Crawler-type tunnel wall mold spraying device for open-type TBM (tunnel boring machine)

Abstract

The invention relates to the technical field of tunnel supporting, and discloses a crawler-type tunnel wall mold spraying device for an open-type TBM. The technical problems that in the prior art, concrete supporting time is too long, rocks deform greatly under the action of gravity, a TBM is stuck, and the construction period is delayed and economic losses are caused are solved. The mechanical arm comprises a center rotating assembly and a mechanical arm body. The center rotating assembly drives the mechanical arm to rotate; concrete spraying equipment is installed at the tail end of the mechanical arm, the mechanical arm drives the concrete spraying equipment to move to the to-be-operated position of the tunnel wall, and crawler-type formworks are installed on the mechanical arm and the position of a guniting opening of the concrete spraying equipment. Concrete spraying equipment can extend to the proper position of the tunnel wall to spray concrete, and the multiple nozzles can greatly improve the concrete spraying speed; and the crawler-type template of the mold spraying device slowly rolls over the surface of the concrete to solidify the concrete, so that a smaller flatness error of the surface of the concrete is ensured.

Description

Technical Field

[0001] This invention relates to the field of tunnel support technology, and more particularly to a tracked tunnel wall spraying device for open-type TBMs. Background Technology

[0002] As a crucial component of infrastructure construction, tunnel engineering, particularly the TBM (Tube-Built Machine) method, represents the optimal choice and inevitable development direction for deep and long tunnel construction. TBM tunnel construction has experienced explosive growth, with full-face tunnel boring machines becoming core equipment in modern tunnel engineering. Open-face TBMs are primarily suitable for rock formations with good stability, requiring timely support of the tunnel walls after excavation. Traditional support methods typically involve installing steel grating or steel arches followed by shotcrete. However, this method suffers from long work cycles, labor intensity, significant concrete rebound, and substantial material waste, resulting in poor surface smoothness and frequent need for secondary repairs. During construction, prolonged concrete support can cause large deformations in the rock under gravity, leading to TBM jamming, project delays, and economic losses.

[0003] To improve support efficiency and quality, the industry has begun exploring shotcrete technology. This technology aims to combine shotcrete with formwork molding, using the formwork to constrain and compact the shotcrete, creating a dense, smooth, and accurately contoured lining in one go. However, applying this technology to the limited space behind an open TBM presents significant challenges: First, the space behind the TBM is cramped, making it difficult to install and operate large traditional formwork systems; second, the tunnel has a circular cross-section, requiring a rotating system capable of accommodating circular operations; and third, the processes of shotcreting, compacting, and densifying concrete require highly efficient coordination, demanding a high degree of equipment integration and automation.

[0004] Currently, there is a lack of dedicated devices and methods on the market that can be integrated into open-type TBMs to achieve rapid, continuous, and automated spraying construction. Existing attempts suffer from problems such as complex structures, cumbersome operation, poor adaptability, or inability to efficiently coordinate with TBMs, making it difficult to meet the urgent needs of modern tunnel engineering for efficient, high-quality, and low-loss construction.

[0005] Therefore, there is an urgent need to propose a tracked tunnel wall spraying device for open-type TBMs. Summary of the Invention

[0006] In view of the above technical problems, this disclosure provides a tracked tunnel wall spraying device for open-type TBMs, which solves the technical problem in the prior art that, during the construction process, the concrete support is carried out in stages, the cycle time is too long, and the rock undergoes large deformation under gravity, causing the TBM to jam, resulting in construction delays and economic losses.

[0007] According to one aspect of this disclosure, a tracked tunnel wall shotcrete device for an open-type TBM is provided, comprising a central rotating assembly, the central rotating assembly including an outer limiting ring, a central gear, and at least one rolling gear meshing with the central gear, a robotic arm mounted on the rolling gear via a robotic arm mounting base; the central rotating assembly drives the robotic arm to rotate; a shotcrete device is mounted at the end of the robotic arm, and the robotic arm drives the shotcrete device to a position on the tunnel wall to be worked on, the upper part of the shotcrete device is provided with multiple shotcrete nozzles; a tracked template is mounted on the robotic arm at the spray nozzle position of the shotcrete device; the tracked template includes an annular track for compacting concrete, and a drive wheel adjustment component is mounted on the inner side of the annular track via a support side plate.

