CN-121760300-B - Steel-concrete combined structure concrete void repair integrated control system and method

CN121760300BCN 121760300 BCN121760300 BCN 121760300BCN-121760300-B

Abstract

The invention discloses a steel-concrete combined structure concrete void repairing integrated control system and method, wherein the system comprises a supporting mechanism, an indexing turntable assembly, a drilling module, a blow-drying air module, a grouting module and a control unit, the supporting mechanism is adsorbed and fixed through a magnetic base, three modules are switched to 120-degree accurate stations through the indexing turntable assembly, the drilling module is automatically stopped based on a pressure sudden drop criterion, the blow-drying air module is self-adaptively blow-dried by depending on a void level parameter library and sensing feedback, grouting module linkage void detection data and inclination angle information calculate order mark slurry pressure, and intelligent stopping is realized through pressure-flow collaborative monitoring.

Inventors

ZENG JUNCHENG
SONG YUANYIN
QIN KAIQIANG
WU SHAOFENG
Xiao Zhuohong
CHEN DEBAO
GUO CHAO
ZHENG HAOFENG
CHEN ZHIWEI
ZHU YAOYU
Wang Luofan
MA Wenshuo
SUN ZUOXUAN
Yuan Geting

Assignees

福建省高速公路科技创新研究院有限公司
中交公路长大桥建设国家工程研究中心有限公司
福州机场复线高速公路有限公司

Dates

Publication Date: 20260512
Application Date: 20260303

Claims (10)

