CN114351541B - Automatic pouring system for foam lightweight concrete - Google Patents
Automatic pouring system for foam lightweight concrete Download PDFInfo
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- CN114351541B CN114351541B CN202111139552.7A CN202111139552A CN114351541B CN 114351541 B CN114351541 B CN 114351541B CN 202111139552 A CN202111139552 A CN 202111139552A CN 114351541 B CN114351541 B CN 114351541B
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- 239000004567 concrete Substances 0.000 title claims abstract description 10
- 239000006260 foam Substances 0.000 title claims abstract description 7
- 238000004458 analytical method Methods 0.000 claims abstract description 16
- 238000007405 data analysis Methods 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 11
- 239000011381 foam concrete Substances 0.000 claims abstract description 10
- 238000005266 casting Methods 0.000 claims description 23
- 238000000354 decomposition reaction Methods 0.000 claims description 16
- 229910000831 Steel Inorganic materials 0.000 claims description 15
- 239000010959 steel Substances 0.000 claims description 15
- 238000004804 winding Methods 0.000 claims description 12
- 238000001514 detection method Methods 0.000 claims description 11
- 230000002262 irrigation Effects 0.000 claims description 8
- 238000003973 irrigation Methods 0.000 claims description 8
- 238000010276 construction Methods 0.000 claims description 6
- 239000004568 cement Substances 0.000 claims description 2
- 230000006378 damage Effects 0.000 abstract description 2
- 239000002689 soil Substances 0.000 description 8
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 238000010257 thawing Methods 0.000 description 1
- 230000001960 triggered effect Effects 0.000 description 1
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Abstract
The invention provides an automatic pouring system for foam lightweight concrete, which belongs to the technical field of lightweight foam concrete pouring, and comprises a three-dimensional model identification device, a data analysis and control center unit and a pouring device, wherein the three-dimensional model identification device and the pouring device are connected with the data analysis and control center unit, the three-dimensional model identification device collects data for analysis and processing by the data analysis and control center unit, then the analyzed data is converted into control instructions, and the pouring device is controlled to perform automatic pouring. Through the model structure of automatic identification branch storehouse bottom, then judge the volume of pouring is what, then pour layer by layer after analyzing according to the model of discernment, do not need the people to get into at the in-process of pouring, avoid the manual work to get into and pour in the storehouse, move the pipe operation, cause the destruction of the inner structure of light foam concrete, pour light foam concrete through the automation, guarantee the homogeneity that every point was pour.
Description
Technical Field
The invention relates to the technical field of light foam concrete pouring, in particular to an automatic foam light concrete pouring system.
Background
The foam light soil is a novel light material in the field of engineering in recent years, and has the characteristics of adjustable volume weight, self-support, good fluidity, excellent shock insulation and freeze thawing resistance and the like. Therefore, the foamed light soil is increasingly widely applied to expressway and secondary road construction. In the current construction of the lightweight soil roadbed, the roadbed section is longer in pouring along a road, the range is larger, the pouring needs to be carried out in a separated mode, and in the separated pouring process, in order to ensure the uniformity of the lightweight pouring, pouring ports need to be moved to the next position for pouring at different positions for a certain time. At present, a manual pipe moving mode is adopted for pouring, however, a large amount of bubbles are contained in the light soil, a large amount of defoaming is caused by manual stepping, the structure in the light soil is damaged, the technical specification of the construction of the light soil clearly stipulates, and pouring process strictly prohibits personnel from entering the unset light soil. However, the pouring range is large after the warehouse separation, and the mountain road section is close to the cliff section, so that the movable pouring pipe cannot be manually entered, the light foam concrete is poured at different positions, and the uniformity of the pouring of the light soil is difficult to ensure by a single pouring point. Therefore, an automatic pouring method is required to be designed, so that the situation that manual entry is not needed is realized, and meanwhile, uniform pouring can be realized.
