CN111828046B - Concrete spraying system and control method thereof - Google Patents
Concrete spraying system and control method thereof Download PDFInfo
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- CN111828046B CN111828046B CN202010717591.XA CN202010717591A CN111828046B CN 111828046 B CN111828046 B CN 111828046B CN 202010717591 A CN202010717591 A CN 202010717591A CN 111828046 B CN111828046 B CN 111828046B
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- 239000004567 concrete Substances 0.000 title claims abstract description 121
- 238000005507 spraying Methods 0.000 title claims abstract description 46
- 238000000034 method Methods 0.000 title claims abstract description 24
- 230000001276 controlling effect Effects 0.000 claims abstract description 34
- 230000001105 regulatory effect Effects 0.000 claims abstract description 33
- 239000000654 additive Substances 0.000 claims abstract description 29
- 230000000996 additive effect Effects 0.000 claims abstract description 23
- 238000001514 detection method Methods 0.000 claims abstract description 19
- 238000002347 injection Methods 0.000 claims abstract description 13
- 239000007924 injection Substances 0.000 claims abstract description 13
- 238000005086 pumping Methods 0.000 claims abstract description 13
- 230000008569 process Effects 0.000 claims abstract description 10
- 239000007921 spray Substances 0.000 claims description 18
- 239000000203 mixture Substances 0.000 claims description 13
- 239000011378 shotcrete Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 12
- 230000008054 signal transmission Effects 0.000 claims description 4
- 238000005422 blasting Methods 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 230000000007 visual effect Effects 0.000 claims description 2
- 238000010276 construction Methods 0.000 abstract description 12
- 238000005457 optimization Methods 0.000 abstract description 2
- 239000004568 cement Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D11/00—Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
- E21D11/04—Lining with building materials
- E21D11/10—Lining with building materials with concrete cast in situ; Shuttering also lost shutterings, e.g. made of blocks, of metal plates or other equipment adapted therefor
- E21D11/105—Transport or application of concrete specially adapted for the lining of tunnels or galleries ; Backfilling the space between main building element and the surrounding rock, e.g. with concrete
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D15/00—Handling building or like materials for hydraulic engineering or foundations
- E02D15/02—Handling of bulk concrete specially for foundation or hydraulic engineering purposes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
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- Engineering & Computer Science (AREA)
- Structural Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Mining & Mineral Resources (AREA)
- Architecture (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Civil Engineering (AREA)
- Paleontology (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
- Lining And Supports For Tunnels (AREA)
Abstract
The invention provides a concrete spraying system and a control method thereof. The concrete injection system comprises a concrete pump, a compressed air pump, a plurality of groups of admixture regulating and controlling equipment, an information control system and a rebound rate detection system, wherein each group of admixture regulating and controlling equipment comprises an admixture pump, a control device and a mixed flow device. The control method comprises the following steps: 1) setting parameter values in an information control system; 2) the pumping is started, the admixture is conveyed to the corresponding mixing devices, the concrete sequentially passes through the mixing devices and is mixed with the admixture, and the control device controls the initial flow and the mixing time of the admixture according to the instruction of the information control system; 3) spraying concrete; 4) and the rebound rate detection system detects and feeds back the data of the rebound rate of the concrete, if the information control system judges that the current data do not reach the standard, an additive adjusting instruction is sent to the control device, and the process is repeated until the data reach the standard. The invention realizes the on-line optimization of the concrete mixing proportion and reduces the construction cost.
Description
Technical Field
The invention relates to the technical field of concrete wet spraying equipment, in particular to a concrete spraying system and a control method thereof.
