Shield tunneling machine integrated on-site synchronous grouting device and grouting method

Abstract

The invention discloses an integrated on-site synchronous grouting device and method for a shield tunneling machine. The integrated on-site synchronous grouting device for the shield tunneling machine comprises material storage equipment, pulping equipment, injection equipment, grouting equipment and a grouting monitoring-feedback-decision system. The material storage equipment comprises a horizontal tank type stock bin and a sealed tank; the injection equipment comprises an injection pump, a pressure feed pipe and a compressor, and is powered by the compressor; the pulping equipment comprises a liquid A mixer and a liquid A stirrer; the grouting equipment comprises a propelling valve, a cleaning pipeline, a material mixing device, a grouting pipeline and grouting control equipment. The monitoring-feedback-decision-making system comprises a monitoring system, a feedback system and a decision-making system and is connected with a grouting process line. The integrated field synchronous grouting equipment integrating slurry preparation, slurry storage and grouting is formed in the shield tunneling machine, the problems that a traditional ground stirring station is unstable in long-distance slurry pumping, high in cost and the like are solved, the slurry quality can be guaranteed, and the grouting effect can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of shield grouting devices, and in particular to an integrated on-site synchronous grouting device and a grouting method for a shield machine. Background Art

[0002] In recent years, my country's economic and social construction has developed rapidly, and the construction of infrastructure has also increased. The underground space of cities has gradually become an important area for alleviating urban traffic pressure, solving land shortage problems, and carrying out infrastructure construction. Traditional tunnel construction methods have problems such as slow construction speed, great impact on the surrounding environment, and poor construction safety. With the development of shield machine technology, shield tunnel construction has become an efficient, accurate, and relatively safe tunnel excavation method. In particular, shield tunnel construction technology with large depth, large cross-section, and long distance can be constructed at greater depths and under more complex geological conditions, and has less impact on the ground and the surrounding environment.

[0003] The research and application of large-diameter shield tunnel technology has promoted the rapid development of urban infrastructure construction, especially in rail transit, water supply and drainage, cross-river tunnels and other projects. Although shield tunnel technology has many advantages, the technical challenges faced by large-diameter shield tunnels are also more complex. There may be greater risks in the construction process of large-diameter shield tunnels, such as groundwater leakage, ground subsidence, tunnel deformation, etc. In view of the current complex soft stratum geology, tunnel collapse, surface subsidence and other problems that are prone to occur, grouting methods are often used to treat them. With the increasing number of tunnel projects in my country, the engineering geological conditions faced are becoming increasingly complex, and higher requirements are also placed on grouting technology.

[0004] Shield grouting technology is a key technology in shield tunnel construction. It is mainly used to improve soil stability, fill gaps generated during shield excavation, and reduce groundwater leakage. However, as the diameter of shield tunnel excavation continues to increase, higher requirements are placed on the stability of the slurry during the grouting process. The problems of traditional ground grouting stations are: (1) During long-distance pumping, the slurry flows in the pipeline for a long time, which is prone to segregation or chemical reaction with other substances in the pipeline, affecting the stability of the slurry. At the same time, the slurry contains large solid particles, which are easy to accumulate in the narrow parts or bends of the pipeline, causing pipeline blockage. (2) Long-distance pumping will reduce the quality of the slurry, leading to surface settlement of the project, poor slurry penetration and grouting filling effects; (3) The ground mixing station used for shield grouting needs to occupy a large area of ​​land to house mixing equipment, raw material storage and related ancillary facilities, which increases the project cost. At the same time, the environmental pollution problems such as dust, noise, and waste caused by the construction and operation of a large area of ​​land need to be solved urgently; (4) The traditional grouting process lacks automated equipment. Human misjudgment or operation delays can lead to untimely grouting or inaccurate grouting volume, low grouting efficiency and poor quality, which seriously affects the quality of the project. (5) The lack of an effective monitoring and feedback mechanism, or the lack of experience of construction personnel, may lead to untimely or inaccurate adjustment of grouting parameters, affecting the grouting effect and construction efficiency, and is not conducive to the efficient implementation of grouting. Summary of the invention

[0005] In order to solve the problem of unstable slurry pumping over long distances, ensure the grouting effect and reduce the grouting cost, the present invention provides an integrated on-site synchronous grouting device for a shield machine and a grouting method thereof, which forms an integrated on-site synchronous grouting equipment of "slurry making-slurry storage-grouting" inside the shield machine, solves the problems of unstable slurry pumping over long distances and high cost in traditional ground mixing stations, can ensure the slurry quality and improve the grouting effect.

[0006] In order to achieve the above-mentioned purpose, the present invention adopts the following technical methods: a shield machine integrated on-site synchronous grouting device, characterized in that it includes material storage equipment, slurry making equipment, injection equipment, grouting equipment and a monitoring-feedback-decision-making system.

[0007] A shield machine integrated on-site synchronous grouting device, including material storage equipment, pulping equipment, injection equipment, grouting equipment and grouting control equipment; the material storage equipment includes a horizontal tank silo, a sealed tank, and a metering device; the pulping equipment includes a liquid A mixer and a liquid A agitator; the injection equipment includes an injection pump, a pressure delivery pipe, etc.; the grouting device includes a propulsion valve, a cleaning pipeline, a mixing device, a liquid B grouting pipe and a liquid A grouting pipe; the grouting control device includes a grouting pump control panel, a flow meter, a pressure gauge and an operation panel.

