WO2024099424A1 - 一种管桩智能压浆机控制系统及控制方法 - Google Patents

一种管桩智能压浆机控制系统及控制方法 Download PDF

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Publication number
WO2024099424A1
WO2024099424A1 PCT/CN2023/130935 CN2023130935W WO2024099424A1 WO 2024099424 A1 WO2024099424 A1 WO 2024099424A1 CN 2023130935 W CN2023130935 W CN 2023130935W WO 2024099424 A1 WO2024099424 A1 WO 2024099424A1
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Prior art keywords
grouting
pressure
control
screw
machine
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PCT/CN2023/130935
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English (en)
French (fr)
Inventor
潘根强
高继红
林东
杨东泽
程镇生
陈越
章银兵
童琪君
乐远波
张兆民
刘安总
边一晗
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中交第三航务工程局有限公司
中交第三航务工程局有限公司宁波分公司
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Priority to DE212023000103.9U priority Critical patent/DE212023000103U1/de
Publication of WO2024099424A1 publication Critical patent/WO2024099424A1/zh

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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
    • G05B19/054—Input/output
    • 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
    • E02D15/04—Placing concrete in mould-pipes, pile tubes, bore-holes or narrow shafts
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/11—Plc I-O input output
    • G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor

Definitions

  • the present invention relates to the technical field of grouting machine control, and in particular to a control system and a control method for a pipe pile intelligent grouting machine.
  • the current intelligent grouting machine control system for pipe piles mainly uses the post-tensioning method for grouting, that is, the grout is pressed into the grouting channel of the pipe pile by a screw grouting machine.
  • the existing intelligent grouting machine control system for pipe piles has the following defects:
  • the existing intelligent grouting machine control system for pipe piles can only control the slurry feeding speed and flow rate by manually adjusting the speed of the screw grouting machine, and cannot automatically adjust according to the real-time grouting pressure;
  • a new intelligent grouting machine control system for pipe piles is needed, which is suitable for pipe section grouting and can adjust the grouting speed and flow rate of the grouting liquid in real time to improve the grouting effect.
  • the object of the present invention is to provide a control system and a control method for a pipe pile intelligent grouting machine, which can automatically adjust and control the grouting speed and improve the grouting effect.
  • a pipe pile intelligent grouting machine control system comprising:
  • a control device that collects the grouting pressure of the grouting channel of the screw grouting machine in real time, and adjusts the speed of the screw grouting machine according to the grouting pressure control to control the slurry speed and flow rate.
  • control device includes a PLC controller, two frequency converters, two analog quantity acquisition modules, two analog quantity output modules, and two pressure sensors;
  • Each of the screw grouting machines comprises a screw grouting pump and a pressure stabilizing tank connected to the outlet of the screw grouting pump; the pressure stabilizing tank grouts the post-tensioned large pipe piles through the grouting channel;
  • the two pressure sensors collect the grouting pressure signals of the corresponding grouting channels, transmit them to the analog quantity acquisition module to obtain the corresponding pressure value, and the pressure value is subjected to PID operation by the PLC controller to obtain the PID (proportional, integral, differential) result, which is converted into analog quantity by the analog quantity output module and output to the corresponding frequency converter; the frequency converter adjusts the output frequency;
  • the two screw grouting pumps adjust their rotation speeds according to the output frequencies of the corresponding frequency converters.
  • it also includes: two remote controllers,
  • the PLC (Programmable Logic Controller) controller receives control signals from the two remote controllers through a remote control receiver, and controls the output action and frequency of the corresponding frequency converter according to the switch signals converted from the control signals.
  • it also includes:
  • An HMI human-machine interface module connected to the control device for human-machine data interaction
  • a host computer connected to the control device and used for inputting grouting control parameters and information, displaying grouting status, drawing and saving a real-time curve of grouting pressure-time process and grouting production reports;
  • An information platform for realizing online communication with the host computer is
  • the HMI module includes a main control page unit and a boot page unit.
  • the boot page unit includes a password input box unit for inputting a password and a login switch unit for login control;
  • the main control page unit includes:
  • a digital input box unit for inputting grouting target pressure and holding time parameters
  • Grouting report unit for generating and displaying grouting data reports.
  • the grouting pressure of the grouting channel collected by the pressure sensor is stabilized at the set pressure, and the grouting pressure is
  • the PLC controller controls the HMI module to generate a grouting data report, and connects with the information platform in real time through the host computer to realize the real-time upload of the tensioning process and report data to the information platform.
  • each of the pressure-stabilizing tanks has two slurry outlets for grouting the pipe pile holes through pipeline transportation.
  • grouting should be carried out slowly and evenly; when the grouting pressure reaches the pressure maintaining control value, it automatically enters the pressure maintaining state.