[0008] In some embodiments of this disclosure, multiple rectangular steel plates are installed at intervals between the outer limiting ring and the central gear; the outer limiting ring has symmetrically arranged outer limiting ring grooves on both sides, and the central gear has a central gear groove on one side; the robotic arm fixing base includes a first fixing platform and a second fixing platform, the first fixing platform has a first fixing platform groove embedding plate to embed the central gear groove, the second fixing platform has a second fixing platform groove embedding plate to embed the outer limiting ring groove, and the second fixing platform has a motor fixing base to install the motor-driven rolling gear.

[0009] In some embodiments of this disclosure, the robotic arm includes a first robotic arm and a second robotic arm that are movably connected. The front of the first robotic arm is provided with a flange for mounting shotcrete equipment. The middle of the first robotic arm is provided with multiple threaded holes for mounting tracked templates. The middle of the first robotic arm is rotatably connected to the front of the second robotic arm via a pivot. The rear of the first robotic arm is connected to the middle of the second robotic arm via a first hydraulic cylinder. The rear of the second robotic arm is mounted on a fixed base via a pivot. The middle of the second robotic arm is connected to the fixed base via a second hydraulic cylinder.

[0010] In some embodiments of this disclosure, the shotcrete equipment includes an outer casing for receiving falling concrete, and the casing is provided with multiple threaded connection holes for mounting flanges to connect robotic arms.

[0011] In some embodiments of this disclosure, the lower end of the outer shell is a curved envelope surface, and several through holes are formed on the curved envelope surface for mounting a vibrating rod.

[0012] In some embodiments of this disclosure, the tail end of the shotcrete equipment is provided with a row of steel brushes that abut against the tracked template.

[0013] In some embodiments of this disclosure, the back of the shotcrete equipment is provided with a polymer film mounting bracket, on which a roll of polymer film is mounted. The polymer film is used to cover the space between the tracked formwork and the concrete.

[0014] In some embodiments of this disclosure, a side plate support arm is installed on the support side plate through a side plate support arm mounting hole, and a side plate support frame is installed on the side plate support frame mounting hole. The end of the side plate support arm has multiple support arm threaded holes for installing a tracked template.

[0015] In some embodiments of this disclosure, the drive wheel adjustment component includes an active roller and an auxiliary roller mounted via a connecting bracket. The connecting bracket is mounted on a support side plate via a first fixing bolt and a second fixing bolt. A pad is installed between the second fixing bolt and the connecting bracket. A spring adjustment component is installed between the connecting bracket and the support side plate. The spring adjustment component includes a spring movable link mounted on the connecting bracket. One end of the spring movable link has a shaft cavity to accommodate a spring fixed link. One end of the spring is mounted on the end face of the spring movable link, and the other end of the spring is mounted on a first fixing bolt via a spring base.

[0016] The beneficial effects of this invention are as follows: The central rotating component provides a stable and powerful torque output, ensuring that the entire spraying device can perform smooth and continuous 360-degree rotation operations, perfectly adapting to the construction requirements of the circular cross-section of the tunnel, and realizing rapid spraying construction without dead angles and in all directions.

[0017] By creatively shifting the mounting point of the robotic arm from the traditional fixed platform to a rotating gear, the robotic arm can move together with the rotating components. This integrated design significantly saves valuable space behind the TBM, solving the core challenge of layout difficulties for large equipment in confined spaces.

[0018] The multi-segment robotic arm, combined with hydraulic drive, provides flexible movement capabilities with multiple degrees of freedom, enabling the end-effectors and templates to not only perform circular motion but also radial extension, retraction, and pitch angle adjustment. It can precisely deliver the equipment to any desired location on the tunnel wall and adaptively fit walls with varying curvatures, greatly enhancing the device's flexibility and adaptability.

[0019] Multiple nozzles enable uniform, wide-area concrete spraying. Simultaneous operation of multiple nozzles can cover a larger area, improve spraying efficiency, and ensure the uniformity of concrete filling within the formwork, laying a good foundation for subsequent compaction and avoiding material accumulation or unevenness that may occur with single-point spraying.

[0020] Tracked formwork enables a continuous molding process of spraying and pressing. The circular track immediately compacts the concrete after spraying, replacing the traditional static formwork, allowing for continuous operation and extremely high construction efficiency. The compaction effectively removes air bubbles from the concrete, improving the density and strength of the lining. The formed surface is smooth and flat, requiring no secondary finishing. It greatly reduces concrete rebound waste and saves material costs.

