Automatic spraying method for tunnel roadway concrete support

Abstract

The invention discloses an automatic spraying method for a tunnel roadway concrete support in the technical field of concrete support spraying, which comprises the following steps of: controlling a traveling chassis, a pumping mechanism, an arm support mechanism and an environment scanning mechanism through a traveling computer to realize automatic spraying of the concrete support of an excavation surface in a tunnel; a worker does not need to enter a tunnel to control the concrete wet spraying machine in a close range, threats of the severe environment to the health of the worker and potential safety hazards are thoroughly avoided, various parameters during concrete support spraying are adjusted according to the actual situation of an excavation face, and therefore the spraying process of concrete support is accurately controlled, and the construction efficiency is improved. The forming quality of the final concrete support is improved, reworking caused by manual errors is reduced, meanwhile, continuous operation without intermittency can be achieved, and the construction efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of concrete support spraying, in particular to an automatic spraying method for tunnel shaft and lane concrete support. Background Art

[0002] Concrete spraying support, as an important process for tunnel shaft support, is widely used in railways, highways, water conservancy, national defense, metallurgy and other fields. Its working principle is to use fluid power to transport ready-mixed concrete through pipelines and spray it at high speed onto the sprayed surface. A concrete layer is formed by the continuous impact and compaction of concrete during the spraying process.

[0003] Operators of traditional wet spraying machines need to operate the equipment at close range, exposing them to long-term exposure to dust, noise, harmful gases, and landslides in tunnels, which can easily lead to respiratory diseases, hearing loss, and even accidents. Especially for engineering equipment, they often face harsh operating environments such as long and deep tunnels, plateau areas, and extreme high and low temperatures. For example, the construction of plateau railways requires the investment of large quantities of tunnel construction equipment, including drilling rigs and excavators. The air in the plateau environment is thin, and construction equipment generally faces problems such as reduced power, increased energy consumption, and increased emissions and pollution. These problems are more prominent during long-distance tunnel construction, and there are safety hazards such as "competing with people for oxygen" and the accumulation of large amounts of harmful gases.

[0004] At the same time, traditional wet spraying machines rely on manual adjustment of the spraying angle, distance and speed, resulting in poor operational consistency, which can easily lead to uneven spraying thickness and difficult to ensure spraying quality. In addition, the training cycle for workers skilled in operating wet spraying machines is long, the labor cost is high, and fatigue work can easily cause quality fluctuations, making it difficult to guarantee the final construction quality.

[0005] Based on this, the present invention designs an automatic spraying method for tunnel shaft concrete support to solve the above problems. Summary of the Invention

[0006] To achieve the above-mentioned object, the present invention provides the following technical solution: a method for automatically spraying concrete support for tunnel shafts and lanes, wherein the automatic spraying of concrete support is performed by a concrete wet spraying machine, the concrete wet spraying machine comprising a driving chassis, a pumping mechanism, a boom mechanism, an environmental scanning mechanism, and a driving computer; the pumping mechanism, boom mechanism, environmental scanning mechanism, and driving computer are all arranged on the driving chassis;

[0007] The automatic spraying method for tunnel shaft and lane concrete support comprises the following steps:

[0008] S1, obtain the coordinates of the tunnel construction location and input them into the driving computer, which controls the driving chassis to move to the tunnel construction location;

[0009] S2, use the environmental scanning mechanism to scan and model the tunnel contour, and calculate the thickness of the concrete base layer based on the concrete support contour and the tunnel contour model;

[0010] S3, start the pumping mechanism and the arm mechanism to spray the base layer in each scan cloud point area, spraying first from the arch foot to the waist of the excavation surface in the tunnel, and then spray from the waist to the top after the concrete from the arch foot to the waist has solidified. The spraying thickness is the base layer thickness calculated in step S2;

[0011] S4, after the base layer solidifies, the arm mechanism controls the nozzle to move to the over-excavation point to spray and fill the over-excavation point to fill the potholes on the surface of the base layer;

[0012] S5, scanning and modeling the base layer surface through the environmental scanning mechanism, and transmitting the modeled data to the on-board computer for analysis to obtain the base layer surface profile data;

[0013] S6, planning the swing speed of the arm mechanism and the spraying speed of the pumping mechanism when spraying the sweeping layer according to the surface profile data of the base layer, and then spraying the sweeping layer on the surface of the base layer to obtain concrete support.

[0014] As a further solution of the present invention, in step S1, the coordinates of the tunnel construction position are obtained through the surveying and mapping report of the tunnel construction position, the starting position coordinates of the concrete wet spraying machine and the tunnel construction position coordinates are input into the driving computer, and the cruise software in the driving computer controls the movement of the driving chassis to move the concrete wet spraying machine to the tunnel construction position.

[0015] As a further solution of the present invention, during the movement of the driving chassis 1 in step S1, the environmental scanning mechanism scans the road surface in the tunnel in real time, and feeds the scanning data back to the driving computer in real time, which is processed by the cruise software for real-time route planning.

[0016] As a further solution of the present invention, in step S2, the modeled data is transmitted to the on-board computer to analyze the size of the excavation surface and the positions of over-excavation and under-excavation. After removing the over-excavation points and under-excavation points that exceed the preset size, the excavation surface is divided into multiple scanning point areas. The concrete support forming contour is compared with the excavation surface to calculate the concrete volume and average thickness required for each scanning point area. The average thickness of the concrete is subtracted from the thickness of the leveling layer to obtain the base layer thickness.

[0017] As a further solution of the present invention, in step S2, the preset size is the over-excavation depth and under-excavation thickness specified in the tunnel construction requirements. When there are no over-excavation points and / or under-excavation points exceeding the preset size, the over-excavation points of the maximum depth and / or the under-excavation points of the maximum thickness are removed.