  • the frequency conversion control can maintain the pressure within the upper and lower limit range.
  • the pressure of each grouting channel is maintained between 0.4-0.6MPa, the pressure change does not exceed 10%, and it is maintained for more than 2 minutes.
  • the control method of the intelligent grouting machine for pipe piles includes the following steps: adopting a single-pump dual-channel grouting process, setting a pressure sensor in each grouting channel to monitor the grouting pressure in real time and collect the grouting pressure of the grouting channel of the screw grouting machine in real time; according to the grouting pressure collected in real time, it is necessary to continuously and steplessly adjust the motor speed of the screw grouting machine to control the slurry feeding speed and flow rate.
  • the two pressure sensors are used to control the pressure maintenance with the one with the lower pressure indication, and the sensor with the higher pressure indication controls the upper pressure limit; the grouting process is controlled by the actual indications of the two pressure sensors, and the control of a specific sensor is not fixed, to ensure that the pressure maintenance process is within the effective control range.
  • the present invention monitors the grouting pressure of each channel in real time through the pressure sensor, and controls the grouting speed by adjusting the output frequency of the frequency converter in real time through PID calculation, so as to achieve stable pressure maintenance and improve the grouting quality.
  • the on-site staff can perform the control without going to the control room to operate, thereby improving the on-site response speed.
  • FIG. 1 is a structural diagram of a control system of an intelligent pipe pile grouting machine according to the present invention.
  • FIG. 2 is a schematic diagram of the electronic control of the intelligent grouting machine for pipe piles of the present invention.
  • FIG. 3 is a diagram showing the control interface of the intelligent grouting of pipe piles according to the present invention.
  • Embodiment 1 is a diagrammatic representation of Embodiment 1:
  • the control system of the intelligent pipe pile grouting machine of the present invention includes: a pair of screw grouting machines, a control device, an HMI module 3 , a host computer 4 , and an information platform 5 .
  • the control device collects the grouting pressure of the grouting channel of the screw grouting machine in real time, and adjusts the speed of the screw grouting machine according to the grouting pressure control to control the slurry speed and flow rate.
  • the screw grouting machine is used to grout the post-tensioning large pipe pile 100.
  • the HMI module 3 is connected to the control device for human-computer data interaction.
  • the host computer 4 is connected to the control device for grouting control parameters, information input, grouting status display, drawing and saving the real-time curve of the grouting pressure-time process and the grouting production report.
  • the information platform 5 realizes online communication with the host computer.
  • control device includes a PLC controller 21, two frequency converters 22, two analog quantity acquisition modules 23, two analog quantity output modules (not shown), and two pressure sensors 24.
  • Each screw grouting machine includes a screw grouting pump 11 and a pressure stabilizing tank 12 connected to the outlet of the screw grouting pump 11.
  • the pressure-stabilizing tank 12 grouts the post-tensioned large pipe pile 100 through the grouting channel.
  • Each pressure-stabilizing tank 12 is divided into two grouting outlets for grouting of the pipe pile channel through pipelines.
  • Two pressure sensors 24 collect the grouting pressure of the corresponding grouting channels, transmit them to the analog quantity acquisition module 23 to obtain the corresponding pressure value, and the pressure value is PID calculated by the PLC controller 21.
  • the PID result is converted into an analog quantity output by the analog quantity output module to the corresponding frequency converter 22; the frequency converter 22 adjusts the output frequency; during the process, the slurry is continuously injected into the pipe pile channel through the screw grouting pump 11.
  • the slurry outlet of the channel is closed.
  • the pressure in the grouting channel will slowly increase.
  • the grouting pressure of the grouting channel collected by the pressure sensor 24 is stabilized at the set pressure, and the timing starts.
  • the screw grouting pump 11 stops working, and the PLC controller 21 controls the HMI module 3 to generate a grouting data report, and connects with the information platform 5 in real time through the host computer 4, so as to realize the tensioning process and the report data being uploaded to the information platform 5 in real time.
  • two remote controllers 25 are provided, and the two remote controllers 25 are connected to the PLC controller 21, that is, the PLC controller 21 receives the control signals of the two remote controllers 25 through the remote control receiver, and controls the output action and frequency of the corresponding frequency converter 22 according to the switch signals converted from the control signals.
  • On-site staff can operate the handheld remote controller to remotely control the grouting equipment, such as start and stop, without having to go to the control room for operation, thereby improving the on-site response speed.
  • on-site grouting personnel can control the start and stop of the two grouting pumps through the remote control device.
  • two red, green and yellow indicator lights are added on the top of the grouting station to remind on-site operators of the working conditions of the two pumps.
