Intelligent shotcrete system and shotcrete support method thereof

Abstract

The present invention discloses an intelligent shotcrete system, including a shotcrete bridge arranged along the axial direction of the tunnel, a slewing device arranged in the circumferential direction of the shotcrete bridge, a shotcrete manipulator connected to the slewing mechanism of the slewing device, a shotcrete nozzle arranged on the shotcrete manipulator, and a multi-degree-of-freedom three-dimensional scanner group connected to a measurement and control center arranged on the shotcrete bridge, wherein the slewing device, the shotcrete manipulator and the shotcrete nozzle are all connected to the measurement and control center. The present invention also discloses a shotcrete support method of an intelligent shotcrete system, including three-dimensional scanning, automatic first shotcrete, scanning detection, judgment of scanning results and automatic fine spray correction. The present invention replaces the indispensable operator of the shotcrete system in the prior art, which not only effectively improves the efficiency of the tunnel shotcrete support, but also fully guarantees the quality of the shotcrete support, and effectively reduces the incidence of construction accidents such as rock bursts and water gushing.

Description

Technical Field

[0001] The invention relates to the technical field of full-face tunnel boring machine shotcrete, in particular to an intelligent shotcrete system and a shotcrete support method thereof. Background Art

[0002] The operation of the traditional TBM shotcrete system requires high comprehensive quality of workers, long operator training cycle, high dependence on operators at the construction site, and harsh environment in the TBM shotcrete operation area. It takes at least three years of practical operation for operators to master this operating system. The operation environment of the shotcrete process is relatively harsh. Various factors have caused a severe shortage of skilled operators, and the effect of shotcrete support is greatly affected by the operator's level. Therefore, experienced and skilled operators on site have always been in short supply. Moreover, the quality of shotcrete is greatly affected by human factors, and the quality of shotcrete is unstable. With the vigorous promotion of TBM excavation methods and the improvement of occupational health requirements in the later period, the shortage of operators will become more and more serious. TBM construction parties and owners have an urgent need for intelligent shotcrete projects.

[0003] The existing TBM intelligent shotcrete system is a very critical system in the TBM machine. It plays a vital role in the smooth excavation of TBM construction and is a product with high technical content and high added value. At present, each TBM is equipped with at least two operators for manual shotcrete. The shotcrete effect is greatly affected by the operator's level, and skilled operators are in short supply. The unstable operator level directly leads to poor tunnel support quality and is very likely to cause construction accidents such as rock bursts and water gushing. It has become a bottleneck restricting the safety of TBM tunnel construction, and the owner also has an urgent need for fully automatic shotcrete. Summary of the invention

[0004] In view of the deficiencies in the above-mentioned background technology, the present invention proposes an intelligent shotcrete system and a shotcrete support method thereof, which solves the problem that the shotcrete quality of the existing mixed shotcrete system is heavily dependent on the proficiency of the operator and the shortage of skilled operators.

[0005] The technical solution of the present invention is implemented as follows: an intelligent shotcrete system comprises a shotcrete bridge arranged along the axial direction of the tunnel, a rotating device is arranged in the circumferential direction of the shotcrete bridge, a shotcrete manipulator is connected to the rotating mechanism of the rotating device, a shotcrete manipulator is arranged on the shotcrete manipulator, a multi-degree-of-freedom three-dimensional scanner group connected to a measurement and control center is arranged on the shotcrete bridge, and the rotating device, the shotcrete manipulator and the shotcrete nozzle are all connected to the measurement and control center.

[0006] The rotating device includes a first rotating device and a second rotating device which are arranged at intervals, and the shotcrete manipulator includes a first shotcrete manipulator and a second shotcrete manipulator. The rotating mechanism of the first rotating device is connected to the first shotcrete manipulator, and the rotating mechanism of the second rotating device is connected to the second shotcrete manipulator.

[0007] The multi-degree-of-freedom three-dimensional scanner group includes a first multi-degree-of-freedom three-dimensional scanner and a second multi-degree-of-freedom three-dimensional scanner. The first multi-degree-of-freedom three-dimensional scanner is arranged at the front side of the first rotating device, and the second multi-degree-of-freedom three-dimensional scanner is arranged between the first rotating device and the second rotating device.

[0008] There are two of each of the first multi-degree-of-freedom three-dimensional scanner and the second multi-degree-of-freedom three-dimensional scanner. The two first multi-degree-of-freedom three-dimensional scanners are symmetrically arranged on the left and right sides of the shotcrete bridge, and the two second multi-degree-of-freedom three-dimensional scanners are symmetrically arranged on the left and right sides of the shotcrete bridge.

