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Wet Spraying Truck Pumping Pulse Control Technology
Release time:
2026-02-18
Source:
Author:
Summary:
Pumping pulses are a common phenomenon in wet spray truck operations, characterized by periodic fluctuations in the concrete discharge rate. These fluctuations not only affect the smoothness of the sprayed surface but also increase the rebound rate and compromise construction quality. By implementing systematic technical measures, it is possible to effectively reduce pumping pulses and enhance the operational stability of the equipment.
I. Analysis of the Pulse Generation Mechanism
Hydraulic system pulsation
The hydraulic system is the primary source of pulsation: the inherent flow pulsation characteristics of piston pumps; pressure surges during directional changes; lag in the system’s pressure-regulating response; and energy accumulation and release caused by the compressibility of hydraulic oil.
Mechanical transmission backlash
The clearance in mechanical systems can amplify pulses: the clearance in the S-valve reversing mechanism; the clearance between the delivery cylinder and the piston connection; the wear-induced clearance at the boom hinge points; and vibrations caused by loose pipe fixings.
Concrete flow state changes
Flow regime changes during material transport: the difference in flow rates between the suction stroke and the push stroke; pressure wave propagation and reflection within the pipeline; volume changes caused by the compressibility of concrete; and flow disturbances induced by sudden changes in local resistance.
II. Optimization Measures for the Hydraulic System
Fine-tuned pumping parameters
Reduce system pulsation through parameter optimization: Appropriately reduce the displacement per pump stroke and increase the pumping frequency; optimize the reversing buffer curve to minimize pressure surges; set a reasonable pressure rise gradient; and adjust the system response time to match the pumping rhythm.
Hydraulic circuit improvement
Adopt advanced hydraulic control technology: Install accumulators to absorb pressure pulsations; use pressure-compensated variable pumps; equip pilot-operated relief valves for smooth pressure relief; and employ a closed-loop hydraulic system to minimize energy loss.
Control system upgrade
Application of intelligent control technology: Employing a PID algorithm for precise control of pumping speed; implementing an adaptive pressure regulation function; achieving smooth multi-pump convergence and switching; and developing an intelligent pulsation-damping control program.
III. Mechanical Structure Improvement Plan
Transmission System Optimization
Reducing the impact of mechanical transmission backlash: Adopting a zero-backlash ball-joint connection mechanism; optimizing the swing-buffer device for the S-valve; improving the piston rod connection structure; and using high-precision guiding mechanisms.
Pipe system vibration reduction
Improving the stability of piping systems: Increasing the density of pipe support points; using vibration-damping supports to secure pipes; employing flexible connections to absorb vibrations; and optimizing pipe routing to reduce sharp bends.
Reinforced key components
Improve the service life of vulnerable parts: Adopt a highly wear-resistant inner wall for the conveying cylinder; enhance the impact resistance of the wear plate; optimize the sealing structure of the cutting ring; and use high-precision machined components.
IV. Improvement of Operation Procedures
Pumping Rhythm Control
Scientific operational practices to reduce pulsation: Maintain a stable pumping rate; avoid frequent changes in speed; adopt gradual acceleration and deceleration; and control the appropriate pumping displacement.
System coordinated operation
Coordinated operation among systems: synchronization between pumping and boom movements; matching the mixing speed with the pumping rate; uniform and stable addition of accelerators; maintaining a continuous feed state.
Dynamic parameter adjustment
Real-time adjustment based on operating conditions: Adjust pressure according to the conveying distance; adjust speed based on the concrete’s condition; optimize parameters for different sections; and respond promptly to changes in system status.
V. Maintenance and Servicing Requirements
Regular inspection items
Establish a comprehensive inspection system: Conduct daily checks on the hydraulic system’s sealing performance; perform weekly pressure tests on accumulators; calibrate system pressure parameters monthly; and carry out quarterly inspections of mechanical wear.
Preventive maintenance
Proactive maintenance reduces failures: Regularly replace hydraulic oil and filter elements; promptly adjust mechanical clearance; replace wear-prone parts on schedule; and maintain system cleanliness at the required level.
Condition Monitoring
Real-time monitoring of equipment status: Install pressure pulsation sensors; monitor system vibration frequencies; record the patterns of pulse generation; establish an early warning mechanism.
VI. Directions for Technological Innovation
Intelligent Control System
Next-generation control technology development: AI-based pulse prediction; adaptive pulsation suppression algorithm; digital twin technology for simulation and optimization; intelligent diagnosis and self-healing systems.
New hydraulic components
Application of high-performance components: Precise control via digital hydraulic pumps; rapid response from intelligent valve assemblies; efficient energy storage with new-type accumulators; smooth operation of composite transmission systems.
Materials Technology Innovation
Research and application of new materials: nano-modified hydraulic oils; high-wear-resistant composite materials; intelligent vibration-damping materials; and new sealing materials.
Conclusion
Reducing the pumping pulses in wet spray rigs is a systematic undertaking that requires coordinated improvements across multiple aspects, including the hydraulic system, mechanical structure, and operational procedures. By adopting advanced technological solutions and implementing scientific maintenance and management practices, we can significantly mitigate the impact of these pulses and enhance construction quality. It is recommended that equipment manufacturers continue to pursue technological innovation, while construction companies strengthen operator training, working together to elevate the industry’s technical standards. At the same time, we should place great emphasis on summarizing and sharing practical experience, establishing a comprehensive system of technical standards, and contributing to the advancement of wet-spray technology.
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