  • the two three-color indicator lights should ensure that workers can clearly see the indicator lights even if they are 100 meters away.
  • the green light means that the pump has started
  • the red light means that the pump has stopped
  • the yellow light means that the equipment is faulty.
  • the green and red lights will give a short bell prompting the start and stop of the pump, and the yellow light needs a buzzing sound to prompt the device.
  • the HMI module 3 includes a main control page unit and a power-on page unit, and the power-on page unit includes a password input box unit for inputting a password and a login switch unit for login control;
  • the main control page unit includes:
  • a digital input box unit for inputting grouting target pressure and holding time parameters
  • Grouting report unit for generating and displaying grouting data reports.
  • the industrial computer can record relevant information in the grouting process in real time, such as grouting pressure, holding pressure, grouting time and holding time, which correspond to the corresponding project name, pile number, channel number, etc., to ensure the accuracy and effectiveness of the data.
  • the data storage volume is more than 30,000 and the storage time is not less than 6 months.
  • grouting should be carried out slowly and evenly; when the grouting pressure reaches the pressure maintaining control value, it automatically enters the pressure maintaining state.
  • the frequency conversion control can maintain the pressure within the upper and lower limit range.
  • the pressure of each grouting channel is maintained between 0.4-0.6MPa, the pressure change does not exceed 10%, and it is maintained for more than 2 minutes.
  • the fully intelligent variable frequency grouting control system uses branch sensors to monitor the pressure of each channel; the pressure signal is detected in real time by the sensor and transmitted to the industrial computer to realize production data recording and improve the traceability of the pipe pile grouting process.
  • the grouting pipe adopts a rough sandblasting pipe (inner diameter 25mm ⁇ outer diameter 50mm ⁇ 9 layers), and the grouting pump outlet needs to be equipped with a corresponding interface; the screw grouting pump adopts frequency conversion control, runs smoothly and efficiently, has no pressure fluctuations in the continuous working mode, and pumps slurry without bubbles, ensuring that the grouting process is slow and uniform; the theoretical workload of each grouting pump is 3 cubic meters/hour, and the maximum pressure can reach 4MPa.
  • the high slurry output and continuous and stable pressure of the two grouting pumps ensure that the slurry use time is controlled within 30 minutes.
  • the two screw grouting pumps can work simultaneously or separately. When one pump fails, the other pump can still work alone to maintain continuous grouting operations.
  • two grouting pumps are controlled by an industrial computer. Workers can set the upper and lower pressure limits and the pressure control value (between the upper and lower limits) and then automatically operate. During the grouting process, two pressure sensors collect signals and transmit them to the PLC, which can accurately and effectively record relevant data.
  • the industrial computer is centrally controlled, and the frequency conversion is stepless. The speed is adjusted to control the grouting and pressure-maintaining process (see Figure 2 for the electronic control system).
  • the frequency conversion control can maintain the pressure within the upper and lower limit values.
  • the pressure holding of each channel is between 0.4-0.6MPa, the pressure change does not exceed 10%, and it is maintained for more than 2 minutes. Compared with manual pressure holding, intelligent pressure holding has lower error and is simpler and more efficient to operate.
  • Embodiment 2 is a diagrammatic representation of Embodiment 1:
  • the control method of the intelligent grouting machine for pipe piles includes the following steps: adopting a single-pump dual-channel grouting process, setting a pressure sensor in each grouting channel to monitor the grouting pressure in real time and collect the grouting pressure of the grouting channel of the screw grouting machine in real time; according to the grouting pressure collected in real time, it is necessary to continuously and steplessly adjust the motor speed of the screw grouting machine to control the slurry feeding speed and flow rate.
  • a single-pump dual-channel grouting process is adopted; at the same time, the two channels are grouting with a single pump and the pressure of the two channels is monitored separately, which has high calculation requirements for the control system.
  • the two pressure sensors with low pressure readings control the pressure maintenance, and the sensor with high pressure readings control the upper limit of pressure (the grouting process is controlled by the actual readings of the two pressure sensors, and the specific sensor control is not fixed, see Table 1, to ensure that the pressure maintenance process is within the effective control range.
  • pressure sensors are installed in the two channels to monitor the grouting quality of the channels.
  • Control requirements for two-way sensors The grouting quality of the two channels can be effectively monitored, and the actual pressure value can be reflected in the report; when the pressure of each channel is found to be abnormal, the problem can be quickly discovered and the fault can be promptly checked to save maintenance time; the slurry usage time is effectively controlled, the grouting pressure is maintained in the normal range, and the channel grouting quality is improved.
  • Embodiment 3 is a diagrammatic representation of Embodiment 3
  • the button control panel is installed on the mixing station operating table. Control buttons are installed on the operating box panel, and an emergency stop button is provided to prevent workers from operating incorrectly. It has a manual/automatic switching function.
