COMPUTER-ASSISTED METHOD AND DEVICE FOR CONTROLLING A CONCRETE MIXING FACILITY

Abstract

The invention relates to a computer-aided method and a device for controlling a concrete mixing plant for the production of ready-mixed concrete (1) or mixed concrete, which is mixed at least from the components cement (6a; 6b) and aggregates (8a, 8b, 8c) with the addition of water (9) in a motor-driven mixer unit (3), wherein at least the required mixing time (t.sub.M) of the mixer unit (3) is calculated before the start of the mixing process by means of an electronic prognosis unit (10), which calculates the current moisture (F), measured by means of at least one moisture sensor (11), of at least the aggregates (8a, 8b, 8c) to be added and the temperature measured by means of at least one temperature sensor (12;13;14) or thermal imaging camera, in order to determine the required mixing time (t.sub.M) of the mixer unit (3) on the basis of a predetermined concrete formulation (18), taking into account the various measured values determined by the sensors.

Claims

1. Computer-aided method for controlling a concrete mixing plant for the production of ready-mixed concrete (1) or mixed concrete, which is mixed at least from the components cement (6a; 6b) and aggregates (8a, 8b, 8c) with the addition of water (9) in a motor-driven mixer unit (3), characterized in that at least the required mixing time (t.sub.M) of the mixer unit (3) is calculated before the start of the mixing process by means of an electronic prognosis unit (10), which considers the current moisture (F) of at least the aggregates (8a, 8b, 8c) to be added, measured via at least one moisture sensor (11), and the component temperature (T.sub.K), the mixer unit temperature (T.sub.M) and/or the outside temperature (T.sub.A) measured or determined via at least one temperature sensor (12;13;14) or thermal imaging camera, in order to determine the required mixing time (t.sub.M) of the mixer unit (3) on the basis of a predetermined concrete formulation (18), taking into account the various measured values determined by the sensors.

2. Method according to claim 1, characterized in that the prognosis of the required mixing time (t.sub.M) is carried out with further consideration of correction characteristic curves (19) for parameters relevant to the formulation.

3. Method according to claim 1, characterized in that the required mixing time (t.sub.M) is transmitted from the prognosis unit (10) to the control unit (21) of the mixer unit (3) for activation.

4. Method according to claim 1, characterized in that the control unit (21) varies the rotational speed of a drum-shaped mixer unit (3) to subsequently extend or shorten the predicted required mixing time (t.sub.M).

5. Method according to claim 1, characterized in that a transport time (t.sub.T) from the stationary concrete mixing plant to a construction site predicted on the basis of a route planning unit (22) and/or an estimated transport temperature profile of the ready-mixed concrete (1) and/or an estimated waiting time until the ready-mixed concrete (1) is placed on the construction site is also taken into account in the calculation by the electronic prognosis unit (10).

6. Method according to claim 1, characterized in that the control unit (21) controls the addition of water (9) according to the concrete recipe (18) and taking into account the measured moisture of at least the aggregates (8a, 8b, 8c) or other components to be added.

7. Method according to claim 1, characterized in that the concrete quality that can be realized under the given circumstances is determined by the prognosis unit (10) for the concrete formulation (18) to be implemented on the basis of the measured values determined by the sensor system.

8. Method according to claim 1, characterized in that a comparison unit (23) compares the predicted realizable concrete quality with the specification required for the construction site before the mixing process is started.

9. Method according to claim 1, characterized in that at least the information generated by the sensor system, the prognosis unit (10), the control unit (21) and the adjustment unit (22) concerning a mixing and delivery process of ready-mixed concrete (1) is stored in a documentation database (24) so that it can be retrieved.

10. Data processing device for controlling a concrete mixing plant for producing ready-mixed concrete (1) or mixed concrete, which a motor-driven mixer unit (3) produces from at least the components cement (6a; 6b) and aggregates (8a, 8b, 8c) with the addition of water (9), the components being stored in respective silos (5a, 5b) connected to the material flow of the mixer unit(3) and/or on at least one stockpile surface (7), characterized in that an electronic prognosis unit (10) for calculating the required mixing time (t.sub.M) of the mixer unit (3) is provided, which takes into account the current moisture (F) of at least the aggregates (8a; 8b; 8c) to be added, measured via at least one moisture sensor (11), and the component temperature (T.sub.K), the mixer unit temperature (T.sub.M) and/or the outside temperature (T.sub.A) measured or determined via at least one temperature sensor (12; 13; 14) or thermal imaging camera, in order to determine the required mixing time (t.sub.M) of the mixer unit (3) on the basis of a concrete formulation (18), taking into account the measured values determined by the sensor system.

11. Device according to claim 10, characterized in that different concrete recipes (18) are stored in a recipe database (17) connected to the prognosis unit (10).

