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    • 专利摘要:
    PROCESS FOR ADJUSTING CONCRETE REOLOGY BASED ON THE RESPONSE PROFILE - NOMINAL DOSE. The invention relates to a process for adjusting concrete rheology requiring only that the load size and target rheology value are initially selected before requiring inputs and queries from a parameter search table such as water and hydration levels, mixing components, temperature, humidity, aggregate components, and others. Dosage of a particular rheology modifying agent or combination of rheology modifying agents is calculated based on a percentage of a nominal dose calculated with reference to a nominal dose response curve ("NDR"). The NDR profile is based in a correlation between a rheology value (for example, consistency, consistency flow, limit stress) and the dose of rheology modifying agent (s) required to change the rheology value by one unit (for example, change in consistency of 5.08 to 7.62 centimeters) so that exemplary processes can employ corrective dosage based on the NDR and the deviation measured by the system.
    公开号:BR112012033266B1
    申请号:R112012033266-0
    申请日:2011-05-10
    公开日:2020-12-22
    发明作者:Eric Koehler；Mark F. Roberts；Roy J. Cooley；Steve Verdino
    申请人:Verifi Llc；
    IPC主号:
    专利说明:

    [001] This patent application claims priority U.S. patent application series No. 12/821 451 filed on June 23, 2010, the disclosure of which is incorporated herein by reference. Field of the Invention
    [002] The present invention relates to the manufacture of concrete, and more particularly to a process for adjusting a rheological property of concrete in a mix truck - ready mixer or stationary mixer through increasing doses of a mixing agent. rheology modification calculated with reference to a nominal dose response profile. Background of the Invention
    [003] It is known to control the "consistency" or flow properties of concrete in mix delivery trucks - ready using sensors to monitor the energy required for mixing drum rotation, such as through torque monitoring applied to the drum by measuring hydraulic pressure (see, for example, US patent 4 008 093, 5,713,663).
    [004] A hydraulic sensor coupled to the hydraulic drive and / or a speed sensor, for example, can be used to monitor the mixing drum rotation. The monitoring of concrete consistency involves calibrating outputs or values obtained from the hydraulic sensor and / or electrical sensor in a mixing truck containing a mixture of concrete and correlating these with consistency values obtained using a test consistency cone pattern. In the consistency cone pattern, a 30.48 centimeter truncated cone containing fresh concrete is removed to allow the concrete to fall, and the vertical height drop of the concrete is measured (for example, ASTM C143-05) . Concrete having this known consistency value is added is added to the mixing drum so that a hydraulic or electrical value, which is obtained as an output from the sensor, can be stored in a memory location and subsequently correlated by computer processing unit. (CPU).
    [005] During the delivery of the concrete to a customer, the concrete stiffens over time as a result of hydration, evaporation, and other factors, and the sensors detect this as the increased hydraulic or electrical energy required to turn the mixing drum. The onboard CPU compares the detected energy value obtained from the sensor or sensors and compares this to values stored in memory. If the sensors and CPU detect that the concrete is starting to stiffen, the theory is that the CPU can be fired to activate delivery or pumping devices for injecting water or other liquid (eg chemical dispersant) into the concrete to restore consistency to the desired value.
    [006] It has long been desired to obtain the ability to add water or chemical mixture to concrete in an efficient manner, or, in other words, to add the precise amount of mixture needed to obtain the target rheology value while avoiding dosing errors and lengthy trial and error. The assumption has been that due to highly sophisticated sensors and CPU being used, an accurate and efficient methodology can inevitably result. However, prior art cement mixing systems, for all their sophisticated physical components in evolution, remain subject to variation in the mixture they control.
    [007] US 5,713,663 to Zandberg et al. stated that consistency readings can be monitored on mixer-ready trucks by inputting information to an in-line CPU and that such information may include the amount of batch water, the amount of particulate material ingredients, moisture content of sand, time, “named” consistency, and other factors (see col. 8, lines 3-14). It was not specifically explained by Zandberg et al., However, which of these factors were to be included or how they should be weighed. The patent established that such information can be stored in memory so that the CPU can calculate from the information entered the required liquid component needed to obtain a desired consistency. It was alternatively explained that the required liquid component can be “pre-calculated” and loaded into the CPU with the other information (Col. 8, lines 15-22). The patent also mentioned that the memory may have information stored “in a search table” related to “a range of possible mixtures” and thus “for particular types of mix and particular values of consistency and particular amounts of mix ingredients. Now, the system will be able to compare values measured by the sensors against known values for the mixture to provide both manual and automatic adjustment of the liquid component that is added ”(Col. 8, lines 29-36).
    [008] In spite of reiterating that the objective was to allow “maximization of mix without an over-supply of liquid component” that otherwise required the concrete mix to be returned before it was delivered, Zandberg et al., it does not specify what factors were to be included in the "search" table. Nor did they show the precise methodology for calculating the dose of the liquid component to be administered.
    [009] Similarly, US patents 6,042,258 and 6,042,259 to Hines et al. (MBT Holding / BASF) showed a mixing dispensing system for stabilizing concrete both overnight, same day (as delivery), or for long transport operations. In each of these modes, mixing doses were to be calculated based on "internal graphics" located within accessible computer memory (see, for example, 6 042 258 in Col. 9, lines 4-30; in Col. 9, lines 42-52; in Col. 10, lines 7-20; and also Fig. 2A in 128, 138, and 148). However, the number of “variables” or conditions required for inclusion in such internal charts or tables appeared to be rather extensive. These variables included the amount of concrete in the mixer, its temperature, the type of cement in the concrete, the amount of time that the concrete is in transit in the delivery truck), the amount of water required, and other factors. It has been suggested that a batch man or driver can generate his own specific graphics or search tables depending on the data chosen for entry into the computer, and that the programming support provider can make adjustments allowing the driver or batch man “Compensate dosage values for factors not considered in data graphs or search tables” (See, for example, US 6 042 258 in col. 9-10; see also US 6 042 259 in col. 9-10) . In addition, it should be emphasized that the intention of adding the mixture was to control cement hydration, rather than consistency or other rheology value.
