CN109676796A - Concrete mixer rheological property monitoring method - Google Patents
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- CN109676796A CN109676796A CN201811619121.9A CN201811619121A CN109676796A CN 109676796 A CN109676796 A CN 109676796A CN 201811619121 A CN201811619121 A CN 201811619121A CN 109676796 A CN109676796 A CN 109676796A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 22
- 238000003756 stirring Methods 0.000 claims abstract description 68
- 238000002156 mixing Methods 0.000 claims abstract description 49
- 238000000518 rheometry Methods 0.000 claims abstract description 19
- 238000004364 calculation method Methods 0.000 claims abstract description 14
- 230000008859 change Effects 0.000 claims abstract description 13
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- 238000006243 chemical reaction Methods 0.000 claims abstract description 3
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- 238000000926 separation method Methods 0.000 claims description 3
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- 238000004519 manufacturing process Methods 0.000 description 10
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C7/00—Controlling the operation of apparatus for producing mixtures of clay or cement with other substances; Supplying or proportioning the ingredients for mixing clay or cement with other substances; Discharging the mixture
- B28C7/02—Controlling the operation of the mixing
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- Mixers Of The Rotary Stirring Type (AREA)
Abstract
The invention provides a concrete mixer rheological property monitoring method which is characterized in that an electric power signal of a mixer host is continuously obtained in real time in the concrete mixing process, electric power digital data is generated after A/D conversion, key characteristic parameters contained in the electric power digital data are extracted, and the key characteristic parameters are input into a rheological property calculation model, so that a rheological property monitoring result is obtained. The invention provides a scheme for monitoring the concrete rheology in real time, continuously and efficiently based on a great deal of full research on the concrete rheology and the change rule of a current signal of a main machine of a concrete mixer in the stirring process.
Description
Technical Field
The invention relates to a method for monitoring rheological property of a concrete mixer.
Background
At present, in the traditional building material production industry, especially in the field of concrete production, the quality control of raw materials, the production process control and even the concrete quality detection process are mainly based on a large number of low-efficiency, non-standard and extensive production management means, which leads to a series of economic and social problems of great waste of raw materials, invalid investment of production cost, extremely unstable product quality, increasingly prominent environmental protection problem and the like.
For the detection of the rheological property of concrete mixtures, in the production process of the existing concrete, after the concrete is discharged, an experienced engineer samples the mixed concrete and then detects the concrete slump, and in some projects, an electric hand drill and gear probe type comprehensive parameter detector is used for indirect measurement. It is worth noting that the problems of material abandonment, heavy mixing and the like caused by the fact that the working performance of concrete is found to be out of standard after mixing often occur in mixing stations all over the country, and the problems seriously affect the construction progress and even harm the building quality. Secondly, the development of the building material industry also puts higher requirements on the production of concrete, and in most cases, the construction period of the building engineering is very urgent, so that the mode of judging the working performance of the concrete by manpower is difficult to adapt. On the other hand, the artificial experience method is a method for introducing unstable factors, which is very unfavorable for accurately controlling the quality of concrete.
The method for monitoring the rheological property of the mixed concrete has the following limitations:
first, the monitoring process is slow and inefficient. When concrete used in current construction engineering is mainly premixed concrete, each production line is in an uninterrupted production state for a concrete mixing plant for a long time, and in this case, each batch of concrete is mixed, and then products are transported to a construction site after waiting for a concrete rheology detection result, which is unacceptable for concrete production enterprises.
Second, quality control is very unstable. A number of uncontrollable factors will be introduced in the above process: the proficiency of the sampling worker, air temperature, humidity, all of which may render the concrete rheology test data invalid.