[0018] As a further solution of the present invention, in step S2, the tunnel contour is divided into multiple scanning point areas according to the spraying range of the nozzle.

[0019] As a further solution of the present invention, the environmental scanning mechanism includes a laser scanner, a mounting platform and a rotating platform. The rotating platform is arranged at one of the two ends of the length direction of the vehicle chassis through the mounting platform, and the laser scanner is arranged on the rotating platform so that the laser scanner has rotational freedom in the X, Y and N axis directions.

[0020] As a further solution of the present invention, the mounting platform includes a base, a push rod motor and a protective cover. The base is fixed on the chassis of the vehicle for mounting a laser scanner. The protective cover is hinged to one end of the base and has a first state in which the laser scanner on the base is covered and a second state in which the laser scanner on the base is exposed. The two ends of the push rod motor are respectively hinged to the base and the protective cover to drive the protective cover to switch between the first state and the second state through the action of the push rod motor.

[0021] As a further solution of the present invention, the driving chassis includes a chassis assembly, wheels and wheel-side motors. At least two connecting bridges are provided at the bottom of the chassis assembly. Wheels and wheel-side motors are provided at both ends of the connecting bridge. The wheel-side motors at both ends of the connecting bridge are respectively used to drive the wheels at both ends of the connecting bridge.

[0022] As a further solution of the present invention, the arm mechanism includes an arm traveling mechanism, an arm slewing platform, one arm, two arms, three arms and four arms; the arm traveling mechanism is fixed on the chassis assembly, so that the arm slewing platform, one arm, two arms, three arms and four arms can travel as a whole along the length direction of the chassis assembly; the arm slewing platform is arranged on the arm traveling mechanism, so that the one arm, two arms, three arms and four arms have rotational freedom in two directions of X-axis and Y-axis; the one arm is connected to the arm slewing platform through a pin and a cylinder for realizing pitch adjustment; the two arms are nested in one arm through a pin and a cylinder, and can be extended and retracted along the length direction of one arm; the three arms are connected to the end of the two arms away from the one arm through a pin and a cylinder, for folding the arm assembly; one end of the four arms is nested in the end of the three arms away from the two arms through the cylinder and the pin, can be extended and retracted along the length direction of the three arms, and the other end is connected to the nozzle by a bolt.

[0023] As a further embodiment of the present invention, the nozzle includes a nozzle, a mixer, a connector and a hydraulic motor; the nozzle, mixer and connector are connected in sequence, the connector is used to connect to the pumping system through a conveying pipeline, the side wall of the mixer is provided with an addition hole for allowing concrete admixture to enter, and the concrete admixture is mixed with concrete through the mixer, and the nozzle is used to atomize concrete and spray it out; the connector is installed on four arms through a hydraulic motor, and the hydraulic motor is used to drive the connector to rotate, thereby driving the nozzle to rotate.

[0024] As a further solution of the present invention, a camera is fixedly installed on the chassis assembly, and the camera, arm mechanism and environmental scanning mechanism are arranged in sequence along the length direction of the chassis assembly to observe the working status of the arm mechanism and the environmental scanning mechanism through the camera.

[0025] The present invention has the following beneficial effects:

[0026] 1. This method uses a driving computer to control the driving chassis, pumping mechanism, boom mechanism, and environmental scanning mechanism to achieve automatic spraying of concrete support on the excavation surface in the tunnel. When spraying concrete support, there is no need for workers to enter the tunnel to closely operate the wet concrete spraying machine, completely avoiding the threat to workers' health and safety hazards caused by the harsh environment;

[0027] 2. This method uses an environmental scanning mechanism to scan the tunnel contour to obtain the size of the tunnel excavation surface and the over-excavation and under-excavation conditions on the excavation surface. According to the actual conditions of the excavation surface, various parameters during the concrete support spraying are adjusted, thereby accurately controlling the concrete support spraying process, improving the final concrete support molding quality, and reducing rework caused by human errors. At the same time, it can achieve continuous operation without interruption and improve construction efficiency.

[0028] In addition to the above-described objects, features and advantages, the present invention has other objects, features and advantages. The present invention will be further described in detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which constitute part of this application, are intended to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are intended to explain the present invention and do not constitute an undue limitation of the present invention. In the accompanying drawings:

[0030] Figure 1 It is a left side schematic diagram of the concrete wet spraying machine in the present invention.

[0031] Figure 2 It is a right side schematic diagram of the concrete wet spraying machine in the present invention.

[0032] Figure 3 It is a left side schematic diagram of the concrete wet spraying machine of the present invention with the boom mechanism removed.

[0033] Figure 4 It is a schematic diagram of the structure of the environment scanning mechanism in the present invention.

[0034] Figure 5 It is a structural schematic diagram of the installation platform in the present invention.

[0035] Figure 6 It is a structural schematic diagram of the wheel-side steering fixed bridge in the present invention.

[0036] Figure 7 It is a structural schematic diagram of the wheel-side steering floating bridge in the present invention.

[0037] Figure 8 It is a structural schematic diagram of the arm mechanism in the present invention.

[0038] Figure 9 It is a structural schematic diagram of the nozzle in the present invention.

[0039] Figure 10 Schematic diagram of the structure of the power battery in the present invention.

[0040] Figure 11 It is a structural schematic diagram of the quick-release rack in the present invention.

[0041] Figure 12 It is a flow chart of the present invention.

[0042] Figure 13 Schematic diagram of the tunnel excavation surface.