    [0010] In US patent publication 2009/0037026, Sostaric et al. (RS Solutions LLC) showed a system for adjusting concrete in ready-mixed delivery vehicles using water or chemical additives. This system included sensors for detecting various parameters: such as temperature, pressure, rotation (speed, energy), and inclination / acceleration for calculating consistency (See, for example, Fig. 4C; Para. 0071-0072). For example, the system may include other sensors for measuring load temperature as well as skin temperature of the mixing drum. The system can also include sensors for measuring “acceleration / deceleration / inclination”. The system can even include sensors for measuring vibration and environmental parameters, such as humidity and barometric pressure. (See paragraph 0132). In addition, the system can automatically add water or other mixtures based on the measured output of the sensors used by the system.
    [0011] Despite the increased technological sophistication for measuring an ever increasing number of parameters, as suggested by the increasing number of sensors being used to measure various aspects of cement during its delivery to a construction site, the present inventors do not believe that the present prior art provides clear guidance on which parameters have to be considered and included in search tables or which parameters are most important for calculating chemical mixture dosage quantities.
    [0012] Obtaining precise and efficient dosing of chemical mixtures in concrete is presumed to be difficult in large part due to the fact that the effect on the rheology of added chemical mixtures is altered to a greater extent than that of water on the rheology by the proportions (for example, water to cement ratio), characteristics (for example, cement fineness), and condition (for example, temperature) of the concrete ingredients and history of the load (age, temperature profile, etc.) . These factors are likely to change over the course of different batches of concrete over the course of a day, week, month, etc. For example, the concrete temperature may increase with each batch during the day as the ambient temperature increases. Different cement deliveries can vary in chemistry and fineness.
    [0013] Before just adjusting consistency, it is desired to adjust other rheological properties of the concrete. Rheology deals with the science of matter flow and deformation. Concrete rheology can be defined in terms of consistency, consistency flow, limit stress, plastic viscosity, apparent viscosity, thixotropy, or flow table test, among other factors. Therefore, it is an object of this invention to select the proper dose of chemical mixture to adjust one or more of such parameters of concrete rheology.
    [0014] In view of the above, the present inventors believe that a new process for adjusting the rheological properties of concrete in mixing drums and other mixing devices is necessary, a process that is more efficient and practical to use than those in current practice . Summary of the Invention
    [0015] In overcoming disadvantages and increasing technical complexity of prior art approaches to the problem of obtaining dosage accuracy and avoiding overdosing in concrete mixtures, the present invention provides a process where the dosage of a particular agent of rheology modification or combination of rheology modification agents is calculated using a nominal dose response profile (“NDR”), one that surprisingly does not require time-consuming compilations in a parameter search table and therefore the input numerous parameters at the beginning of each batch preparation or delivery.
    [0016] A dose response curve refers to the dose of a rheology modifying agent or combination of rheology modifying agents (such as water, a chemical mixture, or a combination thereof) for rheology, resistance, or some other characteristic of the concrete that is modified by the effect of the rheology modifying agent. The dose response curve can be represented in one of a number of ways, for clarity and convenience, and for ease of CPU programming. For example, a dose response curve for a chemical mixture that modifies consistency can be represented as the chemical mixture dose as a function of the dose administered to the concrete consistency. Alternatively, it can be represented as the change in dose of chemical mixture needed to change consistency by an incremental unit (for example, dose of mixture needed to change consistency by one inch).
    [0017] It is common to establish a dose-response curve for a given set of materials under a certain set of conditions, which can be used later to select the appropriate dose during concrete production. This curve will be referred to here as the nominal dose response curve (“NDR”). Because the dose response curve is a function of a large number of variables (material properties, temperature, etc.), the development of dose response curves can be impractically complex considering all relevant variables, programming a CPU with search tables or similar, measure all relevant variables, and select the correct dose of the rheology modifying agent (for example, chemical mixture) to obtain the desired response. It is an object of this invention to provide a means to efficiently and precisely update the nominal dose response curve to satisfy changing external variables, without the need to explicitly take these variables into account. For this reason, nominal dose response curves are generated and then adjusted using an adaptive control methodology.
    [0018] The present invention arises from the surprising finding that concrete mixtures having different parameters (for example, temperature, mixing design, water levels, hydration levels, humidity, different trucks) show “dose response” profiles which vary in amplitude, but otherwise behave similarly in that their dose response curves do not intercept. The concept of “dose response” as used herein should mean and refer to the effect of a particular rheology modifying agent or combination of rheology modifying agents on rheology (such as consistency, flow of consistency, or limit stress) as a function of the dose administered.
    [0019] This unexpected dose response behavior is illustrated in Figure 1, where it is shown that different concrete mixtures, in which a rheology modifying agent such as polycarboxylate cement dispersing mixture was mixed, show similar curves of dose response where consistency is shown as a function of the dose amount (ounces of mixture per cubic yard of concrete) required to change consistency by one unit (such as 2 to 3 inches of consistency, and 3 to 4 inches consistency, and so on). The calculation of a nominal dose response profile (“NDR”) is basically illustrated in Fig. 2, where at least two profile curves (labeled “maximum dose” and “minimum dose” for reference convenience) are considered for provision of an NDR profile.
    [0020] The significance of the behavior not intercepting the dose response curves (Fig. 1) led the present inventors to the practical realization that concrete rheology can be adjusted through the use of an NDR profile based on even a curve obtained from only one data set, although the use of at least two curves is preferred (eg, Fig. 2) and the use of a plurality of curves (eg, Fig. 1) is more preferred from the point of view of precision , the NDR profile can be adjusted by scaling just one parameter - for example, a ratio reflecting the actual mixing performance and that predicted by the nominal dose response curve. Thus, an adaptive control methodology is obtained to update the nominal dose response curve based on real mixing performance. Each mixing dose is selected through the use of a nominal dose response curve adjusted through the escalation factor from previous mixing additions in the same concrete load. Thus, the selected doses are adjusted to the actual conditions associated with the concrete load without the need to explicitly measure and adjust these parameters. In such a case, the second and each subsequent dose of mixing within a load is likely to be significantly more accurate than the first dose. This eliminates a lengthy trial and error process where previous mixing performance in the concrete load is not considered.
    [0021] It may also be possible to adjust the nominal dose response curve based on mixing performance data from previous loads.