Thirdly, the economic and social costs are high. Firstly, each concrete mixing plant needs to be provided with a large number of quality inspectors to control the working performance of concrete; secondly, if the rheology test result is not qualified, it is very likely that the entire batch of goods will be turned into waste material, which cannot be adjusted due to too long waiting time, and this also causes serious waste and pollution problems.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: how to realize continuous, stable, reliable and efficient monitoring of working performance of concrete, the concrete mixer rheological property monitoring method is provided, and the concrete technical content is as follows:
a concrete mixer rheological property monitoring method includes the steps that electric power signals of a mixer main machine are continuously obtained in real time in the concrete mixing process, electric power digital data are generated after A/D conversion, key characteristic parameters contained in the electric power digital data are extracted, and then the key characteristic parameters are input into a rheological property calculation model, so that a rheological property monitoring result is obtained; wherein,
the step of extracting the key characteristic parameters comprises the following steps:
1) extracting operation of key characteristic parameters of definite mix proportion
Determining a mixing proportion, repeatedly stirring for a plurality of times, obtaining the actual power of the host machine stirred each time through a three-phase digital power meter, and continuously outputting data to an A/D converter to obtain continuous electric power data to generate a data curve; comparing the generated data curves and analyzing the change rule of the data when the data curves are about to be completed;
2) key characteristic parameter extraction operation for univariate series mix proportion
Determining multiple groups of univariate mix proportions with the water content as a variable, acquiring the actual power of the main machine for stirring in each group through a three-phase digital power meter, and continuously outputting data to an A/D converter to obtain continuous electric power data to generate a data curve; comparing the generated data curves and analyzing the change rule of the data when the data curves are about to be completed;
3) key characteristic parameter extraction operation for bivariate series mix proportion
Determining a plurality of groups of bivariate mixing ratios, namely two variables in the mixing ratios, acquiring the actual power of a main machine for stirring in each group through a three-phase digital power meter, and continuously outputting data to an A/D converter to obtain continuous electric power data to generate a data curve; comparing the generated data curves, and analyzing the change rule of the data when the data curves are about to be completed and the influence of the variable on the curve trend;
through the steps 1-3, finding a characteristic node of a host power curve when stirring is completed, and carrying out inductive analysis on data of an effective curve area, namely an application curve area corresponding to a full stirring stage, so as to obtain a key characteristic parameter;
the step of establishing a rheological calculation model comprises the following steps:
A. relation between rheological dimensionless coefficient and host power characteristic point under univariate series mix proportion
Determining 50 groups of univariate mix proportions with the water content as a variable, repeatedly stirring for a plurality of times in each mix proportion, obtaining the actual power of a host machine for each stirring, extracting key characteristic parameters of the power of the host machine, testing the concrete rheology with sufficient stirring for each time, and performing dimensionless processing on the measured concrete rheology data for each time; fitting the mathematical relationship between the rheological dimensionless coefficient and the key characteristic parameter by using a linear function:
i.e. assuming that the rheological dimensionless coefficient x and the key characteristic parameter y are arbitrary constants, for the functions f (z, y), h (x, y) and g (x, y),
{af(x,Y)+bh(z,y)}*g(z,y)=-af(x,y)*g(x,y)+bh(x,y)*g(z,y);
the method also comprises the following steps:
f(x,y)*{ah(x,y)+bg(x,y)=af(x,y)*h(x,y)+bf(x,y)*g(x,y);
there are discrete signals x (n) and y (n) whose linear convolution is:
during convolution operation, y (n) is firstly reversely folded to obtain y (-n);
② m >0 indicates that the y (-n) sequence is shifted to the right, m <0 indicates a shift to the left, and different m's give different results
Cxy(m) a value; the rest is the same as the correlation calculation; the compact representation of the linear convolution operation is:
Cxy(m)=x(n)*y(n)
"' in the formula denotes a linear reel operator;
order toAnd
compared with that, then there are
rxy(m)=x(n)y(-n)
Therefore, the length of the sequence point of the linear convolution operation is the length of the sequence x (n) plus the length y (n) minus 1;
reissue to order
Where k is m-n, then n is m-k, to obtain
B. Relation between rheological dimensionless coefficient and host power characteristic point under bivariate series mix proportion
1) Re-selecting a variable and repeating the step A;
2) carrying out induction analysis on the result of the step 1 in the step B and the result of the step A, and analyzing the coupling characteristics of the mathematical relationship under bivariate through a mathematical method;
C. influence of different stirring volume on characteristic points of host power data under same mixing proportion
1) For the same mixing proportion, 50 groups of continuously changed stirring formula amounts are set, the change trend of the characteristic points of the power data of the main engine is researched, and the mixing formula is prepared by a induction method:
a. verifying that there are 50 sets of continuously varying stirring power n propositions P (n) (50 sets of continuously varying stirring power may be a number in an infinite series, such as 2k for an arithmetic geometric inequality, k ≧ 1);
b. assuming that P (k +1) (k.gtoreq.n 0) is true, and deducing that P (k) is true on the basis thereof,
combining a and b, and establishing propositions P (n) for 50 groups of continuously-changed stirring formula amounts n (not less than n 0);
2) analyzing the influence rule of continuously changing stirring volume on the characteristic point of the power data of the main engine under the single variable series mixing ratio;
3) based on the 1 st point and the 2 nd point in the step, obtaining a host power data processing method for eliminating the influence of the stirring amount;
D. and D, performing secondary fitting on the mathematical relationship obtained in the step B and the step C, and finally establishing a rheological analysis model based on double variables of the mixing proportion and the stirring formula.