[0008] A shield machine integrated on-site synchronous grouting device, the material storage equipment includes a horizontal tank silo, a sealed tank, and a metering device; the storage equipment configuration and specifications are selected according to on-site conditions, and when selecting specifications, products with sufficient surplus capacity compared to the amount required for on-site backfill grouting should be selected; powders such as hardening materials and auxiliary materials will be stored in the horizontal tank silo; the sealed tank is used to store liquid materials, including a stabilizer storage tank, an accelerator storage tank, and a water tank; powders need to be measured by weight, and liquids are measured by volume, and the accuracy of the metering equipment needs to be confirmed regularly.

[0009] An integrated on-site synchronous grouting device for a shield machine, the grouting equipment comprises an A-liquid mixer and an A-liquid agitator; the A-liquid mixer is a stirring mixer, which is composed of a round tank and a rotating wing; the A-liquid agitator is a liquid storage tank with a stirrer, and the liquid storage capacity is generally about 2 to 3m; the A-liquid storage tank is used to store the A-liquid stirred evenly in the A-liquid mixer; four mechanical sensors are installed under each slurry storage tank, and slurry can be added according to the weight of the slurry storage tank; the equipment is compactly assembled and can mix and store a certain amount of A-liquid through automatic control.

[0010] An integrated on-site synchronous grouting device for a shield machine, the injection equipment includes an injection pump, a pressure-feeding piping, a pneumatic slurry valve, etc. The injection pump includes a liquid A grouting pump and a liquid B grouting pump, using an extrusion pump or a screw pump, and the discharge volume can be changed by frequency conversion when two pumps are used at the same time; the pressure-feeding piping is used to transport materials, and liquid A generally uses a steel pipe with a diameter of about 60 cm, and liquid B uses a steel pipe with a diameter of about 30 cm; considering that disassembly when extending the piping will cause liquid loss, it is recommended to install a valve at 50 to 100 meters.

[0011] A shield machine integrated on-site synchronous grouting device, the grouting equipment includes a propulsion valve, a cleaning pipeline, a mixing device, a grouting pipeline and a grouting control device; the A liquid piping cleaning method adopts a high-pressure water backwashing method after the grouting is completed; the mixing device is a device for mixing liquid A and liquid B, and the B liquid injection port is used to spray the B liquid; when grouting from the grouting hole, a pressure relief ball valve is installed, and the length from the mixing position to the grouting port is selected, and the gel time needs to be considered. Since the grouting pipe is installed on the grouting machine, it must be washed with water after each grouting is completed; the grouting pump is usually operated on an operating panel, on which there are display meters for the discharge volume, pressure and the injection volume of liquid A and liquid B, and the pump can be automatically stopped when the pressure rises by setting an upper limit pressure.

[0012] A shield machine integrated on-site synchronous grouting device, the grouting monitoring-feedback-decision-making system includes a monitoring system, a feedback system and a decision-making system; the monitoring system includes a grouting pressure monitoring device and a grouting flow monitoring device; the feedback system includes a GPR, an on-site drilling device, a total station system and a three-dimensional laser scanning device; the decision-making system is an interactive application that can integrate engineering hydrogeology and grouting effects, and adjust grouting parameters, stirring rate, feed rate and pumping rate in real time according to the shield speed; a pressure sensor is installed below the slurry storage tank; a pressure sensor and a flow sensor are integrated above the injection pump; and an air pressure sensor and an air volume monitor are added to the compressor.