    [0022] Although the prior art processes have suggested that empirical behavior of the concrete mixture can be compensated through the use of water or chemical mixture, until now it has not been taught or suggested how this compensation was to be done. It is the surprising aspect of the present invention that the rheology of the concrete mixture can be adjusted by entering into a computer processing unit (CPU) only the amount of concrete (load size) and the target rheology value (for example, consistency, flow of consistency, or limit stress), and comparing the actual rheology to the NDR, adding a percentage of the nominal dose of chemical mixture that may be (theoretically) required to change the actual rheology to the target rheology, measurement of resulting change in rheology value and comparison of this to the NDR value that may have been theoretically obtained using the percentage of nominal dose, and then adjusting the rheology by adding a subsequent dose that takes into account the deviation me - given as a result of the first percentage of addition. Therefore, the present invention takes into account a “learning” stage that is incorporated into the methodology, without having to consider numerous parameters such as temperature, mixing design, humidity, and other factors.
    [0023] Thus, an exemplary process of the present invention for rheology control of a hydratable cement composition in a mixer where the energy required to operate said mixer containing the cement composition is measured and correlated with a value of nominal rheology and where the rheology modifying agent is added to the cement composition to modify its rheology comprises: (a) entry into a computer processor unit (“CPU”) of a target rheology value (“TRV”) and charge size for a hydratable cement composition containing or intended to contain a particular rheology modifying agent or rheology modifying agents; and (b) obtaining a current rheology value (“CRV”) of hydratable cement composition contained in a mixer; (c) comparison using the CPU of the current rheology value obtained in step (b) against a nominal dose response profile (“NDR”) stored in accessible CPU memory and where said NDR is based on at least at least one set of data are recoverable, and determining the nominal dose of said particular rheology modifying agent or combination of rheology modifying agents required to change the CRV obtained to the TRV specified in step “(a)”; (d) dosage of said hydratable cement composition in a mixer with a percentage of said particular rheology modifying agent or combination of rheology modifying agents that is selected or preselected from 5% to 99% based on the dose nominal determined in step (c) required to change said CRV obtained to said TRV as specified in step (a); (e) obtaining a subsequent CRV of the hydratable cement composition after the percentage of the nominal dose of the particular rheology modifying agent or combination of rheology modifying agents selected or pre-selected in step (d) is added and uniformly mixed with said hydratable cement composition; comparison of selected or pre-selected dose in step (d) to dose according to the NDR profile for the same change in rheology value from step (b) to step (e), and determining the scaling fact (“SF”) through which to adjust the dose from the NDR profile, where SF is defined with the actual dose of step (d) divided by the nominal dose to obtain the same change in rheology value indicated by the NDR profile; and (f) mixing in the hydratable cement composition of a particular rheology modifying agent or combination of rheology modifying agents in an amount calculated in terms of SF multiplied by the dose from the NDR profile indicated to convert the current measured CRV in step (e) for the TRV specified in step (a).
    [0024] If the target rheology value such as consistency is not obtained by completing the steps mentioned above (which may be due to any of a number of factors, such as temperature or humidity change), then steps (e) and (f) process can be repeated when required. In addition, concrete rheology changes over time. Each time the rheology value decreases by a certain amount, a rheology modifying agent (for example, chemical mixture) has to be added to restore the rheology value. Steps (e) through (f) can be repeated to adjust the rheology value.
    [0025] In preferred processes of the invention, the NDR profiles are calculated based on an average of at least two dose response curve values (see, for example, Fig. 2), and, more preferably, an average of a plurality of dose response curve values obtained from experimenting with a particular rheology modifying agent or combination of rheology modifying agents (Ser, for example, Fig. 3).
    [0026] Still in exemplary achievements, the system CPU can be programmed to assume a learning mode, so batch stories can be incorporated into the NDR profile which is then stored in the accessible CPU memory, and / or the escalation factor can be redefined so that dosage can be made more accurate. In other words, changes in rheology value effected by doses of rheology modifying agent administered during a concrete mix delivery operation are incorporated into the nominal dose response curve (NDR) or escalation factor so the NDR curve or scaling factor (SF) is modified; and changes in rheology value in a subsequent concrete mix operation or delivery operations are made based on the modified NDR or modified SF curve. Exemplary rheology modifying agents include water, a chemical mixture (eg, polycarboxylate water reducer, naphthalene sulfonate condensate water formaldehyde, melamine sulfonate condensate water reducer, formaldehyde, lignon sulfonate water reducer , or mixtures of hydrocolloid viscosity modification such as welan gum or cellulose derivatives), or mixtures thereof. Chemical mixtures such as polycarboxylate cement dispersants are preferred, which are commonly used as superplasticizers (or so-called high-range water reducers) in the concrete field. As much as the same rheology modifying agent or combination of rheology modifying agents is being used as was previously tried to create a nominal dose response profile (NDR), then other variables such as concrete mix design, quantity of water or cement or water / cement ratio, selection or composition of aggregate, degree of hydration, do not need to be sent to the CPU and remain optional. Viscosity modification mixes primarily affect concrete viscosity, while having a relatively minor effect on other properties.
    [0027] Still advantages and characteristics of the invention can be described below. Brief Description of Drawings
    [0028] Still advantages and characteristics of the present invention can be more easily understood when the following detailed description of preferred embodiments is taken in conjunction with the attached drawings where: Fig. 1 is a graphic illustration of the plurality of curves (profiles) dose response of various concrete mixtures, so the effect of a particular rheology modification agent (eg chemical mixture such as polycarboxylate water reducer) is measured on the concrete consistency, as shown in long horizontal axis, and measured against the dose of rheology modifying agent whose quantity, which is measured in terms of pounds per cubic yard required to decrease the consistency of the concrete by one unit, as shown along the vertical axis; Fig. 2 is another graphic illustration where at least two dose response curves (marked minimum and maximum by way of illustration) of a particular rheology modifying agent are used to calculate an average dose response profile, which can function as a nominal dose response profile used in exemplary processes of the invention for automated control over concrete mixture rheology; and Fig. 3 is a graphic illustration where the change in theoretical (or nominal) consistency is plotted against the actual change in consistency when exemplary processes of the invention are used. Detailed Description of Preferred Achievements
    [0029] The term "cement" as used herein refers to a material comprising Portland cement and / or Portland cement substitutes which when mixed with water work as a binder to hold fine aggregates together (for example, sand ), coarse aggregates (for example, crushed stone or gravel), or mixtures thereof.