  • the "1#/Dual Machine/2#" conversion switch on the operating panel is used to select the grouting machine to be operated. When “Dual Machine” is selected, the start and stop of the two pumps can still be controlled separately on the industrial computer.
  • the pipeline selection switch can be single-selected or multiple-selected. Enter the corresponding grouting pressure, holding pressure and holding time in the design parameter input box
  • the corresponding parameter display box displays the real-time pressure and status of the corresponding pipeline in real time.
  • the start button for more than 2 seconds to enter the pressure holding state. If you need to pause the grouting work during the grouting process, you can click the stop switch on the control cabinet or remote control to pause the grouting work. If you need to end the pause state and continue grouting, you can click the start switch to end the pause state and continue grouting. If you need to stop the entire grouting work, you can press and hold the grouting switch for 2 seconds to end the entire grouting work. After the pressure holding is completed, the entire grouting process is completed and a grouting report is generated.
  • the stranded wire bundle is divided into double-twisted wire or triple-twisted wire (the stranded wire diameter is 15.2mm), and the number of holes in each pipe pile is 16 holes (hole diameter is about 42mm).
  • the efficiency calculation of single-pump and double-pump grouting is as follows:
  • the grouting time of the whole pile is estimated to be:
  • R is the radius of the hole
  • r is the radius of the steel strand
  • the rated grouting capacity of the screw grouting pump is 3m 3 /h
  • two screw grouting pumps are used, and the actual efficiency is 0.8.
  • the working efficiency of the screw grouting pump in the grouting process of 68m double-twisted pile is estimated to be 29 minutes. Or the grouting time for short piles will be lower.
  • R is the hole diameter of 42mm
  • r is the steel strand diameter of 15.2mm
  • the rated grouting capacity of the screw grouting pump is 3m3 /h
  • one screw grouting pump is used for operation, with the actual efficiency being 0.8.