[0013] A grouting method for a shield machine integrated on-site synchronous grouting device, comprising the following steps: Step 1: Use the flatbed truck set behind the shield to transport cement powder, bentonite and other powders to the horizontal tank silo of the device and store them. Use the screw conveyor to unload the materials into the silo. The high and low material level sensors are installed inside the silo to monitor the storage volume in real time. When the material is about to bottom out, it will automatically warn. The material supply is stable. The volume of the horizontal tank silo is set to 8~15m³. The accuracy of the high and low material level sensors is ±0.05m. When the remaining material level is less than 0.3m, the warning is triggered. Water is transported to the water tank through the conveying pipeline, and the water flow rate is accurately controlled by the variable frequency water pump. The matching variable frequency water pump flow rate control range is 0~3m³ / h; Store B liquid in a sealed tank, store the stabilizer in the stabilizer storage tank, and store the accelerator in the accelerator storage tank. The sealed tanks where B liquid, stabilizer and accelerator are located are all made of stainless steel, with volumes of 2~4m³, 0.2~0.5m³ and 0.3~0.8m³ respectively. Step 2: Confirm the storage volume of the materials used. In addition to manual verification, an intelligent weighing system is also used to accurately weigh each storage tank and silo. The accuracy of the weighing system is maintained at ±0.3%. Check whether the mixing machine and pumping pipeline can operate normally and whether the measuring instrument is normal. The inspection of the pumping pipeline starts from the appearance to check for cracks and deformations, and then use a pressure pump to perform a segmented pressure test. The pressure is gradually increased to 1.5 times the working pressure, and the pressure is stabilized for 15 minutes to observe whether there is a pressure drop or leakage. The flow meter is calibrated by comparison with a standard flow meter to ensure accurate readings. Step 3: Preparation of single liquid slurry: After checking that everything is correct, mix bentonite and other powders with water in a mixer, and then mix cement powder and water in a certain proportion to make liquid A. The water-cement ratio is set between 2 and 3, the stirring speed is 30 to 40 rpm, and the stirring time is not less than 10 minutes; Step 4: The volume ratio of liquid B to liquid A is 10:1~20:1. Liquid A and liquid B are stored in a slurry storage tank according to the proportion. Liquid B needs to be stored at a low temperature (5-15°C) to avoid expiration, so as to ensure the stability of each liquid before mixing; Step 5. The A liquid grouting pump uses a screw grouting pump with a flow rate of 0-8m³ / h and a grouting pressure of 4-7MPa; the B liquid grouting pump uses an extrusion grouting pump with a flow rate of 0-3m³ / h and a grouting pressure of 3-5MPa; through the frequency conversion transmission of the A liquid grouting pump and the B liquid grouting pump, the A liquid and the B liquid in a specific proportion are pumped to the A liquid storage tank and the B liquid storage tank for standby. The storage tank has a capacity of 2-4m³ and is equipped with a liquid level sensor with an accuracy of ±0.03 m. The reserve and concentration are fed back in real time, and the concentration deviation exceeds ±3% and is adjusted immediately; Step 6: Check whether the grouting pipeline is blocked. If it is correct, store liquid A and liquid B in proportion, and pressurize liquid B to the appropriate valve position for grouting. When the tunneling speed of the shield machine is stable, start liquid A, observe whether the grouting flow and pressure are normal through the grouting control device, and spray liquid B at the same time. The flow fluctuation range is controlled within ±5% of the set value, and the pressure fluctuation is controlled within ±0.2 MPa. Once exceeded, adjust immediately; Step 7: Grouting with single liquid slurry: When the tunneling speed of the shield machine is stable at 8-15 mm / min, start grouting. The initial grouting pressure is set to 0.5-1 MPa. The pressure transmitter and flow sensor are integrated on the injection pump, which can be adjusted dynamically according to the formation water pressure. When the formation water pressure is 0.1-0.2 MPa, the grouting pressure is gradually increased to 1-2 MPa. The flow fluctuation is controlled within ±5%. After each injection of 0.5 m³ of slurry, pause for 2-3 minutes to observe the surface settlement. When the settlement rate exceeds 2 mm / h, slow down the grouting speed to ensure dense filling and suppress settlement. Step 8: After the excavation speed stabilizes, start liquid A and liquid B simultaneously, with an initial grouting pressure of 1-2MPa. Since the dual-liquid slurry solidifies quickly, the flow rate and pressure must be closely monitored. If the pressure fluctuation exceeds ±0.2MPa or the flow rate deviation exceeds ±5%, adjust immediately. At the same time, according to the surface settlement data, fine-tune the grouting speed appropriately within the settlement of 3-5mm to ensure that the grouting is full without causing excessive settlement. Step 9: After the grouting is completed, stop the A and B liquids, use the push valve to push the double liquid slurry out of the injection port, and close the injection port by pushing the valve; flush the mixed pipeline with high-pressure water, and set the pressure of the high-pressure water pump at 10~15 MPa. Collect the flushing water into a special wastewater treatment pool, and recycle it after sedimentation and filtration; Step 10: During the tunnel excavation, the total station system is used to monitor the surface settlement, and the changes in the surface settlement values ​​during the synchronous grouting stage of the shield machine and the backfill grouting hardening stage are monitored in real time, so as to optimize and adjust the grouting parameters. The 3D laser scanning system is used to collect and scan the sample data of the tunnel lining surface, and the orthophoto map generated by the point cloud data is used by the decision system to identify the annular seams and analyze the misalignment of the pipe segments; Step 11. During tunnel excavation, the surface settlement is monitored by the total station system, and the changes in the surface settlement values ​​during the synchronous grouting stage of the shield machine and the backfill grouting hardening stage are monitored in real time; the 3D laser scanning system is used to collect and scan the tunnel lining surface sample data, and the orthophoto image generated by the point cloud data is used by the decision system to identify the annular seams and analyze the misalignment of the segments; the grouting parameters are optimized and adjusted in real time according to the surface settlement changes and the misalignment of the segments.