    [0030] Cement materials considered to be “hydratable” or hydraulic are those that harden through chemical interaction with water.
    [0031] Such cement materials may also include ash, granulated blast furnace slag, limestone, or natural pozzolans, which can be combined with Portland cement or used to replace or replace a portion of portland cement without seriously decreasing hydrable properties. A “mortar” refers to cement or a mixture of cements having a fine aggregate such as sand; while concrete it refers more precisely to a mortar that also contains a coarse aggregate such as crushed stone or gravel.
    [0032] The use of the term "cement material" can be done interchangeably with the term "concrete", as concrete is more commonly provided by ready-mix trucks that have rotating drums. The term "concrete" as used herein does not necessarily exclude the fact that the present invention can be used to deliver materials that contain only cement or cement substitutes (for example, pozzolans) or mortars.
    [0033] Hydratable cement materials, such as concrete mixtures, typically contain one or more rheology modifying agents, which can include water alone or chemical mixtures such as water reducing agents or water reducing agents high-range so-called “superplasticizers”, viscosity modifying agents, corrosion inhibitors, contraction reduction mixtures, fixation accelerators, fixation retardants, air entrailers, air-removing agents, pigments, dyes, fibers for control of plastic contraction or structural reinforcement, and the like.
    [0034] The phrase “rheology modifying agent” will therefore be understood to mean and include water, a chemical mixture, or a mixture thereof. In many cases, a chemical mixture formulation will comprise a dispersant and water, for example. The rheology modifying agent may also comprise one or more cement dispersants (e.g., polycarboxylate water reducer), an air removal agent, or combinations of air removal agent, and other mixtures.
    [0035] As mentioned in the background section, concrete delivery mix trucks having consistency control and monitoring equipment, such as electrical and / or hydraulic sensors for measuring energy to rotate the mixing drum, speed sensors for measuring rotation speed, temperature sensors for monitoring atmospheric temperature as well as mixing temperature, and dispensing equipment, as well as computer processing units (CPU) for monitoring signals from sensors and equipment performance layoffs are now relatively well known in the industry. For example, such consistency control systems, which can be used in association with wireless communication systems, are shown in US patent 5,713,663; US patent 6,484,079; US Serial 09/845 660 (publication No. 2002 / 0015354a1); US Serial No. 10/599 130 (Publication No. 2007 / 0185636a1); US Serial No. 11/764 832 (Publication No. 2008/0316856); US Serial No. 11/834 002 (Publication No. 2009/0037026); and WO 2009/126138. An exemplary system for monitoring and control using wireless communications in combination with sensors for monitoring various physical properties of the concrete mix is taught in the US 6 611 755 patent to Coffee. These teachings, as well as the patent references as previously discussed in the background section above, are expressly incorporated herein by reference.
    [0036] Exemplary mixing drums contemplated for use in the present invention can be those that are usually mounted for rotation on ready-mix delivery trucks, as mentioned above, or on stationary mixers that can be found in mixing facilities. Such mixing drums can have an internal surface on which at least one mixing blade is attached to the internal surface so that it rotates together with the mixing drum and serves to mix the concrete mixture, including the aggregates contained in the mixture.
    [0037] It is believed that a number of exemplary achievements of the invention can be practiced using commercially available automated concrete mix monitoring equipment with slight modifications as may be apparent in view of the invention shown here. Such mixing monitoring equipment is available under the trademark VERIFI of Grace Construction Products, Cambridge, Massachusetts, and also from RS Solutions LLC, West Chester, Ohio.
    [0038] As described in the above summary, an exemplary process of the invention for rheological control of a hydratable cement composition in a mixer where the energy required for the operation of said mixer containing the cement composition is measured and correlated with a nominal rheology value and where a particular rheology modifying agent or combination of rheology modifying agents is added to the cement composition to modify its rheology, comprises the following steps: (g) entry into a computer processor unit (“CPU”) of a target rheology value (“TRV”) and load size for a hydratable cement composition containing or intended to contain a particular rheology modifying agent or combination of rheology modifying agents; and (h) obtaining a current rheology value (“CRV”) of hydratable cement composition contained in a mixer; (i) comparison using CPU of the current rheology value in step (b) against a nominal dose response profile (“NDR”) stored in accessible CPU memory and where said NDR is based on at least one set data where various dose quantities of a particular rheology modifying agent or combination of rheology modifying agents and their related effect on rheology value (such as consistency, flow of consistency, or limit stress) is recoverable stored, and determining the nominal dose of said particular rheology modifying agent or combination of rheology modifying agents required to change the CRV obtained to the TRV specified in step “a”; (j) dosage of hydratable cement composition in a mixer with a percentage of said particular rheology modifying agent or combination of rheology modifying agents that is selected or preselected from 5% to 99% based on the nominal dose determined in step (c) required to change said CRV obtained to said TRV as specified in step (a); (k) obtaining a subsequent CRV of the hydratable cement composition after the percentage of the nominal dose of the particular rheology modifying agent or combination of rheology modifying agents selected or pre-selected in step (d) is added and uniformly mixed with said hydratable cement composition; comparison of selected or pre-selected dose in step (d) to dose according to the NDR profile for the same change in rheology value from step (b) to step (e), and determination of scaling factor (“SF”) through which to adjust the dose from the NDR profile, where SF is defined as the actual dose from step (d) divided by the nominal dose to obtain the same change in rheology value indicated by the profile NDR; and (l) mixing in the hydratable cement composition a particular rheology modifying agent or combination of rheology modifying agents in an amount calculated in terms of SF multiplied by the dose from the indicated NDR profile to convert the current measured CRV in step (e) for the TRV specified in step (a).
    [0039] As described in Step (a), the first step of the exemplary process requires entry into the computer processing unit (“CPU”) of only two pieces of information: the target rheology value (“TRV”) and the load size for the given hydratable cement composition that will be placed in the mixer. These two data points can be entered by the batch master at the mixing plant - ready, by the truck driver, or foreman at the construction site. Actually, this entry can be made by anyone in charge of the concrete delivery and does not require the entry of other parameters such as temperature, humidity, and other factors that are optional.