  • the pressure holding time is calculated as 8 minutes, and the time for workers to disassemble and install the grouting pipe is calculated as 8 minutes.
  • the simultaneous grouting of four channels by a single pump may cause the pressure in the four channels to take a long time to reach the holding pressure or even be difficult to reach the holding pressure, which greatly reduces the work efficiency.
  • the grouting volume of 16 channels of a 68m long pile is about 1.1m3
  • the single grouting volume is about 0.5m3 .
  • the calculated working efficiency of double pumps is 29 minutes, and that of single pump is 43 minutes.
  • the single slurry production is completed in about 15 minutes and 22 minutes respectively.
  • the use time of cement slurry can be controlled within 30 minutes.

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Abstract

本发明公开了一种管桩智能压浆机控制系统及控制方法，其中控制系统包括：用于对后张法大管桩进行灌浆的一对螺杆压浆机；实时采集螺杆压浆机的压浆孔道的压浆压力，并根据压浆压力连续无级调节螺杆压浆机电机转速控制浆液进浆速度和流量的自动控制装置。本发明自动调节控制浆液速度，提高灌浆效果。

Description

一种管桩智能压浆机控制系统及控制方法 技术领域
本发明涉及压浆机控制技术领域，具体涉及一种管桩智能压浆机控制系统及控制方法。
背景技术
目前，后张法大管桩在各类工程中广泛应用，在较高承载力和抗弯性可以代替部分管桩，能节省工程造价。孔道灌浆目前是后张法预应力施工过程中的重要环节，灌浆质量的好坏直接影响大管桩预应力效果，所以需要特别的注意。目前，大多依靠人工观察进行灌浆控制，容易造成误差，降低整个灌浆的质量。
具体地在工程施工中，常常需要对管桩进行压浆处理。目前的管桩智能压浆机控制系统主要采用后张法进行灌浆，即通过螺杆压浆机将浆液压入管桩的压浆孔道。然而，现有的管桩智能压浆机控制系统存在以下缺陷：
无法实时调节浆液的进浆速度和流量：现有的管桩智能压浆机控制系统只能通过手动调节螺杆压浆机的转速来控制浆液的进浆速度和流量，无法根据实时的压浆压力来进行自动调节；
灌浆效果不佳：由于无法实时调节浆液的进浆速度和流量，现有的管桩智能压浆机控制系统无法根据实际需要进行精确的控制，导致灌浆效果不佳，无法满足工程施工的要求。
因此，需要一种新的管桩智能压浆机控制系统，适用于管节灌浆，同时能够实时调节浆液的进浆速度和流量，以提高灌浆效果。
发明内容
本发明的目的在于提供一种管桩智能压浆机控制系统及控制方法，自动调节控制浆液速度，提高灌浆效果。
实现上述目的的技术方案是：
一种管桩智能压浆机控制系统，包括：
用于对后张法大管桩进行灌浆的两个螺杆压浆机；
实时采集螺杆压浆机的压浆孔道的压浆压力，并根据压浆压力控制调整螺杆压浆机转速而控制浆液速度和流量的控制装置。
优选的，所述控制装置包括PLC控制器、两个变频器、、两个模拟量采集模块、两个模拟量输出模块、两个压力传感器；
每个所述螺杆压浆机包括螺杆式压浆泵以及连接所述螺杆式压浆泵的出口的稳压罐；所述稳压罐通过压浆孔道对后张法大管桩进行灌浆；
两个所述压力传感器采集各自对应压浆孔道的压浆压力信号，传输给模拟量采集模块得到对应的压力值，压力值经过PLC控制器进行PID运算，获得PID(比例、积分、微分)结果经模拟量输出模块转换成模拟量输出到对应所述变频器；所述变频器调整输出频率；
两个所述螺杆式压浆泵根据各自对应的所述变频器的输出频率调整转速。
优选的，还包括：两个遥控器，
所述PLC(可编程逻辑控制器)控制器通过遥控接收器接收两个所述遥控器的控制信号，根据控制信号转化成的开关信号控制对应的所述变频器的输出动作、频率。
优选的，还包括：
与所述控制装置相接，用于进行人机数据交互的HMI(人机界面)模块；
与所述控制装置相接，用于压浆控制参数、信息的输入、压浆状态显示、绘制并保存压浆压力-时间过程实时曲线以及压浆生产报表的上位机；