Disclosure of Invention
The invention aims to provide an automatic pouring system for foam lightweight concrete, which solves the technical problems in the background technology.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
the automatic pouring system for the light foam concrete comprises a three-dimensional model identification device, a data analysis and control center unit and a pouring device, wherein the three-dimensional model identification device and the pouring device are connected with the data analysis and control center unit, the three-dimensional model identification device collects data for analysis and processing by the data analysis and control center unit, then the analyzed data is converted into control instructions, and the pouring device is controlled to automatically pour.
Further, three-dimensional model recognition device includes the walking wheel, span the axle, the walking motor, the slide bar, slide the cover shell, first motor, slide the stay cord, second motor and laser detection array, the walking wheel sets up at the both ends of crossing the axle, walking wheel slidable sets up at the side wall top of dividing the storehouse, the walking motor sets up on crossing the epaxial and is connected with the walking wheel through the pivot, the slide bar sets up the bottom of crossing the axle, slide the cover shell slidable cover is established on the slide bar, laser detection array sets up the bottom at slide the cover shell, first motor and second motor set up the both ends at the slide bar, first motor and second motor are all connected with slide the cover shell through slide the stay cord, pull slide cover shell round trip movement, laser detection array detects divided the storehouse bottom.
Further, the pouring device comprises a sub-bin fixed side wall, a linkage motor support column, a servo linkage motor, a pouring rope collecting groove, pouring ropes and pouring pipes, wherein the linkage motor support column is vertically arranged on four corners of the sub-bin fixed side wall, the servo linkage motor is arranged on the linkage motor support column, the pouring rope collecting groove is connected with a rotating shaft of the servo linkage motor, one ends of the pouring ropes encircle the pouring rope collecting groove, the other ends of the pouring ropes are connected with the pouring pipes, and the four pouring ropes are controlled to move to automatically pour.
Further, the data analysis and control center unit comprises a three-dimensional model disassembly module, a three-dimensional coordinate comparison grouping module, a pouring line drawing module, a stress decomposition analysis module and a motor control module, wherein the input end of the three-dimensional model disassembly module is connected with the three-dimensional model identification device, the output end of the three-dimensional model disassembly module is connected with the three-dimensional coordinate comparison grouping module, the output end of the three-dimensional coordinate comparison grouping module is connected with the stress decomposition analysis module through the pouring line drawing module, the input end of the motor control module is connected with the stress decomposition analysis module, the output end of the motor control module is connected with the pouring device, and the motor control module converts the stress and direction into signals for controlling the motor to rotate and controls the electrode of the pouring device to take up or pay off.
Further, the three-dimensional model disassembling module disassembles the three-dimensional model at the bottom of the sub-bin into a three-axis coordinate, a laser array is used for scanning the whole sub-bin from the upper end of the sub-bin, then the top of the side wall plate of the quantitative sub-bin is a three-dimensional coordinate zero point surface, and different vertical heights are returned through the laser array, so that a three-dimensional model can be generated.
Further, the three-dimensional coordinate comparison grouping module compares and groups the disassembled three-axis coordinates, coordinate points in the same vertical direction are grouped into the same group, grouping coordinates are obtained, a three-dimensional coordinate zero point surface is used as a reference surface, and the three-dimensional model is converted into three-dimensional coordinates, namely coordinate axes with the interval of 1cm between the three axes.
Further, the line construction drawing module is used for connecting the grouped coordinates to obtain an irrigation line, and connecting the irrigation line according to the ordered coordinate points, wherein when another coordinate point exists between the two ordered coordinate points during connection, the middle coordinate point is connected to the line, and then all the connection lines form a pouring surface.
Further, the stress decomposition analysis module decomposes the pouring line in a four-axis manner to obtain four-axis pulling force and direction, decomposes the poured line, and then decomposes the force to four pouring ropes according to the required pulling force and force direction when the previous point moves to the next point during decomposition, so as to obtain the real-time pulling force and force direction of each pouring rope.
Due to the adoption of the technical scheme, the invention has the following beneficial effects:
according to the invention, the model structure at the bottom of the sub-bin is automatically identified, then the quantity required to be poured is judged to be more or less, then the layer-by-layer pouring is carried out after the analysis according to the identified model, the automatic pouring can be completely realized, no person is required to enter the pouring bin in the pouring process, the pipe moving operation is avoided, the damage of the internal structure of the light foam concrete is caused, the pouring uniformity of each point is ensured by automatically pouring the light foam concrete, the quick-mounting pouring equipment is provided, and the equipment is convenient to move.
