预制混凝土梁智能喷淋养护系统设计及应用

Design and Application of Intelligent Spray Curing System for Precast Concrete Girders

针对预制混凝土梁传统养护方式的不足,研发了一种智能喷淋养护系统,主要由供水系统、智能控制系统、水资源再利用系统、物联网远程控制云平台、喷淋组件等组成。该系统根据混凝土水化热释放规律、极低功耗无线传感器网络采集的环境温湿度、风速及梁体表面温度,计算预制梁养护面湿度、梁体表面与环境温差及喷淋间隔时间,采用反馈控制策略,实现预制梁智能喷淋养护;基于四级沉淀回收技术,收集未被吸附的养护水和雨水,通过水资源再利用系统处理并循环利用;应用5G远程控制云平台,开发基于MQTT协议的智能喷淋云管理平台,实现远程管控。该系统已应用于多个制梁场,郑济铁路原阳制梁场应用结果表明:智能喷淋养护方式下预制梁表面湿度都不低于95%,且梁体表面与环境温差不超过20℃,混凝土标准试块10 d即能达到设计强度,优于传统人工养护方式,满足预制梁智能喷淋养护需求。

An intelligent spray curing system that overcomes the drawbacks of traditional curing methods is presented,which consists of multiple constituent subsystems,including the water supply system,intelligent control system,water resource recycling system,IoT remote control cloud platform and spraying units.The system is able to calculate the humidity of the curing surfaces of the precast girders,difference between girder core temperature and ambient temperature,and the spraying time intervals,in accordance with the concrete hydration heat release behavior,the ambient temperature and humidity,wind velocities and girder core temperatures collected by the wireless sensor network,and to achieve the spray curing of the precast girders following a feedback control strategy.The curing water and rainwater that is not absorbed can be treated and recycled in the water resource recycling system through a four-stage precipitation recovery process.Based on the 5G remote control cloud platform,an intelligent spray curing management platform is developed under the MQTT protocol.The system has been applied to numerous girder fabrication yards.The data in the Yuanyang girder fabrication yard for the Zhengzhou-Jinan Railway show that the surface humidity of precast girders is no less than 95%,the difference between girder core temperature and ambient temperature does not exceed 15℃,the standard concrete blocks at day 10 can reach design strength,indicating that the intelligent spray curing system performs better than the traditional methods and meets the intelligent curing requirements of the girder fabrication yard.