    [0040] The target rheology value (TRV) can be any of the rheology factors whose measurement in unit values are usually employed, such as: consistency (usually measured in terms of units of length, for example, inches); consistency flow (length, for example, inches); limit stress (usually measured in terms of stress, for example, pounds per square inch or pascals); viscosity (pascals, seconds); flow (length); and thixotropy (pascals / second). Load size can be sent to the CPU in terms of weight or total volume of batch concrete (eg cubic yards) including all components. If the TRV is defined in terms of consistency, then the measurement for consistency can be made according to the following standards: ASTM C 143-05, AASHTO T 119, or EM 12350-2. If the TRV is defined in terms of consistency flow, then this measurement can be made according to ASTM C1611-05. If the TRV is defined in terms of the flow table test, then this can be done according to DIN EN 12350-5.
    [0041] The rheology modifying agent or combination of rheology modifying agents mentioned in Step (a) means and refers to water, chemical mixture (s), or mixtures thereof that are present in the concrete that is used for generation data set or sets that provide the nominal dose response profile (“NDR”) mentioned in Step (c) as well as in the concrete being adjusted, that is, whose load size is entered in the CPU in Step (a ) and whose current rheology value (CRV) is obtained in Step (b). It is important for calibration purposes (ie generation of NDR profile) to use identical or similar rheology modifying agents for the NDR profile as for dosing into concrete.
    [0042] Preferred "chemical mixtures" suitable for use in the processes of the present invention include water reducers and superplasticizers commonly used in the concrete industry. Among these cement-dispersing polymers which contain salt and / or (poly) carboxylic acid groups and (poly) oxyalkylene groups (referred to herein as "polycarboxylate polymers") are preferred.
    [0043] Thus, for example, the "rheology modifying agent or combination of rheology modifying agents", as this phrase is used in Step (a), can refer to one or more active ingredients, such as a or more polycarboxylate polymers, which, in turn, can be used as air entrainers or other mixtures that can have an effect on the rheology of concrete. The concentration of one or more active ingredients is very important. It may be necessary to establish and use another nominal dose response profile (NDR) by adding or omitting a particular active ingredient from the chemical mixture (s) formulation. Dispersant polymers will be seen to affect rheology and will be judged to be “active ingredients” so that it is preferable that the same polymers are used in the NDR profile; this same reason applies to other components such as drag and / or exhaust components if through their quantity and / or nature they will have a profound effect on rheology.
    [0044] As one of the benefits of the present invention which is self-correcting, it may be possible to obtain high precision even where the cement dispersion polymer is different and where other active ingredients may be different in nature and quantity. However, when using the process of the present invention, it is preferable to start with the same rheology modifying agents or the same combination of rheology modifying agents and to compensate for any differences in their concentrations.
    [0045] In step (b) of the exemplary process, this second step requires the system to determine the current rheology value (“CRV”) of the hydratable cement composition contained in the mixer. This is stored in accessible CPU memory because it will provide a reference point for further steps.
    [0046] In Step (c) of the exemplary process, the CPU compares the current rheology value (CRV) obtained in Step (b) with the nominal dose response profile (“NDR”) stored in the accessible CPU memory. As mentioned earlier, this NDR profile is based on at least one data set where the effect of varying dose quantities of a particular rheology modifying agent or agents on rheology (eg, consistency, flow of consistency, limit stress , etc.) is measured. Although the process of the invention can work with a data set where the effect of the rheology modifying agent on rheology is correlated, it is preferred to use an NDR profile that is generated using at least two data sets, and it is more preferable to use an NDR profile that is generated using a plurality of data sets.
    [0047] For example, Fig. 2 illustrates two response curves (called minimum and maximum) so that the consistency (inches) of a concrete composition is plotted against the quantity of the particular rheology modifying agent (a mixture concrete consistency modification) needed to change consistency by one unit (for example, a consistency change one inch, such as from 2 inches to three inches). The nominal dose response profile (or curve) is then taken as the average of the two dose response curves (minimum and maximum).
    [0048] As a more preferred example, Fig. 1 illustrates a plurality of dose response curves whose mean provides a nominal dose response profile (“NDR”) that can be used as a reference during an operation. delivery.
    [0049] In step (d), the CPU is programmed to dose the hydratable cement composition in the mixer using a selected or pre-selected percentage of the ideal amount of rheology modifying agent (s) that can be determined by the NDR profile for change the current rheology value (CRV), as determined in Step (b), to the target rheology value (TRV) entered in Step (a). The percentage can be 50% to 95% of the ideal amount (or nominal, and more preferably it can be about 50% - 90%; and more preferably it can be 50% -80%. Generally, the lowest percentage in these ranges is preferable for this first dose until confidence is obtained.
    [0050] In Step, (e), the CPU can be programmed to obtain a subsequent current rheology value (CRV) of the hydratable cement composition after the percentage of the nominal dose of the particular rheology modifying agent (for example, chemical mixture) administered in Step (d) be added and uniformly mixed with the hydratable cement composition. The CPU can compare the nominal (or theoretical) effect on the rheology value of the dose percentage selected or pre-selected in step (d) to the subsequent current rheology value (subsequent CRV) and then determine the escalation factor (“SF”) through which to adjust the dose from the NDR profile, where SF is defined as the actual dose from step (d) divided by the nominal dose to obtain the same rheology change indicated by the profile NDR.
    [0051] In Step (f), the CPU can be programmed to mix a subsequent dose of the rheology modifying agent into the hydratable cement composition. The amount of this subsequent dose can be calculated by multiplying the escalation factor (SF) calculated in Step (e) by the amount theoretically necessary, according to the nominal dose response profile (NDR), to change the subsequent value current rheology (CRV) measured in Step (e) to the target rheology (TRV) value specified in Step (a).
    [0052] Steps (e) and (f) can be repeated when the current rheology value (CRV) is less than or greater than the target rheology value (TRV) by a predetermined amount. This can be done automatically, for example, through CPU programming to repeat these steps when the difference between CRV and TRV exceeds a predetermined amount. If the difference between CRV and TRV is less than the predetermined amount, the CPU can be programmed to trigger an alarm to indicate to the operator that the concrete mix is ready to be discharged and poured.