[0043] Legend:

[0044] 1. Driving chassis; 11. Chassis assembly; 12. Wheel; 13. Wheel-side motor; 141. Deceleration brake box; 142. Steering cylinder; 143. Bridge body; 144. Motor seat; 145. Articulated rocker arm; 146. Limit frame; 2. Pumping mechanism; 3. Boom mechanism; 31. Travel mechanism; 32. Boom slewing platform; 33. One arm; 34. Two arms; 35. Three arms; 36. Four arms; 4. Environmental scanning mechanism; 41. Laser scanner; 42. Mounting platform; 421. Base; 422. Push rod motor; 423. Protective cover; 43. Rotating platform; 5. Driving computer; 6. Nozzle; 61. Nozzle; 62. Mixer; 63. Connector; 64. Hydraulic motor; 7. Camera; 8. Cab; 91. Power battery; 92. Charging socket; 93. Quick-release rack; 94. Reel. DETAILED DESCRIPTION

[0045] The embodiments of the present invention are described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered below.

[0046] See also Figure 1-12The present invention provides a technical solution: a method for automatic spraying of concrete support for tunnel shafts and lanes, wherein the automatic spraying of concrete support is performed by a concrete wet spraying machine, the concrete wet spraying machine comprising a driving chassis 1, a pumping mechanism 2, an arm mechanism 3, an environmental scanning mechanism 4, and a driving computer 5; the driving chassis 1 is used for traveling on a road surface, and the pumping mechanism 2, the arm mechanism 3, the environmental scanning mechanism 4, and the driving computer 5 are all arranged on the driving chassis 1; a nozzle 6 is provided on the arm mechanism 3, and the nozzle 6 is connected to the pumping mechanism 2 through a conveying pipeline so as to convey concrete to the nozzle 6 through the pumping mechanism 2; the driving computer 5 is connected to the driving chassis 1, the pumping mechanism 2, the arm mechanism 3, and the environmental scanning mechanism 4 by telecommunication, and is used to receive data from the environmental scanning mechanism 4 and control the driving chassis 1, the pumping mechanism 2, the arm mechanism 3, and the environmental scanning mechanism 4;

[0047] The automatic spraying method for tunnel shaft concrete support includes the following steps:

[0048] S1: After tunnel excavation is completed, the coordinates of the tunnel construction position are obtained from the tunnel surveying report. The coordinates of the starting position of the concrete spraying machine and the coordinates of the tunnel construction position are input into the driving computer 5. The cruise software in the driving computer 5 controls the movement of the driving chassis 1 to move the concrete spraying machine to the tunnel construction position.

[0049] When constructing in accordance with national construction standards, drilling and blasting, excavation, and support processes are closely linked. During the construction process, tunnels are surveyed and mapped, and a survey report is generated. The coordinates of the excavation surface in the tunnel that requires wet shotcrete support are obtained from the survey report. The construction location coordinates and the initial position coordinates of the wet shotcrete machine are input into the driving computer 5. The cruise software automatically generates a path and drives the driving chassis 1 to move to the construction location.

[0050] S2, using the environmental scanning mechanism 4 to scan and model the tunnel profile, and transmitting the modeled data to the on-board computer 5 for analysis of the excavation surface dimensions and over-excavation and under-excavation locations. After removing over-excavation and under-excavation points exceeding a preset dimension, the excavation surface is divided into a plurality of scanning point areas. The concrete support profile is compared with the excavation surface to calculate the required concrete volume and average thickness for each scanning point area. The thickness of the base layer is obtained by subtracting the sweeping layer thickness from the average concrete thickness.

[0051] After the wet concrete spraying machine moves to the construction location, due to the tunnel drilling and blasting process, over-excavation and under-excavation will be formed, which will lead to uneven excavation surface in the tunnel. When spraying concrete support, it is necessary to adjust the thickness of the concrete spraying according to the actual tunnel contour. The tunnel contour at the working location is scanned by the environmental scanning mechanism 4, and the data after the tunnel contour modeling is transmitted to the driving computer 5 for analysis. The size of the excavation surface in the tunnel contour and the location of over-excavation and under-excavation in the excavation surface are analyzed to provide a basis for subsequent concrete spraying.

[0052] After obtaining the size of the excavation surface at the tunnel construction location, the concrete volume and average thickness required for shotcrete support can be calculated based on the size of the excavation surface. However, before calculating the concrete volume and average thickness, it is necessary to remove the over-excavation and under-excavation positions that exceed the preset size. First, the over-excavation positions that exceed the preset size can no longer achieve the support effect through shotcrete support, and the under-excavation positions that exceed the preset size have exceeded the concrete support forming contour and can no longer be shotcreted at the under-excavation positions. Secondly, it will also affect the calculated average thickness, resulting in the average thickness being too large or too small, affecting the normal spraying of subsequent concrete support. Therefore, removing the over-excavation and under-excavation positions that exceed the preset size can more accurately calculate the concrete volume and average thickness required for shotcrete support on the excavation surface.

[0053] At the same time, before calculating the average thickness, the excavation surface is divided into multiple scanning point areas. The required concrete volume and average thickness are calculated separately for each scanning point area, so that a more matching average thickness can be obtained according to the size of different areas, making the average thickness dimension data more accurate.

[0054] If the concrete volume and average thickness are calculated based on the overall excavation surface, and the average thickness of concrete is sprayed on the excavation surface, the contour of the concrete support will be consistent with the contour of the excavation surface before spraying concrete. However, if the excavation surface is divided into multiple scanning point areas, the required concrete volume and average thickness are calculated separately, and concrete is sprayed on the excavation surface according to the average thickness of different scanning point areas, the contour of the final concrete support can be made closer to the formed contour and the contour of the concrete support can be made smoother.