1. The integrated control system for concrete void repair of the steel-concrete combined structure is characterized by comprising a supporting mechanism (1), an indexing turntable assembly (2), a drilling module (3), a blow-drying air module (4), a grouting module (5) and a control unit (6), The supporting mechanism (1) is adsorbed on the outer surface of the steel plate through a magnetic base or a permanent magnet-electromagnetic composite base and is used for providing a reference positioning and counter force transmission path of the whole machine; the indexing turntable assembly (2) is coaxially arranged on the supporting mechanism (1), the indexing turntable assembly (2) comprises a base (21), an indexing turntable (24) and a spring lock pin mechanism (23), the indexing turntable (24) is rotatably arranged on the base (21), the spring lock pin mechanism (23) is fixedly arranged on the side face of the base (21), 3 positioning holes or grooves which are uniformly distributed at 120 degrees are formed in the outer ring of the indexing turntable (24), the lock pin heads of the spring lock pin mechanism (23) can be matched with the positioning holes or grooves to realize indexing locking, the drilling module (3), the blow-drying air module (4) and the grouting module (5) are uniformly distributed and fixed at 120 degrees along the outer edge of the indexing turntable (24), the working ends of the drilling module (3) face the central working position of the indexing turntable assembly, the drilling module (3) is provided with an axial pressure sensor for monitoring the change of drilling reaction in real time, the blow-drying air module (4) is provided with a temperature and humidity sensor or a micro pressure sensor for detecting the humidity of discharged gas, the grouting module (5) comprises a grouting pump, a grouting nozzle, a grouting pipe, a grouting nozzle and a grouting pipe, and one end of the grouting pipe is connected with the grouting pipe, and the grouting pipe is connected with the grouting pipe, the slurry pipeline is provided with a pressure sensor and a flow sensor, and the grouting module (5) is also provided with an inclination sensor which is used for detecting the space posture of a component in a matching way, wherein the control unit (6) is electrically connected with the indexing turntable assembly (2), the drilling module (3), the blow-drying air module (4) and the grouting module (5) and is used for driving the indexing turntable assembly (2) to rotate and switch working stations and controlling the operation of each module; The control unit (6) is internally provided with a parameter library of 'void level-blow-dry duration-air pressure/flow rate' based on experimental calibration, and the control unit (6) calculates the target grouting pressure according to the void shape, size and component gesture by means of linkage of the grouting module (5) and the earlier-stage void detection data, and realizes automatic shutdown of the grouting module (5) based on pressure-flow rate collaborative monitoring.
2. The integrated control system for concrete void repair of a steel-concrete combined structure according to claim 1, wherein a central shaft hole of the indexing turntable (24) is in clearance fit with a positioning shaft sleeve of the base (21), the fit clearance is 0.02-0.05mm, an annular boss is arranged on the lower surface of the indexing turntable (24), and an adaptive annular guide rail groove is arranged on the upper surface of the base (21) to form a sliding support structure.
3. The integrated control system for concrete void repairing with the steel-concrete combined structure according to claim 2, wherein the spring lock pin mechanism (23) comprises an electromagnetic coil, a return spring, a lock pin rod and a guide sleeve, the return spring is adsorbed by the electromagnetic coil to compress the return spring to release a lock pin when the electromagnetic coil is electrified, the return spring pushes the lock pin rod to be embedded into a positioning hole or a groove to realize locking when the electromagnetic coil is powered off, the lock pin head is of a hemispherical structure, and the control unit (6) can drive the indexing turntable (24) to rotate and release the spring lock pin mechanism (23) to be locked again after the electromagnetic coil is rotated to a target angle.
4. The integrated control system for repairing the concrete void of the steel-concrete composite structure according to any one of claims 1 to 3, wherein the drilling module (3) comprises a drilling motor and a feeding mechanism, the axial pressure sensor is arranged on a stress path of the supporting mechanism (1) and the steel plate, and the control unit (6) controls the drilling module (3) to stop running when the pressure value is lower than a preset threshold value and the pressure change rate reaches a 'dip' criterion by collecting the pressure value of the axial pressure sensor and calculating the pressure change rate.
5. The integrated control system for concrete void repair of a steel-concrete composite structure according to any one of claims 1 to 3, wherein the void grades are divided into small-grade void e≤5 mm and A≤50 cm 2 , medium-grade void 5mm < e <15mm or 50cm 2 ＜A≤150cm 2 , large-grade void e≤15 mm or A >150cm 2 based on the void depth e and the void area A.
6. The integrated control system for concrete void repair of a steel-concrete composite structure according to any one of claims 1 to 3, wherein the grouting module is designed to mark the grouting pressure by a formula The calculation results show that, among others, In order to achieve a slurry density, The acceleration of the gravity is that, In order to empty the height difference between the lowest point and the highest point along the gravity direction, For the pressure drop across the pipeline, Is the safety margin pressure.
7. The steel-concrete composite structure concrete void repair integrated control system according to any one of claims 1 to 3, wherein the control unit (6) comprises a signal acquisition module, a logic processing module, a driving output module and a timing module; The signal acquisition module is used for receiving and processing detection signals of the sensors; the logic processing module is used for storing a program, a parameter library and generating a control instruction, and the driving output module is used for converting the control instruction into a driving signal; The timing module is used for measuring the time of the blow-drying process.
8. The steel-concrete combined structure concrete void repair integrated control method is characterized by being realized by applying the steel-concrete combined structure concrete void repair integrated control system as claimed in any one of claims 1-7, and comprises the following steps: s1, obtaining plane shape, area and volume information of a steel-concrete combined section void defect through a nondestructive detection means, and dividing a void grade according to a preset void thickness or volume model; s2, adsorbing and fixing the integrated equipment on a target repair area on the outer surface of the steel plate through a magnetic base or a permanent magnet-electromagnetic composite base of a supporting mechanism; The drilling process comprises the steps of driving an indexing turntable assembly (2) by a control unit (6) to release a lock pin, rotating to a drilling station, then re-locking, starting a drilling module (3) to drill a steel plate, acquiring a counter-force signal in real time by an axial pressure sensor in the drilling process, transmitting the counter-force signal to the control unit (6), periodically acquiring a grouting pressure value by the control unit (6) and calculating a pressure change rate, judging that the steel plate is penetrated when the pressure value is detected to be lower than a preset threshold value and the pressure change rate reaches a sudden drop criterion, and immediately controlling the control unit (6) to stop the operation of the drilling module (3); S4, a blow-drying procedure, namely, a control unit (6) drives the indexing turntable assembly (2) to rotate, so that a blow-drying air module (4) is switched to a central working position, the control unit (6) calls corresponding blow-drying time and air pressure/flow combination from a parameter library according to the blow-off level, starts the blow-drying air module (4) to blow compressed air into a blow-off area through a drilled hole, and combines sensing feedback on the blow-drying air module (4) to realize self-adaptive blow-drying; S5, a grouting procedure, namely, driving the indexing turntable assembly (2) to rotate by the control unit (6) to enable the grouting module (5) to be switched to a central working position, starting the grouting module (5) to press grouting liquid to a void area through a grouting hole, and calculating the height difference between the lowest point and the highest point of the void along the gravity direction by the control unit (6) according to the void shape and the size obtained by early nondestructive detection and the space posture of a member measured by the inclination angle sensor in the grouting process Combined with slurry density Acceleration of gravity Pressure drop across pipeline Safety margin By the formula Calculating the destination marking slurry pressure Realizing automatic grouting shutdown based on pressure-flow collaborative monitoring and preset criteria; And S6, recording the repairing whole process parameters including drilling reaction force, blow-drying time, air pressure/flow and grouting pressure-flow by the control unit (6).
9. The integrated control method for concrete void repairing of a steel-concrete composite structure according to claim 8, wherein in step S4, after the blow-dry time reaches a preset minimum value, the temperature and humidity sensor or the micropressure sensor detects the humidity or the pressure drop of the exhaust gas in real time, if the change of the temperature and humidity sensor or the micropressure sensor is detected to be smaller than a threshold value in the preset time, the void area is judged to be basically dried, the control unit (6) controls the blow-dry air module to stop running in advance, and if the change of the humidity or the pressure drop of the exhaust gas is detected to be larger than or equal to the threshold value in the preset time, or a signal that the humidity/the pressure drop tends to be stable is not detected, blow-drying is continued until the preset maximum time is reached.
10. The integrated control method for concrete void repairing of the steel-concrete composite structure according to claim 9 is characterized in that in the step S5, automatic stop of grouting is achieved based on pressure-flow collaborative monitoring and preset criteria, the pressure sensor collects grouting pressure values in real time, the flow sensor collects grouting flow in real time, the control unit compares measured pressure with target grouting pressure and monitors pressure change trend and flow attenuation, and when the grouting pressure values reach or approach 0.9-1.1 times of the target grouting pressure, and the flow is stably lower than a threshold value in a preset time window and the pressure change tends to be stable, the control unit judges that a void area is basically full and gives out an instruction to stop grouting pump operation.