与所述上位机实现网上通信的信息化平台。
优选的，所述HMI模块包括主控页面单元、开机页面单元，
所述开机页面单元包括用于输入密码的密码输入框单元和用于登录控制的登录开关单元；
所述主控页面单元包括：
用于输入压浆目标压力、保压时间参数的数字输入框单元；
用于显示压浆状态、变频运行频率、压浆孔道实时压力值的状态显示单元；
用于生成和显示压浆数据报表的压浆报表单元。
优选的，所述压力传感器采集的压浆孔道的压浆压力稳定在设定压力上，开始 计时，当保压达到设定保压时间时，螺杆式压浆泵停止工作，PLC控制器控制HMI模块生成压浆数据报表，并通过上位机与信息化平台进行实时对接，实现张拉过程与报表数据实时上传到信息化平台。
优选的，每个所述稳压罐分出两个出浆口通过管道输送进行管桩孔道注浆。
优选的，压浆应缓慢、均匀地进行；压浆压力达到保压控制值时自动进入保压状态，变频控制可使压力维持在上下限值范围内，每个压浆孔道保压在0.4-0.6MPa之间，压力变化不超过10％，并保持2min以上。
管桩智能压浆机控制方法，包括以下步骤：采用单泵双孔道压浆工艺，在每个压浆孔道中设置一个压力传感器，用于实时监测压浆压力实时采集螺杆压浆机的压浆孔道的压浆压力；根据实时采集到的压浆压力，需要连续无级调节螺杆压浆机的电机转速，以控制浆液的进浆速度和流量。
优选的，将两个压力传感器以压力示数低的控制保压，压力示数高的传感器控制压力上限；以两个压力传感器实际示数控制压浆过程，不固定特定传感器控制，确保保压过程在有效控制范围内。
本发明的有益效果是：本发明通过压力传感器实时监控各孔道的压浆压力，通过PID运算，实时通过调整变频器的输出频率来控制浆液速度，实现平稳保压，提高灌浆质量。同时，现场工作人员可执行控制，不必到控制室操作，提高现场反映速度。
附图说明
图1是本发明的管桩智能压浆机控制系统的结构图。
图2是本发明的管桩智能压浆机电控示意图。
图3是本发明的管桩智能压浆的控制界面图。
具体实施方式
下面将结合附图对本发明作进一步说明。
实施例1：
请参阅图1，本发明的管桩智能压浆机控制系统，包括：一对螺杆压浆机、控制装置、HMI模块3、上位机4、信息化平台5。
控制装置实时采集螺杆压浆机的压浆孔道的压浆压力，并根据压浆压力控制调整螺杆压浆机转速而控制浆液速度和流量，螺杆压浆机用于对后张法大管桩100进行灌浆。HMI模块3与控制装置相接，用于进行人机数据交互。上位机4与控制装置相接，用于压浆控制参数、信息的输入、压浆状态显示、绘制并保存压浆压力-时间过程实时曲线以及压浆生产报表。信息化平台5与上位机实现网上通信。
具体地，控制装置包括PLC控制器21、两个变频器22、两个模拟量采集模块23、两个模拟量输出模块(图中未示)、两个压力传感器24。每个螺杆压浆机包括螺杆式压浆泵11以及连接螺杆式压浆泵11的出口的稳压罐12。
其中，稳压罐12通过压浆孔道对后张法大管桩100进行灌浆。每个稳压罐12分出两个出浆口通过管道输送进行管桩孔道注浆。两个压力传感器24采集各自对应压浆孔道的压浆压力，传输给模拟量采集模块23得到对应的压力值，压力值经过PLC控制器21进行PID运算，获得PID结果经模拟量输出模块转换成模拟量输出到对应所述变频器22；所述变频器22调整输出频率；过程中，浆液通过螺杆式压浆泵11连续注入管桩孔道，当浆液在孔道末端流出，封闭孔道出浆口，随着浆液源源不断注入孔道，压浆孔道中的压力会慢慢升高。压力传感器24采集的压浆孔道的压浆压力稳定在设定压力上，开始计时，当保压达到设定保压时间时，螺杆式压浆泵11停止工作，PLC控制器21控制HMI模块3生成压浆数据报表，并通过上位机4与信息化平台5进行实时对接，实现张拉过程与报表数据实时上传到信息化平台5。
另外，设置两个遥控器25，两个遥控器25连接PLC控制器21，即：PLC控制器21通过遥控接收器接收两个所述遥控器25的控制信号，根据控制信号转化成的开关信号控制对应的所述变频器22的输出动作、频率。现场工作人员可操作手持遥控器远距离控制压浆设备，如启动、停止等，不必到控制室操作，提高现场反映速度。
在实践中，现场灌浆人员可通过遥控装置分别控制两台压浆泵的启停。同时，灌浆站顶部增加两部红绿黄指示灯，分别提示现场操作人员两台泵的工作情况，两部三色指示灯应能保证工人在100米以外也能清楚看到指示灯的提示。绿色灯代表泵已启动，红色等代表泵已停止，黄色灯代表设备故障；三色灯切换时应有铃声提示，绿色灯及红色灯一声短促铃声提示泵的启动和停止，黄色灯需嗡鸣声音提示设 备故障。通过增加遥控装置，既能保证现场施工便利，也可应对爆管、漏浆等突发情况。
另外，HMI模块3包括主控页面单元、开机页面单元，开机页面单元包括用于输入密码的密码输入框单元和用于登录控制的登录开关单元；
主控页面单元包括：
用于输入压浆目标压力、保压时间参数的数字输入框单元；
用于显示压浆状态、变频运行频率、压浆孔道实时压力值的状态显示单元；
用于生成和显示压浆数据报表的压浆报表单元。
实现了人机交互，方便整体控制。