Drawings
FIG. 1 is a schematic diagram of a system architecture of the present invention;
FIG. 2 is a front view of the casting apparatus of the present invention;
FIG. 3 is a front view of the three-dimensional model identification device of the present invention;
fig. 4 is a schematic structural view of a three-dimensional model recognition device according to the present invention.
In the drawing, a side wall is fixed by 1-bin, a supporting column of a 2-linkage motor, a 3-servo linkage motor, a 4-pouring rope collecting tank, a 5-pouring rope, a 6-pouring pipe, a 7-travelling wheel, an 8-crossing shaft, a 9-travelling motor, a 10-sliding rod, a 11-sliding sleeve, a 12-first motor, a 13-sliding pull rope, a 14-second motor, a 15-laser detection array, a 16-positioning sensor, a 17-connecting rod and a 18-triangular stable connecting rod.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described in detail below by referring to the accompanying drawings and by illustrating preferred embodiments. It should be noted, however, that many of the details set forth in the description are merely provided to provide a thorough understanding of one or more aspects of the invention, and that these aspects of the invention may be practiced without these specific details.
As shown in fig. 1-4, an automatic pouring system for light foam concrete is provided, the system comprises a three-dimensional model identification device, a data analysis and control center unit and a pouring device, wherein the three-dimensional model identification device and the pouring device are connected with the data analysis and control center unit, the three-dimensional model identification device collects data for the data analysis and control center unit to analyze and process, then the analyzed data is converted into a control instruction, and the pouring device is controlled to perform automatic pouring.
In the embodiment of the invention, the model identification device comprises a travelling wheel 7, a crossing shaft 8, a travelling motor 9, a sliding rod 10, a sliding sleeve shell 11, a first motor 12, a sliding pull rope 13, a second motor 14 and a laser detection array 15, wherein the travelling wheel 7 is arranged at two ends of the crossing shaft 8, the travelling wheel 7 is slidably arranged at the top of a side wall of a sub-bin, the travelling motor 9 is arranged on the crossing shaft 8 and is connected with the travelling wheel 7 through a rotating shaft, the sliding rod 10 is arranged at the bottom of the crossing shaft 8, the sliding sleeve shell 11 is slidably sleeved on the sliding rod 10, the laser detection array 15 is arranged at the bottom of the sliding sleeve 11, the first motor 12 and the second motor 14 are respectively connected with the sliding sleeve 11 through the sliding pull rope 13, the sliding sleeve 11 is pulled to move back and forth, and the laser detection array 15 detects the bottom of the sub-bin.
The sliding pull rope 13 is pulled by the first motor 12 and the second motor 14 to control the sliding sleeve 11 to slide back and forth on the sliding rod 10, when one motor contracts, the other motor pays out, and the laser detection array 15 can scan back and forth on a straight line to obtain a model of the bottom by matching with the back and forth pulling.
