A concrete mixer system includes a control system configured to provide a first input to a drum drive system to rotate a drum of a concrete mixer at a target speed while the drum is empty and clean, acquire operating data regarding an operating characteristic of the drum drive system to determine a baseline operating characteristic of the drum drive system in response to the first input, provide a second input to the drum drive system to rotate the drum at the target speed following one or more uses of the concrete mixer and while the drum is empty, acquire the operating data to determine a current operating characteristic of the drum drive system in response to the second input, and provide a buildup notification indicating that there is a buildup of drum contents within the drum in response to a difference between the baseline operating characteristic and the current operating characteristic exceeding a threshold differential.

An inference system for monitoring a cementitious mixture for three-dimensional printing is provided. The inference system includes an ambient condition sensor, a temperature sensor, a moisture sensor and an image capturing device. The inference system also includes a controller coupled to the ambient condition sensor, the temperature sensor, the moisture sensor, and the image capturing device. The controller receives sensed ambient conditions, a temperature signal, and a moisture content signal. The controller receives an image feed of a portion of a cementitious mixture. The controller also receives signals indicative of a motor speed and a motor torque associated with a mixing container. The controller builds a model and determines a material suitability of the cementitious mixture using the model based on the received ambient conditions, the temperature signal, the moisture content signal, the image feed, the motor speed, and the motor torque and determines one or more corrective actions.

There are described methods and systems for handling fresh concrete inside a drum . In an aspect, a method of determining calibration data for use in determining workability of fresh concrete inside a rotating drum based on hydraulic pressure is described. This method has receiving a probe pressure value indicative of pressure exerted on a rheological probe mounted inside the drum and immerged in the fresh concrete; determining a workability value indicative of workability of the fresh concrete based on the probe pressure value and on calibration data for the rheological probe; receiving a hydraulic pressure value indicative of pressure of a hydraulic fluid used for rotating the drum; and determining hydraulic calibration data by associating the hydraulic pressure value and the workability value to one another.

A vehicle includes an engine, a drum, a drum drive system, and a control system. The drum drive system includes a pump configured to pump a fluid through a hydraulic system and a motor positioned to rotate the drum to agitate drum contents. The control system is configured to perform a calibration test to determine a baseline operating pressure of the fluid in the hydraulic system, perform a buildup detection test to determine a current operating pressure of the fluid in the hydraulic system, and determine that there is a buildup of the drum contents within the drum in response to a difference between the baseline operating pressure and the current operating pressure exceeding a threshold differential. In some embodiments, the calibration test and the buildup detection test are only performed if a temperature of the fluid exceeds a threshold temperature.

Disclosed is a method for determining volume of a concrete mix load in a mixer drum based on use of an in-and-out sensor probe which submerges into and exits from the concrete during drum rotation and which provides data to a processor used for calculating volume based on the data. To provide for concavity, convexity, and/or cascading surface flow effects that can hinder accurate determination of the concrete load volume, the processor may be configured to compare original batch volume and/or rheology of the concrete load monitored during drum rotation. The calibration of load volume value, highly useful for monitoring or admixture dosing purposes, can be done based on comparison of real-time data with historic data gathered over time and stored in processor-accessible memory. Further exemplary embodiments also take into account the speed and/or tilt of the drum (due to roadway conditions), concrete mix design, and other factors.

There is described a method for determining cleanliness of a drum of a fresh concrete mixer truck. The method generally has: rotating the drum about the rotation axis with a constant torque; using a rotational speed sensor, measuring a plurality of speed values corresponding to speeds at which the drum rotates at different moments in time during said rotating; and using a controller, receiving the plurality of speed values; accessing calibration data having different reference speed values-related data associated to corresponding reference degrees of cleanliness of the drum; comparing at least some of the speed values to the calibration data; and determining a degree of cleanliness of the drum based on said comparison.

Disclosed are exemplary process and system for managing a mix design catalog of a concrete producer that involves collecting slump curve data obtained during in-transit monitoring of delivered concrete loads made from a plurality of various mix designs, wherein each mix design is identified by a different identification code (regardless of whether components are different), clustering slump curve data having same movement characteristics according to assigned strength value, and selecting a mix design to produce, to display, or both to produce and to display, from among the two or more slump data curves of individual mix designs within the same data curve cluster. The selection is based on same movement characteristic and assigned strength value, and at least one factor relative to cost, performance, physical aspect, quality, or other characteristic of the concrete mix or its components. Exemplary methods for generating new mix designs are also disclosed.

An inference system for monitoring a cementitious mixture for three-dimensional printing is provided. The inference system includes an ambient condition sensor, a temperature sensor, a moisture sensor and an image capturing device. The inference system also includes a controller coupled to the ambient condition sensor, the temperature sensor, the moisture sensor, and the image capturing device. The controller receives sensed ambient conditions, a temperature signal, and a moisture content signal. The controller receives an image feed of a portion of a cementitious mixture. The controller also receives signals indicative of a motor speed and a motor torque associated with a mixing container. The controller builds a model and determines a material suitability of the cementitious mixture using the model based on the received ambient conditions, the temperature signal, the moisture content signal, the image feed, the motor speed, and the motor torque and determines one or more corrective actions.

A printhead for an additive manufacturing system includes a hopper, an outlet, a mixing shaft, and a drive shaft. The hopper includes an inner volume configured to store a slurry material for mixing. The outlet includes a passageway fluidly coupled with the hopper. The outlet includes an open end for discharging the slurry material to a surface through the passageway. The mixing shaft extends through the inner volume of the hopper and includes a member that extends radially outwards from the mixing shaft. The member is configured to mix the slurry material within the hopper as the mixing shaft rotates. The drive shaft extends through the inner volume of the hopper and at least partially into the passageway of the outlet. The drive shaft includes a sloped surface configured to drive the slurry material from the hopper to the surface through the passageway of the outlet.

A method of preparing a concrete composition for downhole injection includes utilizing a controller to control a process including circulating process water in a process water supply loop for a predetermined period while monitoring and controlling the temperature and flow rate of the process water, circulating aqueous-based air entrainment solution in an aqueous-based air entrainment solution supply loop for the predetermined period and controlling the flow rate of the aqueous-based air entrainment solution and after the predetermined period of time in which the flow of process water and aqueous-based air entrainment solution have stabilized, simultaneously actuating valves to divert and mix the process water, the aqueous-based air entrainment solution and compressed air to produce an air-entrained foam and mixing the foam with a concrete composition to be deployed downhole.