[0055] After calculating the average thickness, subtract the thickness of the leveling layer from the average thickness to get the base thickness. The leveling layer is used to finally level the contour of the base layer so that the final concrete support surface is flat. Generally, the leveling layer thickness is 20-50mm.

[0056] S3, start the pumping mechanism 2 and the arm mechanism 3 to spray the base layer in each scanning cloud point area. When spraying, first spray the arch foot to the waist of the excavation surface in the tunnel. After the concrete at the arch foot to the waist is solidified, spray the waist to the top. The spraying thickness is the base layer thickness calculated in step S2;

[0057] After the average thickness of the base layer is calculated, concrete spraying can begin. The driving computer 5 controls the arm mechanism 3 to start, and the arm mechanism 3 moves the nozzle 6 to the spraying position and points the nozzle 6 toward the working surface to be sprayed with concrete. Then, the driving computer 5 controls the pumping mechanism 2 to start, and the pumping mechanism 2 delivers concrete to the nozzle 6 through the delivery pipeline. The concrete is then atomized and sprayed onto the excavation surface by the nozzle 6, thereby achieving spraying of the base layer on the excavation surface.

[0058] like Figure 13 As shown, the excavation surface in the tunnel is generally arched. Therefore, when spraying the base layer on the excavation surface, first start spraying upward from the arch foot on the first side of the excavation surface until it reaches the waist of the excavation surface. Then start spraying upward from the arch foot on the second side of the excavation surface until it reaches the waist of the arch. At this time, the concrete from the arch foot to the waist on the first side of the excavation surface has solidified. At this time, spraying starts from the waist on the first side of the excavation surface to the arch crown, and then spraying starts from the waist on the second side of the excavation surface to the arch crown. When spraying the base layer from the waist to the arch crown, the solidified base layer from the arch foot to the waist can serve as support to ensure that the concrete can be normally formed when spraying from the waist to the arch crown of the excavation surface.

[0059] S4, after the base layer solidifies, the arm mechanism 3 controls the nozzle 6 to move to the over-excavation point to spray and fill the over-excavation point to fill the potholes on the surface of the base layer;

[0060] After the base layer is sprayed and solidified, the base layer surface will also be uneven due to the uneven excavation surface. At the same time, the base layer will increase the size of the concave position, and the concave position is the over-excavation position on the excavation surface. Since the over-excavation and under-excavation position data of the excavation surface are all stored in the driving computer 5, the driving computer 5 can control the arm mechanism 3 to move the nozzle 6 to the over-excavation position of the excavation surface, that is, the concave position of the current base layer surface, to fill the concave position of the base layer surface, so as to eliminate the concave position of the base layer surface and make the base layer surface basically flat, so as to ensure that the final concrete support surface is flat.

[0061] S5, scanning and modeling the base layer surface by the environmental scanning mechanism 4, and transmitting the modeled data to the on-board computer 5 for analysis to obtain the base layer surface profile data;

[0062] After the filling of the depression on the base layer surface is completed, the environment scanning mechanism 4 scans the base layer surface again to obtain the profile data of the base layer surface, which provides a basis for the subsequent spraying and leveling of the layer;

[0063] S6, planning the swing speed of the arm mechanism 3 and the spraying speed of the pumping mechanism 2 when spraying the sweeping layer according to the surface profile data of the base layer, and then spraying the sweeping layer on the surface of the base layer to obtain concrete support;

[0064] After obtaining the surface profile data of the base layer, the surface profile data of the base layer is imported into the driving computer 5. The spraying software analyzes the flatness error of the base layer surface, and the error information is calculated into the spraying process of the sweeping layer. The error information is used to plan the swing speed of the arm mechanism 3 and the spraying speed of the pumping mechanism 2 during the spraying of the sweeping layer to ensure the flatness of the final sweeping layer surface.

[0065] After obtaining the surface profile data of the base layer, when the arm mechanism 3 drives the nozzle 6 to move to a concave position on the base layer surface, the speed of the pumping mechanism 2 can be increased to increase the spray flow rate of the nozzle 6, or the arm mechanism 3 controls the nozzle 6 to stay at the concave position, thereby increasing the volume of concrete sprayed at the concave position. When the arm mechanism 3 drives the nozzle 6 to move to a convex position on the base layer surface, contrary to the previous situation, the speed of the pumping mechanism 2 can be reduced to reduce or stop the spray flow rate of the nozzle 6, or the arm mechanism 3 controls the nozzle 6 to quickly pass through the convex position, thereby reducing the volume of concrete sprayed at the convex position, ultimately achieving the effect of leveling the base layer surface and forming a smooth concrete support surface on the tunnel excavation surface.

[0066] The method utilizes a concrete wet spraying machine to automatically spray concrete support in a tunnel. The driving computer 5 controls the movement of the driving chassis 1 to realize the automatic movement of the concrete wet spraying machine, and the driving computer 5 controls the arm mechanism 3 and the pumping mechanism 2 to realize the automatic spraying of the concrete support. At the same time, in conjunction with the environmental scanning mechanism 4, the contour inside the tunnel can be scanned, and the average thickness of the spraying base layer can be controlled according to the tunnel contour. At the same time, the real-time pumping speed of the pumping mechanism 2 and the position of the arm mechanism 3 when spraying the base layer, sweeping the leveling layer, and filling the groove are controlled to realize the automatic spraying of the concrete support in the tunnel. There is no need for workers to enter the construction site to operate and stand guard, providing a good working environment for the workers. In some extreme working environments, it can effectively reduce the safety hazards of the workers when working.

