An automatic detection system for rockfill dam material compactness suitable for high altitude areas

Abstract

The utility model discloses a kind of rockfill dam material compactness automation detection systems suitable for high altitude area, the system includes: master-slave arm synchronous operation intelligent pit measuring machinery, automatic screening measurement system and volume scanning equipment;The master-slave arm synchronous operation intelligent pit measuring machinery includes two ends respectively with bionic excavating module and slewing platform connection two-stage power telescopic arm;The bionic excavating module includes excavator module, planing module and clamping module;The automatic screening measurement system carries four different size screen and five grade discharge port;The high-precision volume scanning equipment includes mechanical structure and three-dimensional point cloud radar;The utility model can solve the problem of poor precision and low efficiency of test pit detection, especially in high-cold high-altitude area.

Description

Technical Field

[0001] This utility model relates to an automated testing system, and more particularly to an automated testing system for the compactness of rockfill dam materials in high-altitude areas. Background Technology

[0002] With rapid economic development and the ever-expanding demand for energy and water conservancy construction, the number of water conservancy and hydropower projects in various river basins and regions is constantly increasing. In the construction of rockfill dams, the construction quality of the filling area is directly related to the stability and safety of the dam body. Traditional methods for testing filling quality mainly rely on manual excavation of test pits. Although simple and intuitive, these methods suffer from poor accuracy and low efficiency. Especially in high-altitude and cold regions, manual excavation of test pits is not only time-consuming and labor-intensive but also increases construction costs and delays the construction period. These factors mean that traditional manual test pit testing methods can no longer meet the needs of refined and intelligent construction management.

[0003] In traditional test pit testing, technicians need to excavate, sample, and test at designated representative sampling points. They calculate key parameters such as density, moisture content, and particle size distribution to ensure the performance of the filling material meets design requirements. However, manual excavation of test pits is not only inefficient but also highly susceptible to external environmental factors, such as sunlight, temperature, and blood oxygen concentration, which can interfere with test results and thus affect construction progress. Therefore, developing more efficient and accurate automated testing technologies is urgently needed. Utility Model Content

[0004] Purpose of the utility model: The purpose of this utility model is to provide an automated testing system for the compactness of rockfill dam materials in high-altitude areas to improve the efficiency and accuracy of test pit testing and reduce testing costs, especially in applications in cold and high-altitude regions.

[0005] Technical solution: The automated testing system for the compactness of rockfill dam materials described in this utility model includes:

[0006] Intelligent pit-testing machinery with synchronous operation of master and slave arms, automatic screening and metering system, and volume scanning equipment;

[0007] The master-slave arm synchronous operation intelligent pit-testing machine includes a two-stage power telescopic arm, one end of which is connected to a bionic excavation module and the other end is connected to a rotary platform; the bionic excavation module includes a bucket module, a loosening module, and a clamping module for excavating rockfill of different particle sizes.

[0008] The automatic screening and metering system includes a shell material box that carries the test pit; a high-frequency vibration device is installed at the bottom of the shell material box, and multiple layers of screens are provided inside the shell material box; each layer of screens has a discharge port at the end, and a material mass extraction device is connected after the discharge port, and the material mass extraction device is equipped with a mass sensor for moving and transporting rockfill of different particle sizes.

[0009] The volume scanning equipment includes a mechanical structure and a three-dimensional point cloud radar, which is connected to the bottom plate of the bucket via the mechanical structure.

[0010] Preferably, the intelligent pit-testing machine with synchronous operation of master and slave arms also includes an electrical control system.

[0011] Preferably, the intelligent pit-testing machine with synchronous operation of master and slave arms also includes a power system.

[0012] Preferably, the intelligent pit-testing machine with synchronous operation of master and slave arms also includes a hydraulic system.

[0013] Preferably, the uppermost layer of the multi-layer screen has a feed inlet at one end.

[0014] Preferably, the uppermost layer of the multi-layer screen is provided with material baffles on both sides.

[0015] Preferably, the inner wall of the side of the casing hopper is provided with a T-shaped groove, and the fixed ends on both sides of the screen are matching T-shaped tenons, and the T-shaped groove and the T-shaped tenon form a bayonet pull-out connection.