In the embodiment of the invention, the pouring device comprises a sub-bin fixed side wall 1, a linkage motor support column 2, a servo linkage motor 3, pouring rope collecting grooves 4, pouring ropes 5 and pouring pipes 6, wherein the linkage motor support column 2 is vertically arranged on four corners of the sub-bin fixed side wall 1, the servo linkage motor 3 is arranged on the linkage motor support column 2, the pouring rope collecting grooves 4 are connected with rotating shafts of the servo linkage motor 3, one ends of the pouring ropes 5 encircle the pouring rope collecting grooves 4, the other ends of the pouring ropes are connected with the pouring pipes 6, and the other ends of the four pouring ropes 5 are connected with the pouring pipes 6 to control the movement of the pouring pipes 6 to perform automatic pouring. The servo linkage motor 3 is used for winding or paying off, and is mainly controlled according to the stress magnitude and the stress direction of the pouring rope 5 at one point and the stress magnitude and the stress direction of the next point, and paying off is needed if the force is reduced and the included angle of the direction is reduced. The casting pipe 6 is controlled to be cast on a specific line, and the casting time is controlled simultaneously
In the embodiment of the invention, the data analysis and control center unit comprises a three-dimensional model disassembly module, a three-dimensional coordinate comparison grouping module, a pouring line drawing module, a stress decomposition analysis module and a motor control module, wherein the input end of the three-dimensional model disassembly module is connected with the three-dimensional model identification device, the output end of the three-dimensional model disassembly module is connected with the three-dimensional coordinate comparison grouping module, the output end of the three-dimensional coordinate comparison grouping module is connected with the stress decomposition analysis module through the pouring line drawing module, the input end of the motor control module is connected with the stress decomposition analysis module, the output end of the motor control module is connected with the pouring device, and the motor control module converts the stress size and direction into signals for controlling the rotation of the motor and controls the wire winding or the wire unwinding of an electrode of the pouring device.
The three-dimensional model disassembling module disassembles the three-dimensional model at the bottom of the sub-bin into three-axis coordinates, scans the whole sub-bin from the upper end of the sub-bin by using a laser array, then quantificationally divides the top of the side wall plate of the sub-bin into three-dimensional coordinate zero point surfaces, returns different vertical heights by using the laser array, and can generate the three-dimensional model. 3. The three-dimensional coordinate comparison grouping module compares and groups the disassembled three-axis coordinates, coordinate points in the same vertical direction are grouped into the same group to obtain grouped coordinates, a three-dimensional coordinate zero point surface is used as a reference surface, and the three-dimensional model is converted into three-dimensional coordinates, namely, coordinate axes with the interval of 1cm between the three axes is set. And the line construction drawing module is used for connecting the grouped coordinates to obtain an irrigation line, and connecting the irrigation line according to the ordered coordinate points, wherein when the other coordinate points exist between the two ordered coordinate points during the connection, the middle coordinate points are connected on line, and then all the connection lines form a casting surface. The stress decomposition analysis module decomposes the pouring line in a four-axis manner to obtain four-axis tension and direction, decomposes the pouring line, and then decomposes the force to four pouring ropes according to the required tension and force direction when the previous point moves to the next point during decomposition, so as to obtain the real-time tension and force direction of each pouring rope.
The pouring process is as follows:
step 1: and identifying the three-dimensional model of the bottom of the sub-bin at the upper end of the sub-bin by using a three-dimensional model identification device. The laser array is used for scanning the whole sub-bin from the upper end of the sub-bin, then the top of the quantitative sub-bin side wall plate is a three-dimensional coordinate zero point surface, and different vertical heights are returned through the laser array, so that a three-dimensional model can be generated. After the laser array scans back and forth, a rugged bottom three-dimensional model structure can be obtained.
Step 2: and disassembling the three-dimensional model at the bottom of the sub-bin into three-axis coordinates. And converting the three-dimensional model into three-dimensional coordinates by taking the zero point surface of the three-dimensional coordinates as a reference surface, namely setting the interval between the three axes as a coordinate axis of 1 cm. In concrete pouring, the interval between the common pouring routes is 5cm, and the pouring routes are molten and can flow, so that the interval of 5cm is used, and the pouring efficiency is higher.
Step 3: and comparing and grouping the disassembled triaxial coordinates, and dividing coordinate points in the same vertical direction into the same group to obtain grouped coordinates. And setting a fixed interval by taking the coordinate axes in the vertical direction as reference axes, taking the coordinate axes in the same vertical direction as a group when the coordinate axes in the same vertical direction are in the same interval, storing coordinate point data in one group, and then sorting from small to large in the group according to the coordinate axes in the vertical direction.
Step 4: and connecting the group coordinates to obtain the irrigation line. And connecting lines according to the ordered coordinate points, wherein when another coordinate point exists between the two ordered coordinate points during the connection, the middle coordinate point is connected to the lines, and then all the connecting lines form a pouring surface.