    [0053] As mentioned above, preferred processes of the invention involve the use of a nominal dose response profile (NDR) that is derived from an average of at least two sets of dose response curves for the particular agent (s) rheology modification, as illustrated in Fig. 2; and, more preferably, an average of a plurality of dose response curves for the particular chemical mixture (s), as illustrated in Fig. 1. The dose response curves of Fig. 1 suggest in particular, through of variation of curve amplitudes, that various parameters such as concrete mix design, temperature, degree of hydration, water / cement ratio, and aggregate quantities may be varying slightly (or even significantly) from batch to batch. Still, the fact that the various dose response curves do not intersect has led the present inventors to believe that these other various parameters do not necessarily need to be kept constant in order to establish a nominal dose response profile (NDR) because the The mean of these dose response curves may behave similarly in terms of calculating the amounts of rheology modifying agent (s) needed to change the rheology value (eg, consistency) from one value to the next (eg, from consistency of 2 inches to, say, five inches).
    [0054] Therefore, exemplary processes of the invention involve a nominal dose response profile (NDR) involving the use of a plurality of data sets having at least one non-homogeneous parameter. This parameter can, for example, be the concrete mix design, reaction temperature, degree of cement hydration, the water / cement ratio, and the amount of aggregate or cement / aggregate ratio. These can be varied from batch to batch in the data sets that make up the NDR profile (See, for example, Fig. 1).
    [0055] Thus, still exemplary processes of the invention comprise the use of a nominal dose response profile (NDR) that is derived from data sets having at least two non-homogeneous parameters, and even more than two non-homogeneous parameters, such as different concrete mix design, concrete mix ingredient source, temperature, hydration, water / cement ratios, different amounts or aggregate ratios, and concrete mix designs. As far as the particular rheology modifying agent (s) (for example, water and / or concrete mixture or combination of chemical mixtures) used to establish the NDR profile and to obtain a current rheology value is / are identical or substantially similar, the slope behavior of dose response curves is similar from one unit of rheology value to the following. In fact, even if two rheology modifiers vary in composition but are similar in performance, it may be possible to use the same NDR profile for both.
    [0056] Still in exemplary embodiments of the invention, the process of monitoring rheology change may involve the use of more than one type of rheology modifying agent (or chemical mixture) with each type of rheology modifying agent having its own escalation factor (SF), nominal dose response profile, or both. For example, NDR profiles can be established for combinations of chemical mixtures such as: high range water reducer with viscosity modifying mixture; normal range water reducer with high range water reducer; water reducers with fixed accelerators, fixed retarders, or combinations thereof; high-range water reducers with thixotropic modification mixtures; and the like.
    [0057] Still in exemplary embodiments, the process of the invention can be modified so that more than one rheology target can be specified and satisfied within the same concrete mixture delivery operation. For example, multiple rheology targets can be used, such as target consistency during transit (from batch installation or job site operation) and during placement (after the truck arrives at the job site where the mixture is to be poured). As another example, it is possible to define two rheology targets that the concrete mix must obtain within the same operation / delivery process and at the same time, such as flow of consistency and plastic viscosity. In other words, it is possible to have a rheology modifying agent or combination of agents (for example, mixtures packaging) for modifying the consistency flow (characterized by the spreading of concrete from a con- strength removed) and another rheology modifying agent or combination of agents for modifying plastic viscosity (characterized by shear stress divided by the shear rate).
    [0058] Still in an exemplary realization, the escalation factor is calculated as a weighted average of all dose responses in a given load or mixing project. In other words, in a series of delivery operations in which various escalation factors are derived, the escalation factor used in the current delivery operation can be based on an average of all computed escalation factors, but primarily based on data obtained from the most recent delivery operations.
    [0059] Although the invention is described here using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as otherwise described and claimed herein. Modifications and variations from the described achievements exist. More specifically, the following example is given as a specific illustration of an embodiment of the invention. It should be understood, that the invention is not limited to the specific details shown in the example. All parts and percentages in the examples, as well as the rest of the specification, are by weight unless otherwise specified.
    [0060] Still, any range of numbers recited in the specification or claims, such as that representing a particular set of properties, unit of measurement, conditions, physical states or percentages, is intended here to expressly incorporate literally by reference or otherwise, any number falling within such a range, including any subset of numbers within any range thus recited. For example, whenever a numerical range with a lower limit, RL, and an upper limit RU, is shown, any R number falling within the range is specifically shown. In particular, the following R numbers within the range are specifically shown: R = RL + k * (RU-RL), where k is a variable ranging from 1% to 100% with an increase of 1%, for example, k is 1%, 2%, 3%, 4%, 5%, ... 50%, 51%, 52%, ... 95%, 96%, 97%, 98%, 99%, or 100%. In addition, any numerical range represented by any two values of R, as calculated above, is also specifically shown. Example 1
    [0061] A concrete mix was manufactured in a laboratory mixer without any chemical mixtures added. Consistency was measured by removing samples and placing them in a consistency cone in accordance with ASTM C143-05. When this test was performed, the first mixture was discarded. Immediately thereafter, another concrete mix having the same concrete mix design was manufactured in the same lab mixer but this time with a chemical mixture (polycarboxylate water reducer), and consistency was again measured using the same standard cone). When this test was done, the mixture was discarded. A plurality of still successive concrete mixtures from the same concrete mixing project and identical mixing factors (for example, temperature, type of cement, amount of air and water, water / cement ratio, etc.) were also manufactured. in the laboratory mixer, but each varying only in the dosage amount of the polycarboxylate polymer water reducer. Except for the mixing dose of the water reducer, all other variables were kept constant. Each successive mixture was discarded after a cone consistency test.
    [0062] The data for the concrete mixtures above are illustrated as a plotted line shown in Fig. 1.
    [0063] The above process was repeated, but for each repetition one of the mixing factors was varied while all the other mixing factors were kept constant. The varied mixing factors included: material temperature, the amount and type of cement, type of fine aggregate, type of coarse aggregate, amount of air in the concrete, amount of water, and ratio of water to cement .