[0021] The rectangular steel plates significantly enhance the overall structural rigidity and stability of the central rotating assembly. They form a robust connection and support between the gears, preventing deformation or swaying of the large gears under heavy loads, thus ensuring transmission accuracy and the smooth operation of the entire device in vibration environments.

[0022] The design of the gear groove and the recessed plate of the fixed platform achieves a rigid connection between the robot arm's fixed base and the rotating components without relative sliding. This embedded fit effectively transmits enormous torque and withstands complex loads, ensuring the reliability and stability of power transmission.

[0023] Polymer films provide an efficient anti-adhesion and isolation measure. The polymer film forms a physical isolation layer between the formwork and the concrete, completely solving the problem of concrete sticking to the formwork, ensuring smooth demolding; protecting the formwork surface and extending its service life; and ensuring the integrity of the formed concrete surface.

[0024] The vibrator achieves deep compaction of concrete. The curved envelope can conform to the concrete surface, and the vibration force generated by the vibrator can be effectively transmitted to the interior of the concrete, fully expelling internal air and moisture, reducing porosity, and significantly improving the compactness, overall strength, and impermeability of the lining.

[0025] The drive wheel adjustment unit provides constant tension and adaptive compaction force for the tracked formwork. The spring adjustment mechanism compensates for track wear and minor unevenness in the tunnel wall, ensuring that the annular track always presses against the concrete surface with the most suitable pressure, guaranteeing consistent compaction results and stable forming quality. Attached Figure Description

[0026] Figure 1 A schematic diagram of a tracked tunnel wall spraying device used in open-type TBMs; Figure 2 A schematic diagram of the central rotating assembly of a tracked tunnel wall molding spraying device for open-type TBMs. Figure 3 A schematic diagram of the mounting base structure for the robotic arm of a tracked tunnel wall molding spraying device used in an open-type TBM. Figure 4 Another structural diagram of the mechanical arm mounting base structure for a tracked tunnel wall molding spraying device used in an open-type TBM. Figure 5 A schematic diagram of the robotic arm structure for a tracked tunnel wall molding and spraying device used in an open-type TBM. Figure 6 A schematic diagram of the equipment structure for a tracked tunnel wall spraying device used in open-type TBMs. Figure 7 Another structural schematic diagram of a tracked tunnel wall spraying equipment for use in open-type TBMs. Figure 8 A schematic diagram of the tracked template structure for a tracked tunnel wall spraying device used in open-type TBMs; Figure 9 A schematic diagram of the roller structure of a tracked tunnel wall spraying device for open-type TBMs; Figure 10 for Figure 2 Sectional view of plane AA; Component names in the diagram: 1. Tracked formwork; 2. Shotcrete equipment; 3. Robotic arm; 4. Central rotating assembly; 11. External limiting ring; 12. External limiting ring groove; 13. Rectangular steel plate; 14. Rolling gear; 15. Central gear; 16. Central gear groove; 21. First fixed platform; 22. Second fixed platform; 23. Motor mounting base; 24. Second fixed platform recessed plate; 25. First fixed platform recessed plate; 26. Motor; 27. Fixed base connecting threaded hole; 31. Flange; 32. First robotic arm; 33. Robotic arm threaded hole; 34. First hydraulic cylinder hydraulic rod; 35. First hydraulic cylinder base; 36. Second robotic arm; 37. Second hydraulic cylinder hydraulic rod; 3 8. Second hydraulic cylinder base; 39. Robotic arm fixed base; 41. Polymer film; 42. Steel brush; 43. Housing; 44. Concrete nozzle; 45. Threaded connection hole; 46. Polymer film mounting bracket; 47. Vibrator; 51. Circular track; 52. Drive wheel adjustment component; 53. Side plate support arm mounting hole; 54. Support side plate; 55. Side plate support frame mounting hole; 56. Side plate support arm; 57. Support arm threaded hole; 61. Auxiliary roller pin; 62. Connecting bracket; 63. Auxiliary roller; 64. Spring movable link; 65. Spring; 66. Spring base; 67. Drive roller; 68. First fixing bolt; 69. Drive roller pin; 70. Pad; 71. Second fixing bolt. Detailed Implementation