Step 5: and decomposing the irrigation line in a four-axis way to obtain four-axis pulling force and direction. And decomposing the poured line, and then decomposing the force to four pouring ropes according to the required pulling force and the force direction when the previous point moves to the next point, so as to obtain the real-time pulling force and the pulling force direction of each pouring rope.
Step 6: and the controller controls the servo motor to rotate to pull the pouring pipe according to the four-axis tension and the machine direction to pour. According to the pulling force magnitude and direction of the four servo motors at each moment, setting an initial position, controlling the four servo motors to pull the pouring pipe to an initial pouring point, pulling the pouring pipe to move along a pouring line, and returning to the initial position to pour one pouring surface on the pouring surface after one pouring surface is poured.
The concrete pouring control process comprises the following steps:
first, the coordinates of the pouring point P 'are set as (x', y '), and the coordinates of the moving point P' are set as (x ', y'). Center of circle P of pulley i The coordinates are (x) i ，y i ). Q ' and Q ' are the tangent points of the steel wire rope and the pulley, respectively, l ' i And l i The lengths of the wire rope P 'Q' and P "Q" sections, respectively.
Obtained by Pythagorean theorem:
the angles theta ' and theta ' are respectively the positive direction of the x-axis and rotated anticlockwise to Q ' P i And Q' P i Is a function of the angle of (a).
Suppose that the x-axis rotates counter-clockwise to P' P i The angle of (a) is alpha', and has:
a value according to formula (3) and x' -x i Determining the value of alpha' by determining the positive and negative values of alpha
When tan alpha'>0, and x' -x i >At 0, in the first quadrant,
when tan alpha '< 0, and x' -x i When < 0, in the second quadrant,
when tan alpha'>0, and x' -x i When < 0, in the third quadrant,
when tan alpha '< 0, and x' -x i At > 0, in the fourth quadrant,
assume line segment P' P i Rotated to line segment Q' P i The angle of (2) is beta', the anticlockwise direction is positive, the clockwise direction is negative, and the range is
All that is available is:
θ′＝α′+β′ (5)
(5) Negative values may occur for the equation, indicating that the positive x-axis direction is rotated clockwise.
Similarly, the θ' can be calculated
When the casting point moves from P ' to P ', the steel wire rope extends by a length of l ' i Become l i Resulting from two part variation:
part of which is made of steelThe other end of the wire rope is stretched to a length delta l i ；
Expanded length s of steel wire rope with θ 'to θ' i ；
s i Is dependent on the way the wire rope is wound around the pulley, s when θ becomes large i Negative value, s when θ becomes large i Positive values.
s i ＝-R(θ″-θ′) (6)
From l i -l′ i ＝Δl i +s i Obtaining
Δl i ＝l″ i -l′ i +R(θ″-θ′) (7)
The stretching length Deltal of the other end of the steel wire rope can be calculated by sequentially calculating the above types i 。
The winding motor drives the wheel (pouring rope collecting groove 4) on the winding motor to stretch the steel wire rope, and the tensioning pulley can enable the steel wire rope between the winding motor and the angle sensor pulley to be tensioned through the spring mechanism, so that the precision is improved. And an angle sensor is arranged in the angle sensor pulley, and the rotating angle of the pulley is calculated.
To reduce the impact of slipping between the wire rope and the sheave, rubber ferrules may be added to the grooves of the sheave as shown in the figure to increase friction.
Assuming that the radius of the angle sensor pulley is r, the rotation angle of the angle sensor pulley is calculated as
γ i ＝Δl i /r (8)
The positive and negative values of which represent the angular direction of rotation.
When the rotation angle of the pulley of the angle sensor is finished, the winding motor is triggered to stop working.
Each adjacent pulley is formed by connecting spliced connecting rods, and the stability of connection is enhanced by triangular stable connecting rods. Each pulley P 1 ，P 2 ，P 3 ，P 4 And the pouring point P can be additionally provided with or internally provided with a positioning sensor so as to obtain the coordinates of the corresponding point.
First, two points are selected as reference points, e.g. point P on the graph 4 And P 3 ，P 4 As origin of coordinates, P 3 As points in the positive x-axis direction, the other points are all above the x-axis, i.e. their y-coordinates are all greater than 0.