[0014] The beneficial effects of the present invention are: 1. The present invention provides a breakthrough in the traditional slurry making mode, forming an integrated system of "slurry making-slurry storage-grouting" inside the shield machine, solving the problem of instability in long-distance slurry pumping, ensuring the slurry making effect, and improving the stability of grouting; 2. The present invention changes the traditional ground mixing station to the shield machine trolley, and performs mixing operations on the shield machine trolley. After the slurry is prepared, it can be used for grouting construction immediately, which greatly shortens the transportation path of the slurry and effectively avoids the problems of slurry instability and high loss caused by long-distance pumping; 3. The present invention combines the pulping device with the storage device, reduces the pipeline laying, solves the problem of high cost of pulp pipeline laying, improves resource utilization, saves engineering costs, and reduces the disturbance and impact of the surrounding environment during the construction process, which meets the increasingly stringent environmental protection requirements of the country; 4. The present invention installs a monitoring device on the integrated on-site synchronous grouting device, which can monitor the grouting parameters in real time and feed them back to the decision-making system, and adjust the grouting parameters in real time according to the slurry flow and grouting pressure, which greatly reduces human intervention and realizes unmanned or less-manned operation of grouting operations, effectively avoiding problems such as untimely grouting or inaccurate grouting amount caused by human misjudgment or operation delay, and significantly improves the efficiency and quality of grouting operations; 5. The present invention combines the slurry making-grouting-slurry storage integrated system with the monitoring-feedback-decision-making system, which can adjust the grouting parameters in real time according to the hydrogeological parameters and the grouting effect, greatly improving the grouting effect and construction efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a front view of the overall structure of the present invention.

[0016] Figure 2 It is a side view of the overall structure of the present invention.

[0017] Figure 3 It is a top view of the superstructure of the present invention.

[0018] Figure 4 It is a top view of the lower structure of the present invention.

[0019] Figure 5 It is a schematic diagram of the grouting pipeline of the grouting equipment of the present invention.

[0020] Figure 6 It is a schematic diagram of the cleaning pipeline of the grouting equipment of the present invention.

[0021] Figure 7 It is a cross-sectional schematic diagram of the grouting pipeline delivery port of the present invention.

[0022] Figure 8It is a cross-sectional schematic diagram of the connection between the grouting pipeline and the valve of the present invention.

[0023] In the figure: 1. Hardening material storage tank; 2. Vibrator; 3. Pneumatic slurry valve; 4. Meter; 5. Mortar mixer; 6. Pneumatic slurry valve; 7. A liquid agitator; 8. A liquid grouting pump; 9. B liquid grouting pump; 10. Clean water tank; 11. Stabilizer storage tank; 12. Stabilizer grouting pump; 13. Water pump; 14. Flow control panel; 15. Compressor; 16. Guardrail; 17. Accelerator storage tank; 18. Sealed Tank; 19. Propulsion valve; 20. Cleaning pipeline; 21. A liquid grouting pipeline; 22. Valve; 23. B liquid injection port; 24. B liquid grouting pipeline; 25. Mechanical sensor; 26. Pressure delivery pipeline; 6-1. Grouting pipe body; 6-2. Piston; 6-3. Push rod; 6-4. Spring; 6-5. Diaphragm; 6-6. Pressure signal inlet; 6-7. Sealing filler; 26-1. Connecting flange; 26-2. Dense mesh. DETAILED DESCRIPTION

[0024] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0025] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present invention, so they have no substantial technical significance. Any modification of the structure, change of the proportion relationship or adjustment of the size, without affecting the effects and purposes that can be produced by the present invention, should still fall within the scope of the technical contents disclosed by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "outer" and "inner" quoted in this specification are only for the convenience of description, and are not used to limit the scope of the implementation of the present invention. The change or adjustment of their relative relationship should also be regarded as the scope of the implementation of the present invention without substantially changing the technical contents.

[0026] like Figure 1-4 The integrated grouting device for a shield machine is characterized by comprising material storage equipment, slurry making equipment, injection equipment, grouting equipment and grouting control equipment.

[0027] like Figure 1-4The integrated grouting device for a shield machine is characterized in that the material storage equipment includes a horizontal tank silo 1, a sealed tank 18, and a metering device 4; the configuration and specifications of the storage equipment are selected according to the site conditions, and when selecting the specifications, it is necessary to select products with sufficient surplus capacity compared to the amount required for on-site backfill grouting; powders such as hardening materials and auxiliary materials will be stored in the horizontal tank silo 1; the sealed tank 18 is used to store liquid materials, including a stabilizer storage tank 11, an accelerator storage tank 17, and a water tank 10; powders need to be measured by weight and liquids are measured by volume, and the accuracy of the metering equipment needs to be confirmed regularly.

[0028] like Figure 1-4 The integrated grouting device for a shield machine is characterized in that the slurry making equipment includes a liquid A mixer 5 and a liquid A stirrer 7; the liquid A mixer 5 is a stirring mixer, which is composed of a round tank and a rotating wing; the liquid A stirrer 7 is a liquid storage tank with a stirrer, and the liquid storage capacity is generally about 2 to 3m; the liquid A storage tank is used to store the liquid A that is stirred evenly in the liquid A mixer; four mechanical sensors are installed under each slurry storage tank, and slurry can be replenished according to the weight of the slurry storage tank; the equipment is compactly assembled and can mix and store a certain amount of liquid A through automatic control.