[0016] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0017] 1. The biomimetic excavation module in the intelligent pit testing machine, which operates synchronously with the master and slave arms, accurately simulates the manual excavation process, achieving efficient and non-destructive excavation of test pits; the power system combined with the hydraulic system closed-loop control ensures stable operation in complex terrain; the long-range Bluetooth control system supports remote control, significantly improving the convenience and safety of operation, and is suitable for harsh environments such as high altitude and cold regions, which can greatly reduce the intensity of manual labor and improve the efficiency of test pit testing; the biomimetic excavation module can simultaneously meet the functional excavation of large-scale particles, and is also capable of detecting surface loosening, large particle clamping, and small particle digging.

[0018] 2. The automatic screening and metering system makes the entire system compact, facilitating transportation and installation; the vibration system provides maximum excitation force, combined with multi-layer screens to achieve efficient screening; the material quality extraction device can count the mass of rock piles of different particle sizes in real time, significantly improving screening efficiency and data accuracy, and can meet the rapid metering of rock particle size distribution in the 20-200mm range, improving detection accuracy, avoiding human experience errors, and reducing labor intensity.

[0019] 3. The volume scanning equipment can quickly and accurately measure the volume of the test pit, realize the automatic segmentation, registration and stitching of the test pit point cloud, and calculate and accumulate the volume of each layer by combining the polar angle filtering slicing method, completely replacing the traditional water filling method; avoiding human operation error, significantly improving the accuracy and efficiency of volume measurement, and suitable for large-scale test pit detection needs. Compared with related test pit volume detection algorithms, there is no need to manually adjust the radar position and angle. The radar can automatically output volume information after it runs on its own.

[0020] 4. By integrating intelligent pit testing machinery with synchronous operation of master and slave arms, automatic screening and metering system and volume scanning equipment, a complete automated testing system is formed; the collaborative operation of each module can significantly improve testing efficiency, reduce labor costs and labor intensity, and modular design and highly reliable components ensure stable operation of the equipment in harsh environments, providing efficient and accurate technical support for the quality assessment of rockfill dam filling, and has important engineering application value. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the system of this utility model;

[0022] Figure 2 This is a schematic diagram of the intelligent pit-measuring machine with synchronous operation of master and slave arms according to this utility model;

[0023] Figure 3 This is a schematic diagram of the automatic screening and metering system of this utility model;

[0024] Figure 4 This is a schematic diagram of the volume scanning equipment of this utility model. Detailed Implementation

[0025] The technical solution of this utility model will be further described below with reference to the accompanying drawings.

[0026] An automated testing system for the compaction of rockfill dam materials is designed for high-altitude areas. The entire system is designed with full consideration of the special environment of high-altitude areas, has good adaptability and reliability, and can meet the compaction testing needs of rockfill dam materials in complex terrain.

[0027] In the diagram: 1-Intelligent pit-testing machine with synchronized operation of master and slave arms; 2-Automatic screening and metering system; 3-High-precision volume scanning equipment; 101-Two-stage power telescopic boom; 102-Bucket module; 103-Loosening module; 104-Clamping module; 105-Electrical cabinet; 106-Electrical control system; 107-Hydraulic system; 108-Power system; 109-Hydraulic cylinder; 110-Rotating platform; 111-Crawler chassis; 112-Control handle; 201-Feed inlet; 202-Machine shell and material box; 203-High-strength vibration spring; 204-High-frequency vibration device; 205-Heavy-duty channel steel base; 206-Multi-layer screen, where 206-1 is a 10cm screen, 206-2 is a 60cm screen, 206-3 is a 4cm screen, and 206-4 is a 2cm screen; 301-High-precision volume scanning radar; 302-Mechanical structure.