Background
The sprayed concrete is formed by mixing materials such as gelled materials, coarse and fine aggregates, additives and the like according to a certain proportion, then sending the mixture into spraying equipment, and spraying the mixture to a sprayed surface at a high speed by means of compressed air or other power transmission. According to the difference between the mixing method and the pressure feeding method, the construction process of sprayed concrete can be mainly divided into a dry spraying method and a wet spraying method, wherein the dry spraying method and the wet spraying method have the problems of large dust, poor concrete homogeneity and the like and are gradually eliminated, and the wet spraying method has the advantages of relatively less dust, easy control of the quality of wet sprayed concrete and the like in the spraying process and is the main construction method of sprayed concrete at present. In the aspect of wet blasting equipment, the currently used concrete spraying manipulator is difficult to play the role in the environment with complicated geology and severe conditions, and the concrete wet blasting trolley has the advantages of large production capacity, long conveying distance, small machine type, multiple functions and high automation degree, and is enough to meet the construction requirements of changeable terrain and complicated terrain in China.
However, the existing concrete spraying trolley has the problems of unreasonable concrete mixing ratio, inaccurate wet spraying control and the like during operation, the concrete spraying rebound rate is often overlarge, not only is a great deal of concrete wasted, but also the construction cost is greatly increased, the construction period is prolonged, the construction efficiency is seriously influenced, and the safety risk of personnel construction operation is increased. Therefore, it is of great practical value to develop a technique for controlling the rebound resilience of wet shotcrete.
The rebound resilience of shotcrete is generally expressed as the average rebound resilience, which is the percentage of the total mass of concrete sprayed on the sprayed surface (i.e., the amount of rebound) to the total mass of concrete sprayed. As mentioned above, an important factor influencing the resilience is the mix design, which essentially adjusts the concrete properties until it meets the construction requirements (e.g. good mechanical properties, durability and low resilience). The currently common method for determining the mix proportion design is as follows: firstly, trial preparation is carried out on a plurality of formulas according to the design requirements of the performance of the mixture, the dosage of the cementing material, the sand rate and the water-cement ratio of the concrete reference mixing ratio are slightly adjusted according to the trial preparation results, and then the mixing ratio is optimized according to the rebound rate and the concrete quality under the condition that the water-cement ratio is kept unchanged.
The addition of the additive is a key ring in the optimization process of the mix proportion of the sprayed concrete and is a main measure for adjusting the performance of the sprayed concrete at present, so that the adjustment of the performance of the concrete can be realized by changing the using amount of the additive, and the rebound rate of the wet sprayed concrete is further controlled. However, the existing problem is how to adjust the performance of the concrete by accurately controlling the dosage of the additive, so that the concrete has good fluidity during pumping and has larger viscosity during spraying, thereby achieving the purpose of controlling the rebound resilience.
The method is limited by the structure of the existing wet spraying trolley, the mix proportion of concrete cannot be optimized in real time by the existing spraying method, and therefore when the best spraying effect and the minimum rebound rate are required to be obtained by trial spraying or when the problems of pipe blockage or high rebound rate occur in actual construction, manual material re-distribution is usually needed for many times, materials are transported in a reciprocating mode in a circulating mode, the operation process is repeated, and a large amount of material waste and time consumption are caused.
Disclosure of Invention
The invention aims to provide a technical scheme for adjusting the mix proportion of concrete in real time during operation so as to regulate and control the rebound rate, so as to solve the problems in the background technology.
In order to achieve the aim, the invention provides a concrete spraying system which comprises a power system, an additive regulating and controlling system, an information control system, a rebound rate detection system and a spray head;
the power system comprises a concrete pump, and the concrete pump is arranged on the concrete pipeline and is used for providing power for conveying concrete;
the admixture regulating and controlling system comprises at least one group of admixture regulating and controlling equipment, each group of admixture regulating and controlling equipment comprises an admixture pump, a control device and a mixing device, the admixture pump is arranged on an admixture pipeline and used for providing power for conveying the admixture, the control device is arranged on the admixture pipeline and used for detecting and regulating various parameters of the admixture, and the mixing device is arranged at the intersection position of the admixture pipeline and the concrete pipeline and used for uniformly mixing the concrete and the admixture;
the spray head is arranged at the tail end of the concrete pipeline and is used for spraying the mixed shotcrete on an operation surface;
the rebound rate detection system is used for detecting the rebound rate data in real time;
and the information control system, the rebound rate detection system and each control device realize signal transmission, and send a regulation and control instruction to the corresponding control device by analyzing and processing the fed back concrete rebound data and additive parameter data.