[0067] At the same time, detailed tunnel profile data can be obtained through scanning by the environmental scanning mechanism 4, from which the excavation surface, over-excavation and under-excavation size data can be accurately obtained, and the parameters of the boom mechanism 3 and the pumping mechanism 2 can be adjusted according to these data, so as to accurately control the injection of concrete support and increase the quality of the final concrete support.

[0068] Preferably, in step S3, when spraying the base layer on the tunnel excavation surface, the spraying process adopts N-shaped brushing. Since the tunnel excavation surface is uneven and most of it has arches, the use of N-shaped spraying process can not only fill the back of the arch I-beam, but also make it easier to control the spraying profile.

[0069] Preferably, in step S6, when spraying and leveling the surface of the base layer, the spraying process is an 8-shaped brushing from the arch foot to the arch top. Since the previous arch frame filling and recess filling have been completed, the surface of the base layer is basically flat. The use of an 8-shaped brushing will increase the scattering area of ​​the spray ring, make the spraying amount better controlled, and make the spraying surface smoother.

[0070] The pumping system is a conventional technical means in this field and is not limited in this application.

[0071] Specifically, in step S1, during the movement of the driving chassis 1, the environment scanning mechanism 4 scans the road surface in the tunnel in real time, and feeds the scanning data back to the driving computer 5 in real time, which is processed by the cruise software to perform real-time route planning;

[0072] The environmental scanning mechanism 4 can not only scan the tunnel contour after the concrete spraying machine arrives at the construction location, but also scan the road conditions in the tunnel in real time during the process of the concrete spraying machine moving from the initial position to the construction location, and feed back the scanned road conditions to the driving computer 5 in real time. After processing by the cruise software in the driving computer 5, the driving route is planned in real time, so that the concrete spraying machine can avoid obstacles in the tunnel and move smoothly from the initial position to the construction location.

[0073] Specifically, in step S2, the preset dimensions are the overbreak depth and underbreak thickness specified in the tunnel construction requirements. If there are no overbreak points or / and underbreak points exceeding the preset dimensions, the overbreak points of the maximum depth and / or the underbreak points of the maximum thickness are removed.

[0074] Before tunnel construction, requirements will be set for the tunnel excavation surface size and the sizes of over-excavation and under-excavation. The tunnel excavation surface will have a theoretical outline. However, the drilling and blasting method cannot guarantee the excavation accuracy, and over-excavation and under-excavation will definitely occur. Positions that do not reach the theoretical outline of the excavation surface will protrude from the theoretical outline of the excavation surface. These positions are under-excavated, and positions that exceed the theoretical outline of the excavation surface will be recessed from the theoretical outline of the excavation surface. These positions are over-excavated. Since concrete support also has a theoretical outline, if the under-excavation position exceeds the theoretical outline of the concrete support, it is directly determined that the under-excavation position cannot be sprayed with concrete support. Of course, in the actual construction process, the under-excavation area is very It is often close to the theoretical outline of the concrete support, and it is impossible to spray concrete on its surface. Therefore, it is necessary to set a preset size according to the actual concrete support thickness. When the height of the underbreak position exceeds the preset size, it is directly removed from the tunnel excavation face. Similarly, when the overbreak depth is too large, it is no longer possible to achieve support through sprayed concrete support. Therefore, it is necessary to set a preset size according to the tunnel excavation face size. When the overbreak position depth exceeds the preset size, it is directly removed from the tunnel excavation face and does not participate in the calculation of the average thickness of the base layer and the subsequent spraying of the base layer and the flat sweeping layer. After the concrete support spraying is completed, the removed overbreak position and underbreak position are processed separately.

[0075] During the actual construction process, the sizes of over-excavation and under-excavation positions on the excavation surface generally do not exceed the preset sizes. At this time, the over-excavation position with the largest depth is selected from multiple over-excavation positions, and the under-excavation position with the largest height is selected from several under-excavation positions. After removing the largest over-excavation position and the largest under-excavation position, the concrete volume and average thickness required for shotcrete support are calculated to eliminate the interference of extreme values ​​and better reflect the centralized trend of most data.

[0076] Specifically, in step S2, the tunnel contour is divided into a plurality of scanning point areas according to the spray range of the nozzle 6;

[0077] When the excavation surface is divided into multiple scanning point areas, the length of the scanning point area in the direction of the tunnel length is controlled according to the spraying range of the nozzle 6. During the spraying process through the concrete wet spraying machine, the concrete sprayed by the nozzle 6 can just cover the scanning point area in the direction of the tunnel length, and cover the entire scanning point area by brushing the nozzle 6. The full spraying of concrete in the scanning point area can be completed by brushing the nozzle 6, making the movement path of the swing arm in the base layer spraying process simpler, and at the same time making the final formed base layer smoother.

[0078] Specifically, such as Figure 4 As shown, the environment scanning mechanism 4 includes a laser scanner 41, a mounting platform 42, and a rotating platform 43. The rotating platform 43 is mounted on one of the two ends of the vehicle chassis 1 in the longitudinal direction through the mounting platform 42. The laser scanner 41 is mounted on the rotating platform 43 so that the laser scanner 41 has rotational freedom in the X, Y, and N axis directions.

[0079] During operation, the laser scanner 41 is controlled to rotate by the rotating platform 43, and the tunnel can be scanned in all directions to obtain the excavation surface and road surface contours in the tunnel. The rotating platform 43 is installed at one end of the driving chassis 1 in the length direction through the mounting platform 42, reducing the side blocking range of the measuring beam of the laser scanner 41, so that the laser scanner 41 can obtain a good measuring angle when measuring road conditions.

