Mixer Drum Grey Water Sensing for Accurate Concrete Batching
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Solution Overview
Problem
Current systems fail to accurately measure and account for grey water remaining in concrete mixer drums, leading to inconsistencies in concrete strength and rheology due to unrecorded water content, which affects both production and delivery processes.
Innovation Solution
A method and system using sensors inside the mixer drum to detect and measure grey water by tracking submersion fractions and adjusting subsequent batching processes to maintain desired water and cement content, or discharging the grey water to prevent its influence on subsequent batches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grey water is left in the mixer drum to circumvent automated slump monitoring systems, then slump is increased (easier placing), but concrete strength decreases due to unaccounted water content
Solution Approach 1:
The system performs preliminary detection of grey water presence and measurement of its volume before the batching process begins. The sensor detects water in the drum and the system calculates the volume based on submersion fraction, allowing the batching process to be adjusted in advance to compensate for the grey water, thus maintaining both ease of operation and concrete strength.
Solution Approach 2:
The system implements a feedback mechanism where the detected grey water volume is used to automatically adjust the batching process. The controller receives information about grey water presence and volume, then modifies the water and cement batching quantities accordingly, creating a closed-loop system that maintains concrete quality despite the presence of grey water.
2Device complexity
If grey water is not measured and accounted for, then batching process remains simple, but water content accuracy deteriorates leading to strength variations
Solution Approach 1:
The system replaces manual water content measurement and calculation methods with an automated sensor-based detection system. The sensor electronically detects grey water presence and the controller automatically calculates volume and adjusts batching, substituting mechanical/manual processes with automated electronic systems that improve precision while adding minimal complexity.
3Measurement precision
If a moisture meter is used to detect water in the drum, then grey water presence is detected, but accurate volume measurement fails without considering drum angle and data collection rate
Solution Approach 1:
The system dynamically adjusts the measurement process by continuously monitoring drum angle and data collection rate. Rather than using fixed measurement parameters, the system adapts the measurement frequency and angle compensation calculations in real-time based on the actual operating conditions, improving measurement accuracy while keeping the system responsive to changing conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures accurate material batching and alerts operators to grey water presence, allowing for adjustments to maintain consistent concrete strength and rheology, thereby improving production efficiency and quality.
Implementation Method 1
Either type of water meter can employ several different types of technologies such as (but not limited to) measuring electrical resistance
Implementation Method 2
measuring capacitance
Implementation Method 3
measuring microwaves
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
Method and system to measure and monitor the grey water content in a rotating concrete mixer drum mixer truck using a sensor attached to the interior of the concrete mixer drum. By measuring the grey water content before a batching process takes place, the batched water (and cement content and admixture type and content) can be modified in order to maintain expected performance of the batched load in terms of both strength and rheology, or more simply, some or all of the grey water can be discharged from the concrete mixer drum before batching.