TBM follow-up pre-pressing type shotcrete rapid forming device and construction method thereof

Abstract

The application discloses a TBM follow-up pre-pressing type shot concrete rapid forming device and a construction method thereof, and belongs to the technical field of tunnel engineering equipment, and solves the technical problems of large dust, material waste and poor surface smoothness in the prior art. It comprises a TBM body, a TBM follow-up system, a pre-pressing concrete rapid forming device and a follow-up pre-pressing shot control system. The TBM body is provided with a TBM synchronous track, the TBM follow-up system is movably connected with the TBM synchronous track through a synchronous platform stabilizing frame, and the pre-pressing concrete rapid forming device is connected with a rotary gear ring through a TBM rotary support. The TBM follow-up pre-pressing type shot concrete rapid forming device and the construction method thereof can realize no concrete rebound in the construction process, can reduce the amount of the quick hardener, and can effectively improve the construction efficiency and the construction quality in the subsequent chiseling, tunnel cleaning and other processes.

Description

Technical Field

[0001] This invention relates to the field of tunnel engineering equipment technology, specifically to a TBM-driven pre-compression shotcrete rapid prototyping device and its construction method. Background Technology

[0002] In the initial lining of existing TBM tunnels, shotcrete machines are a common type of construction machinery. The working principle of a shotcrete machine is to use compressed air to transport pre-mixed concrete through pipelines to the nozzle of the machine. After adding an accelerator, the mixture forms a jet, which is then sprayed at high speed onto the receiving surface under the action of compressed air. The accelerator causes the concrete to quickly set and harden, thus forming a concrete support layer. Shotcrete technology, with its simple process, has been widely used in various engineering fields. In the Sejila Mountain Tunnel on the Sichuan-Tibet Highway, the TBM clearly demonstrated its superiority in the geologically complex mountain tunnel, significantly shortening the construction period. According to data, the dust concentration generated by shotcrete operations in China generally reaches 80-120 mg / m³. 3 (The health standard stipulated in my country is 2mg / m³) 3 While the rebound rate of shotcrete is generally 30%-50%, shotcrete, as an important component, has three prominent drawbacks during construction: first, it generates a large amount of dust, which worsens the tunnel working environment; second, it causes concrete rebound, resulting in material waste; and third, the surface smoothness of the support after it is formed is poor, and it is necessary to reshape the surface, which prolongs the construction period.

[0003] Currently, in order to ensure that the concrete support layer can meet the strength requirements within a certain period of time, a large amount of concrete quick-setting agent needs to be added to the concrete. Moreover, the high rebound rate of the sprayed concrete causes unnecessary waste. After the support is formed, its surface smoothness is poor and it is necessary to perform surface shaping treatment. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a TBM-driven pre-compression shotcrete rapid prototyping device with low dust and good surface finish, as well as its construction method.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] The present invention provides a TBM follow-up pre-compression shotcrete rapid molding device, including a TBM body, a TBM follow-up system connected to the TBM body, a pre-compression concrete rapid molding device and a follow-up pre-compression shotcrete control system connected to the TBM follow-up system.

[0007] The TBM follow-up system includes a synchronization platform, a rotary gear ring disposed on the outside of the synchronization platform, a synchronization platform stabilizer connected to the inside of the synchronization platform, and a follow-up synchronization cylinder; the TBM body is provided with a TBM synchronization track, and the TBM follow-up system is movably connected to the TBM synchronization track through the synchronization platform stabilizer; the pre-compressed concrete rapid molding device is connected to the rotary gear ring through the TBM rotary support.

[0008] Optionally or preferably, the pre-compressed concrete rapid molding device includes a TBM rotary support, a synchronous motor, a rotary reducer, a first boom, and a concrete pre-compressing molding component connected to the first boom.

[0009] The concrete pre-compression molding assembly includes a second boom, which is connected to the first boom via a boom drive cylinder and a first steering mechanism. The second boom includes a sliding part and a nozzle connection part. A nozzle boom drive cylinder, a second steering mechanism, and a rotary reducer are respectively provided at both ends of the sliding part. A nozzle boom slide rail is provided on the upper end face of the sliding part, and the nozzle connection part is slidably connected to the sliding part via the nozzle boom slide rail.

[0010] The nozzle connection is equipped with a spray mixing mechanical head and a nozzle swing cylinder; the synchronous motor meshes with the rotary gear ring.

[0011] Optionally or preferably, a belt template assembly is connected to the side of the sliding part near the rotary reducer;

[0012] The belt template assembly includes a nano-coated flexible template, a side mold fixing frame, and a scraper bracket connected to the side mold fixing frame.

[0013] The nano-coated flexible template is connected to the side mold fixing frame through multiple drive rollers, guide rollers and limiting rollers. The side mold fixing frame is also equipped with a tensioning device. The follow-up pre-compression spraying control system controls the contact pressure between the nano-coated flexible template and the steel arch frame through the tensioning device.

[0014] The inner side of the nano-coated flexible template is provided with a limiting toothed rail, which meshes with the limiting roller. The limiting roller is used to prevent the nano-coated flexible template from deviating.