[0080] Specifically, such as Figure 5 As shown, the mounting platform 42 includes a base 421, a push rod motor 422 and a protective cover 423. The base 421 is fixedly mounted on the vehicle chassis 1 for mounting the laser scanner 41. The protective cover 423 is hinged to one end of the base 421 and has a first state in which the laser scanner 41 on the base 421 is covered, and a second state in which the laser scanner 41 on the base 421 is exposed. The two ends of the push rod motor 422 are hinged to the base 421 and the protective cover 423 respectively, so that the action of the push rod motor 422 drives the protective cover 423 to switch between the first state and the second state.

[0081] In the first state, the open end of the protective cover 423 will be in close contact with the top surface of the base 421. The protective cover 423 can cover the laser scanner 41 which is also installed on the top surface of the base 421. The protective cover 423 can prevent the laser scanner 41 from being exposed to rain or external impact, thereby ensuring the safety of the laser scanner 41. When the laser scanner 41 needs to be used to scan the tunnel contour, the output shaft of the push rod motor 422 can be extended to push the protective cover 423 away from the top surface of the base 421, so that the protective cover 423 is switched from the first state to the second state, exposing the laser scanner 41 installed on the top surface of the base 421. When switching from the second state to the first state, the output shaft of the push rod motor 422 only needs to be retracted to drive the protective cover 423 to flip over. The laser scanner 41 is protected by the first state of the protective cover 423. When the laser scanner 41 is not needed, the laser scanner 41 can be prevented from being exposed to rain or external impact, thereby ensuring the safety of the laser scanner 41.

[0082] Specifically, such as Figure 2 and Figure 6 As shown, the driving chassis 1 includes a chassis assembly 11, wheels 12 and wheel-side motors 13. At least two connecting bridges are provided at the bottom of the chassis assembly 11. Wheels 12 and wheel-side motors 13 are provided at both ends of the connecting bridge. The wheel-side motors 13 at both ends of the connecting bridge are used to drive the wheels 12 at both ends of the connecting bridge respectively.

[0083] like Figure 2-7 As shown, in this example, two connecting bridges are provided at the bottom of the chassis assembly 11, and wheels 12 and wheel-side motors 13 are installed at both ends of the two connecting bridges. The wheel-side motors 13 are used to drive the wheels 12 to rotate to realize the movement of the driving chassis 1. Each wheel 12 is driven by a wheel-side motor 13 separately, and the power of each wheel 12 can be controlled separately. When the concrete wet spraying machine is driving in the tunnel, the road environment in the tunnel is scanned by the laser scanner 41. After the road environment is imported into the driving computer 5, the cruise software controls the power of each wheel 12 separately, thereby improving the passability of the driving chassis 1 in complex road environments and ensuring that the concrete wet spraying machine can smoothly reach the construction location.

[0084] like Figure 6-7 As shown, in this example, a wheel-side steering fixed bridge and a wheel-side steering floating bridge are provided at the bottom of the chassis assembly 11;

[0085] like Figure 6As shown, the wheel-side steering fixed bridge includes a deceleration brake box 141, a steering cylinder 142, a bridge body 143 and a motor seat 144. The wheel 12 is fixedly arranged on the deceleration brake box 141. The deceleration brake box 141 and the wheel-side motor 13 are both fixed on the motor seat 144, and the wheel-side motor 13 is connected to the deceleration brake box 141 through a coupling, which is used to output torque to the deceleration brake box 141 to drive the wheel 12 to rotate. Piston rods are provided at both ends of the steering cylinder 142. The two piston rods are respectively hinged to the motor seats 144 at both ends of the bridge body 143 through pins. The two motor seats 144 are also hinged to the two ends of the bridge body 143 through pins. The contraction of the piston rods at both ends of the steering cylinder 142 drives the motor seats 144 at both ends of the bridge body 143 to rotate, so as to adjust the angle of the wheel 12 and achieve the steering effect of the concrete wet spraying machine.

[0086] like Figure 7 As shown, the wheel-side steering floating bridge includes a deceleration brake box 141, a motor base 144, a steering cylinder 142, an articulated rocker arm 145, a limit frame 146 and a bridge body 143. The difference from the steering fixed bridge is that an articulated rocker arm 145 and a limit frame 146 are provided between the wheel-side floating bridge and the chassis assembly 11. The articulated rocker arm 145 is connected to the bridge body 143 through a pin in the middle, which is used for the floating of the wheel-side steering floating bridge and adapting to the floating driving under complex road conditions; the limit frame 146 is fixed to the chassis assembly 11 by welding and is used to limit the floating angle of the wheel-side steering floating bridge, so that the concrete wet spraying machine can adapt to complex and changeable environments and increase the passability of the driving chassis 1.

[0087] Specifically, the arm mechanism 3 is a conventional technical means in this field and is not limited in this application.

[0088] Figure 8 An example of the boom mechanism 3 is shown. In this example, the boom mechanism 3 includes a boom traveling mechanism 31, a boom rotating platform 32, a first arm 33, a second arm 34, a third arm 35, and a fourth arm 36.

[0089] The arm travel mechanism 31 is fixed to the chassis assembly 11, so that the arm slewing platform 32, the first arm 33, the second arm 34, the third arm 35 and the fourth arm 36 can move along the length direction of the chassis assembly 11 as a whole;

[0090] The boom slewing platform 32 is mounted on the boom travel mechanism 31, so that the first arm 33, the second arm 34, the third arm 35 and the fourth arm 36 have rotational freedom in both the X-axis and the Y-axis directions.