在实践中，工控机上可实时记录压浆过程中的相关信息，如压浆压力、保压压力、压浆时间和保压时间等数据，与相应的工程名称、管桩编号、孔道编号等相对应，保证数据的准确有效性，数据存储量在3万条以上，存储时间不少于6个月。实现数据查询后，按车间提供的数据报表以EXCEL文件形式导出，表格中手动输入的信息在输入后，后续表格内容保持不变，相关内容如有变更另行更改。
在上述实施过程中，压浆应缓慢、均匀地进行；压浆压力达到保压控制值时自动进入保压状态，变频控制可使压力维持在上下限值范围内，每个压浆孔道保压在0.4-0.6MPa之间，压力变化不超过10％，并保持2min以上。
具体地全智能变频压浆控制系统，分路传感器实施监控各孔道压力；通过传感器实时检测压力信号传送到工控机，实现生产数据记录，提高管桩灌浆工序的可追溯性
压浆管采用毛面喷砂管(内径25mm×外径50mm×9层)，压浆泵的出浆口需配相应接口；螺杆式压浆泵采用变频控制，运行平稳高效，连续式工作方式压力无波动，泵送浆体无气泡，保证压浆过程缓慢、均匀地进行；每台压浆泵理论工作量3立方米/小时，最大压力可达4MPa，两台压浆泵高输浆量和持续稳定的压力保证浆液的使用时间控制在30min之内。两台螺杆式压浆泵既能同时进行作业，也可分别工作，当其中一台泵出现故障时，另一台泵仍可单独工作，能保持连续灌浆作业。
在操作室通过一台工控机控制两台压浆泵工作，工人可通过设置压力上下限值和保压控制值(在上下限值之间)后自动运行，压浆过程通过2只压力传感器采集信号并传送到PLC，可准确、有效记录相关数据，通过工控机集中控制，变频无级 调速控制压浆和保压过程(电控系统见附图2)。
压浆压力达到保压控制值时自动进入保压状态，变频控制可使压力维持在上下限值范围内，每孔道保压在0.4-0.6MPa之间，压力变化不超过10％，并保持2min以上；智能保压与人工保压相比误差较低，操作也更加简捷高效。
实施例2：
管桩智能压浆机控制方法，包括以下步骤：采用单泵双孔道压浆工艺，在每个压浆孔道中设置一个压力传感器，用于实时监测压浆压力实时采集螺杆压浆机的压浆孔道的压浆压力；根据实时采集到的压浆压力，需要连续无级调节螺杆压浆机的电机转速，以控制浆液的进浆速度和流量。
在保证压浆质量的前提下，为提高压浆泵工作效率，采用单泵双孔道压浆工艺；同时两个孔道分别单泵双孔道压浆并分别监测两个孔道的压力，对控制系统的计算要求较高。为解决上述难题，要求将两个压力传感器以压力示数低的控制保压，压力示数高的传感器控制压力上限(以两个压力传感器实际示数控制压浆过程，不固定特定传感器控制，见表1，确保保压过程在有效控制范围内。同时两个孔道分别安装压力传感器，监测孔道的压浆质量。
表1压浆过程控制表
两路传感器的控制要求：对两个孔道的压浆质量可实现有效监控，报表中可体现实际压力值；当发现每个孔道的压力异常时，能快速发现问题，及时排查故障，节约维修时间；浆液使用时间有效控制，注浆压力保持在正常范围，提高孔道压浆质量。
实施例3：
如图3所示，按钮控制面板安装在搅拌站操作台，在操作盒面板上装设控制按钮，并设有急停按钮，防止工人误操作；具有手动/自动切换功能，用操作面板上“1#/双机/2#”的转换开关选择需工作的压浆机，选择“双机”时仍可在工控机上分别控制两台泵启停。
在工程名称输入框输入工程名称，工程编号输入框和孔道编号输入框中输入相应的工程编号和压浆的孔道编号，点击压浆管路选择开关“1#选择”或“2#选择”选择压浆管路，管路选择开关可单选，也可复选。在设计参数输入框中输入相应的压浆压力、保压压力和保压时间
连接好压浆管道，按控制柜或手持遥控器上的启动开关启动压浆，压浆时，相应的参数显示框中实时显示相应的管路的实时压力和状态，到达压浆压力时，长按启动按钮2秒以上进入保压状态，压浆过程中需要暂停压浆工作时，可点击控制柜或遥控器上的停止开关暂停压浆工作，如需结束暂停状态继续压浆，可点击启动开关结束暂停状态继续压浆，如需停止整个压浆工作，可长按压浆开关2秒以结束整个压浆工作。保压完成后，整个压浆过程完成并生成压浆报表。
具体地，以生产的大管桩本体长度一般在52m至68m之间为例，钢绞线穿束方式分为双绞线或三绞线(钢绞线直径为15.2mm)，每根管桩的孔道数为16孔(孔径约为42mm)。采用单泵和双泵压浆的工效计算如下：
(1)双泵工效
按照68m管桩双绞线计算，整根管桩的压浆时间预计为：
说明：R为孔道半径，r为钢绞线半径，螺杆式压浆泵额定输浆量为3m3/h，采用2台螺杆式压浆泵作业，实际功效取0.8。
工作过程中为4孔同时压浆，16孔共需保压4次，每次保压2min总计保压时间为8min，整桩压浆过程中人工拆装压浆管时间约8min。压浆总时间约为T＝13min+8min+8min＝29min。
螺杆式压浆泵在68m双绞线管桩压浆过程中的工效预计为29min，若为三绞线 或短桩压浆时间会更低。
(2)单泵工效
日常工作时，若其中一台螺杆泵因故障停用，单泵工作时工效计算如下：
说明：R为孔道直径42mm，r为钢绞线直径15.2mm，螺杆式压浆泵额定输浆量为3m3/h，采用1台螺杆式压浆泵作业，实际功效取0.8。
