Intelligent precast beam process quality real-time monitoring system

Abstract

The utility model belongs to the technical field of precast beam production, and particularly discloses an intelligent precast beam process quality real-time monitoring system which comprises a sensor module, a wireless communication module, a single chip microcomputer, a central control module, a power supply module and a user interface. The wireless communication module is in communication connection with the sensor module, the single-chip microcomputer, the central control module and the user interface. The power supply module is electrically connected with the sensor module, the wireless communication module, the single-chip microcomputer and the central control module. And the sensor module is fixed at the monitoring position of facility equipment and production environment in each process of precast beam production. Through real-time monitoring of the Internet of Things, all-weather automatic acquisition of production data of the precast beam is realized, so that the monitoring efficiency is remarkably improved. The problems that in the prior art, precast beam process quality monitoring is low in efficiency, poor in real-time performance, limited in data analysis capacity and incomplete in monitoring are solved.

Description

Technical Field

[0001] The utility model belongs to the technical field of prefabricated beam production, and specifically relates to the design of an intelligent real-time monitoring system for the quality of prefabricated beam processes. Background Art

[0002] Precast beams are an important structure commonly used in bridge construction and are usually produced in a special precast yard according to design requirements. The production process of precast beams includes multiple key steps such as steel bar processing, binding and installation, formwork installation, concrete pouring, vibration, maintenance, tensioning, grouting, anchor sealing, etc. The quality control of each step directly affects the product performance of the precast beam.

[0003] In the traditional precast beam production process, quality control mainly relies on manual inspection and some simple mechanical tests. For example, the accuracy of the formwork and the position and spacing of the steel bars are checked by visual inspection or measurement, and the strength of the concrete is sampled and tested using a testing machine. These methods have the problems of low efficiency, limited accuracy and inability to achieve comprehensive real-time monitoring. Utility Model Content

[0004] The utility model aims to solve the problems of low efficiency, poor real-time performance, limited data analysis capability and incomplete monitoring in the quality monitoring of prefabricated beam process in the prior art, and proposes an intelligent real-time monitoring system for the quality of prefabricated beam process.

[0005] The technical solution of the utility model is: an intelligent real-time monitoring system for the quality of prefabricated beam processes, characterized in that: it includes a sensor module, a wireless communication module, a single-chip microcomputer, a central control module, a power supply module and a user interface; the wireless communication module is respectively communicated and connected with the sensor module, the single-chip microcomputer, the central control module and the user interface; the power supply module is respectively electrically connected with the sensor module, the wireless communication module, the single-chip microcomputer and the central control module; the sensor module is fixed to the monitoring position of the facilities and equipment of each process of prefabricated beam production and the production environment.

[0006] The beneficial effects of the utility model are:

[0007] 1. Through the application of intelligent Internet of Things monitoring system, the quality of prefabricated beam process can be automatically monitored, the monitoring efficiency can be improved, the input of human resources can be reduced, and the accuracy and reliability of monitoring can be improved.

[0008] 2. Develop a real-time quality monitoring system covering all key processes of precast beams, which can monitor the entire production process of precast beams in real time, discover quality problems in a timely manner, issue early warning reminders at the first time, assist in targeted rectification measures and management decisions, eliminate quality risks, prefabricate according to standards, and effectively ensure the quality of precast beam products.

[0009] Preferably, the sensor module includes a temperature sensor, a humidity sensor, a displacement sensor, a stress sensor and a vibration sensor.

[0010] The beneficial effects of the above preferred solution are:

[0011] Through comprehensive real-time monitoring of temperature, humidity, displacement, stress and vibration, it can be ensured that each step of the process meets the quality standards, thereby improving the overall quality of precast beams.

[0012] Preferably, the temperature sensor is a BD-PT100-X temperature sensor.

[0013] The beneficial effects of the above preferred solution are:

[0014] The low-cost, ultra-small and highly reliable BD-PT100-X temperature sensor is used to accurately monitor the temperature during the precast beam production process while reducing maintenance costs.

[0015] Preferably, the humidity sensor adopts a XH71-MA humidity sensor.

[0016] The beneficial effects of the above preferred solution are:

[0017] The XH71-MA humidity sensor with stable performance and high measurement accuracy is used to accurately monitor humidity during the production of prefabricated beams and reduce maintenance costs.