[0091] An arm 33 is connected to the arm slewing platform 32 through a pin and a cylinder to achieve pitch adjustment;

[0092] The second arm 34 is nested in the first arm 33 through a pin and a cylinder, and can be extended and retracted along the length direction of the first arm 33;

[0093] The third arm 35 is connected to the end of the second arm 34 away from the first arm 33 through a pin and a cylinder, and is used for folding the arm assembly. The mechanism is similar to a scissors frame structure (not shown in the figure), which is a conventional technical means in this field;

[0094] One end of the fourth arm 36 is nested in the end of the third arm 35 away from the second arm 34 through the cylinder and the pin shaft, and can be extended and retracted along the length direction of the third arm 35. The other end is connected to the nozzle 6 through a bolt;

[0095] like Figure 8 As shown, the position of the nozzle 6 is adjusted by the cooperation of the first arm 33, the second arm 34, the third arm 35 and the fourth arm 36. At the same time, the adjustment is very flexible and the position of the nozzle 6 can be accurately controlled.

[0096] Specifically, the nozzle 6 is a conventional technical means in this field and is not limited in this application;

[0097] Figure 9 An example of a spray head 6 is shown. In this example, the spray head 6 includes a nozzle 61, a flow mixer 62, a connector 63, and a hydraulic motor 64.

[0098] The nozzle 61, the mixer 62 and the connector 63 are connected in sequence. The connector 63 is used to connect to the pumping system through a delivery pipeline. The side wall of the mixer 62 is provided with a hole for adding concrete admixtures. The concrete admixtures are mixed with the concrete through the mixer 62. The nozzle 61 is used to atomize the concrete and spray it out.

[0099] When spraying concrete onto the excavation face in the tunnel, concrete admixtures, such as accelerating agents, can be added to the concrete through the adding holes provided on the side wall of the mixer 62 to accelerate the setting speed of the concrete after being sprayed onto the excavation face, thereby helping the concrete support to take shape;

[0100] The connecting body 63 is mounted on the four arms 36 via a hydraulic motor 64. The hydraulic motor 64 is used to drive the connecting body 63 to rotate, thereby driving the nozzle 61 to rotate;

[0101] When concrete is sprayed onto the excavation surface in the tunnel through the nozzle 61 , the nozzle 61 is driven to swing back and forth by the hydraulic motor 64 , thereby achieving a brushing motion of the nozzle 61 .

[0102] like Figure 2-3 As shown, in some examples, a camera 7 is fixedly mounted on the chassis assembly 11. The camera 7, the arm mechanism 3, and the environment scanning mechanism 4 are sequentially arranged along the length direction of the chassis assembly 11 so that the working status of the arm mechanism 3 and the environment scanning mechanism 4 can be observed through the camera 7.

[0103] When the concrete spraying machine is working, the staff can remotely observe the working status of the concrete spraying machine through the camera 7 so as to shut down the concrete spraying machine in time when a malfunction occurs, thereby ensuring the safe operation of the concrete spraying machine;

[0104] like Figure 1-3 As shown, a cab 8 is also provided on the driving chassis 1. When the concrete spraying machine needs to be moved other than during operation, the concrete spraying machine can be moved by manual driving, providing multiple driving mode options for the concrete spraying machine.

[0105] Furthermore, the cab 8 is installed on the end of the driving chassis 1 away from the environmental scanning mechanism 4, so as not to block the laser scanner 41. At the same time, the camera 7 is fixed at the top of the cab 8 facing the arm mechanism 3, so that the camera 7 has a good field of view, which is convenient for observing the working status of the arm mechanism 3 and the environmental scanning mechanism 4.

[0106] like Figure 10 As shown, the chassis assembly 11 is provided with an energy supply system for providing electrical energy to the concrete spraying machine. The energy supply system includes a power battery 91 and a cable.

[0107] The power battery 91 can provide the necessary electrical energy for the operation of the concrete spraying machine, and a charging socket 92 is provided on the driving chassis 1, and the power battery 91 can be recharged by connecting an external charging gun. At the same time, the power battery 91 is installed on the driving chassis 1 through a quick-release frame 93. The quick-release frame 93 allows the power battery 91 to be quickly disassembled and replaced, and can be quickly recharged when the power battery 91 is low on power.

[0108] At the same time, when the power battery 91 is low on power and there is no spare power battery 91 to replace, the concrete wet spraying machine can be directly powered by an external power supply cable, such as Figure 10 As shown, a reel 94 for winding the cable is provided on the driving chassis 1. When the cable is not needed, the cable can be wound onto the reel 94 to prevent the cable from being damaged or affecting the movement of the concrete wet spraying machine.

[0109] This example provides the concrete wet spraying machine with the required electrical energy through two energy supply methods: cables and power batteries 91. Different energy supply methods can be selected according to different working environments. At the same time, when the power battery 91 is used to supply energy to the concrete wet spraying machine, there are multiple energy replenishment methods, which can also be selected according to different environments, and the scope of application is wider.

[0110] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A method for automatic spraying of concrete support for tunnel shafts and lanes, wherein the method uses a concrete wet spraying machine to automatically spray concrete support, and is characterized by: The concrete wet spraying machine comprises a driving chassis (1), a pumping mechanism (2), an arm mechanism (3), an environment scanning mechanism (4) and a driving computer (5); The pumping mechanism (2), the arm mechanism (3), the environmental scanning mechanism (4) and the vehicle computer (5) are all arranged on the vehicle chassis (1); The automatic spraying method for tunnel shaft and lane concrete support comprises the following steps: S1, obtaining the coordinates of the tunnel construction location and inputting them into the driving computer (5), and the driving computer (5) controls the driving chassis (1) to move to the tunnel construction location; S2, using the environment scanning mechanism (4) to scan and model the tunnel profile, and calculating the thickness of the concrete base layer based on the concrete support profile and the tunnel profile model; S3, start the pumping mechanism (2) and the arm mechanism (3) to spray the base layer in each scanned cloud point area, spray the arch foot to the waist of the excavation surface in the tunnel first, and then spray the waist to the top after the concrete from the arch foot to the waist is solidified; S4, after the base layer solidifies, the arm mechanism (3) controls the nozzle (6) to move to the over-excavation point to spray and fill the over-excavation point, thereby filling the holes on the surface of the base layer; S5, scanning and modeling the base layer surface through the environmental scanning mechanism (4), transmitting the modeled data to the on-board computer (5) for analysis to obtain the base layer surface profile data; S6, planning the swing speed of the arm mechanism (3) and the spraying speed of the pumping mechanism (2) when spraying the sweeping layer according to the surface profile data of the base layer, and then spraying the sweeping layer on the surface of the base layer to obtain concrete support.