12. Device according to claim 10, characterized in that the correction characteristics (19) for recipe-relevant parameters are stored in a correction line database (20) connected to the prognosis unit.

13. Device according to claim 10, characterized in that the correction characteristics (19) for recipe-relevant parameters are selected from a characteristic curve group comprising: temperature mixing time correction characteristic, speed mixing time correction characteristic.

14. Device according to claim 10, characterized in that the components to be mixed also comprise concrete admixtures and/or concrete additives whose properties are taken into account by the prognosis unit (10) in accordance with the formulation.

15. Device according to claim 10, characterized in that the information on a mixing and delivery process, comprising the concrete formulation (18) used, measured temperature values during the mixing and/or transport process, measured moisture values of at least one component of the concrete formulation (18) used, quantities of the components of the concrete formulation (18) used, the predicted mixing time (t.sub.M) and correction values thereto and/or the subsequent transport and waiting time are stored in the form of a documentation data record (25) and can be retrieved in a documentation database (24).

16. Concrete mixing plant for the production of ready-mix concrete (1), comprising an electronic device according to any one of claims 10 to 15.

17. Data format of a documentation data record (25) for a concrete mixing plant for the production of ready-mixed concrete (1) or mixed concrete, at least comprising the following data fields (I-VI) associated with an order identifier (26): used concrete formulation (18), temperature readings (T) during the mixing and/or transport process, moisture readings (F) of at least one component used in the concrete mix design (18), actual quantities (M) of all components used for to the concrete mix design (18), predicted mixing duration (t.sub.M) of the mixer unit (3), and transport time to with waiting time (t) on construction site.

18. Computer program comprising instructions which, when the program is executed by a computerized device according to any one of claims 10 to 15, cause the computerized device to execute the method according to any one of claims 1 to 9.

Description

DETAIL DESCRIPTION BASED ON THE DRAWING

[0032] Further measures improving the invention are shown in more detail below together with a description of a preferred embodiment of the invention with reference to the figures. It shows:

[0033] FIG. 1 a schematic representation of a concrete mixing plant with computer-aided control equipment implemented therein,

[0034] FIG. 2 a schematic flow chart of a method for controlling the concrete mixing plant according to FIG. 1, and

[0035] FIG. 3 a data format of an order record for the concrete mixing plant.

[0036] According to FIG. 1, a concrete mixing plant for the production of ready-mixed concrete 1, which is transported from there by truck mixer 2 to a construction site—not further shown here—for shoring, essentially consists of a mixer unit 3, which is designed here as a drum mixer, which can be set in rotary motion for mixing by means of an electric drive motor 4.

[0037] For the supply of components to be mixed, the mixer unit 3 is in connection with cement silos 5a to 5c, which contain different types of cement 6a; 6b; 6c, which are injected into the mixer unit 3 in a valve-controlled manner via a compressed air conveying device. In addition, the mixer unit 3 is in material flow connection with a stockpile area 7, on which bulk material stockpiles with different aggregates 8a to 8c, i.e. different gravels and sands, are stored. These are transported to the mixer unit 3 by conveyor belt equipment. In addition, the mixer unit 3 can be connected to a connection for water 9.

[0038] For the calculation of a required mixing time t.sub.M for the operation of the mixer unit 3, an electronic prognosis unit 10 is provided within the control system of the concrete mixing plant. On the input side, the electronic prognosis unit 10 in this embodiment example is connected to a moisture sensor 11 for measuring the current moisture F of the aggregate 8a; 8b; 8c to be fed. In addition, the component temperature T.sub.K of the aggregate 8a; 8b; 8c to be fed is measured via temperature sensor 12. In addition, the process temperature inside the mixer unit3 is also monitored via a further temperature sensor 13, as is the outside temperature TA via a temperature sensor 14. At this point, it should be pointed out once again that, within the scope of the solution according to the invention, only a partial selection of these sensors or additional sensors can also be provided, which report measured values relevant to the mixing duration to the electronic prognosis unit 10.

[0039] Based on a ready-mix concrete order 16 stored and to be processed within an order database 15, the electronic forecasting unit 10 determines the associated concrete recipe 18, for example for a special lightweight concrete, which can be retrieved from a recipe database 17.

[0040] In addition, the various measured values determined by the sensor system described above are fed to the prognosis unit 10. Based on this, the prognosis unit 10 determines at least the required mixing duration t.sub.M of the mixer unit 3 at a specific nominal speed. In addition, other control data can also be predicted.

[0041] When determining the control data, the prognosis unit 10 also takes into account correction characteristics 19, which are stored in a correction line database 20 so that they can be called up. For example, a temperature-mixing time correction curve can be used to extend the mixing time t.sub.M with increased water addition, for example, if unusually dry and heated components are used. The same applies in the opposite case.