[0009] A sliding support is arranged below the shotcrete bridge, and a sliding track is arranged in cooperation with the sliding support.

[0010] A shotcrete support method for an intelligent shotcrete system comprises the following steps:

[0011] Step 1: 3D scanning: the measurement and control center controls the first multi-degree-of-freedom 3D scanner to scan the inner annular surface contour of the tunnel, and transmits the scanned image data back to the measurement and control center;

[0012] Step 2: Automatic first shotcrete, the measurement and control center automatically controls the first rotary device to output a matching rotation speed according to the scanned image data in step 1, automatically controls the first shotcrete manipulator to drive the shotcrete nozzle toward a matching spraying direction, and then controls the first rotary device to drive the shotcrete nozzle on the first shotcrete manipulator to perform the first shotcrete on the inner annular surface of the tunnel;

[0013] Step 3: Scanning and testing: after the first grouting is completed in step 2, the measurement and control center controls the second multi-degree-of-freedom three-dimensional scanner to scan the inner annular surface of the tunnel after the first grouting, and transmits the scanned image data back to the measurement and control center;

[0014] Step 4: Determine the scanning results. The measurement and control center compares the scanning image data obtained in step 3 with the set support contour data. If the comparison result is within the error range, the shotcrete bridge moves forward along the sliding track and enters the next shotcrete support cycle, repeating steps 1 to 4.

[0015] If the comparison result in step 4 exceeds the error range, proceed to step 5: automatic fine spraying correction. The measurement and control center automatically controls the second rotary device to output a matching rotation speed according to the comparison result, and automatically controls the second spraying manipulator to drive the spraying nozzle to face the matching spraying direction, and then controls the second rotary device to drive the spraying nozzle on the second spraying manipulator to automatically perform fine spraying correction on the inner annular surface of the tunnel after the first spraying in step 2 is completed, and then enters the next spraying support cycle, and repeats steps 1 to 5.

[0016] The present invention not only replaces the indispensable shotcrete system operators in the prior art, but also breaks through the problem that the quality of shotcrete support is severely limited by the skills of the shotcrete system operators. It not only effectively improves the efficiency of shotcrete support, but also fully guarantees the quality of shotcrete support, and effectively reduces the incidence of construction accidents such as rock bursts and water gushing. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying any creative work.

[0018] Figure 1 It is a side view structural schematic diagram of the present invention;

[0019] Figure 2 for Figure 1 Sectional view of the AA plane;

[0020] Figure 3 for Figure 1 Sectional view of the BB plane. DETAILED DESCRIPTION

[0021] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0022] Embodiment 1, an intelligent spraying system, such as Figure 1 and Figure 3 As shown, it includes a shotcrete bridge 1 arranged along the axial direction of the tunnel, a swivel device is arranged in the circumferential direction of the shotcrete bridge 1, a shotcrete manipulator is connected to the swivel mechanism of the swivel device, and a shotcrete nozzle 4 is arranged on the shotcrete manipulator. The swivel device can drive the shotcrete manipulator to rotate along the inner annular surface of the tunnel through the swivel mechanism, the shotcrete manipulator can extend and retract while rotating with the swivel device, and the shotcrete nozzle 4 on the shotcrete manipulator can conveniently spray the inner annular surface of the tunnel with the movement of the shotcrete manipulator.

[0023] The shotcrete bridge 1 is provided with a multi-degree-of-freedom three-dimensional scanner group connected to the measurement and control center. The rotary device, the shotcrete manipulator and the shotcrete nozzle 4 are all connected to the measurement and control center. The measurement and control center can detect the data of the inner annular surface of the tunnel through the three-dimensional scanner group, and then control the rotary device, the shotcrete manipulator and the shotcrete nozzle 4 to make corresponding actions. A sliding support 6 is provided below the shotcrete bridge 1, and a sliding track 7 is provided in cooperation with the sliding support 6. After a shotcrete cycle is completed, the shotcrete bridge 1 moves forward along the sliding track 7, thereby driving the multi-degree-of-freedom three-dimensional scanner group, the rotary device, the shotcrete manipulator and the shotcrete nozzle 4 to enter the next shotcrete support position.