After the coordinates are determined, each casting point is moved from the point P' to the point p″ and the telescopic length of the wire rope corresponding to each pulley is calculated through the above (1) to (7), and then each winding motor is driven to move and the motor is controlled to stop through the corresponding angle sensor pulley.
And automatically generating pouring point tracks by setting the distance D between the pouring points on a system operation interface through initial coordinate acquisition.
According to the set intervals, automatically drawing a virtual grid, selecting the intersection point coordinates of the grid as pouring points, and then selecting the sequence of traversing the pouring points, namely the pouring sequence. And (3) performing folding pouring with the y value increasing, and also performing random pouring.
The system can also automatically control the casting time at each casting point, wherein the casting time is related to three factors:
the area S of the relevant shape of the area surrounding the pouring point.
The number M of adjacent edge points of the pouring points;
the number N of adjacent corner points of the pouring points;
the casting time of each casting point can be calculated by the following formula:
t＝(αS+βM+γN)*D
the alpha, beta, gamma parameters are related to the characteristics of the casting cement and are constant.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and variations could be made by those skilled in the art without departing from the principles of the present invention, and such modifications and variations should also be considered as being within the scope of the present invention.
Claims (1)
1. An automatic pouring system of foam lightweight concrete, its characterized in that: the pouring system is used for pouring the light foam concrete and comprises a three-dimensional model identification device, a data analysis and control center unit and a pouring device, wherein the three-dimensional model identification device and the pouring device are connected with the data analysis and control center unit, the three-dimensional model identification device collects data for analysis and processing by the data analysis and control center unit, then the analyzed data is converted into a control instruction, and the pouring device is controlled to automatically pour;
the three-dimensional model identification device comprises a travelling wheel (7), a crossing shaft (8), a travelling motor (9), a sliding rod (10), a sliding sleeve (11), a first motor (12), a sliding pull rope (13), a second motor (14) and a laser detection array (15), wherein the travelling wheel (7) is arranged at two ends of the crossing shaft (8), the travelling wheel (7) is slidably arranged at the top of a side wall of a sub-bin, the travelling motor (9) is arranged on the crossing shaft (8) and is connected with the travelling wheel (7) through a rotating shaft, the sliding rod (10) is arranged at the bottom of the crossing shaft (8), the sliding sleeve (11) is slidably sleeved on the sliding rod (10), the laser detection array (15) is arranged at the bottom of the sliding sleeve (11), the first motor (12) and the second motor (14) are respectively connected with the sliding sleeve (11) through the sliding pull rope (13) to pull the sliding sleeve (11) to move back and forth, and the laser detection array (15) is used for detecting the bottom of the sub-bin;
the pouring device comprises a sub-bin fixed side wall (1), a linkage motor support column (2), a servo linkage motor (3), a pouring rope collecting tank (4), pouring ropes (5) and pouring pipes (6), wherein the linkage motor support column (2) is vertically arranged on four corners of the sub-bin fixed side wall (1), the servo linkage motor (3) is arranged on the linkage motor support column (2), the pouring rope collecting tank (4) is connected with a rotating shaft of the servo linkage motor (3), one end of each pouring rope (5) surrounds the corresponding pouring rope collecting tank (4), the other end of each pouring rope is connected with each pouring pipe (6), and the other ends of the four pouring ropes (5) are connected with the corresponding pouring pipes (6) to control the movement of the corresponding pouring pipes (6) to perform automatic pouring;
the data analysis and control center unit comprises a three-dimensional model disassembly module, a three-dimensional coordinate comparison grouping module, a casting line drawing module, a stress decomposition analysis module and a motor control module, wherein the input end of the three-dimensional model disassembly module is connected with the three-dimensional model identification device, the output end of the three-dimensional model disassembly module is connected with the three-dimensional coordinate comparison grouping module, the output end of the three-dimensional coordinate comparison grouping module is connected with the stress decomposition analysis module through the casting line drawing module, the input end of the motor control module is connected with the stress decomposition analysis module, the output end of the motor control module is connected with the casting device, and the motor control module converts the stress size and direction into signals for controlling the motor to rotate and controls the electrode wire winding or wire unwinding of the casting device;