[0027] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example 1

[0028] This example discloses a tracked tunnel wall spraying device for open-type TBMs. See [link to documentation]. Figures 1 to 10 The system includes a central rotating assembly 4, which includes an outer limiting ring 11, a central gear 15, and at least one rolling gear 14 meshing with the central gear 15. A robotic arm 3 is mounted on the rolling gear 14 via a robotic arm fixing base. The central rotating assembly 4 drives the robotic arm 3 to rotate. A shotcrete device 2 is mounted at the end of the robotic arm 3. The robotic arm 3 drives the shotcrete device 2 to move to the working position on the tunnel wall. Multiple shotcrete nozzles 44 are provided on the upper part of the shotcrete device 2. A tracked template 1 is installed on the robotic arm 3 at the spray nozzle position of the shotcrete device 2. The tracked template 1 includes an annular track 51 for compacting concrete. A drive wheel adjustment component 52 is installed on the inner side of the annular track 51 via a support side plate 54.

[0029] Multiple rectangular steel plates 13 are installed at intervals between the outer limiting ring 11 and the central gear 15; the outer limiting ring 11 has symmetrical outer limiting ring grooves 12 on both sides, and the central gear 15 has a central gear groove 16 on one side; the robotic arm fixing base includes a first fixing platform 21 and a second fixing platform 22. The first fixing platform 21 is provided with a first fixing platform groove embedding plate 25 to embed the central gear groove 16, the second fixing platform 22 is provided with a second fixing platform groove embedding plate 24 to embed the outer limiting ring groove 12, and the second fixing platform 22 is provided with a motor fixing base 23 to install a motor 26 to drive the rolling gear.

[0030] The robotic arm 3 includes a first robotic arm 32 and a second robotic arm 36 that are movably connected. The front of the first robotic arm 32 is provided with a flange 31 for installing the shotcrete equipment 2. The middle of the first robotic arm 32 is provided with multiple robotic arm threaded holes 33 for installing the tracked template 1. The middle of the first robotic arm 32 is rotatably connected to the front of the second robotic arm 36 via a pivot. The rear of the first robotic arm 32 is connected to the middle of the second robotic arm 36 via a first hydraulic cylinder. The first hydraulic cylinder includes a first hydraulic cylinder hydraulic rod 34 and a first hydraulic cylinder base 35. The rear of the second robotic arm 36 is mounted on a robotic arm fixed base 39 via a pivot. The middle of the second robotic arm 36 is connected to the robotic arm fixed base 39 via a second hydraulic cylinder. The second hydraulic cylinder includes a second hydraulic cylinder hydraulic rod 37 and a second hydraulic cylinder base 38.

[0031] The shotcrete equipment 2 includes an outer shell 43 for receiving falling concrete. The shell 43 is provided with multiple threaded connection holes 45 for mounting flanges to connect to the robotic arm 3. The lower end of the shell 43 is a curved envelope surface with several through holes for mounting vibrators 47.

[0032] A row of steel brushes 42 is installed at the tail end of the shotcrete equipment 2 to abut against the tracked formwork 1.

[0033] The back of the shotcrete equipment 2 is provided with a polymer film mounting bracket 46, on which a roll of polymer film is mounted. The polymer film is used to cover the space between the tracked formwork 1 and the concrete.

[0034] Side plate support arms 56 are installed on the side plate support arm mounting holes 53 and side plate support frames are installed on the side plate support frame mounting holes 55. Multiple support arm threaded holes 57 are opened at the end of the side plate support arm 56 to install the tracked template 1.

[0035] The drive wheel adjustment component 52 includes a drive roller 67 and an auxiliary roller 63. The drive roller 67 is mounted on one end of the connecting bracket 62 via a drive roller pin 69, and the auxiliary roller 63 is mounted on the other end of the connecting bracket 62 via an auxiliary roller pin 61. The connecting bracket 62 is mounted on the support side plate 54 via a first fixing bolt 68 and a second fixing bolt 71. A pad 70 is installed between the second fixing bolt 71 and the connecting bracket 62. A spring adjustment component is installed between the connecting bracket 62 and the support side plate 54. The spring adjustment component includes a spring movable link 64 mounted on the connecting bracket 62. One end of the spring movable link 64 is provided with a shaft cavity to accommodate a spring fixing rod. One end of the spring 65 is mounted on the end face of the spring movable link 64, and the other end of the spring 65 is mounted on the first fixing bolt 68 via a spring base 66.

