Concrete Admixture Dispensing via Distributed Intelligent Controllers
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Solution Overview
Problem
Concrete plants face challenges in accurately measuring and dispensing admixtures due to pre-mixed admixtures, complex calculations, and limited feedback from existing batch panels, leading to inefficiencies and potential environmental concerns from admixture leaks.
Innovation Solution
Implementing distributed intelligent controllers with field boxes that communicate through a CAN-bus network, allowing for real-time monitoring and control of concrete plant equipment, including admixture flow detection and inventory management, and enabling the creation of customized admixtures based on building specifications and available ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pre-mixed admixtures are used in concrete batches, then the complexity of admixture formulation is reduced, but measurement accuracy deteriorates because the pre-mixed admixtures cannot be precisely controlled according to specific batch requirements
Solution Approach 1:
The system segments the admixture delivery process into multiple controllable stages: bulk admixture storage, precise metering/dosing, and individual batch dispensing. This allows pre-mixed admixtures to be stored in bulk while still enabling precise measurement and control for each specific concrete batch through automated metering equipment and software control.
2Reliability
If distributed intelligent controllers with CAN-bus network are implemented, then real-time monitoring and control capability is improved, but device complexity increases due to additional sensors, controllers, and communication infrastructure
Solution Approach 1:
The intelligent controllers are designed as multi-functional devices that simultaneously perform monitoring, control, communication, and data processing functions. The CAN-bus network serves multiple purposes including real-time data transmission, diagnostic communication, and coordinated control of multiple plant components, reducing the need for separate dedicated systems for each function.
3Productivity
If automated admixture dispensing systems are implemented, then productivity is improved, but the difficulty of detecting and measuring admixture flow conditions increases
Solution Approach 1:
The system introduces intermediary sensing devices and flow measurement equipment between the admixture storage and dispensing points. These intermediaries include flow meters, level sensors, and automated valves that facilitate accurate detection and measurement of admixture flow conditions, enabling automated control while maintaining productivity.
4Manufacturing precision
If real-time feedback systems are implemented, then manufacturing precision is improved, but loss of information increases due to the complexity of data handling and processing
Solution Approach 1:
The system implements automated feedback loops where sensors continuously monitor admixture flow, inventory levels, and dispensing accuracy. This real-time feedback is automatically processed by control software that adjusts dispensing parameters to maintain precision, reducing manual data handling and minimizing information loss through automated data capture and processing.
Data Source
AI summary
A control system for a concrete plant adds intelligent capabilities in the concrete plant that may enhance safety, localize control of the concrete plant, and assist with troubleshooting. The control system may also enhance accuracy for determining an amount of mixed concrete dispensed, or amounts of concrete ingredients to dispense, and may eliminate the need for equipment used to verify the amount of mixed concrete or concrete ingredients dispensed.