[0028] The system includes a master-slave arm synchronous operation intelligent pit-digging machine 1, an automatic screening and metering system 2, and a high-precision volume scanning equipment 3. The master-slave arm synchronous operation intelligent pit-digging machine 1 includes a two-stage power telescopic arm 101 connected at both ends to a bionic excavation module and a rotary platform 110, respectively. The two-stage power telescopic arm 101 is driven by hydraulic cylinders 109. One end of the two-stage power telescopic arm 101 is connected to the bionic excavation module, and the lower body and upper body are respectively connected to the inner and outer rings of the rotary platform 110. An electrical cabinet 105 integrates a protection and control system 106; the control system 106 mainly consists of a motor start / stop device, a protection circuit, a long-range Bluetooth control system, a controller, a rectifier power supply, an alarm circuit, a lighting circuit, and the electrical cabinet. The long-range Bluetooth control system has a built-in Bluetooth module and can be paired and connected to the control handle 112 via the long-range Bluetooth control system. The hydraulic system 107 consists of a hydraulic main pump, a hydraulic main valve, a double-acting hydraulic cylinder, a hydraulic rotary motor, a safety valve, a pressure reducing valve, a balance valve, and other hydraulic components, ensuring precise control of mechanical movement, excavation, and attachment actions.

[0029] The biomimetic excavation module includes a bucket module 102, a loosening module 103, and a clamping module 104 for excavating riprap of different particle sizes. The bucket module 102 is equipped with a reinforced bucket tooth to excavate loose material with a particle size ≤200mm, ensuring that fine-grained riprap is effectively transported to the screening machine, avoiding inaccurate testing due to insufficient riprap composition. The loosening module 103 is used to loosen the riprap within the test pit area. Its top carbon steel rock teeth adopt an adjustable amplitude reciprocating impact design, which can effectively loosen the dense surface riprap, especially effective for hard riprap. The clamping module 104 adopts a hydraulic gripper design with an opening angle of 0°-120°. Inspired by a human hand, it performs a gripping-shaking-transfer operation on oversized stones with a particle size >200mm, enabling stable gripping of long strips or large pieces of riprap and ensuring the accuracy of experimental results.

[0030] The automatic screening and metering system 2 includes four heavy-duty channel steel bases 205, which are reinforced by welding metal frames to maintain stability. High-strength vibration springs 203 are connected to the four heavy-duty channel steel bases 205. The upper part of the high-strength vibration springs 203 is connected to the housing material box 202. A high-frequency vibration device 204 is installed at the bottom of the housing material box 202. The interior of the housing material box 202 is equipped with multiple layers of screens 206. Each layer of screen has a discharge port 207 at its end. A material mass extraction device 208 is connected after the discharge port 207. The material mass extraction device 208 is equipped with a mass sensor 209 that can move and transfer the mass of stones of different particle sizes and output the material gradation. The other end of the uppermost screen of the housing material box 202 is equipped with a feed port 201. Material baffles are provided on both sides of the uppermost screen. The material baffles are detachable. The connection between the housing material box 202 and the screen is fixed with quick-locking bolts for easy transportation, storage and handling of the entire housing.

[0031] The heavy-duty channel steel base 205 uses cylindrical metal legs. The front and rear heavy-duty channel steel bases 205 are designed with height differences. The rear heavy-duty channel steel base (at the feed inlet 201 end) is slightly longer than the front heavy-duty channel steel base (at the discharge outlet 201 end), so that the material box 202 of the machine casing forms a certain angle, using gravity to assist the movement of materials. Each heavy-duty channel steel base also has two spring clips at the top, which facilitates the connection between the support legs and the vibration springs. Each clip connects to one vibration spring. The inner side wall of the material box 202 of the machine casing has T-shaped grooves. The fixed ends of the screen on both sides are matched with T-shaped protrusions, which are slightly smaller than the T-shaped grooves on both sides of the material box 202 of the machine casing. The two form a snap-fit ​​connection, which realizes the quick insertion and removal of the screen, and the screen can be replaced according to the actual working needs.

[0032] The mechanical structure 302 of the volume scanning equipment 3 connects the high-precision volume scanning radar 301 to the bottom plate of the excavator bucket, so that it is vertically inverted at the center of the test pit and can move up and down. Combined with the rotation scanning mechanism, it realizes full data acquisition of a single station. By acquiring data in two dimensions, fast axis (vertical direction) and slow axis (horizontal direction), it gradually forms a two-dimensional slice test pit and finally accumulates it into a three-dimensional test pit.