[0029] like Figure 1-4 The integrated grouting device of a shield machine is characterized in that the injection equipment includes an injection pump, a pressure-feeding piping, a pneumatic slurry valve 3, etc.; the injection pump includes a liquid A grouting pump 8, a liquid B grouting pump 9 and a water pump 13, using an extrusion pump or a screw pump, and the discharge volume can be changed by frequency conversion when two pumps are used at the same time; the pressure-feeding piping is used to transport materials, and liquid A generally uses an iron pipe with a diameter of about 60 cm and liquid uses an iron pipe with a diameter of about 30 cm. Considering that the disassembly when extending the piping will cause liquid loss, it is recommended to install the valve at 50-100 meters.

[0030] like Figure 5-6 The integrated grouting device of a shield machine is characterized in that the grouting equipment includes a propulsion valve 19, a cleaning pipeline 20, a mixing device, a B liquid grouting pipe 24 and an A liquid grouting pipe 21; the A liquid piping cleaning method adopts a high-pressure water backwashing method after the grouting is completed; the mixing device is a device for mixing liquids A and B, and the B liquid injection port 23 is used to spray the B liquid; when grouting is performed from the grouting hole, a pressure relief ball valve is installed, and the length from the mixing part to the grouting port is selected, and the gel time needs to be considered. Since the grouting pipe is installed on the grouting machine, it must be washed with water at the end of each grouting.

[0031] like Figure 1-4The integrated grouting device for a shield machine is characterized in that the grouting control equipment generally includes a flow control panel 14, a flow meter 4, a pressure gauge and an operating panel; the operation of the grouting pump is usually carried out on an operating panel, on which there are display meters for the discharge volume, pressure, and the injection volume of liquid A and liquid B. The pump can be automatically stopped when the pressure rises by setting an upper limit pressure.

[0032] like Figure 1-6 The on-site grouting method for the shield machine integrated on-site synchronous grouting device is characterized by comprising the following steps: Step 1: Use the flatbed truck set behind the shield tail to transport cement powder, bentonite and other powders to the horizontal tank silo 1 of the device for storage, and use the screw conveyor to accurately unload the materials into the silo. The silo is equipped with high and low level sensors to monitor the storage volume in real time. When the material is about to bottom out, it will automatically warn to maintain a stable material supply. The volume of the horizontal tank silo is set at 8~15 m³, and the accuracy of the high and low level sensors is ±0.05 m. When the remaining material level is less than 0.3 m, the warning is triggered; water is transported to the water tank 10 through the conveying pipeline, and the water flow rate is accurately controlled by the variable frequency water pump. The matching variable frequency water pump has a flow rate control range of 0~3m³ / h; liquid B is stored in a sealed tank 18, the stabilizer is stored in the stabilizer storage tank 11, and the accelerator is stored in the accelerator storage tank 17. The sealed tanks where liquid B, stabilizer and accelerator are located are all made of stainless steel, with volumes of 2~4m³, 0.2~0.5 m³ and 0.3~0.8 respectively. m³; Step 2: Confirm the storage volume of the materials used. In addition to manual verification, an intelligent weighing system is also used to accurately weigh each storage tank and silo. The accuracy of the weighing system is maintained at ±0.3%. Check whether the mixing machine and pumping pipeline can operate normally and whether the measuring instrument is normal. The inspection of the pumping pipeline starts from the appearance to check for cracks and deformations, and then use a pressure pump to perform a segmented pressure test. The pressure is gradually increased to 1.5 times the working pressure, and the pressure is stabilized for 15 minutes to observe whether there is pressure drop and leakage. The flow meter is calibrated by comparison with a standard flow meter to ensure accurate readings. Step 3: Preparation of single liquid slurry: After checking that everything is correct, mix bentonite and other powders with water in a mixer, and then mix cement powder and water in a certain proportion to make liquid A. The water-cement ratio is set between 2 and 3, the stirring speed is 30 to 40 rpm, and the stirring time is not less than 10 min. Step 4: Preparation of double liquid slurry: The volume ratio of liquid B to liquid A is 10:1~20:1. Liquid A and liquid B are stored in a slurry storage tank according to the proportion. Liquid B needs to be stored at a low temperature (5-15°C) to avoid expiration, so as to ensure the stability of each liquid before mixing; Step 5: The A liquid grouting pump uses a screw grouting pump 8 with a flow rate of 0-8 m³ / h and a grouting pressure of 4~7 MPa; the B liquid grouting pump uses an extrusion grouting pump 9 with a flow rate of 0~3 m³ / h and a grouting pressure of 3~5 MPa; through the frequency conversion transmission of the A liquid grouting pump and the B liquid grouting pump, the A liquid and the B liquid in a specific ratio are pumped to the A liquid storage tank and the B liquid storage tank for standby, respectively. The storage tank has a capacity of 2~4 m³ and is equipped with a liquid level sensor with an accuracy of ±0.03 meters, which can provide real-time feedback on the reserves and concentration. If the concentration deviation exceeds ±3%, it will be adjusted immediately; Step 6: Check whether the grouting pipeline is blocked. If it is correct, store liquid A and liquid B in proportion, and pressurize liquid B to the appropriate valve position for injection; when the tunneling speed of the shield machine is stable, start liquid A, observe whether the grouting flow and pressure are normal through the grouting control device, and spray liquid B at the same time. The flow fluctuation range is controlled within ±5% of the set value, and the pressure fluctuation is controlled within ±0.2 MPa. Once exceeded, adjust immediately; Step 7, single-liquid grouting: start grouting when the tunneling speed of the shield machine is stable at 8-15 mm / min, and the initial grouting pressure is set to 0.5-1 MPa. The injection pump 19 is integrated with a pressure transmitter and a flow sensor, which can be dynamically adjusted according to the formation water pressure. When the formation water pressure is 0.1-0.2 MPa, the grouting pressure is gradually increased to 1-2 MPa; the flow fluctuation is controlled within ±5%, and pause for 2-3 min after each injection of 0.5 m³ to observe the surface settlement. When the settlement rate exceeds 2 mm / h, slow down the grouting speed to ensure dense filling and suppress settlement; Step 8: Dual-liquid grouting: After the excavation speed stabilizes, start liquid A and liquid B simultaneously, with an initial grouting pressure of 1~2 MPa. Since the dual-liquid grout solidifies quickly, it is necessary to pay close attention to the flow rate and pressure. If the pressure fluctuation exceeds ±0.2 MPa or the flow rate deviation exceeds ±5%, it should be adjusted immediately. At the same time, according to the surface settlement data, the grouting speed should be fine-tuned appropriately within the settlement of 3~5mm to ensure that the grouting is full without causing excessive settlement. Step 9: After the grouting is completed, stop the A and B liquids, use the push valve to push the double liquid slurry out of the injection port, and close the injection port by pushing the valve; flush the mixed pipeline with high-pressure water, and set the pressure of the high-pressure water pump at 10~15 MPa. Collect the flushing water into a special wastewater treatment pool, and recycle it after sedimentation and filtration; Step 10: During the tunnel excavation, the total station system is used to monitor the surface settlement, and the changes in the surface settlement values ​​during the synchronous grouting stage of the shield machine and the backfill grouting hardening stage are monitored in real time, so as to optimize and adjust the grouting parameters. The 3D laser scanning system is used to collect and scan the sample data of the tunnel lining surface, and the orthophoto map generated by the point cloud data is used by the decision system to identify the annular seams and analyze the misalignment of the pipe segments; Step 11. After the grouting is completed, the geological radar is used to detect the grouting backfill effect of the shield tunnel. The SIR-4000 ground penetrating radar is selected, and the radar detection speed is controlled at about 3km / h. The sampling mode is continuous detection. The measuring lines are arranged on the arch top, left arch waist, left wall, right arch waist, right wall and tunnel bottom respectively to detect the defects on the back of the tunnel lining. The grouting effect is judged by the feedback radar scanning analysis chart and the grouting parameters are adjusted in time.

