Intelligent Grouting Control System Based on Sliding Mode Control

Zhi-gang ZHOU , Fan HUANG , Ye DING , Yan-pu HUANG , Jun XIA

Science Technology and Engineering ›› 2025, Vol. 25 ›› Issue (29) : 12519 -12527.

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Science Technology and Engineering ›› 2025, Vol. 25 ›› Issue (29) : 12519-12527 DOI: 10.12404/j.issn.1671-1815.2406674
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Intelligent Grouting Control System Based on Sliding Mode Control
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Abstract

Cement grouting technology is widely adopted in hydraulic engineering. However, traditional manual recording methods are confined to inaccuracy and poor real-time performance. Low grouting precision and frequent overpressure are often induced due to the manual regulation of pressure, rate, and water-cement ratio. To address these challenges, an intelligent grouting control system was designed and developed based on sliding mode control to enhance the automation and intelligence of the grouting process. By integrating intelligent sensors, programmable logic controller(PLC), and analog modules, the hardware for the intelligent grouting control system was developed. A comprehensive grouting pressure control model was established to derive a nonlinear orifice pressure mathematical model by calculating the orifice pressure and control the grouting pressure through regulating the valve opening. It is guaranteed that the actual orifice pressure tracks the calculated reference orifice pressure, achieving the desired control effect. The intelligent grouting monitoring and control system software, developed with Python, was composed of five modules: data acquisition module, parameter setting module, report generation module, historical record module, and process control module. It is indicated that the sliding mode control algorithm employed in the system is of significant advantages in dynamic response speed and steady-state error compared with the traditional control algorithms. It is indicated by the results that the designed intelligent grouting control system achieves real-time acquisition of data such as grouting pressure, flow rate, and density, as well as the automated control of grouting pumps and electric valves. During the stable grouting stage, a pressure control precision of ± 0.02 MPa can be achieved by the sliding mode control algorithm, with fast response speed, small steady-state error, and robust performance. When the system is applied in actual engineering projects, automated and intelligent control of the grouting process can be achieved, grouting construction quality and efficiency can be enhanced. A foundational basis is provided for the full-process intelligent development of future grouting engineering.

Keywords

intelligent grouting / data collection / automated control / pressure control / sliding mode control

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Zhi-gang ZHOU, Fan HUANG, Ye DING, Yan-pu HUANG, Jun XIA. Intelligent Grouting Control System Based on Sliding Mode Control. Science Technology and Engineering, 2025, 25(29): 12519-12527 DOI:10.12404/j.issn.1671-1815.2406674

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