[0018] Preferably, the displacement sensor adopts KTR11-10mm displacement sensor.

[0019] The beneficial effects of the above preferred solution are:

[0020] The use of KTR11-10mm displacement sensor with infinitesimal drift and wear resistance enables accurate monitoring of the displacement of precast beams or equipment in the production process during the precast beam production process, while reducing maintenance costs.

[0021] Preferably, the stress sensor adopts a HAL50-S stress sensor.

[0022] The beneficial effects of the above preferred solution are:

[0023] The HAL50-S stress sensor with high measurement accuracy and small size is used to accurately monitor the stress changes in the prefabricated beam production process and is easy to install.

[0024] Preferably, the vibration sensor is a TE 53-0050 vibration sensor.

[0025] The beneficial effects of the above preferred solution are:

[0026] The compact TE 53-0050 vibration sensor with its long-term stability enables accurate vibration measurement during the precast beam production process while reducing maintenance costs.

[0027] Preferably, the central control module includes a data receiving module, a data analysis module and an early warning module; the data receiving module is communicatively connected with the wireless communication module, the data analysis module and the early warning module respectively.

[0028] The beneficial effects of the above preferred solution are:

[0029] Build a monitoring system with powerful data processing and analysis capabilities, which can conduct in-depth analysis of the collected data and provide scientific data support for the quality control of precast beams and the optimization of production processes; set up an early warning module to issue alarm information in a timely manner, avoid errors caused by human factors, and reduce maintenance needs and costs.

[0030] Preferably, the user interface is provided with a monitoring module and an operating module; the monitoring module is used for monitoring the quality status of the precast beams in real time; and the operating module is used for adjusting the production process.

[0031] The beneficial effects of the above preferred solution are:

[0032] It provides an intuitive and easy-to-use user interface, allowing operators to easily view monitoring data and system analysis results, and convenient for managers to remotely view the quality status of beams in real time, thereby improving work efficiency.

[0033] Preferably, the power supply module is powered by a solar panel; the solar panel is provided with a power storage module.

[0034] The beneficial effects of the above preferred solution are:

[0035] By using solar panels to supply power and setting up power storage modules, energy is saved and pollution to the environment is effectively reduced. At the same time, the situation where the system cannot continue to work due to insufficient energy supply when there is no sun at night or on rainy days is avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 Shown is a structural diagram of an intelligent real-time monitoring system for prefabricated beam process quality.

[0037] Description of the accompanying drawings: 1—sensor module, 2—wireless communication module, 3—single chip microcomputer, 4—central control module, 5—power supply module, 6—user interface. DETAILED DESCRIPTION

[0038] Now, the exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be understood that the embodiments shown and described in the accompanying drawings are merely exemplary, intended to explain the principles and significance of the present invention, but not to limit the scope of the present invention.

[0039] like Figure 1 As shown, an intelligent real-time monitoring system for the quality of prefabricated beam processes is characterized in that it includes a sensor module 1, a wireless communication module 2, a single-chip computer 3, a central control module 4, a power supply module 5 and a user interface 6; the wireless communication module 2 is respectively communicated and connected with the sensor module 1, the single-chip computer 3, the central control module 4 and the user interface 6; the power supply module 5 is respectively electrically connected with the sensor module 1, the wireless communication module 2, the single-chip computer 3 and the central control module 4; the sensor module 1 is fixed to the monitoring position of the facilities and equipment of each process of prefabricated beam production and the production environment.

[0040] In this embodiment, the sensor module 1 includes a temperature sensor, a humidity sensor, a displacement sensor, a stress sensor and a vibration sensor.

[0041] In this embodiment, the temperature sensor is a BD-PT100-X temperature sensor.

[0042] In this embodiment, the humidity sensor is a XH71-MA humidity sensor.

[0043] In this embodiment, the displacement sensor is a KTR11-10mm displacement sensor.

[0044] In this embodiment, the stress sensor is a HAL50-S stress sensor.

[0045] In this embodiment, the vibration sensor is a TE 53-0050 vibration sensor.

