increased to increase the operating frequency of the drive motor 3, thereby enhancing the centrifugal force and promoting the redistribution of concrete.

[0054] like Figure 6 As shown, a method for preparing concrete poles with uniform wall thickness, employing an adaptive speed-regulating centrifugal molding device, includes the following steps:

[0055] S1. Injection and formwork closing: Inject concrete into the pole steel formwork 7 and close the formwork, then hoist it onto the roller assembly 2;

[0056] S2. Start-up: Start drive motor 3 and rotate it at an initial low speed of 100-200r / min to initially distribute the concrete on the inner wall of the mold.

[0057] S3, Signal Acquisition: Vibration and speed signals are acquired through vibration sensor 4 and speed sensor 5 and transmitted to adaptive controller 6;

[0058] S4, Attitude Control: The adaptive controller 6 filters and performs fast Fourier transform on the vibration signal to obtain the vibration spectrum;

[0059] The uniformity of concrete distribution in the axial and circumferential directions of the mold is determined based on the spectral characteristics.

[0060] If the distribution is determined to be uneven, dynamic adjustment is performed: the drive motor 3 is accelerated or decelerated within a set time by differential control, generating tangential acceleration fluctuations of 0.05g-0.2g, which breaks the equilibrium state of the concrete and promotes the concrete to flow towards the thin-walled area.

[0061] Once the effective value and kurtosis index of the vibration signal tend to stabilize, indicating uniform distribution, the rotation speed is gradually increased to medium speed (300-500 r / min) and then to high speed (600-900 r / min) according to the preset slope for centrifugal compaction.

[0062] S5. Shutdown: During the high-speed phase, the adaptive controller 6 fine-tunes the rotation speed based on the vibration intensity feedback, controlling the vibration intensity within the set threshold range of 5-15 mm / s to ensure that the concrete is fully vented and compacted. After compaction is completed, the drive motor 3 is controlled to slowly decelerate to a stop within 60-120 seconds to prevent sudden shutdown from causing damage to the concrete structure.

[0063] Preferably, the dynamic adjustment also includes: when the vibration sensor 4 detects that the amplitude of a certain section of the mold continuously exceeds that of other sections by more than 20%, the adaptive controller 6 controls the drive motor 3 to instantly increase its speed by 50-100 r / min when passing the support roller assembly 2 in that section, so as to perform local material replenishment.

[0064] In this embodiment, the localized material replenishment strategy can specifically address the problem of severely uneven axial distribution of concrete. When a specific section of the mold rotates above the support roller assembly 2, the instantaneous increase in rotation speed by 50-100 r / min can generate greater centrifugal force in that localized area, throwing the accumulated concrete toward the thin-walled area, achieving precise material replenishment, effectively avoiding the phenomenon of the pole having a thinner wall thickness at both ends or a thicker wall thickness in the middle, and improving the product qualification rate.

[0065] Preferably, the differential control execution time lasts for 10-30 seconds, and the frequency of acceleration fluctuations avoids the natural frequency of the pole steel mold 7 to prevent resonance.

[0066] In this embodiment, a differential speed control time of 10-30 seconds is sufficient to break the bond equilibrium state inside the concrete, causing the concrete to flow axially and redistribute without causing segregation. The natural frequency of the pole steel mold 7 is obtained by pre-testing, and the frequency of acceleration fluctuation is set in a range far from the natural frequency (such as 5Hz below or above the natural frequency) to ensure that the entire centrifugation process is stable and to avoid equipment damage and safety accidents caused by resonance.

[0067] Preferably, the initial low speed of the drive motor 3 is 100-200 r / min, the medium speed is 300-500 r / min, and the high speed is 600-900 r / min.

[0068] In this embodiment, the above-mentioned rotation speed range is set according to the common specifications of concrete poles (such as length and taper) and concrete slump. The initial low speed ensures that the concrete is evenly distributed without splashing, the medium speed is used for further compaction and to expel some gas, and the high speed provides a strong centrifugal force to make the concrete finally form. For poles of different specifications, the adaptive controller 6 can adaptively select specific values ​​within this range, which is highly versatile.

[0069] Preferably, after step S1 and before S2, the total weight of the concrete in the mold is obtained by a weighing sensor, and the adaptive controller 6 automatically matches the initial low-speed running time and the target high-speed rotation speed value according to the weight.

[0070] In this embodiment, for example, when the weighing sensor detects that the total weight of the concrete is large, the adaptive controller 6 automatically extends the initial low-speed running time to ensure that the concrete is fully distributed; at the same time, it matches a higher target high-speed rotation speed value according to the weight to ensure sufficient centrifugal force, thereby achieving adaptive matching of process parameters for poles of different weights, improving production efficiency and product quality consistency.

[0071] Preferably, during the centrifugation process, if the speed sensor 5 detects a deviation of more than ±2% between the actual speed and the set speed, the adaptive controller 6 immediately triggers an alarm and adjusts the output torque of the drive motor 3 to maintain a stable speed.