Further, the characteristic node of the main engine power curve and the rheological calculation model are respectively established for a plurality of mixer types, so that the rheological measurement is performed before:
first, blender type selection, including: single horizontal shaft mixer, double horizontal shaft mixer, vertical shaft mixer, planetary mixer;
secondly, inputting the rated power We, the maximum power Wm and the rated rotating speed N of the stirrer. The rated power We is used as a basis for judging whether the stirring is abnormal, and the maximum power Wm is used as a reference analog quantity;
thirdly, inputting a mixing ratio of 1: x: y: n; inputting a stirring formula: G.
furthermore, the obtained electric power signal of the main machine of the stirrer, which is obtained in real time and continuously, takes the maximum power Wm of the stirrer as a reference standard and outputs a relative power value.
Furthermore, the power curve of the main machine of the stirring machine is changed according to different mixing ratios, different stirring amounts and different models or types of the stirring machine, and a mathematical model based on two variables of the mixing ratios and the stirring amounts is gradually obtained through a separation variable method.
The invention has the beneficial effects that: in the concrete mixing process, electric power signals of a mixer main machine are continuously obtained in real time through a three-phase digital power meter, the electric power signals are converted into digital signals through an AD converter and then are converted into current data, key characteristic points of the data are extracted after the data are filtered, and the characteristic points are input into a rheological property calculation model to obtain a rheological property monitoring result; based on a large amount of full research on the concrete rheology and the change rule of current signals of a concrete mixer main machine in the stirring process, the invention provides a set of method for monitoring the concrete rheology in real time, continuously and efficiently, has better technical performance and practicability, and is suitable for popularization and application.
Drawings
FIG. 1 is a schematic flow chart of a method for monitoring rheology of a concrete mixer according to the present invention.
FIG. 2 is a schematic diagram of a characteristic node acquisition process of a host power curve according to the present invention.
FIG. 3 is a schematic diagram of the procedure for building a model for calculating rheology according to the present invention.
Detailed Description
The scheme of the present application is further described below with reference to the accompanying drawings 1 to 3:
①, selecting the stirring form of the stirrer, namely a single horizontal shaft, a double horizontal shaft, a vertical shaft or a planetary stirrer, and selecting corresponding data processing methods according to different stirrer types during data screening and feature point extraction;
②, inputting the rated power We, the maximum power Wm and the rated rotating speed N of the stirrer, wherein the rated power We is used as a basis for judging whether the stirring is abnormal, and the maximum power Wm is used as a reference analog quantity;
③, before the concrete is stirred, inputting the mixing ratio of 1: X: Y: N and the stirring amount of G;
④, after stirring, continuously acquiring the actual power of the main machine of the monitoring stirrer in real time through the three-phase digital power meter;
⑤, transmitting the power data measured in ④ to the AD converter, and outputting a relative power value by taking the maximum power of the blender as a reference standard;
⑥, extracting key characteristic data from ⑤ data according to the stirring stage, the method is as follows:
the primary concrete mixing process is (taking a ready-mixed concrete mixing station as an example): in the process of initial mixing and full mixing, the actual power of a mixer host exists in 2 stages, and for the rheological analysis process of fresh concrete, the data of the full mixing stage is effective, but the power data node of the full mixing needs to be accurately judged, and the characteristics reflected by the data curve when the mixing is full are analyzed.