[0033] The working principle is as follows:

[0034] The master-slave arm synchronous operation intelligent pit testing machine 1 is started and paired with the control handle 112 via Bluetooth; the position of the master-slave arm synchronous operation intelligent pit testing machine 1 is adjusted so that the machine body is facing and horizontally placed in the detection area (center of the density detection ring), ensuring that the outer edge of the machine body track is ≥50cm away from the edge of the density detection ring; the rock teeth at the top of the loosening module 103 of the two-stage power telescopic arm 101 are operated to reciprocate to impact and loosen the surface of the detection layer, loosening the dense piled stone. The bucket module 102 is switched to dig out the loosened loose granular piled stone (particle size ≤200mm), and the excavated loose material is directly poured into the feed inlet 201 of the automatic screening and metering system 2. Finally, the clamping module 104 is switched to clamp the stone with hydraulic claws, and a slight shaking action is performed to make the attached fine material fall back into the test pit to avoid experimental errors; the processed oversized stone is transferred to the test cloth laid next to the test pit.

[0035] According to the required depth of the test pit, fine-tune the position of the machinery as needed (keeping it level); repeat the steps of loosening, excavating loose material, and handling oversized material to carry out layered excavation; continue excavation until the depth reaches the designed filling thickness of the compaction layer; control the overall shape of the test pit to be a pot-shaped arc (with a smooth transition at the bottom and a stable slope of the pit walls). Place the automatic screening and metering system 2 stably in front of the master-slave arm synchronous operation intelligent pit testing machinery 1, and reliably connect the automatic screening and metering system 2 to the generator set using the matching cable to ensure stable power supply. Confirm that the automatic screening and metering system 2 is equipped with four layers of screens, with screen aperture sizes from top to bottom of 10cm, 6cm, 4cm, and 2cm, corresponding to five output particle size ranges of 20-10cm, 10-6cm, 6-4cm, 4-2cm, and <2cm; place weighing buckets below each level of discharge port 207 to collect the screened stone materials and facilitate subsequent weighing; check that the screens are firmly installed, all connecting parts are tight, and the safety guards are intact.

[0036] Start the generator set and, after the output voltage stabilizes, start the automatic screening and metering system 2. Operate the master-slave arm synchronous operation intelligent pit testing machine 1, and use the bucket module 102 to directly unload the loose granular rock material with a particle size ≤200mm excavated from the test pit into the feed inlet 201 of the automatic screening and metering system 2. Follow the principles of small-volume, uniform, and continuous feeding to avoid overloading or clogging the screen due to excessive feeding at one time. Under the action of the screen box's tilting vibration, the material is thrown forward along the screen surface and falls through the screen according to particle size levels into the corresponding collection hopper. Closely observe the screening status to ensure stable operation without abnormal noise or vibration.

[0037] Measure the dimensions of oversized stones (>200mm) placed on the test fabric using a tape measure, and weigh and record the weight using an electronic platform scale. Collect the loose material carried by the oversized stones from the test fabric and feed it into the inlet 201 of the screening machine. Repeat the above screening process until all the stones excavated from the test pit (including loose material and fine material attached to oversized stones) have been screened. After the screening operation is paused or completed in stages, take out the stones from the weighing buckets below each discharge port 207 in sequence, and weigh each batch of stones in each size range using an electronic platform scale with the corresponding range (300kg, 30kg) (record accurate to 0.1kg).

[0038] in:

[0039] For stones with a particle size >100 μm: it is necessary to use a measuring tape to measure their maximum size (record with an accuracy of 1 cm) and classify and stack them according to particle size range (20-10 cm, 10-6 cm, etc.);

[0040] For fine materials with a particle size <20mm: After collection and weighing, three representative samples are evenly extracted from the sample bag, sealed and labeled, and brought back to the laboratory for indoor fine material sieving;

[0041] The high-precision 3D point cloud radar 3 (rotating 3D laser scanner) is vertically inverted and installed on the pre-set connection port at the bottom of the bucket of the intelligent pit testing machine 1 with synchronous operation of master and slave arms via its dedicated mechanical structure. Ensure a secure installation, turn on the radar power switch, and start the equipment for self-testing. Operate the two-stage power telescopic arm 101 to precisely move the bucket module 102, equipped with the radar, to directly above the center of the test pit (i.e., the center position of the density detection ring). Slowly lower the height of the bucket module 102 until the bottom scanning surface of the high-precision 3D point cloud radar 3 is flush with the upper edge of the density detection ring, ensuring no risk of contact between the radar and the pit bottom or walls.