Claims

1. A shield machine integrated on-site synchronous grouting device, characterized in that: Including material storage equipment, pulping equipment, injection equipment, grouting equipment and grouting monitoring-feedback-decision-making system; The material storage equipment includes a horizontal tank silo, a sealed tank, and a metering device; the pulping equipment includes a liquid A mixer and a liquid A agitator; the injection equipment includes an injection pump, a pressure delivery pipe, a pneumatic slurry valve, etc.; the grouting equipment includes a propulsion valve, a cleaning pipeline, a mixing device, a grouting pipeline, and a grouting pump control device; the grouting monitoring-feedback-decision-making system includes a monitoring system, a feedback system, and a decision-making system; The material storage equipment includes horizontal tank silos, sealed tanks, and metering equipment; the configuration and specifications of the material storage equipment are selected according to the site conditions, and when selecting the specifications, products with sufficient surplus capacity for the amount required for on-site backfill grouting should be selected; powders such as hardening materials and auxiliary materials will be stored in horizontal tank silos; sealed tanks are used to store liquid materials, including stabilizer storage tanks, accelerator storage tanks, and water tanks; Powders need to be measured by weight, liquids by volume, and the accuracy of the measuring equipment needs to be regularly confirmed; The slurry making equipment comprises a liquid A mixer and a liquid A stirrer; the liquid A mixer is used to mix cement particles, clean water, bentonite and various additives; the liquid A stirrer keeps various particles in the slurry in a suspended state by continuous stirring, thereby ensuring the stability of the liquid A; the liquid A storage tank is used to store the liquid A stirred evenly in the liquid A mixer; The injection equipment includes an injection pump, a pressure delivery pipe, a pneumatic slurry valve, a compressor, etc. The injection pump includes a liquid A grouting pump and a liquid B grouting pump, which are used to transport liquid A and liquid B from the storage container to the grouting pipeline; the pressure delivery pipe is used to transport materials; the pneumatic slurry valve is used to accurately control the flow of liquid A and liquid B; the compressor is used to provide a power source for the grouting pump and the pneumatic slurry valve; The grouting equipment includes a propulsion valve, a cleaning pipeline, a mixing device, a grouting pipeline and a grouting control device; a method for cleaning the A liquid piping, and a high-pressure water backwashing method is used after the grouting is completed; the mixing device is a device for mixing A liquid and B liquid, and the B liquid injection port is used to spray the B liquid; when grouting from the grouting hole, a pressure relief ball valve is installed, and the length from the mixing part to the grouting port is selected, and the gel time needs to be considered. Since the grouting pipe is installed on the grouting machine, it must be washed with water at the end of each grouting; the operation of the grouting pump is usually carried out on the operating panel, on which there are display meters for the discharge volume, pressure, and the injection volume of A liquid and B liquid, and the pump can be automatically stopped when the pressure rises by setting the upper limit pressure; The grouting monitoring-feedback-decision-making system includes a monitoring system, a feedback system and a decision-making system; the monitoring system includes a grouting pressure monitoring device and a grouting flow monitoring device; the feedback system includes a total station monitoring system, a geological radar, a three-dimensional laser scanning system and an on-site drilling device; The decision-making system is an interactive application that can adjust grouting parameters, mixing rate, feed rate and pumping rate in real time based on engineering hydrogeology, tunneling parameters and grouting effects.