[0042] The required mixing duration t.sub.M predicted by the prognosis unit 10 is then transmitted to the control unit 21 of the mixer unit 3 for controlling the motor 4 at a defined nominal speed. In addition, it is also possible for the control unit 21 to lower or increase the speed of the electric motor 4 in order to vary the predicted required mixing duration t.sub.M. If, for example, a truck mixer 2 is not yet available to accept the ready-mixed concrete 1, the rotational speed of the mixer unit3 can be lowered during the waiting time.

[0043] In addition, in this embodiment, the electronic forecasting unit 10 also takes into account a transport time t.sub.T from the stationary concrete mixing plant to the construction site, which is forecast on the basis of a route planning unit 22 and results from the route planning data. This can also be used to vary the required mixing time t.sub.M accordingly. In addition, concrete admixtures that extend the potting time can be added as part of the concrete mix design 18 if it turns out that the delivery of the ready-mixed concrete 1 to the construction site would take longer due to traffic. This ensures that the concrete quality used is as uniform as possible.

[0044] A matching unit 23, also connected to the prognosis unit 10, compares the prognosticated realizable concrete quality with the specification required for the construction site, which results from the ready-mix concrete order 16. If this specification is not achievable, there is a possibility that a start of the filling and mixing process is prevented, since it is foreseeable that the required concrete quality is not achievable in view of an extreme heating of components in the summer time or a delayed transport time due to dust. This information generated by the adjustment unit 23 can also be transmitted to the construction site, for example, for the purpose of changing the construction schedule.

[0045] Furthermore, it is provided that the information generated by the sensor system, the prognosis unit 10, the control unit 21 as well as the adjustment unit 23 regarding a mixing and delivery process of ready-mixed concrete 1 is stored in a documentation database 24 in a retrievable manner, which ensures later verifiability.

[0046] According to FIG. 2, the method for controlling a concrete mixing plant for the production of ready-mix concrete 1 comprises at least the following steps:

[0047] In step A, the concrete recipe to be produced is first loaded for the execution of a ready-mix concrete order. In step B, various current measured status values of the required components are read in via the sensors of the concrete mixing plant. Based on these values, at least the required mixing time is predicted in a step C. The result of this prognosis is used as a basis for the concrete mix. In step D, this result is corrected by further logistic influencing parameters. In step E, the mixture is filled into a truck mixer for transport to the construction site.

[0048] According to FIG. 3, a data format of an order record 25 for a concrete batching plant for the production of ready-mixed concrete includes the following data fields associated with an order identifier 26, which are also archived in the documentation database 24:

[0049] The concrete formulation 18 used is stored in a data field I, the measured temperature values T during mixing and/or transport are stored in a data field II, the measured moisture values F of at least one component used in the concrete formulation are stored in a data field III, the actual quantities M of all components used according to the concrete formulation are stored in a data field IV, the predicted mixing time t.sub.M of the mixer unit is stored in a data field V, and the total transport and waiting time t of the ready-mixed concrete to or at the construction site is stored in a data field VI.

[0050] This concentrated data set documents essential quality information about an ordered and used ready-mix concrete, which is also accessible for later evaluation in terms of pattern recognition, damage analysis, formulation improvements and the like.

[0051] The invention is not limited to the preferred embodiment described above. On the contrary, variations thereof are also conceivable, which are included in the scope of protection of the following claims. For example, it is also conceivable, in addition to or instead of the concrete quality-determining control parameter of the required mixing time t.sub.M , to predict other or further variables, such as the actually required quantities of the individual components of the concrete. In the event of cold weather conditions at the construction site, the concrete mix can also be specifically preheated, for example. Thanks to the solution according to the invention, the quality of a concrete delivery can also be made an enforceable contractual condition of a so-called smart contract and secured along the production and utilization chain using blockchain technology.

LIST OF REFERENCE SIGNS

[0052] 1 Transport concrete [0053] 2 Driving mixer [0054] 3 Mixing unit [0055] 4 Electric motor [0056] 5 Silo [0057] 6 Cement [0058] 7 Dump area [0059] 8 Grain aggregate [0060] 9 Water [0061] 10 Forecast unit [0062] 11 Humidity sensor [0063] 12 First temperature sensor [0064] 13 Second temperature sensor0 [0065] 14 Third temperature sensor [0066] 15 Ordering database [0067] 16 Transport concrete order [0068] 17 Recipe database [0069] 18 Concrete recipe [0070] 19 Correction characteristic [0071] 20 Correction characteristics database [0072] 21 Control unit [0073] 22 Route planning unit [0074] 23 Adjustment unit [0075] 24 Documentation database [0076] 25 Documentation record [0077] 26 Order identifier