the three-dimensional model disassembling module disassembles the three-dimensional model at the bottom of the sub-bin into three-axis coordinates, scans the whole sub-bin from the upper end of the sub-bin by using a laser array, and then quantificationally takes the top of a side wall plate of the sub-bin as a zero plane of the three-dimensional coordinates, and returns different vertical heights through the laser array to generate the three-dimensional model;
the three-dimensional coordinate comparison grouping module compares and groups the disassembled three-axis coordinates, coordinate points in the same vertical direction are grouped into the same group to obtain grouped coordinates, a three-dimensional coordinate zero point surface is used as a reference surface, and the three-dimensional model is converted into three-dimensional coordinates, namely coordinate axes with the interval of 1cm between the three axes;
the line construction drawing module is used for connecting the grouped coordinates to obtain an irrigation line, and connecting the irrigation line according to the ordered coordinate points, wherein when another coordinate point exists between the two ordered coordinate points during the connection, the middle coordinate point is connected to the line, and then all the connection lines form a pouring surface;
the stress decomposition analysis module decomposes the pouring line to obtain four-axis tension and direction, decomposes the pouring line, and then decomposes the force to four pouring ropes according to the required tension and force direction when the previous point moves to the next point during decomposition, so as to obtain the real-time tension and force direction of each pouring rope;
the system pouring process comprises the following steps:
step 1: the three-dimensional model recognition device is used for recognizing a three-dimensional model at the bottom of the sub-bin at the upper end of the sub-bin, a laser array is used for scanning the whole sub-bin from the upper end of the sub-bin, then the top of a quantitative sub-bin side wall plate is a three-dimensional coordinate zero point surface, different vertical heights are returned through the laser array, a three-dimensional model can be generated, and an uneven bottom three-dimensional model structure can be obtained after the laser array scans back and forth;
step 2: the three-dimensional model at the bottom of the sub-bin is disassembled into three-axis coordinates, a zero plane of the three-dimensional coordinates is taken as a reference plane, the three-dimensional model is converted into the three-dimensional coordinates, namely, the coordinate axes with the interval of 1cm between three axes are set, and when concrete pouring is carried out, the interval of a common pouring route is 5cm, and the three-dimensional model can flow due to meltability, so that the pouring efficiency is higher due to the use of the interval of 5 cm;
step 3: comparing and grouping the disassembled triaxial coordinates, dividing coordinate points in the same vertical direction into the same group to obtain grouped coordinates, setting a fixed interval by taking the coordinate axes in the vertical direction as a reference axis, taking the coordinate axes in the same vertical direction as a group when the coordinate axes in the same vertical direction are in the same interval, storing coordinate point data in one group, and sorting from small to large in the group according to the coordinate axes in the vertical direction;
step 4: connecting the grouped coordinates to obtain a pouring line, and connecting according to the ordered coordinate points, wherein when another coordinate point exists between the two ordered coordinate points during connection, the middle coordinate point is connected to the line, and then all the connection lines form a pouring surface;
step 5: decomposing the pouring line to obtain four-axis pulling force and direction, decomposing the pouring line, and decomposing the force to four pouring ropes according to the required pulling force and force direction when the previous point moves to the next point during decomposition, so as to obtain the real-time pulling force and force direction of each pouring rope;
step 6: the controller controls the servo motors to rotate and pull the pouring pipe to pour according to the four-axis pulling force and the machine direction, and then sets an initial position according to the pulling force and the direction of the four servo motors at each moment, then controls the four servo motors to pull the pouring pipe to an initial pouring point, then pulls the pouring pipe to move along a pouring line, and returns to the initial position to pour one pouring surface above after one pouring surface is poured;