    [0064] The data for these concrete mixtures having a varied mixing factor are also plotted as several lines shown in Fig. 1.
    [0065] Surprisingly, the inventors have found that the dosing response curves, as shown in Fig. 1, do not intersect. The present inventors thus found that the consistency of the concrete mixture can be adjusted by reference to the behavior of any curve or an average of all such dosing response curves, and that the behavior of such a curve or plurality of curves can serve as a nominal dose response curve or reference during real-time production operation.
    [0066] Fig. 2 is a simplified version of Fig. 1 showing “minimum”, “maximum” and average dose response curves. The average dose response curve shown in Fig. 2 can serve as a nominal dose response curve during real-time production operation. Example 2
    [0067] The exemplary process of the invention was field tested using a concrete mixing truck having an automated dosing and monitoring system provided by RS Solutions LLC of Ohio, commercially available under the trademark VERIFI. This monitoring system can measure consistency based on hydraulic pressure and mixing drum speed. This system can also inject liquid chemical mixture into the mixing drum from a small chemical mixture storage tank mounted on the mudguard. (Reference is also made to US patent publication 2009/0037026, Sostaric et al., Described in the background section).
    [0068] Over a period of months a variety of concrete mixes were prepared in the concrete mixing truck. Before testing, a nominal dose response profile was obtained, similar to the process described above in Example 1, and this was used as the “nominal” or “reference” (“NDR”) reference dose profile.
    [0069] A number of tests were run using the exemplary process of the invention for different concrete mixing delivery operations, where the NDR was used by the computer processing unit of the automated dosing and monitoring system for each successive sample of concrete mixing. concrete prepared in the mixing drum. Mixtures produced in the drum over the next few weeks experienced natural variations in terms of temperature, raw materials, mixing ratios (eg water / cement ratio, water / aggregate ratio, fine / coarse aggregate ratio, etc.).
    [0070] The amount of water reduction mixture (based on polycarboxylic acid) was dosed according to the process of the invention as described in the previous summary section.
    [0071] As shown in Fig. 3, the use of the process resulted in changes in consistency in the concrete mix that were very close to the expected changes when the nominal dose response curve (NDR) was used as a reference . See process steps (a) through (f) in the Summary section above. When the NDR curve is first applied, the consistency change is then used to develop the escalation factor (SF) which is then used over the next addition of mixture. Fig. 3 illustrates that the actual measured consistency change values (shown by the dots) closely match the theoretical consistency change values.
    [0072] The principles, preferred embodiments, and modes of operation of the present invention have been described in the previous specification. The invention that is intended to be protected here, however, is not to be constructed as limited to the particular forms shown, since these are to be seen as illustrative rather than restrictive. Those skilled in the art can make variations and changes without departing from the spirit of the invention.
    权利要求:
    Claims (18)
    [0001]
    1. Process for controlling the rheology of a hydratable cement composition in a rotary mixer where the energy required to operate said mixer containing the cement composition is measured and correlated with a nominal rheology value and where a rheology modifying agent or combination of rheology modifying agents is added to the cement composition to modify its rheology, the process FEATURED by the fact that it comprises: provision of a truck having a rotary mixer to mix a hydratable cement composition and a processor unit computer ("CPU") to monitor the consistency of the hydratable cement composition and to control dosage of chemical mixture or mixtures in said hydratable cement composition contained in said truck rotary mixer; and (a) entering into said CPU a target rheology value (“TRV”) and load size for a hydratable cement composition containing or intended to contain a particular rheology modifying agent or combination of rheology modifying agents within the said truck rotary mixer; and (b) obtaining a current rheology value (“CRV”) of hydratable cement composition contained within said truck's rotary mixer; (c) comparison using the said CPU of the current rheology value obtained in step (b) against a nominal dose response profile (“NDR”) stored in accessible CPU memory and where said NDR is based on at least a data set where various dose quantities of a particular rheology modifying agent or combination of rheology modifying agents and their correlated effect on rheology value is recoverable, and determining the nominal dose of said particular rheology modifying agent or combination of rheology modifying agents required to change the CRV obtained to the TRV specified in step “(a)”; (d) dosage of the hydratable cement composition contained in said rotary mixer of the truck with a percentage of said particular rheology modifying agent or combination of rheology modifying agents that is selected or preselected from 5% to 99% based on nominal dose determined in step (c) required to change said CRV obtained to said TRV as specified in step (a); (e) obtaining a subsequent CRV of the hydratable cement composition contained in said rotary mixer of the truck after the percentage of the nominal dose of the particular rheology modifying agent or combination of rheology modifying agents selected or pre-selected in step (d ) be added and uniformly mixed with said hydratable cement composition; comparison of the dose selected or pre-selected in step (d) with the dose according to the NDR profile for the same change in the rheology value from step (b) to step (e), and determination of the escalation factor (“SF” ) through which it adjusts the dose from the NDR profile, where SF is defined as the actual dose of step (d) divided by the nominal dose to obtain the same change in rheology value indicated by the NDR profile; and (f) mixing in the hydratable cement composition a particular rheology modifying agent or combination of rheology modifying agents in an amount calculated in terms of SF multiplied by the dose from the indicated NDR profile to convert the current CRV measured in step (e) for the TRV specified in step (a).
    [0002]
    2. Process according to claim 1, CHARACTERIZED by the fact that steps (e) and (f) are repeated whenever the CRV is less than or greater than the TRV by a predetermined amount.
    [0003]
    3. Process according to claim 1, CHARACTERIZED by the fact that said NDR profile described in step (c) is derived as an average of at least two sets of dose response curves for the particular rheology modifying agent or combination of rheology modifying agents.
    [0004]
    4. Process according to claim 1, CHARACTERIZED by the fact that said NDR profile described in step (c) is derived as an average of a plurality of dose response curves for the particular rheology modifying agent or combination of rheology modifying agents.
    [0005]
    5. Process according to claim 4, CHARACTERIZED by the fact that, in said NDR profile, at least two dose response curves contain at least one non-homogeneous parameter selected from the concrete mixing design, source of the mixing ingredient of concrete, temperature, degree of hydration, water / cement ratio, and amount of aggregate.