[0042] Open the accompanying radar scanning control software and ensure that the device is properly connected to the radar via the local area network. On the scanning software interface, select or confirm the scanning parameters (usually using the default or preset pit test mode), and click the start scan or dual-side scan operation button to begin data acquisition.

[0043] During the scanning process, the radar's fast and slow axes rotate in tandem, emitting a 905nm laser beam to capture the spatial coordinates of the pit wall. The software interface monitors the progress and equipment operating status to ensure no abnormal interruptions. After the scan is completed, the software automatically performs point cloud noise reduction filtering (radius outlier removal) and surface reconstruction (Poisson surface reconstruction) to generate a three-dimensional closed triangular mesh model of the test pit. Based on the reconstructed surface model, the software automatically applies the Gaussian divergence theorem integral to calculate the volume of the test pit with an accuracy of up to 95%.

[0044] Save the generated raw point cloud data file, 3D model file, and volume calculation results. File names must include key identifying information; recommended format: Volume Scan_[Date]_[Station]_[Elevation].txt (or other naming conventions conforming to project file management requirements). Before scanning, ensure the test pit is regularly shaped like a rounded bottom, with stable walls free from looseness or collapse, and no residual materials or tools inside. Maintain a safe distance during scanning; personnel are strictly prohibited from entering the scanning area or peering over the test pit to prevent accidents. Preliminarily check whether the generated model's visualization fully reflects the test pit's shape and whether the volume value is within a reasonable range. If there are obvious abnormalities (such as incomplete models, excessively large or small volume values), analyze the cause (such as unstable pit walls, obstructions, or improper scanning height) and consider rescanning.

Claims

1. An automated testing system for the compaction of rockfill dam materials suitable for high-altitude areas, characterized in that, include: The intelligent pit-measuring machine with synchronous operation of master and slave arms (1), the automatic screening and metering system (2), and the volume scanning equipment (3) are all included. The master-slave synchronized operation intelligent pit-testing machine (1) includes a two-stage power telescopic arm (101), one end of which is connected to a bionic excavation module and the other end is connected to a rotary platform (110); the bionic excavation module includes a bucket module (102) for excavating rockfill of different particle sizes, a loosening module (103) and a clamping module (104); The automatic screening and metering system (2) includes a housing hopper (202) that carries the test pit; a high-frequency vibration device (204) is installed at the bottom of the housing hopper (202), and multiple layers of screens (206) are provided inside the housing hopper (202); each layer of screens is provided with a discharge port (207) at the end, and a material mass extraction device (208) is connected after the discharge port (207), and the material mass extraction device (208) is equipped with a mass sensor (209) for moving and transporting rockfill materials of different particle sizes; The volume scanning equipment (3) includes a mechanical structure (302) and a three-dimensional point cloud radar (301), and the three-dimensional point cloud radar (301) is connected to the bottom plate of the bucket through the mechanical structure (302).

2. The automated detection system for the compactness of rockfill dam material according to claim 1, characterized in that, The master-slave synchronous operation intelligent pit-testing machine (1) also includes an electrical control system (106).

3. The automated detection system for the compactness of rockfill dam material according to claim 1, characterized in that, The intelligent pit-testing machine (1) with synchronous operation of master and slave arms also includes a power system (108).

4. The automated detection system for the compactness of rockfill dam material according to claim 1, characterized in that, The intelligent pit-testing machine (1) with synchronous operation of master and slave arms also includes a hydraulic system (107).

5. The automated detection system for the compaction of rockfill dam material according to claim 1, characterized in that, The uppermost screen of the multi-layer screen (206) is provided with a feed inlet (201) at one end.

6. The automated detection system for the compaction of rockfill dam material according to claim 1, characterized in that, Material baffles are provided on both sides of the uppermost layer of the multi-layer screen (206).

7. The automated detection system for the compactness of rockfill dam material according to claim 1, characterized in that, The inner wall of the machine housing hopper (202) is provided with a T-shaped groove, and the fixed ends on both sides of the screen are matching T-shaped tenons. The T-shaped groove and the T-shaped tenon form a bayonet pull-out connection.

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