[0046] In this embodiment, the central control module 4 includes a data receiving module, a data analysis module and an early warning module; the data receiving module is respectively connected to the wireless communication module 2, the data analysis module and the early warning module for communication.

[0047] In this embodiment, the user interface 6 is provided with a monitoring module and an operating module; the monitoring module is used to monitor the quality status of the precast beams in real time; and the operating module is used to adjust the production process.

[0048] In this embodiment, the power supply module 5 is powered by a solar panel; a power storage module is provided on the solar panel.

[0049] The specific working principle and process of the utility model are:

[0050] During the production of prefabricated beams, the sensor module 1 is first installed at the monitoring position of the facilities and equipment of each process and the production environment of the prefabricated beam production process to monitor the temperature, humidity, stress, vibration and displacement data in real time. These data are transmitted to the single-chip microcomputer 3 for preliminary processing and sent to the central control module 3 through the wireless communication module 2. The data receiving module of the central control module 4 receives the data, and then the analysis software of the data analysis module is used for in-depth analysis to determine whether the maintenance environment of the prefabricated beam is suitable, whether the facilities and equipment of each process and the production environment of the prefabricated beam production process meet the requirements, and the database is used to store historical data for long-term trend analysis and quality traceability. The operator can monitor the quality status of the prefabricated beam in real time through the monitoring module of the user interface 6, and optimize the production process and prefabrication parameters according to the system feedback to ensure the quality of the prefabricated beam. When the data analysis determines that there is a quality problem, the early warning module issues an alarm to the operator and provides corresponding processing suggestions, and the operator makes corresponding adjustments accordingly.

[0051] During the curing stage of the precast beam, the temperature and humidity sensors monitor the temperature and humidity of the curing environment. The single chip computer 3 collects these data and sends them to the central control system through the wireless communication module 2. The analysis software performs data analysis, monitors the temperature and humidity in the curing process in real time, and analyzes the optimal temperature and humidity for the fastest reaching of the design strength during the curing process by connecting to the concrete strength testing equipment. The curing equipment is automatically adjusted through the corresponding information signal to achieve the best curing environment conditions.

[0052] Those skilled in the art will appreciate that the embodiments described herein are intended to help readers understand the principles of the present invention, and should be understood that the protection scope of the present invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific variations and combinations based on the technical inspirations disclosed in the present invention without departing from the essence of the present invention, and these variations and combinations are still within the protection scope of the present invention.

Claims

1. An intelligent real-time monitoring system for prefabricated beam process quality, characterized by: The invention comprises a sensor module (1), a wireless communication module (2), a single chip computer (3), a central control module (4), a power supply module (5) and a user interface (6); the wireless communication module (2) is respectively connected to the sensor module (1), the single chip computer (3), the central control module (4) and the user interface (6); the power supply module (5) is respectively connected to the sensor module (1), the wireless communication module (2), the single chip computer (3) and the central control module (4); the sensor module (1) is fixed to the monitoring position of the facilities and equipment of each process of the prefabricated beam production and the production environment.

2. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 1 is characterized by: The sensor module (1) comprises a temperature sensor, a humidity sensor, a displacement sensor, a stress sensor and a vibration sensor.

3. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 2 is characterized by: The temperature sensor is a BD-PT100-X temperature sensor.

4. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 2 is characterized in that: The humidity sensor is a XH71-MA humidity sensor.

5. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 2 is characterized by: The displacement sensor adopts KTR11-10mm displacement sensor.

6. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 2 is characterized by: The stress sensor adopts HAL50-S model stress sensor.

7. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 2 is characterized by: The vibration sensor is a TE 53-0050 vibration sensor.

8. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 1 is characterized by: The central control module (4) comprises a data receiving module, a data analysis module and an early warning module; the data receiving module is respectively connected to the wireless communication module (2), the data analysis module and the early warning module for communication.

9. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 1 is characterized by: The user interface (6) is provided with a monitoring module and an operating module; the monitoring module is used for real-time monitoring of the quality status of the prefabricated beams; and the operating module is used for adjusting the production process.

10. The intelligent real-time monitoring system for prefabricated beam process quality according to claim 1 is characterized by: The power supply module (5) is powered by a solar cell panel; the solar cell panel is provided with a power storage module.

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