同样单泵四孔道灌浆，保压时间按8min计算，工人拆装压浆管时间按8min计算，整根桩灌浆理论时间为T灌浆+T保压＝27min+8min+8min＝43min。
由于管桩为非全密闭式封锚，钢绞线泌水量较大，单泵四孔道同时灌浆可能导致四个孔道压力达到保压压力的时间较长甚至难以达到保压压力，工效大大降低；68m长桩16个孔道的压浆量在1.1m3左右，单次制浆量在0.5m3左右。
双泵计算工效为29min，单泵计算工效43min，单次制浆量分别在15min、22min左右使用完毕，均可控制水泥浆使用时间在30min以内。
通过与原活塞式灰浆泵实际工效对比后得出(见表2)，采用两台螺杆泵同时压浆的工作效率最大。
表2压浆工时工效对比表
以上实施例仅供说明本发明之用，而非对本发明的限制，有关技术领域的技术人员，在不脱离本发明的精神和范围的情况下，还可以作出各种变换或变型，因此所有等同的技术方案也应该属于本发明的范畴，应由各权利要求所限定。

Claims (10)

  1. 一种管桩智能压浆机控制系统，其特征在于，包括：
    用于对后张法大管桩(100)进行灌浆的两个螺杆压浆机；
    实时采集螺杆压浆机的压浆孔道的压浆压力，并根据压浆压力控制调整螺杆压浆机转速而控制浆液速度和流量的控制装置。
  2. 根据权利要求1所述的管桩智能压浆机控制系统，其特征在于，所述控制装置包括PLC控制器(21)、两个变频器(22)、两个模拟量采集模块(23)、两个模拟量输出模块、两个压力传感器(24)；
    每个所述螺杆压浆机包括螺杆式压浆泵(11)以及连接所述螺杆式压浆泵(11)的出口的稳压罐(12)；所述稳压罐(12)通过压浆孔道对后张法大管桩(100)进行灌浆；
    两个所述压力传感器(24)采集各自对应压浆孔道的压浆压力信号，传输给模拟量采集模块(23)得到对应的压力值，压力值经过PLC控制器(21)进行PID运算，获得PID结果经模拟量输出模块转换成模拟量输出到对应所述变频器(22)；所述变频器(22)调整输出频率；
    两个所述螺杆式压浆泵(11)根据各自对应的所述变频器(22)的输出频率调整转速。
  3. 根据权利要求2所述的管桩智能压浆机控制系统，其特征在于，还包括：两个遥控器(25)，
    所述PLC控制器(21)通过遥控接收器接收两个所述遥控器(25)的控制信号，根据控制信号转化成的开关信号控制对应的所述变频器(22)的输出动作、频率。
  4. 根据权利要求2所述的管桩智能压浆机控制系统，其特征在于，还包括：
    与所述控制装置相接，用于进行人机数据交互的HMI模块(3)；
    与所述控制装置相接，用于压浆控制参数、信息的输入、压浆状态显示、绘制并保存压浆压力-时间过程实时曲线以及压浆生产报表的上位机(4)；
    与所述上位机实现网上通信的信息化平台(5)。
  5. 根据权利要求4所述的管桩智能压浆机控制系统，其特征在于，所述HMI模块(3)包括主控页面单元、开机页面单元，
    所述开机页面单元包括用于输入密码的密码输入框单元和用于登录控制的登 录开关单元；
    所述主控页面单元包括：
    用于输入压浆目标压力、保压时间参数的数字输入框单元；
    用于显示压浆状态、变频运行频率、压浆孔道实时压力值的状态显示单元；
    用于生成和显示压浆数据报表的压浆报表单元。
  6. 根据权利要求4所述的管桩智能压浆机控制系统，其特征在于，所述压力传感器(24)采集的压浆孔道的压浆压力稳定在设定压力上，开始计时，当保压达到设定保压时间时，螺杆式压浆泵(11)停止工作，PLC控制器(21)控制HMI模块(3)生成压浆数据报表，并通过上位机(4)与信息化平台(5)进行实时对接，实现张拉过程与报表数据实时上传到信息化平台(5)。
  7. 根据权利要求2所述的管桩智能压浆机控制系统，其特征在于，每个所述稳压罐(12)分出两个出浆口通过管道输送进行管桩孔道注浆。
  8. 根据权利要求1所述的管桩智能压浆机控制系统，其特征在于，压浆应缓慢、均匀地进行；压浆压力达到保压控制值时自动进入保压状态，变频控制可使压力维持在上下限值范围内，每个压浆孔道保压在0.4-0.6MPa之间，压力变化不超过10％，并保持2min以上。
  9. 管桩智能压浆机控制方法，其特征在于，包括以下步骤：
    采用单泵双孔道压浆工艺，在每个压浆孔道中设置一个压力传感器，用于实时监测压浆压力实时采集螺杆压浆机的压浆孔道的压浆压力；
    根据实时采集到的压浆压力，需要连续无级调节螺杆压浆机的电机转速，以控制浆液的进浆速度和流量。
  10. 根据权利要求9所述的管桩智能压浆机控制方法，其特征在于，将两个压力传感器以压力示数低的控制保压，压力示数高的传感器控制压力上限；以两个压力传感器实际示数控制压浆过程，不固定特定传感器控制，确保保压过程在有效控制范围内
PCT/CN2023/130935 2022-11-11 2023-11-10 一种管桩智能压浆机控制系统及控制方法 WO2024099424A1 (zh)

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