the concrete pouring control process comprises the following steps:
firstly, setting the P 'coordinate of the pouring point as (x'After moving, the point P ' is reached, the coordinates are (x ', y '), and the center of the pulley P is the center of the circle i The coordinates are (x) i ，y i ) Q ' and Q ' are the tangent points of the steel wire rope and the pulley, respectively, l ' i And l i The lengths of the steel wire rope P 'Q' and P "Q" sections, respectively;
obtained by Pythagorean theorem:
the angles theta ' and theta ' are respectively the positive direction of the x-axis and rotated anticlockwise to Q ' P i And Q' P i R is the radius of the pulley;
suppose that the x-axis rotates counter-clockwise to P' P i The angle of (a) is alpha', and has:
a value according to formula (3) and x' -x i Determining the value of alpha' by determining the positive and negative values of alpha
When tan alpha'>0, and x' -x i >At 0, in the first quadrant,
when tan alpha'<0, and x' -x i <At 0, in the second quadrant,
when tan alpha'>0, and x' -x i <At 0, in the third quadrant,
when tan alpha'<0, and x' -x i >At 0, in the fourth quadrant,
assume line segment P' P i Rotated to line segment Q' P i The angle of (2) is beta', the anticlockwise direction is positive, the clockwise direction is negative, and the range is
The method comprises the following steps:
θ′＝α′+β′ (5)
calculating θ ";
when the casting point moves from P ' to P ', the steel wire rope extends by a length of l ' i Become l i Resulting from two part variation:
a part of the length Deltal is stretched from the other end of the steel wire rope i ；
Expanded length s of steel wire rope with θ 'to θ' i ；
s i ＝-R(θ″-θ′) (6)
From l i -l′ i ＝Δl i +s i Obtaining
Δl i ＝l″ i -l′ i +R(θ″-θ′) (7)
Calculating the tensile length Deltal of the other end of the steel wire rope i ；
The winding motor drives the wheel to stretch the steel wire rope, the tensioning pulley tightens the steel wire rope between the winding motor and the angle sensor pulley through the spring mechanism, the angle sensor is arranged in the angle sensor pulley, and the rotating angle of the pulley is calculated;
assuming that the radius of the angle sensor pulley is r, the rotation angle of the angle sensor pulley is calculated as
γ i ＝Δl i /r (8)
Positive and negative values represent the angular direction of rotation;
when the rotation angle of the pulley of the angle sensor is finished, triggering the winding motor to stop working;
each adjacent pulley P is formed by connecting spliced connecting rods and the stability of connection is enhanced by triangular stable connecting rods 1 ，P 2 ，P 3 ，P 4 Positioning sensors are additionally arranged or built in the pouring points P so as to obtain coordinates of corresponding points;
first, two points are selected as reference points, and a point P is selected 4 And P 3 ，P 4 As origin of coordinates, P 3 As points in the positive x-axis direction, other points are all above the x-axis, i.e., all have y coordinates greater than 0;
after the coordinates are determined, each pouring point moves from a point P 'to a point P', the telescopic length of the steel wire rope corresponding to each pulley is calculated through the above (1) - (7), then each winding motor is driven to move, and the motor is controlled to stop through the corresponding angle sensor pulley;
through initial acquisition of coordinates, a pouring point track is automatically generated by setting a distance D between pouring points on a system operation interface;
according to the set spacing, automatically drawing a virtual grid, selecting intersection coordinates of the grid as pouring points, and then selecting a sequence of traversing the pouring points, namely a pouring sequence, and performing incremental folding pouring by a y value or random pouring;
the system can also automatically control the casting time at each casting point, wherein the casting time is related to three factors:
the area S of the relevant shape of the area surrounding the pouring point is the calculated area of the pouring point A and the calculated area of the pouring point B respectively;
the number M, S1, S2, S3 and S4 of adjacent edge points of the pouring point is the number M, S1, S2, S3 and S4 of adjacent edge points of the pouring point B;
the number N, C1, C2, C3 and C4 of the adjacent corner points of the pouring point is the number N, C1, C2, C3 and C4 of the adjacent corner points of the pouring point B;
the casting time of each casting point can be calculated by the following formula:
t＝(αS+βM+γN)*D
the alpha, beta, gamma parameters are related to the characteristics of the casting cement and are constant.
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