Preferably, the power system further comprises a compressed air pump which is connected with each flow mixing device and used for providing power for the sufficient mixing and the subsequent conveying of the admixture and the concrete.
Preferably, the information control system is a computer.
Preferably, the mixing devices are sequentially arranged on the concrete pipeline according to the adding sequence of the admixture of the concrete.
Preferably, a regulating device for regulating the flow rate of the concrete is further arranged on the concrete pipeline, the regulating device is positioned between the concrete pump and the first mixed flow device, and signal transmission is realized between the regulating device and the information control system.
Preferably, a concrete component detector is arranged at the spray head position, so that the spraying characteristics of the concrete after the mix proportion is adjusted can be known conveniently. The concrete component detector can be arranged in the spray head or above the outlet position of the spray head.
Preferably, the concrete injection system is used in conjunction with a wet spray trolley.
Specifically, the admixture regulating and controlling system is respectively arranged at different positions on the wet spraying trolley according to different functions of an internal device of the admixture regulating and controlling system. The front plurality of admixture regulating and controlling devices of the admixture regulating and controlling system are mainly used for regulating and controlling the flowability of concrete, for example, a water reducing agent and the like are added, so that the admixture regulating and controlling system has good flowability during pumping, is favorable for smooth conveying, and prevents the phenomena of pipe blockage and the like, and therefore the part is mainly distributed in a pumping area of a wet spraying trolley; the latter additive regulating and controlling devices of the additive regulating and controlling system are mainly used for regulating and controlling the viscosity of concrete, such as adding a tackifier, an accelerator and the like, so that the concrete has good cohesive force during spraying, the falling and the slippage of the concrete are reduced, and the rebound rate is controlled, therefore, the part is mainly distributed in an area close to a spray head.
Preferably, a pumping area of the wet spraying trolley is provided with a pumping pressure abnormity monitoring and alarming device so as to monitor and prevent the phenomenon of concrete pipe blockage.
The invention also provides a control method based on the concrete injection system, which comprises the following steps:
step 1) setting parameter values in an information control system;
step 2) starting pumping, sequentially conveying concrete to each mixed flow device through a concrete pipeline, conveying each admixture to the corresponding mixed flow device through an admixture pipeline, and controlling the initial flow and mixing time of the corresponding admixture entering the mixed flow device by each control device according to an instruction from an information control system;
step 3) spraying the mixed concrete on an operation surface through a spray head;
and 4) in the spraying period, the rebound rate detection system detects the rebound rate data of the concrete in real time according to the rebound material falling off from the working face and feeds the data back to the information control system, the information control system judges whether the current rebound rate data exceeds a set range value, if not, the current rebound rate data is kept unchanged, if yes, the information control system sends an instruction to the control device by combining the real-time parameters of the admixture to adjust the added admixture, and the detection-feedback-judgment-adjustment process is repeated until the rebound rate data meets the set requirement.
In the present invention, the control means controls the mixing time of the admixture with the concrete by controlling the actions of starting and stopping the addition of the admixture.
The technical scheme provided by the invention at least has the following beneficial effects:
1. the invention is matched with the rebound rate detection system to set the information control system and the additive regulation and control system, realizes the accurate regulation of the flow of the additive in the operation process, optimizes the mix proportion of the concrete in real time on line, and improves the fluidity and cohesiveness of the concrete, thereby controlling the rebound rate of the concrete, avoiding the repeated manual batching operation, improving the trial spraying efficiency, reducing the material waste caused by the consumption of the concrete and the rebound and reducing the construction cost.
2. The number of the admixture regulating and controlling devices is multiple, each group of admixture regulating and controlling devices corresponds to one admixture, and the admixture regulating and controlling devices are independent and do not interfere with each other before entering the mixing device, so that the independent regulation and control of all the admixtures in the concrete formula can be realized.