[0072] In this embodiment, the closed-loop control mechanism effectively prevents speed loss due to load fluctuations or motor failures. When the actual speed deviation exceeds ±2%, the controller triggers an audible and visual alarm to remind the operator, and at the same time, quickly adjusts the output torque of the drive motor 3 through a vector control algorithm to pull the speed back to the set value, ensuring the stability of the centrifugation process and the uniformity of the pole wall thickness, and ensuring the safe operation of the equipment.

[0073] The working principle and usage process of this invention are as follows: First, the mixed concrete is poured into the pole steel mold 7. After the mold is closed, the steel mold is hoisted onto the support roller assembly 2 using lifting equipment. At this time, if a weighing sensor is installed, the total weight of the mold and concrete is weighed, and the weight signal is sent to the adaptive controller 6. The controller automatically matches the initial low-speed running time and the target high-speed rotation speed value according to the weight. Next, the drive motor 3 is started, and the pole steel mold 7 begins to rotate at an initial low speed of 100-200 r / min, and the concrete is initially distributed inside the mold.

[0074] During rotation, vibration sensors 4, installed on the bearing housing of the support roller or the rigid support of the frame 1, collect the vibration signals of the mold in real time, while speed sensors 5 collect the actual speed signals and transmit them to the adaptive controller 6. The adaptive controller 6 filters and performs fast Fourier transform on the vibration signals, extracts indicators such as amplitude, effective value, and kurtosis, and compares them with a pre-stored mapping relationship model to determine the uniformity of concrete distribution in the axial and circumferential directions of the mold.

[0075] If uneven distribution is detected, the controller immediately performs dynamic adjustment: by differential control, the drive motor 3 accelerates or decelerates within 10-30 seconds, generating a tangential acceleration fluctuation of 0.05g-0.2g, breaking the equilibrium state of the concrete and causing the concrete to flow towards the thin-walled area; or when the vibration sensor 4 detects that the amplitude of a certain section of the mold continuously exceeds that of other sections by more than 20%, the drive motor 3 is controlled to instantaneously increase its speed by 50-100r / min when passing the support roller assembly 2 in that section, to perform local material replenishment.

[0076] As centrifugation proceeds, when the effective value and kurtosis index of the vibration signal tend to stabilize, indicating uniform concrete distribution, the controller gradually increases the speed of drive motor 3 to medium speed (300-500 r / min) and high speed (600-900 r / min) according to a preset slope for centrifugal compaction. During the high-speed stage, the controller fine-tunes the rotation speed based on vibration intensity feedback, controlling the vibration intensity within 5-15 mm / s to ensure sufficient air release and compaction of the concrete.

[0077] After compaction is complete, the controller slowly decelerates the drive motor 3 to a stop within 60-120 seconds to prevent sudden shutdown from damaging the concrete structure. Finally, the pole formwork 7 is lifted out, completing production. Throughout the process, if the speed sensor 5 detects a deviation of more than ±2% between the actual speed and the set speed, the adaptive controller 6 immediately triggers an alarm and adjusts the output torque of the drive motor 3 to maintain stable speed and ensure operational safety.

[0078] In the above scheme, it should be noted that the vibration sensor 4, speed sensor 5, adaptive controller 6, weighing sensor, etc. in this application are all existing products, and the specific structure, electrical connection method (circuit layout) and working principle of the vibration sensor 4, speed sensor 5, adaptive controller 6, weighing sensor, etc. are all existing publicly disclosed technical means, and will not be described in detail here.

Claims

1. An adaptive speed-regulating centrifugal molding device, characterized in that, Includes frame (1), roller assembly (2), pole steel mold (7), drive motor (3), sensing system and adaptive controller (6); The roller assembly (2) is fixedly installed on the frame (1), which is fixedly installed on the plane below the pit to support the pole steel mold (7) and drive the pole steel mold (7) to rotate around its axis. The drive motor (3) is connected to the roller assembly (2) for outputting rotational power; The sensing system includes a vibration sensor (4) and a speed sensor (5). The vibration sensor (4) is used to collect vibration signals when the pole steel mold (7) rotates in real time, and the speed sensor (5) is used to detect the real-time speed of the drive motor (3) or the roller assembly (2). The adaptive controller (6) is electrically connected to the drive motor (3) and the sensing system respectively. It has a pre-stored mapping relationship model between vibration signal and concrete distribution state. The mapping relationship model is the correspondence between vibration characteristic parameters and concrete distribution state stored in the adaptive controller (6) after centrifugal calibration test with a calibration sample equipped with a known eccentricity and a known axial stacking distribution state. The axial distribution uniformity is the degree of uniformity of concrete distribution along the axis, and the circumferential distribution uniformity is the degree of uniformity of concrete distribution around the axis. The axial distribution uniformity is judged based on the difference of vibration characteristic parameters of multiple sets of vibration sensors (4) arranged along the axis, and the circumferential distribution uniformity is judged based on the amplitude change of the rotational frequency component in the vibration signal. The adaptive controller (6) is used to analyze the axial and circumferential distribution uniformity of concrete in the pole steel mold (7) according to the real-time vibration signal, and output speed adjustment command to the drive motor (3) to dynamically adjust the speed and / or output torque.