2. A shield machine integrated on-site synchronous grouting method, characterized in that: The shield machine integrated on-site synchronous grouting device is used, comprising the following steps: (1) Through the flatbed truck set behind the shield, cement powder, bentonite and other powders are transported and stored in the horizontal tank silo of the device, and unloaded into the silo by a screw conveyor. The silo is equipped with high and low material level sensors to monitor the storage volume in real time. When the material is about to bottom out, it will automatically warn. The material supply is stable. The volume of the horizontal tank silo is set to 8~15m³, and the accuracy of the high and low material level sensors is ±0.05m. When the remaining material level is less than 0.3m, the warning is triggered; water is transported to the water tank through a conveying pipeline, and the water flow rate is accurately controlled by a variable frequency water pump. The matching variable frequency water pump flow rate control range is 0~3m³ / h; Liquid B is stored in a sealed tank, the stabilizer is stored in a stabilizer storage tank, and the accelerator is stored in an accelerator storage tank. The sealed tanks where Liquid B, stabilizer, and accelerator are located are all made of stainless steel, with volumes of 2~4m³, 0.2~0.5m³, and 0.3~0.8m³, respectively; (2) Confirm the storage volume of the materials used. In addition to manual verification, an intelligent weighing system is also used to accurately weigh each storage tank and silo. The accuracy of the weighing system is maintained at ±0.3%; check whether the mixing machine and pumping pipeline can operate normally and whether the measuring instrument is normal; the inspection of the pumping pipeline starts from the appearance, check for cracks and deformation, and then use a pressure pump to perform a sectioned pressure test, gradually increase the pressure to 1.5 times the working pressure, stabilize the pressure for 15 minutes, and observe whether there is pressure drop and leakage; the flow meter is calibrated by comparison with a standard flow meter to ensure accurate readings; (3) Preparation of single liquid slurry: After checking that everything is correct, mix bentonite and other powders with water in a mixer, and then mix cement powder and water in a certain proportion to make liquid A. The water-cement ratio is set between 2 and 3, the stirring speed is 30 to 40 rpm, and the stirring time is not less than 10 min; (4) Preparation of double liquid slurry: The volume ratio of liquid B to liquid A is 10:1~20:

1. Liquid A and liquid B are stored in the slurry storage tank according to the proportion. Liquid B needs to be stored at a low temperature (5-15°C) to avoid expiration, so as to ensure the stability of each liquid before mixing; (5) The A liquid grouting pump uses a screw grouting pump with a flow rate of 0-8m³ / h and a grouting pressure of 4-7MPa; the B liquid grouting pump uses an extrusion grouting pump with a flow rate of 0-3m³ / h and a grouting pressure of 3-5MPa; through the frequency conversion transmission of the A liquid grouting pump and the B liquid grouting pump, the A liquid and the B liquid in a specific proportion are pumped to the A liquid storage tank and the B liquid storage tank for standby. The storage tank has a capacity of 2-4m³ and is equipped with a liquid level sensor with an accuracy of ±0.03m, which provides real-time feedback on the reserve and concentration. If the concentration deviation exceeds ±3%, it will be adjusted immediately; (6) Check whether the grouting pipeline is blocked. If it is blocked, store liquid A and liquid B in proportion and pressurize liquid B to an appropriate valve position for grouting. When the tunneling speed of the shield machine is stable, start liquid A and observe whether the grouting flow and pressure are normal through the grouting control device. At the same time, spray liquid B. The flow fluctuation range is controlled within ±5% of the set value, and the pressure fluctuation is controlled within ±0.2 MPa. If it exceeds the limit, adjust it immediately. (7) Single-liquid grouting: Grouting is started when the tunneling speed of the shield machine is stable at 8-15 mm / min. The initial grouting pressure is set at 0.5-1 MPa. The injection pump is equipped with an integrated pressure transmitter and flow sensor, which can be adjusted dynamically according to the formation water pressure. When the formation water pressure is 0.1-0.2 MPa, the grouting pressure is gradually increased to 1-2 MPa. The flow fluctuation is controlled within ±5%. After each injection of 0.5 m³ of slurry, a 2-3 min pause is performed to observe the surface settlement. When the settlement rate exceeds 2 mm / h, the grouting speed is slowed down to ensure dense filling and suppress settlement. (8) Dual-liquid grouting: After the excavation speed stabilizes, liquid A and liquid B are started simultaneously, with an initial grouting pressure of 1-2 MPa. Since the dual-liquid grout solidifies quickly, the flow rate and pressure must be closely monitored. If the pressure fluctuation exceeds ±0.2 MPa or the flow rate deviation exceeds ±5%, adjustments should be made immediately. At the same time, according to the surface settlement data, the grouting speed should be appropriately adjusted within a settlement of 3-5 mm to ensure that the grouting is full without causing excessive settlement. (9) After grouting is completed, stop the A and B liquids, use the push valve to push the double liquid slurry out of the injection port, and close the injection port by pushing the valve; flush the mixed pipeline with high-pressure water, and set the pressure of the high-pressure water pump at 10-15 MPa. Collect the flushing water into a special wastewater treatment pool and recycle it after sedimentation and filtration; (10) During tunnel excavation, the total station system is used to monitor the ground settlement and the changes in the ground settlement values ​​during the shield machine synchronous grouting stage and the backfill grouting hardening stage are monitored in real time. The 3D laser scanning system is used to collect and scan the tunnel lining surface sample data, and the decision system is used to identify the annular seams on the orthophoto map generated by the point cloud data and analyze the misalignment of the segments. The grouting parameters are optimized and adjusted in real time according to the changes in the ground settlement values ​​and the misalignment of the segments. (11) After the grouting is completed, the grouting backfill effect of the shield tunnel is detected by geological radar. The SIR-4000 ground penetrating radar is selected. The radar detection speed is 3 km / h and the sampling mode is continuous detection. Survey lines are arranged on the arch crown, left arch waist, left wall, right arch waist, right wall and tunnel bottom to detect defects on the back of the tunnel lining. The grouting effect is judged by the feedback radar scanning analysis chart and the grouting parameters are adjusted in time.