3. The compressed air pump connected with the flow mixing device is arranged, so that the additive and the concrete can be fully mixed as auxiliary power, and the subsequent conveying and injection of the concrete are facilitated.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, it is obvious that the drawings described below are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without inventive efforts, wherein:
FIG. 1 is a schematic view showing the construction of a concrete spraying system according to example 1 of the present invention;
FIG. 2 is a flow chart of a method of controlling the concrete injection system of FIG. 1;
in the figure, 01 concrete pipeline, 02 additive pipeline, 03 working face and 04 resilience material are shown; 1 concrete pump, 2 admixture pumps, 3 control devices, 4 mixed flow devices, 5 compressed air pumps, 6 information control systems, 7 rebound rate detection systems and 8 spray heads.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1:
referring to fig. 1, a concrete spraying system comprises a power system, an admixture regulating and controlling system, an information control system 6, a rebound rate detection system 7 and a spray head 8.
The power system comprises a concrete pump 1, and the concrete pump 1 is arranged on a concrete pipeline 01 and used for carrying out dense extrusion conveying on concrete.
The admixture regulating and controlling system comprises a plurality of groups of admixture regulating and controlling equipment, and each group of admixture regulating and controlling equipment comprises an admixture pump 2, a control device 3 and a mixed flow device 4. The additive pump 2 is arranged on the additive pipeline 02 and used for providing power for conveying additives, the control device 3 is arranged on the additive pipeline 02 and used for detecting and regulating various parameters of the additives, including flow, density, pressure, temperature, mixing time and the like, the mixed flow device 4 is arranged at the intersection position of the additive pipeline 02 and the concrete pipeline 01 and used for realizing uniform mixing of the concrete and the additives, and the mixed flow devices are sequentially arranged along the concrete pipeline according to the additive adding sequence of the concrete.
The power system also comprises a compressed air pump 5, and the compressed air pump 5 is connected with each flow mixing device 4 and is used for providing power for the sufficient mixing and the subsequent conveying of the admixture and the concrete.
The spray head 8 is provided at the end of the concrete pipe 01 and is used to spray the mixed shotcrete onto the working surface 03.
And the rebound rate detection system 7 is used for detecting the rebound rate data in real time. In this embodiment, the rebound resilience detection system is specifically a visual detection device capable of freely moving in space, the device can obtain the volume of the concrete (i.e. the volume of the rebound material) falling on the ground through scanning, and since the density parameter of the sprayed concrete is known (the parameters of the concrete itself and the parameters of the admixture are input in the information control system), the rebound resilience can be calculated in the information control system, and then the rebound resilience of the concrete under the condition of the current mix proportion is calculated.
And the information control system 6, the rebound rate detection system 7 and each control device 3 realize signal transmission, and send a regulation and control instruction to the corresponding control device 3 by analyzing and processing the fed back concrete rebound data and additive parameter data.
In this embodiment, the information control system 6 is specifically a computer.
In this embodiment, a concrete component detector is provided in the head 8.
In this embodiment, the concrete injection system is used in cooperation with a wet spraying trolley, and a pumping area of the wet spraying trolley is provided with a pumping pressure abnormality monitoring and alarming device.
Referring to fig. 2, the control method of the concrete spraying system includes the following steps:
step 1) mixing cement, coarse and fine aggregates, mineral admixtures and water with certain mass according to the calculated mixing ratio, and transporting the mixture to an operation site by using a concrete transportation tank truck;
step 2) inputting the initial dosage, mixing time, allowable range value of rebound rate, temperature, density of concrete before mixing and other information of each admixture in the calculated mixing ratio into an information control system 6, and transferring the concrete into a hopper of a wet spraying trolley;
step 3) pumping is started, concrete is conveyed along a concrete pipeline 01 under the action of a concrete pump 1 and sequentially passes through the mixed flow devices 4, meanwhile, all the additives are conveyed into the mixed flow devices 4 through corresponding additive pipelines in an additive pump 2, and each control device 3 controls the initial flow and mixing time of the corresponding additive entering the mixed flow devices 4 according to instructions from an information control system 6, so that the mixing process of the concrete and different additives in the mixed flow devices is carried out according to a preset target;
step 4), spraying the mixed concrete on the working surface 03 through a spray head 8;
and step 5) during spraying, the rebound rate detection system 7 detects the rebound rate data of the concrete in real time according to the rebound material 04 falling off from the working face 03 and feeds the data back to the information control system 6, the information control system 6 judges whether the current rebound rate data exceeds a set range value, if not, the data is kept unchanged, if yes, the data is combined with real-time parameters of the admixture to send an instruction to the control device 3 so as to adjust the admixture correspondingly added, and the detection-feedback-judgment-adjustment process is repeated until the rebound rate data meets the set requirement.