[0036] A method for spraying formwork on the walls of a tracked tunnel for an open-type TBM, applicable to the aforementioned spraying formwork device for the walls of an open-type TBM, includes the following steps: S1: Positioning and attitude adjustment: The robotic arm is driven to rotate by the central rotating component, and the relative angle between the first and second robotic arms is adjusted by the first and second hydraulic cylinders to position the shotcrete equipment and tracked formwork to the work area on the tunnel wall. S2: Concrete spraying operation: Start the shotcrete equipment and spray the concrete mixture evenly onto the tunnel wall through multiple concrete nozzles on its upper part. S3: Template rolling and shaping: While spraying concrete, the robotic arm is controlled to make the ring track of the tracked template press tightly against the surface of the newly sprayed concrete with a predetermined pressure. The tension of the track is adjusted by the drive wheel adjustment component to continuously roll the concrete and form the tunnel wall contour required by the design. S4: Concrete compaction treatment: Start the vibrator installed on the curved envelope surface of the shotcrete equipment shell to eliminate the voids inside the concrete through vibration. S5: Membrane isolation protection: Release the polymer membrane from the polymer membrane mounting bracket and lay it between the tracked formwork and the freshly sprayed concrete; S6: Continuous Cyclic Operation: After completing one work section, the robotic arm is driven to rotate to the next work section through the central rotating component, or in conjunction with the propulsion of the TBM host, steps S1 to S5 are repeated to achieve full-circumference continuous spraying construction of the tunnel wall.

[0037] Although some preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0038] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this application and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A tracked tunnel wall spraying device for open-type TBMs, characterized in that: The system includes a central rotating assembly, which comprises an outer limiting ring, a central gear, and at least one rolling gear meshing with the central gear. A robotic arm is mounted on the rolling gear via a robotic arm mounting base. The central rotating assembly drives the robotic arm to rotate. A shotcrete device is mounted at the end of the robotic arm, and the robotic arm moves the shotcrete device to the desired work position on the tunnel wall. The shotcrete device has multiple shotcrete nozzles on its upper part. Tracked templates are installed on the robotic arm and at the spray nozzle positions of the shotcrete device. The tracked template includes an annular track for compacting concrete, and a drive wheel adjustment component is installed on the inner side of the annular track via a support side plate.

2. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: Multiple rectangular steel plates are installed at intervals between the outer limiting ring and the central gear; the outer limiting ring has symmetrically arranged grooves on both sides, and the central gear has a central gear groove on one side; the robotic arm fixing base includes a first fixing platform and a second fixing platform, the first fixing platform has a first fixing platform groove embedding plate to embed the central gear groove, the second fixing platform has a second fixing platform groove embedding plate to embed the outer limiting ring groove, and the second fixing platform has a motor fixing base to install the motor-driven rolling gear.

3. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The robotic arm includes a first robotic arm and a second robotic arm that are movably connected. The front of the first robotic arm is provided with a flange for installing shotcrete equipment. The middle of the first robotic arm is provided with multiple threaded holes for installing tracked templates. The middle of the first robotic arm and the front of the second robotic arm are rotatably connected via a pivot. The rear of the first robotic arm and the middle of the second robotic arm are connected via a first hydraulic cylinder. The rear of the second robotic arm is mounted on a fixed base via a pivot. The middle of the second robotic arm and the fixed base are connected via a second hydraulic cylinder.

4. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The shotcrete equipment includes an outer shell for receiving falling concrete, and multiple threaded connection holes on the shell for mounting flanges to connect to the robotic arm.

5. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The lower end of the outer shell is a curved envelope surface, with several through holes for mounting the vibrator.

6. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The tail end of the shotcrete equipment is equipped with a row of steel brushes that abut against the tracked formwork.

7. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The back of the shotcrete equipment is equipped with a polymer film mounting bracket, on which a roll of polymer film is mounted. The polymer film is used to cover the space between the tracked formwork and the concrete.

8. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The side plate supports the side plate with the side plate support arm mounting holes and the side plate supports ...

9. The tracked tunnel wall spraying device for open-type TBMs as described in claim 1, characterized in that: The drive wheel adjustment component includes an active roller and an auxiliary roller mounted on a connecting bracket. The connecting bracket is mounted on a support side plate via a first fixing bolt and a second fixing bolt. A pad is installed between the second fixing bolt and the connecting bracket. A spring adjustment component is installed between the connecting bracket and the support side plate. The spring adjustment component includes a spring movable link mounted on the connecting bracket. One end of the spring movable link has a shaft cavity to accommodate a spring fixed link. One end of the spring is mounted on the end face of the spring movable link, and the other end of the spring is mounted on a first fixing bolt via a spring base.

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