PDF(7010 KB)
Intelligent Sensing and Efficient Control Equipment for Cement Grouting Parameters
ZHAN Cheng-yuan, LIANG Lei, XU De-you
Journal of Changjiang River Scientific Research Institute ›› 2025, Vol. 42 ›› Issue (8) : 162-169.
PDF(7010 KB)
PDF(7010 KB)
Intelligent Sensing and Efficient Control Equipment for Cement Grouting Parameters
[Objective] In water conservancy and hydropower engineering, grouting is a key construction process to ensure the stability and leakage safety of hydraulic retaining structures. However, traditional grouting monitoring equipment exhibits deficiencies in accuracy, level of intelligence, and construction efficiency. This study aims to achieve fully automated operation and early warning feedback control of the grouting process by innovatively designing a new generation of intelligent sensing and efficient control equipment for grouting parameters, thereby improving engineering management efficiency, construction quality, and safety. [Methods] This study designed an intelligent centralized slurry station, an intelligent pressure regulation and flushing device, an intelligent grouting control coordination center, and a digital grouting recording unit, and integrated them into a new generation of intelligent sensing and efficient control equipment for grouting parameters. Additionally, a multi-channel, user-friendly human-computer interaction interface based on multi-touch control was developed to realize the fully automated operation and unified coordination management of the grouting process, including slurry preparation, slurry delivery, pressure regulation, and grouting. [Results] Through experiments and practical engineering applications, this equipment was verified to achieve fully automated operation of the grouting process, significantly improving the accuracy and intelligence of grouting construction. By implementing early warning feedback control and unified coordination management functions during the grouting process, construction safety was effectively ensured, and project management efficiency was enhanced. Compared to traditional grouting monitoring equipment, construction efficiency was increased by more than 30%, and construction quality was significantly improved. [Conclusions] The new generation of intelligent sensing and efficient control equipment for grouting parameters shows remarkable effectiveness in the grouting construction of water conservancy and hydropower projects, achieving automated, intelligent, and efficient grouting process, providing strong support for high-quality project construction and showing broad application prospects.
digital grouting / intelligent sensing / efficient control and management / early-warning and feedback / quality management
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Since cement grouting project is a hidden work, it is difficult to check and control the grouting quality directly. Automatic monitoring of the grouting parameters is thus very crucial. In this paper we made a review on the technological progresses and the process of developing automatic grouting recorder, and expounded the development of digital grouting monitoring system. Also we looked into the future of intelligent grouting recorder, intelligent monitoring cloud platform, anti-counterfeiting of online monitoring data, as well as BIM+GIS-based monitoring system integrating latest achievements of modern electronic technology, Internet of Things technology, big data technology, and blockchain technology. The intelligent monitoring systems are beneficial for the safety and quality of hydropower projects, and will reduce cost and promote the management of project construction.
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河北丰宁抽水蓄能电站(一期)在灌浆施工中存在大量的趾板帷幕灌浆。趾板帷幕灌浆在超压的情况下容易发生趾板变形破坏,常常需要对趾板抬动变形进行24 h不间断监测。但目前用于抬动监测的设备充电时间长达8 h,每次充电后设备只能连续工作3~4 d,难以满足连续监测的需求。结合抬动监测的特点,对该设备的充电和工作模式通过微型控制系统进行了管理,缩短了抬动监测装置充电时间并降低了装置的平均工作电流。对设备进行相关技术应用后,充电时间缩减到1.8 h,设备的连续运行时间提高到134 h,提高了设备的监测效率,满足了对趾板抬动变形进行24 h不间断监测的需求。
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Largely applied for the toe plate of Fengning pumped storage power station, curtain grouting easily brings about deformation to the toe plate under excessive pressure. Such uplift deformation of the toe plate requires consecutive monitoring for 24 hours a day. Nevertheless, current devices for uplift monitoring costs 8 hours to be fully charged, while only works uninterruptedly for 3-4 hours. In view of this, the working mode of the device was adjusted through micro-control according to the variation of monitoring value, and fast charging was designed by adjusting the charging current using PWM. The charging time was reduced to 1.8 hours, whereas the consecutive working time of the device elongated to be 134 hours, and meanwhile the average working current was reduced, remarkably enhancing the monitoring efficiency.
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In the aim of improving project management efficiency, controlling project quality, and reducing the impact of human factors on project quality, the construction information, concrete temperature, concrete vibrating, and grouting in the construction process are intelligently monitored and controlled via information technology, digitalization, automatic control and other technologies. In view of this, an intelligent management system for construction quality under the intelligent construction environment for Yangfanggou Hydropower Station is developed based on the quality management modules of the BIM management system as well as the intelligent temperature control, intelligent vibrating, intelligent grouting, and whole-process image acquisition system integrated by the BIM management system. The construction quality information is managed dynamically through real-time collection, real-time analysis, and decision feedback. The problems in construction quality control, information collection, analysis, and decision-making in the EPC and traditional construction mode have been solved. The present intelligent system has improved management efficiency and management quality, and achieved better management results.
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An intellectual device for warning and information decision-making based on ARM platform is designed for grouting construction. The device adopts ucos-2 embedded operating system for task scheduling, SD card for alarm standards and recommended decision storage, and file management system for alarm history record. The device integrates functions of data acquisition, data transmission, file storage, intelligent decision-making, audible and visual alarm. With ZigBee network as a basis, the device could timely obtain data and information of the construction site, and provides scientific guidance for on-site alarm processing. By employing this device, the processing of anomaly in grouting construction is accelerated, and the construction efficiency and management is enhanced.
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In grouting pressure control, traditional alarming based on pressure threshold is sometimes erroneous and delayed. In view of this, a network monitoring alarming system for grouting pressure is developed based on the theory of Statistical Process Control (SPC). Fengning pumped storage power plant (stage I) in Hebei Province with a large amount of toe plate curtain grouting is taken as a case study. The system identifies the position of sampling points and the pressure change trend by monitoring the grouting pressure value through sampling and generates pressure control diagrams based on SPC. Moreover, different pressure judgment criteria for different stages of grouting are set. Hence, the monitoring, alarming, and prediction of grouting pressure can be accomplished. Compared with traditional pressure threshold alarming, the present system reduced the time-consumption of alarming by 25% while promotes the alarming efficiency by 8%. By integrating SPC and threshold algorithm, we could identify abnormal information in advance, favorable for grouting management and control.
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