The above description is only a preferred embodiment of the present invention and is not intended to limit the scope of the present invention, and various modifications and changes may be made by those skilled in the art. Any improvement or equivalent replacement directly or indirectly applied to other related technical fields within the spirit and principle of the invention and the contents of the specification and the drawings of the invention shall be included in the protection scope of the invention.
Claims (8)
1. A concrete spraying system is characterized by comprising a power system, an additive regulating and controlling system, an information control system, a rebound rate detection system and a spray head;
the power system comprises a concrete pump, and the concrete pump is arranged on the concrete pipeline and is used for providing power for conveying concrete;
the admixture regulating and controlling system comprises at least one group of admixture regulating and controlling equipment, each group of admixture regulating and controlling equipment comprises an admixture pump, a control device and a mixing device, the admixture pump is arranged on an admixture pipeline and used for providing power for conveying the admixture, the control device is arranged on the admixture pipeline and used for detecting and regulating various parameters of the admixture, and the mixing device is arranged at the intersection position of the admixture pipeline and the concrete pipeline and used for uniformly mixing the concrete and the admixture;
the spray head is arranged at the tail end of the concrete pipeline and is used for spraying the mixed shotcrete on an operation surface;
the rebound rate detection system comprises a visual detection device which can move freely in space; the device is used for detecting the rebound rate data in real time;
and the information control system, the rebound rate detection system and each control device realize signal transmission, and send a regulation and control instruction to the corresponding control device by analyzing and processing the fed back concrete rebound data and additive parameter data.
2. The concrete injection system of claim 1, wherein the power system further comprises a compressed air pump connected to each of the mixing devices for providing power for sufficient mixing and subsequent delivery of the admixture to the concrete.
3. The concrete injection system of claim 2, wherein the information control system is a computer.
4. The concrete injection system of claim 2, wherein the mixing devices are sequentially arranged on the concrete pipeline according to the adding sequence of the admixture of the concrete.
5. The concrete spraying system of claim 2, wherein a concrete composition detector is provided at the location of the spray head.
6. The concrete injection system of any one of claims 2-5, wherein the concrete injection system is used in conjunction with a wet-spray trolley.
7. The concrete injection system of claim 6, wherein a pumping pressure anomaly monitoring and warning device is provided in a pumping area of the wet blasting trolley.
8. A control method for a concrete injection system according to any one of claims 2 to 7, comprising the steps of:
step 1) setting parameter values in an information control system;
step 2) starting pumping, sequentially conveying concrete to each mixed flow device through a concrete pipeline, conveying each admixture to the corresponding mixed flow device through an admixture pipeline, and controlling the initial flow and mixing time of the corresponding admixture entering the mixed flow device by each control device according to instructions from an information control system;
step 3) spraying the mixed concrete on an operation surface through a spray head;
and 4) in the spraying period, the rebound rate detection system detects the rebound rate data of the concrete in real time according to the rebound material falling off from the working face and feeds the data back to the information control system, the information control system judges whether the current rebound rate data exceeds a set range value, if not, the current rebound rate data is kept unchanged, if yes, the information control system sends an instruction to the control device by combining the real-time parameters of the admixture to adjust the added admixture, and the detection-feedback-judgment-adjustment process is repeated until the rebound rate data meets the set requirement.
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