[0024] The rotary device includes a first rotary device 2-1 and a second rotary device 2-2 arranged at intervals, and the shotcrete manipulator includes a first shotcrete manipulator 3-1 and a second shotcrete manipulator 3-2. The rotary mechanism of the first rotary device 2-1 is connected to the first shotcrete manipulator 3-1, and the rotary mechanism of the second rotary device 2-2 is connected to the second shotcrete manipulator 3-2. The first shotcrete manipulator 3-1 and the second shotcrete manipulator 3-2 are both provided with a shotcrete nozzle 4. The two sets of rotary devices, shotcrete manipulators and shotcrete nozzles 4 are provided, so that the inner annular surface of the tunnel can be shotcrete-supported more conveniently and fully.

[0025] The multi-degree-of-freedom three-dimensional scanner group includes a first multi-degree-of-freedom three-dimensional scanner 5-1 and a second multi-degree-of-freedom three-dimensional scanner 5-2. The first multi-degree-of-freedom three-dimensional scanner 5-1 is arranged at the front side of the first rotating device 2-1, and provides pre-spraying data for the first rotating device 2-1 and the first spraying manipulator 3-1 and the spraying nozzle 4 thereon. The second multi-degree-of-freedom three-dimensional scanner 5-2 is arranged between the first rotating device 2-1 and the second rotating device 2-2, and provides pre-spraying data for the second rotating device 2-2 and the second spraying manipulator 3-2 and the spraying nozzle 4 thereon.

[0026] Embodiment 2, an intelligent spraying system, such as Figure 2 As shown, the scanning area is indicated at C in the figure. The first multi-degree-of-freedom three-dimensional scanner 5-1 and the second multi-degree-of-freedom three-dimensional scanner 5-2 are both provided with two, and the two first multi-degree-of-freedom three-dimensional scanners 5-1 are symmetrically arranged on the left and right sides of the shotcrete bridge 1, and the two second multi-degree-of-freedom three-dimensional scanners 5-2 are symmetrically arranged on the left and right sides of the shotcrete bridge 1, which can effectively improve the scanning efficiency and ensure the integrity of the scanning area, avoiding the high cost problem caused by using an overly complex multi-degree-of-freedom three-dimensional scanner.

[0027] The other structures of this embodiment are the same as those of Embodiment 1.

[0028] Embodiment 3, a shotcrete support method of an intelligent shotcrete system, comprising the following steps:

[0029] Step 1: 3D scanning: the measurement and control center controls the first multi-degree-of-freedom 3D scanner 5-1 to scan the inner annular surface contour of the tunnel, and transmits the scanned image data back to the measurement and control center;

[0030] Step 2: Automatic first shotcrete, the measurement and control center automatically controls the first rotary device 2-1 to output a matching rotation speed according to the scanned image data in step 1, automatically controls the first shotcrete manipulator 3-1 to drive the shotcrete nozzle 4 toward a matching spraying direction, and then controls the first rotary device 2-1 to drive the shotcrete nozzle 4 on the first shotcrete manipulator 3-1 to perform the first shotcrete on the inner annular surface of the tunnel;

[0031] Step 3: Scanning and testing. After the first grouting is completed in step 2, the measurement and control center controls the second multi-degree-of-freedom three-dimensional scanner 5-2 to scan the inner annular surface of the tunnel after the first grouting, and transmits the scanned image data back to the measurement and control center;

[0032] Step 4: Determine the scanning results. The measurement and control center compares the scanning image data obtained in step 3 with the set support contour data. If the comparison result is within the error range, the shotcrete bridge 1 moves forward along the sliding track 7 and enters the next shotcrete support cycle, repeating steps 1 to 4.

[0033] If the comparison result in step 4 exceeds the error range, step 5 is performed: automatic fine spraying correction. The measurement and control center automatically controls the second rotating device 2-2 to output a matching rotation speed according to the comparison result, and automatically controls the second spraying manipulator 3-2 to drive the spraying nozzle 4 to face the matching spraying direction, and then controls the second rotating device 2-2 to drive the spraying nozzle 4 on the second spraying manipulator 3-2 to automatically perform fine spraying correction on the inner annular surface of the tunnel after the first spraying in step 2 is completed, and then enters the next spraying support cycle, and repeats steps 1 to 5.

[0034] The details not described in detail in the present invention are all conventional technical means known to those skilled in the art.