2. The adaptive speed-regulating centrifugal molding device according to claim 1, characterized in that, The vibration sensor (4) is a triaxial acceleration sensor, velocity sensor or displacement sensor, which is installed on the bearing seat of the roller assembly (2) or the rigid support part of the frame (1), and at least two sets are distributed along the axial direction of the electric pole steel mold (7) to collect vibration signals at both ends and the middle of the mold respectively.

3. The adaptive speed-regulating centrifugal molding device according to claim 1, characterized in that, The drive motor (3) is a variable frequency motor or servo motor with vector control function, and its speed regulation response time is no more than 100ms, so as to realize stepless speed regulation and differential speed control.

4. The adaptive speed-regulating centrifugal molding device according to claim 1, characterized in that, The sensing system also includes a weighing sensor or strain gauge for monitoring the weight distribution of concrete inside the pole steel mold (7). It is installed on the support shaft of the roller assembly (2) or at the bottom of the frame (1) for real-time weighing after the pole steel mold (7) is installed, and transmits the weight signal to the adaptive controller (6) to help determine the initial concrete distribution state.

5. The adaptive speed-regulating centrifugal molding device according to claim 1, characterized in that, The adaptive controller (6) has a built-in signal discrimination module for filtering the vibration signal collected by the vibration sensor (4). The adaptive controller (6) has a built-in fuzzy PID control algorithm, neural network algorithm or adaptive sliding mode control algorithm. The controller is configured to perform the following operations: extract time-domain feature parameters of the vibration signal, including amplitude, effective value, kurtosis index and / or waveform factor; compare the extracted feature parameters with a preset threshold determined by calibration test to identify areas of concrete accumulation or sparse distribution; and generate PID adjustment based on the comparison result to dynamically change the operating frequency of the drive motor (3).

6. A method for preparing concrete poles with uniform wall thickness, comprising using the adaptive speed-regulating centrifugal molding device as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. Injecting concrete and closing the mold: Inject concrete into the steel mold of the pole (7) and close the mold, then hoist it onto the roller assembly (2); S2, Start-up: Start the drive motor (3) and rotate it at an initial low speed of 100-200r / min to initially distribute the concrete on the inner wall of the mold; S3, Signal Acquisition: Vibration signals and rotational speed signals are acquired through vibration sensor (4) and speed sensor (5) and transmitted to adaptive controller (6); S4, Attitude control: The adaptive controller (6) filters and performs fast Fourier transform on the vibration signal to obtain the vibration spectrum; The uniformity of concrete distribution in the axial and circumferential directions of the mold is determined based on the spectral characteristics. If the distribution is determined to be uneven, dynamic adjustment is performed: the drive motor (3) is accelerated or decelerated within a set time by differential control, generating tangential acceleration fluctuations of 0.05g-0.2g, breaking the equilibrium state of the concrete, and causing the concrete to flow towards the thin-walled area. Once the effective value and kurtosis index of the vibration signal tend to stabilize, indicating uniform distribution, the rotation speed is gradually increased to medium speed (300-500 r / min) and then to high speed (600-900 r / min) according to the preset slope for centrifugal compaction. S5. Shutdown: During the high-speed phase, the adaptive controller (6) fine-tunes the rotation speed based on the vibration intensity feedback, and controls the vibration intensity within the set threshold range of 5-15 mm / s to ensure that the concrete is fully vented and compacted. After compaction, the drive motor (3) is controlled to slowly decelerate to a stop within 60-120 seconds to prevent the concrete structure from being damaged by sudden shutdown.

7. The method for preparing a concrete pole with uniform wall thickness according to claim 6, characterized in that, The dynamic adjustment also includes: when the vibration sensor (4) detects that the amplitude of a certain section of the mold continuously exceeds 20% of other sections, the adaptive controller (6) controls the drive motor (3) to instantly increase the speed by 50-100 r / min when passing the roller assembly (2) in that section, and to perform local material replenishment.

8. The method for preparing a concrete pole with uniform wall thickness according to claim 6, characterized in that, The differential control lasts for 10-30 seconds, and the frequency of acceleration fluctuations avoids the natural frequency of the pole steel mold (7) to prevent resonance.

9. The method for preparing a concrete pole with uniform wall thickness according to claim 6, characterized in that, The initial low speed of the drive motor (3) is 100-200 r / min, the medium speed is 300-500 r / min, and the high speed is 600-900 r / min.

10. The method for preparing a concrete pole with uniform wall thickness according to claim 6, characterized in that, It also includes obtaining the total weight of the concrete in the mold through a weighing sensor after step S1 and before step S2, and the adaptive controller (6) automatically matching the initial low-speed running time and the target high-speed rotation speed value according to the weight; In addition, during the centrifugation process, if the speed sensor (5) detects that the deviation between the actual speed and the set speed exceeds ±2%, the adaptive controller (6) immediately triggers an alarm and adjusts the output torque of the drive motor (3) to maintain a stable speed.

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