    [0006]
    6. Process according to claim 5, CHARACTERIZED by the fact that, in said NDR profile, at least two dose response curves contain at least two non-homogeneous parameters selected from the concrete mixing project, source of the mixing ingredient of concrete, temperature, degree of hydration, water / cement ratio, and amount of aggregate.
    [0007]
    Process according to claim 4, CHARACTERIZED by the fact that the particular rheology modifying agent or combination of rheology modifying agents comprises water, at least one cement dispersant, or mixtures thereof.
    [0008]
    8. Process according to claim 7, CHARACTERIZED by the fact that said at least one rheology modifying agent is a cement dispersant.
    [0009]
    Process according to claim 8, CHARACTERIZED by the fact that said cement dispersant is a lignosulfonate, naphthalene sulfonate, melamine sulfonate, polycarboxylate, or mixtures thereof.
    [0010]
    10. Process according to claim 8, CHARACTERIZED by the fact that said cement dispersant is a polycarboxylate polymer.
    [0011]
    11. Process according to claim 1, CHARACTERIZED by the fact that said rheology value is consistency that is correlated with the consistency of a standard cone of 30.48 centimeters (12 inches).
    [0012]
    12. Process according to claim 1, CHARACTERIZED by the fact that said rheology value is flow of consistency.
    [0013]
    13. Process according to claim 1, CHARACTERIZED by the fact that said rheology value is limit voltage.
    [0014]
    14. Process according to claim 1, CHARACTERIZED by the fact that said rheology value is thixotropy.
    [0015]
    15. Process according to claim 1, CHARACTERIZED by the fact that said rheology value is plastic viscosity.
    [0016]
    16. Process according to claim 1, CHARACTERIZED by the fact that said rheology value is spread on a flow table.
    [0017]
    17. Process according to claim 1, CHARACTERIZED by the fact that changes in rheology value made by doses administered during a concrete mixture delivery operation are incorporated in the said nominal dose response curve (NDR) or factor of escalation whereby the said NDR curve or escalation factor (SF) is modified; and subsequent changes in the rheology value thereon or a subsequent concrete mix delivery operation are carried out based on said modified NDR curve or said modified SF.
    [0018]
    18. Process for controlling the rheology of a hydratable cement composition in a rotary mixer of a concrete delivery truck where the energy required to operate said rotary mixer containing the cement composition is measured and correlated with a nominal rheology value and where a rheology modifying agent or combination of rheology modifying agents is added to the cement composition to modify its rheology, the process CHARACTERIZED by the fact that it comprises: (a) entry into a computer processor unit ( “CPU”) of a target rheology value (“TRV”) and load size for a hydratable cement composition placed in said rotary mixer of the truck, said hydratable cement composition containing or intended to contain a particular rheology modifying agent or combination of rheology modifying agents; and (b) obtaining a current rheology value (“CRV”) of hydratable cement composition contained within said truck's rotary mixer; (c) comparison using the CPU of the current rheology value obtained in step (b) against a nominal dose response profile (“NDR”) stored in accessible CPU memory and where said NDR is based on at least one data set where various dose quantities of a particular rheology modifying agent or combination of rheology modifying agents and their correlated effect on rheology value is recoverable, and determining the nominal dose of said particular rheology modifying agent or combination of rheology modifiers required to change CRV obtained to TRV specified in step “(a)”, said NDR profile is an average of a plurality of dose response curves for the particular rheology modifier or combination of rheology modifying agents, and at least two dose-response curves of said plurality of dose-response curves contain at least one non-homogeneous parameter selected from p concrete mixing rod, source of concrete mixing ingredient, temperature, degree of hydration, water / cement ratio, and amount of aggregate; (d) dosage of the hydratable cement composition in said rotary mixer of the truck with a percentage of said particular rheology modifying agent or combination of rheology modifying agents that is selected or preselected from 5% to 99% based on the dose nominal determined in step (c) required to change said CRV obtained to said TRV as specified in step (a); (e) obtaining a subsequent CRV of the hydratable cement composition after the percentage of the nominal dose of the particular rheology modifying agent or combination of rheology modifying agents selected or pre-selected in step (d) is added and uniformly mixed with said hydratable cement composition; comparison of the selected or pre-selected dose in step (d) with the dose according to the NDR profile for the same change in the rheology value from step (b) to step (e), and determination of the escalation factor (“SF” ) through which it adjusts the dose from the NDR profile, where SF is defined as the actual dose of step (d) divided by the nominal dose to obtain the same change in rheology value indicated by the NDR profile; and (f) mixing in the hydratable cement composition a particular rheology modifying agent or combination of rheology modifying agents in an amount calculated in terms of SF multiplied by the dose from the indicated NDR profile to convert the current CRV measured in step (e) for the TRV specified in step (a).
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    同族专利:
    公开号 | 公开日
    HK1186772A1|2014-03-21|
    WO2011162878A1|2011-12-29|
    AU2011269743B9|2014-11-27|
    KR101914963B1|2018-11-05|
    EP2585809A1|2013-05-01|
    JP5795062B2|2015-10-14|
    CN103180710A|2013-06-26|
    CO6670528A2|2013-05-15|
    US20110320040A1|2011-12-29|
    JP2013531241A|2013-08-01|
    KR20140002590A|2014-01-08|
    US8311678B2|2012-11-13|
    CA2802367C|2018-04-17|
    MX2012014931A|2013-03-18|
    BR112012033266A2|2016-11-22|
    EP2585809A4|2017-05-03|
    EP2585809B1|2020-04-08|
    AU2011269743A1|2013-01-31|
    CN103180710B|2015-04-08|
    AU2011269743B2|2014-10-30|
    CA2802367A1|2011-12-29|
    MY166298A|2018-06-25|
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    法律状态:
    2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-08-20| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-03-24| B07A| Technical examination (opinion): publication of technical examination (opinion)|
    2020-11-03| B09A| Decision: intention to grant|
    2020-12-22| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 10/05/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US12/821,451|US8311678B2|2010-06-23|2010-06-23|Method for adjusting concrete rheology based upon nominal dose-response profile|
    US12/821,451|2010-06-23|
    PCT/US2011/035851|WO2011162878A1|2010-06-23|2011-05-10|Method for adjusting concrete rheology based upon nominal dose-response profile|
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