3. According to claim 1, a shield machine integrated on-site synchronous grouting device is characterized in that: The pulping equipment comprises a liquid A mixer and a liquid A stirrer; the liquid A mixer is a stirring mixer, which is composed of a round tank and a rotating wing; the liquid A stirrer is a stirrer with a liquid storage tank, and the liquid storage capacity is generally about 2 to 3m; the liquid A storage tank is used to store the liquid A that is stirred evenly in the liquid A mixer; four pressure sensors are installed under each slurry storage tank, and slurry can be replenished according to the weight of the slurry storage tank; the equipment is compactly assembled and can mix and store a certain amount of liquid A through automatic control.

4. According to claim 1, a shield machine integrated on-site synchronous grouting device is characterized in that: The A-liquid agitator and the A-liquid mixer are equipped with torque sensors inside, which can determine the slurry viscosity by monitoring the torque changes of the agitator shaft; the pressure sensor under the A-liquid storage tank is connected to the grouting control device. When the surface seepage water seriously causes the formation pore water pressure to increase, the pressure sensor feedback prompts the storage tank to release an appropriate amount of A-liquid in advance to balance the pressure, thereby avoiding obstruction of subsequent grouting.

5. The shield machine integrated on-site synchronous grouting device according to claim 1, characterized in that: The injection equipment includes an injection pump, pressure delivery piping, pneumatic slurry valves, etc.; the A liquid grouting pump adopts a screw grouting pump with stable flow and uniform pressure delivery. The B liquid grouting pump uses an extrusion pump to meet the high-pressure delivery requirements of B liquid. The use of two pumps at the same time can change the discharge volume through frequency conversion; the pumping rate is generally 20 L / min, which is adjusted according to soil conditions and equipment configuration; A hydraulic delivery piping generally uses a steel pipe with a diameter of about 60 cm, and B liquid uses a steel pipe with a diameter of about 30 cm. Considering that disassembly will cause liquid loss when extending the piping, it is recommended to install valves at 50-100 meters.

6. The shield machine integrated on-site synchronous grouting device according to claim 1, characterized in that: The injection pump is integrated with a pressure sensor and a flow sensor. The flow sensor has a measurement accuracy of ±1% and is connected to the grouting control device. When approaching a sensitive area of ​​surface subsidence, it can automatically reduce the flow rate and perform precise micro-injection. An air pressure sensor and a gas volume monitor are added to the compressor, which can provide real-time feedback on the power source status to the grouting control equipment, increase gas production according to formation resistance, maintain a stable grouting power supply, and ensure a stable grouting rate.

7. The shield machine integrated on-site synchronous grouting device according to claim 1, characterized in that: The grouting equipment includes a propulsion valve, a cleaning pipeline, a mixing device, a B-liquid grouting pipe and an A-liquid grouting pipe; the propulsion pump uses an electromagnetic propulsion pump to accurately grasp the start and stop timing of grouting, and the valve mouth seal uses a rubber sealing ring; the cleaning pipeline uses a high-pressure resistant rubber hose with a smooth inner wall that can minimize flushing residues; the B-liquid grouting pipe and the A-liquid grouting pipe are made of high-strength stainless steel to ensure high-pressure and corrosion-resistant performance; the B-liquid grouting pipe uses a 30-cm steel pipe, and the A-liquid grouting pipe uses a 60-cm steel pipe.

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