The scheme is researched according to three stages of fixed mix proportion, single-variable series mix proportion and double-variable series mix proportion.
A. The mixture ratio is determined, see figure 2
1) Taking a laboratory stirrer as a research prototype;
2) determining a mixing proportion, and repeatedly stirring for 10 times (adjusting the stirring times as required);
3) acquiring the actual power of the host machine for each stirring through a power meter, and continuously outputting data to an AD converter to obtain continuous data;
4) and comparing 10 times of stirring to obtain a data curve, and analyzing the change rule of the data when the stirring is to be finished.
B. Single variable series of mixing ratio
And (3) determining 50 groups of univariate mix proportions (the preferred water content is a variable), repeating the steps 2) -4) in the step A, and analyzing curves among the mix proportions and a data characteristic distribution rule.
C. Double variable series mixing ratio
And B, on the basis of the step B, researching the characteristics of the data curve under multivariate coupling, and mainly researching the influence of the mix proportion variable on the curve trend.
Through the three steps, the characteristics of the power curve of the main engine when the stirring is finished can be found, and the key characteristic parameters can be obtained by carrying out inductive analysis on the data of the effective curve area.
⑦, inputting the key characteristic data into a rheological calculation model, wherein the rheological calculation model is established by the following method:
the rheological calculation model is the key and difficult point of concrete rheological real-time analysis, and the variables influencing the construction of the mathematical model are as follows: different mix ratios, different mix volumes, and different mixer models or classes will cause the mixer main power curve to change. By a separation variable method, a mathematical model based on two variables of the mixing proportion and the stirring amount is gradually obtained.
A. Researching relation between rheological dimensionless coefficient and host power characteristic point under univariate series mix proportion
1) Determining 50 groups of univariate mix ratios (still taking the water content as a variable);
2) repeatedly stirring for 5 times (adjusting stirring times according to needs) according to each mixing proportion to obtain power characteristic parameters, and testing the rheological property of the concrete fully stirred each time;
3) performing dimensionless treatment on the measured concrete rheological data each time;
4) fitting the mathematical relation between the rheological dimensionless coefficient and the host power characteristic point by using a linear function:
i.e. assuming that the rheological dimensionless coefficient x and the key characteristic parameter y are arbitrary constants, for the functions f (z, y), h (x, y) and g (x, y),
{af(x,Y)+bh(z,y)}*g(z,y)=-af(x,y)*g(x,y)+bh(x,y)*g(z,y);
the method also comprises the following steps:
f(x,y)*{ah(x,y)+bg(x,y)=af(x,y)*h(x,y)+bf(x,y)*g(x,y);
there are discrete signals x (n) and y (n) whose linear convolution is:
during convolution operation, y (n) is firstly reversely folded to obtain y (-n);
② m >0 indicates that the y (-n) sequence is shifted to the right, m <0 indicates a shift to the left, and different m's give different results
Cxy(m) a value; the rest is the same as the correlation calculation; the compact representation of the linear convolution operation is:
Cxy(m)=x(n)*y(n)
"' in the formula denotes a linear reel operator;
order toAnd
compared with that, then there are
rxy(m)=x(n)y(-n)
Therefore, the length of the sequence point of the linear convolution operation is the length of the sequence x (n) plus the length y (n) minus 1;
reissue to order
Where k is m-n, then n is m-k, to obtain
B. Researching relation between rheological dimensionless coefficient and host power characteristic point under bivariate series mix proportion
1) Reselecting a variable and repeating A;
2) and (3) carrying out inductive analysis on the result of the B (1) and the result of the A, and analyzing the coupling characteristics of the mathematical relationship under the bivariate through a mathematical method.