2. The automatic spraying method for tunnel shaft and lane concrete support according to claim 1 is characterized in that: In step S1, the coordinates of the tunnel construction position are obtained through the surveying and mapping report of the tunnel construction position, and the coordinates of the starting position of the concrete spraying machine and the coordinates of the tunnel construction position are input into the driving computer (5). The cruise software in the driving computer (5) controls the movement of the driving chassis (1) to move the concrete spraying machine to the tunnel construction position.

3. The automatic spraying method for tunnel shaft and lane concrete support according to claim 2 is characterized in that: In step S1, during the movement of the driving chassis (1), the environment scanning mechanism (4) scans the road surface in the tunnel in real time, and feeds the scanning data back to the driving computer (5) in real time, and performs real-time route planning after processing by the cruise software.

4. The automatic spraying method for tunnel shaft and lane concrete support according to claim 1 is characterized in that: In step S2, the modeled data is transmitted to the on-board computer (5) to analyze the size of the excavation surface and the positions of over-excavation and under-excavation. After removing the over-excavation points and under-excavation points exceeding the preset size, the excavation surface is divided into multiple scanning point areas. The concrete support profile is compared with the excavation surface to calculate the concrete volume and average thickness required for each scanning point area. The average concrete thickness is subtracted from the leveling layer thickness to obtain the base layer thickness.

5. The automatic spraying method for tunnel shaft and lane concrete support according to claim 3 is characterized in that: In step S2, the preset dimensions are the over-excavation depth and under-excavation thickness specified in the tunnel construction requirements. When there are no over-excavation points and / or under-excavation points exceeding the preset dimensions, the over-excavation points of the maximum depth and / or the under-excavation points of the maximum thickness are removed.

6. The automatic spraying method for tunnel shaft and lane concrete support according to claim 4 is characterized in that: In step S2, the tunnel contour is divided into a plurality of scanning point areas according to the spraying range of the nozzle (6).

7. The automatic spraying method for tunnel shaft and lane concrete support according to claim 1 is characterized in that: The environmental scanning mechanism (4) comprises a laser scanner (41), a mounting platform (42) and a rotating platform (43). The rotating platform (43) is arranged at one of the two ends in the length direction of the vehicle chassis (1) through the mounting platform (42). The laser scanner (41) is arranged on the rotating platform (43) so that the laser scanner (41) has rotational freedom in the X, Y and N axis directions.

8. The automatic spraying method for tunnel shaft and lane concrete support according to claim 7 is characterized in that: The mounting platform (42) comprises a base (421), a push rod motor (422) and a protective cover (423). The base (421) is fixed on the vehicle chassis (1) for mounting the laser scanner (41). The protective cover (423) is hinged to one end of the base (421) and has a first state of covering the laser scanner (41) on the base (421) and a second state of exposing the laser scanner (41) on the base (421). The two ends of the push rod motor (422) are hinged to the base (421) and the protective cover (423) respectively, so that the protective cover (423) is driven by the action of the push rod motor (422) to switch between the first state and the second state.

9. The automatic spraying method for tunnel shaft and lane concrete support according to claim 1, characterized in that: The driving chassis (1) comprises a chassis assembly (11), wheels (12) and wheel-side motors (13); at least two connecting bridges are provided at the bottom of the chassis assembly (11); wheels (12) and wheel-side motors (13) are provided at both ends of the connecting bridge; the wheel-side motors (13) at both ends of the connecting bridge are respectively used to drive the wheels (12) at both ends of the connecting bridge.

10. The automatic spraying method for tunnel shaft and lane concrete support according to claim 1, characterized in that: The arm mechanism (3) includes an arm traveling mechanism (31), an arm rotating platform (32), an arm (33), a second arm (34), a third arm (35) and a fourth arm (36); The arm travel mechanism (31) is fixed on the chassis assembly (11), so that the arm slewing platform (32), the first arm (33), the second arm (34), the third arm (35) and the fourth arm (36) can move as a whole along the length direction of the chassis assembly (11); The arm slewing platform (32) is arranged on the arm walking mechanism (31), so that the first arm (33), the second arm (34), the third arm (35) and the fourth arm (36) have rotational freedom in the X-axis and Y-axis directions; The one arm (33) is connected to the arm support rotating platform (32) via a pin and an oil cylinder, and is used to achieve pitch adjustment; The two arms (34) are nested in one arm (33) through a pin and an oil cylinder and can be extended and retracted along the length direction of the one arm (33); The three arms (35) are connected to one end of the second arm (34) away from the first arm (33) through a pin and an oil cylinder, and are used for folding the arm assembly; One end of the four-arm (36) is nested in one end of the three-arm (35) away from the two-arm (34) through an oil cylinder and a pin shaft, and can be telescopic along the length direction of the three-arm (35). The other end is connected to the nozzle (6) through a bolt.

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