Description

Steel-concrete combined structure concrete void repair integrated control system and method Technical Field The invention belongs to the technical field of bridge engineering repair, and particularly relates to a concrete void repair integrated control system and method of a steel-concrete combined structure. Background In a large-span bridge steel-concrete combined structure system, a steel-concrete combined section is a core key part for realizing cooperative stress of steel and concrete and transmitting interface shearing force, and effective transmission of shearing-resistant connecting pieces such as studs and the like is generally adopted to ensure the force, and the structural integrity of the steel-concrete combined structure system directly determines the overall bearing capacity, service stability and service life of a bridge. However, due to the fluctuation of the concrete pouring process, uneven vibration operation quality, shrinkage and creep characteristics of the concrete material, coupling effect of environmental load and structural stress in the long-term service process and other multiple factors, the root parts and peripheral areas of the bolts at the joint sections are extremely easy to generate concrete void defects. The void defects can directly lead to the shortening of the effective working length of the shear connector and the remarkable attenuation of the constraint rigidity, when the structure bears the shear-bending coupling load, the void area becomes a stress concentration source, the fatigue damage process of the connector is accelerated, and the structural bearing performance degradation and even the bridge operation safety are endangered when the fatigue damage process is serious, so that the void defects are particularly important to timely and effective repair. The repairing method for the concrete void defect of the steel-concrete combined section in the prior engineering field mainly comprises the following steps of firstly, drilling holes on the outer surface of a steel plate by manual work, then injecting slurry into a void area by using a simple pressure slurry pump, secondly, carrying out drilling operation by using a handheld magnetic drill and a simple bracket, wherein key parameters such as the depth and the position of the drilling holes are completely dependent on experience of operators, thirdly, drying or draining treatment of the void area lacks of standard process specifications, is mainly based on extensive operation of experience, does not have definitely and quantifiable time parameters and process control indexes, fourthly, key information such as void geometric forms, component space inclination angles, dynamic changes of grouting pressure and the like are not fully fused in the grouting process, and the grouting operation is usually terminated only according to an empirical pressure value or a simple criterion of 'slurry-see shutdown'. The repairing technology has the technical defects that firstly, repairing equipment is in scattered configuration, positioning accuracy is low, three core processes of drilling, blow-drying and grouting are required to be completed by adopting independent tools, repeated clamping times are high, positioning errors are accumulated and overlapped, collinear accurate control of multiple processes at the same emptying position cannot be achieved, repairing accuracy and construction efficiency are seriously affected, secondly, drilling termination criteria are too rough, whether a steel plate is drilled through is judged according to subjective perception of cutting resistance of a drill bit (such as 'light' of a sensing drill bit) or past experience of operators, drilling of a lower concrete matrix is easily continued after the steel plate is penetrated, even the condition of damaging internal stressed steel bars is caused, secondary structural damage is caused, and secondly, blow-drying time is set and the actual state of emptying is seriously disjointed, the blow-drying time is mostly a fixed experience value, the size of the uncoupling volume, the inclination angle of a component and the internal water content state are not combined, the adhesive quality of a follow-up grouting slurry and a concrete interface is influenced, the construction efficiency is reduced, finally, the situation that the quality of the repairing effect of the hollow region is difficult to be completely and accurately judged by the fact that the internal stability of the uncorrupted grouting machine is completely, and the situation of the repairing effect is difficult to be completely and completely-read by the pressure meter is completely and completely-read. Therefore, research and development of integrated, precise and intelligent steel-concrete combined section concrete void repairing equipment and a matched control method solve the technical pain points of equipment dispersion, large positioning error, rough process control, unreliable repairi