C. Research on influence of different stirring volume on characteristic points of host power data under same mixing proportion
1) For the same mixing proportion, 50 groups of continuously changed stirring formula amounts are set, the change trend of the characteristic points of the power data of the main engine is researched, and the mixing formula is prepared by a induction method:
①, verifying that n propositions P (n) hold for 50 sets of continuously varying stirring square quantities (50 sets of continuously varying stirring square quantities may be numbers in an infinite series, such as 2k for an arithmetic geometric inequality, k ≧ 1);
② assuming that P (k +1) (k.gtoreq.n 0) holds, and deducing that P (k) holds on the basis thereof,
the general formulas (1) and (2) are all established for 50 groups of continuously-changed stirring formula amounts n (not less than n0) and propositions P (n);
2) analyzing the influence rule of continuously changing stirring volume on the characteristic point of the power data of the main engine under the single variable series mixing ratio;
3) based on 1) and 2), a host power data processing method for eliminating the influence of the stirring amount is obtained.
D. Performing secondary fitting on the mathematical relationship obtained in the step B and the step C, and finally establishing a rheological analysis model based on bivariate mixing ratio and stirring amount
⑧, outputting the result of monitoring the rheology.
The above preferred embodiments should be considered as examples of the embodiments of the present application, and technical deductions, substitutions, improvements and the like similar to, similar to or based on the embodiments of the present application should be considered as the protection scope of the present patent.
Claims (4)
1. A concrete mixer rheological property monitoring method is characterized in that an electric power signal of a mixer main machine is continuously obtained in real time in the concrete mixing process, electric power digital data is generated after A/D conversion, key characteristic parameters contained in the electric power digital data are extracted, and then the key characteristic parameters are input into a rheological property calculation model, so that a rheological property monitoring result is obtained; wherein,
the step of extracting the key characteristic parameters comprises the following steps:
1) extracting operation of key characteristic parameters of definite mix proportion
Determining a mixing proportion, repeatedly stirring for a plurality of times, obtaining the actual power of the host machine stirred each time through a three-phase digital power meter, and continuously outputting data to an A/D converter to obtain continuous electric power data to generate a data curve; comparing the generated data curves and analyzing the change rule of the data when the data curves are about to be completed;
2) key characteristic parameter extraction operation for univariate series mix proportion
Determining multiple groups of univariate mix proportions with the water content as a variable, acquiring the actual power of the main machine for stirring in each group through a three-phase digital power meter, and continuously outputting data to an A/D converter to obtain continuous electric power data to generate a data curve; comparing the generated data curves and analyzing the change rule of the data when the data curves are about to be completed;
3) key characteristic parameter extraction operation for bivariate series mix proportion
Determining a plurality of groups of bivariate mixing ratios, namely two variables in the mixing ratios, acquiring the actual power of a main machine for stirring in each group through a three-phase digital power meter, and continuously outputting data to an A/D converter to obtain continuous electric power data to generate a data curve; comparing the generated data curves, and analyzing the change rule of the data when the data curves are about to be completed and the influence of the variable on the curve trend;
through the steps 1-3, finding a characteristic node of a host power curve when stirring is completed, and carrying out inductive analysis on data of an effective curve area, namely an application curve area corresponding to a full stirring stage, so as to obtain a key characteristic parameter;
the step of establishing a rheological calculation model comprises the following steps:
A. relation between rheological dimensionless coefficient and host power characteristic point under univariate series mix proportion
Determining 50 groups of univariate mix proportions with the water content as a variable, repeatedly stirring for a plurality of times in each mix proportion, obtaining the actual power of a host machine for each stirring, extracting key characteristic parameters of the power of the host machine, testing the concrete rheology with sufficient stirring for each time, and performing dimensionless processing on the measured concrete rheology data for each time; fitting the mathematical relationship between the rheological dimensionless coefficient and the key characteristic parameter by using a linear function:
i.e. assuming that the rheological dimensionless coefficient x and the key characteristic parameter y are arbitrary constants, for the functions f (z, y), h (x, y) and g (x, y),
{af(x,Y)+bh(z,y)}*g(z,y)=-af(x,y)*g(x,y)+bh(x,y)*g(z,y);
the method also comprises the following steps:
f(x,y)*{ah(x,y)+bg(x,y)=af(x,y)*h(x,y)+bf(x,y)*g(x,y);
there are discrete signals x (n) and y (n) whose linear convolution is:
during convolution operation, y (n) is firstly reversely folded to obtain y (-n);
②m>0 represents a right shift of the y (-n) sequence, m<0 denotes a shift to the left, different m give different Cxy(m) a value; the rest is the same as the correlation calculation; the compact representation of the linear convolution operation is:
Cxy(m)=x(n)*y(n)
"' in the formula denotes a linear reel operator;
order toAnd
compared with that, then there are
rxy(m)=x(n)y(-n)
Therefore, the length of the sequence point of the linear convolution operation is the length of the sequence x (n) plus the length y (n) minus 1;
reissue to order
Where k is m-n, then n is m-k, to obtain
B. Relation between rheological dimensionless coefficient and host power characteristic point under bivariate series mix proportion
1) Re-selecting a variable and repeating the step A;
2) carrying out induction analysis on the result of the step 1 in the step B and the result of the step A, and analyzing the coupling characteristics of the mathematical relationship under bivariate through a mathematical method;
C. influence of different stirring volume on characteristic points of host power data under same mixing proportion
1) For the same mixing proportion, 50 groups of continuously changed stirring formula amounts are set, the change trend of the characteristic points of the power data of the main engine is researched, and the mixing formula is prepared by a induction method:
a. verifying that there are 50 sets of continuously varying stirring power n propositions P (n) (50 sets of continuously varying stirring power may be a number in an infinite series, such as 2k for an arithmetic geometric inequality, k ≧ 1);
b. assuming that P (k +1) (k.gtoreq.n 0) is true, and deducing that P (k) is true on the basis thereof,
combining a and b, and establishing propositions P (n) for 50 groups of continuously-changed stirring formula amounts n (not less than n 0);
2) analyzing the influence rule of continuously changing stirring volume on the characteristic point of the power data of the main engine under the single variable series mixing ratio;
3) based on the 1 st point and the 2 nd point in the step, obtaining a host power data processing method for eliminating the influence of the stirring amount;
D. and D, performing secondary fitting on the mathematical relationship obtained in the step B and the step C, and finally establishing a rheological analysis model based on double variables of the mixing proportion and the stirring formula.
2. The method of monitoring the rheology of a concrete mixer according to claim 1, further comprising: the characteristic node of the main engine power curve and the rheological calculation model are respectively established for a plurality of mixer types, so that the rheological measurement is performed before:
first, blender type selection, including: single horizontal shaft mixer, double horizontal shaft mixer, vertical shaft mixer, planetary mixer;
secondly, inputting the rated power We, the maximum power Wm and the rated rotating speed N of the stirrer. The rated power We is used as a basis for judging whether the stirring is abnormal, and the maximum power Wm is used as a reference analog quantity;
thirdly, inputting a mixing ratio of 1: x: y: n; inputting a stirring formula: G.
3. the method of monitoring the rheology of a concrete mixer according to claim 2, further comprising: and outputting a relative power value by taking the maximum power Wm of the stirrer as a reference standard for the obtained electric power signal of the stirrer host which is obtained in real time and continuously.
4. The method of monitoring the rheology of a concrete mixer according to claim 3, wherein: according to different mixing ratios, different stirring amounts and different types or classes of the stirring machines, the power curve of the main machine of the stirring machine is changed, and a mathematical model based on two variables of the mixing ratios and the stirring amounts is gradually obtained through a separation variable method.
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Cited By (3)
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CN111775309A (en) * | 2020-06-18 | 2020-10-16 | 中建西部建设湖南有限公司 | Method for detecting plastic viscosity of concrete in stirrer in real time |
CN112903526A (en) * | 2021-01-22 | 2021-06-04 | 河南理工大学 | Method for calibrating optimal stirring time of full-tailing paste |
CN112976332A (en) * | 2020-12-24 | 2021-06-18 | 中山艾尚智同信息科技有限公司 | Neural network based method for predicting rheological property of ready-mixed concrete |
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CN112976332A (en) * | 2020-12-24 | 2021-06-18 | 中山艾尚智同信息科技有限公司 | Neural network based method for predicting rheological property of ready-mixed concrete |
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