Concrete Volume Determination via Sensor Probe Calibration
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Solution Overview
Problem
Existing methods for determining the volume of concrete in a rotating mixer drum are inaccurate due to surface flow anomalies such as concavity, convexity, and cascading effects caused by high viscosity and elevated drum rotation speeds, which deceive system processors used for calculating volume and viscosity based on rotational entry and exit points of a sensor probe.
Innovation Solution
A method and system that uses a processor to compare current in-and-out sensor probe data with historical data to calibrate concrete load volume calculations, considering factors like rheology, slump, tilt angle, and mixer drum speed, to adjust and recalculate the volume value, ensuring accurate determination of concrete load volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drum rotation speed is increased to improve productivity, then concrete mixing efficiency is improved, but surface flow anomalies occur that reduce measurement precision
Solution Approach 1:
The system dynamically adjusts measurement parameters based on drum rotation speed. At different rotation speeds, the probe sampling frequency, data processing algorithms, and calibration factors are modified to compensate for speed-induced surface flow anomalies, maintaining accurate volume measurements across the full operating range
Solution Approach 2:
The system continuously monitors surface flow characteristics through the probe and uses this feedback to adjust measurement calculations in real-time. When surface flow anomalies are detected, the system modifies the interpretation of probe signals to account for the distorted concrete surface, ensuring accurate volume determination despite high-speed rotation effects
2Ease of operation
If the concrete viscosity is increased to improve workability, then concrete flow characteristics are improved, but surface flow anomalies such as concavity and convexity increase that reduce measurement precision
Solution Approach 1:
The system adapts measurement parameters based on concrete viscosity characteristics. For high-viscosity concrete that exhibits pronounced surface flow anomalies, the probe sampling rate, signal filtering parameters, and volume calculation algorithms are adjusted to compensate for the distorted surface geometry, maintaining measurement accuracy across different concrete rheologies
3Device complexity
If a simple entry/exit probe method is used to reduce device complexity, then system simplicity is improved, but measurement precision is reduced due to inability to detect surface flow anomalies
Solution Approach 1:
The probe is designed to perform multiple functions: it detects concrete presence for volume measurement, characterizes surface flow anomalies through signal pattern analysis, and determines concrete rheological properties. This multi-functionality allows a single relatively simple device to achieve complex measurement objectives without requiring multiple specialized sensors
Solution Approach 2:
The system introduces an intermediate data processing and analysis layer that mediates between the simple probe signals and the complex volume determination task. This intermediary processing layer interprets probe signals in the context of surface flow patterns, extracting accurate volume information even when the physical probe structure remains relatively simple
Data Source
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AI summary
Disclosed is a method for determining volume of a concrete mix load in a mixer drum based on use of an in-and-out sensor probe which submerges into and exits from the concrete during drum rotation and which provides data to a processor used for calculating volume based on the data. To provide for concavity, convexity, and/or cascading surface flow effects that can hinder accurate determination of the concrete load volume, the processor may be configured to compare original batch volume and/or rheology of the concrete load monitored during drum rotation. The calibration of load volume value, highly useful for monitoring or admixture dosing purposes, can be done based on comparison of real-time data with historic data gathered over time and stored in processor-accessible memory. Further exemplary embodiments also take into account the speed and/or tilt of the drum (due to roadway conditions), concrete mix design, and other factors.