[0035] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An intelligent spraying system, characterized in that: The invention comprises a shotcrete bridge (1) arranged along the axial direction of the tunnel, a rotating device is arranged in the circumferential direction of the shotcrete bridge (1), a shotcrete manipulator is connected to the rotating mechanism of the rotating device, a shotcrete nozzle (4) is arranged on the shotcrete manipulator, the rotating device drives the shotcrete manipulator to rotate along the inner annular surface of the tunnel through the rotating mechanism, the shotcrete manipulator retracts and contracts while rotating with the rotating device, and the shotcrete nozzle (4) on the shotcrete manipulator sprays the inner annular surface of the tunnel along with the movement of the shotcrete manipulator; the rotating device (2) comprises a first rotating device (2-1) and a second rotating device (2-2) arranged at intervals, the shotcrete manipulator comprises a first shotcrete manipulator (3-1) and a second shotcrete manipulator (3-2), the rotating mechanism of the first rotating device (2-1) is connected to the first shotcrete manipulator (3-1), and the rotating mechanism of the second rotating device (2-2) is connected to the second shotcrete manipulator (3-2); A multi-degree-of-freedom three-dimensional scanner group connected to a measurement and control center is arranged on the shotcrete bridge (1); the rotating device, the shotcrete manipulator and the shotcrete nozzle (4) are all connected to the measurement and control center; the multi-degree-of-freedom three-dimensional scanner group comprises a first multi-degree-of-freedom three-dimensional scanner (5-1) and a second multi-degree-of-freedom three-dimensional scanner (5-2); the first multi-degree-of-freedom three-dimensional scanner (5-1) is arranged on the front side of the first rotating device (2-1); the second multi-degree-of-freedom three-dimensional scanner (5-2) is arranged between the first rotating device (2-1) and the second rotating device (2-2); the first multi-degree-of-freedom three-dimensional scanner (5-1) and the second multi-degree-of-freedom three-dimensional scanner (5-2) are arranged between the first rotating device (2-1) and the second rotating device (2-2); Two multi-degree-of-freedom three-dimensional scanners (5-2) are provided, the two first multi-degree-of-freedom three-dimensional scanners (5-1) are symmetrically arranged on the left and right sides of the shotcrete bridge (1), and the two second multi-degree-of-freedom three-dimensional scanners (5-2) are symmetrically arranged on the left and right sides of the shotcrete bridge (1); the first multi-degree-of-freedom three-dimensional scanner (5-1) provides pre-shotcrete data for the first rotating device (2-1) and the first shotcrete manipulator (3-1) and the shotcrete nozzle (4) thereon, and the second multi-degree-of-freedom three-dimensional scanner (5-2) provides pre-shotcrete data for the second rotating device (2-2) and the second shotcrete manipulator (3-2) and the shotcrete nozzle (4) thereon.

2. The intelligent spraying system according to claim 1, characterized in that: A sliding support (6) is provided below the shotcrete bridge (1), and a sliding track (7) is provided in cooperation with the sliding support (6).

3. The shotcrete support method of the intelligent shotcrete system according to claim 2 is characterized in that The following steps are involved: Step 1: Three-dimensional scanning, the measurement and control center controls the first multi-degree-of-freedom three-dimensional scanner (5-1) to scan the inner annular surface contour of the tunnel, and transmits the scanned image data back to the measurement and control center; Step 2: Automatic first grouting, the measurement and control center automatically controls the first rotating device (2-1) to output a matching rotation speed according to the scanned image data in step 1, automatically controls the first grouting manipulator (3-1) to drive the grouting nozzle (4) toward a matching spraying direction, and then controls the first rotating device (2-1) to drive the grouting nozzle (4) on the first grouting manipulator (3-1) to perform the first grouting on the inner annular surface of the tunnel; Step 3: Scanning and testing. After the first grouting is completed in step 2, the measurement and control center controls the second multi-degree-of-freedom three-dimensional scanner (5-2) to scan the inner annular surface of the tunnel after the first grouting, and transmits the scanned image data back to the measurement and control center; Step 4: Determine the scanning result. The measurement and control center compares the scanning image data obtained in step 3 with the set support profile data. If the comparison result is within the error range, the shotcrete bridge (1) moves forward along the sliding track (7) to enter the next shotcrete support cycle, and repeats steps 1 to 4.

4. The shotcrete support method of the intelligent shotcrete system according to claim 3, characterized in that: If the comparison result in step 4 exceeds the error range, step 5 is performed: automatic fine spray correction. The measurement and control center automatically controls the second rotary device (2-2) to output a matching rotation speed according to the comparison result, and automatically controls the second shotcrete manipulator (3-2) to drive the shotcrete nozzle (4) toward a matching spray direction, and then controls the second rotary device (2-2) to drive the shotcrete nozzle (4) on the second shotcrete manipulator (3-2) to automatically perform fine spray correction on the inner annular surface of the tunnel after the first shotcrete in step 2 is completed, and then enters the next shotcrete support cycle, and repeats steps 1 to 5.

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