[0015] Optionally or preferably, the scraper bracket is provided with a retractable scraper and a scraper drive cylinder, and the follow-up pre-compression spraying control system controls the scraper drive cylinder to make the retractable scraper scrape off the concrete attached to the nano-coated flexible template.

[0016] Optionally or preferably, the side formwork fixing frame is further provided with adaptive telescopic template assemblies on both sides. The adaptive telescopic template assembly includes a lateral adaptive telescopic template and a side formwork driving cylinder. The follow-up pre-compression spraying control system adjusts the pressure between the adaptive telescopic template and the surrounding rock by controlling the side formwork driving cylinder.

[0017] The adaptive expansion formwork is equipped with a side formwork flexible support at one end near the surrounding rock. The side formwork flexible support is used to fill the small gaps between the adaptive expansion formwork and the surrounding rock, preventing concrete from flowing out of the gaps during construction.

[0018] Optionally or preferably, the pre-stressed concrete rapid prototyping device has an overall inverted trapezoidal structure to facilitate concrete spraying and prevent concrete from sticking to the nano-coated flexible template.

[0019] A TBM-driven pre-compression shotcrete rapid prototyping construction method includes the following steps:

[0020] S1. Start the TBM servo system and control the synchronization platform to maintain relative stillness with the TBM body through the TBM servo system;

[0021] S2. Select the number of pre-stressed concrete rapid molding devices according to actual work needs. The pre-stressed concrete rapid molding devices can be set on one or both sides of the excavation face.

[0022] S3. The pre-compression concrete rapid forming device is controlled to move from bottom to top along the steel arch frame by the follow-up pre-compression spraying control system, and sprayed concrete is carried out on the top of the excavation face through the concrete pre-compression forming component.

[0023] S4. After completing the current section of the jet grouting work, the first boom is adjusted to leave the steel arch frame by controlling the follow-up pre-compression jet grouting control system. At the same time, the TBM follow-up system moves in the direction of excavation and moves to the adjacent steel arch frame to prepare for the tunnel outline support of the next section.

[0024] S5. Repeat steps S1 to S4 until the initial support construction of the entire tunnel is completed.

[0025] Optionally or preferably, when the pre-stressed concrete rapid prototyping device in S2 is set on both sides of the excavation face, the shotcrete construction method is as follows: under the control of the synchronous motor, the pre-stressed concrete rapid prototyping devices on the left and right sides of the excavation face slowly move from bottom to top along the steel arch frame, and simultaneously carry out shotcrete construction towards the top of the excavation face; after reaching the top of the excavation face, the pre-stressed concrete rapid prototyping device on one side is turned off, and the shotcrete construction on the top of the excavation face is carried out through the pre-stressed concrete rapid prototyping device on the other side.

[0026] Optionally or preferably, when the pre-stressed concrete rapid forming device in S2 is set on one side of the excavation face, the first arm on the opposite side is controlled to retract by the follow-up pre-stressed spraying control system, thereby retracting the pre-stressed concrete rapid forming device on the opposite side and avoiding mutual interference between the two pre-stressed concrete rapid forming devices. Under the control of the synchronous motor, the single-sided pre-stressed concrete rapid forming device slowly moves from bottom to top along the steel arch frame to spray concrete towards the top of the excavation face. After reaching the top of the arch, the first arm on the opposite side is controlled by the follow-up pre-stressed spraying control system to make the device leave the steel arch frame and move the device to the corner of the opposite wall. Since the second arm is equipped with a nozzle arm drive cylinder, the nozzle arm drive cylinder is controlled to move the nozzle connection part along the nozzle arm slide rail to the end of the second arm. The second steering mechanism is started to rotate the nozzle connection frame, and then the pre-stressed concrete rapid forming device is started to construct from the corner to the top of the arch. After filling and smoothing at the overlap, the support of the tunnel outline of the section is completed.

[0027] Optionally or preferably, the method for applying shotcrete to the top of the excavation face using a pre-compressed concrete assembly in S3 includes the following steps:

[0028] S31. Adjust the first arm through the follow-up pre-compression spraying control system to control the pitch angle of the pre-compression concrete rapid forming device so that the nano-coated flexible template just contacts the steel arch frame. Then adjust the tensioning device through the follow-up pre-compression spraying control system to control the contact pressure between the nano-coated flexible template and the steel arch frame.

[0029] S32. During the construction of tunnels without steel arch frames, the side formwork drive cylinder is controlled by the follow-up pre-compression shotcrete control system to extend the lateral adaptive telescopic formwork to the side of the surrounding rock. At the same time, the flexible support of the side formwork is tightly attached to the surrounding rock, reducing the small gaps between the lateral adaptive telescopic formwork and the surrounding rock, and preventing concrete from flowing out of the gaps during shotcreting.

[0030] When constructing tunnels with steel arch frames, the steel arch frames can be used as side forms, and the adaptive telescopic formwork can be controlled to not extend through the follow-up pre-compression spraying control system.

[0031] S33. When the adaptive telescopic template extends, the telescopic scraper is controlled to contact the nano-coated flexible template through the follow-up pre-compression spraying control system. It can be used as a bottom form when constructing the first form of concrete to prevent the first form of concrete from flowing out from the bottom of the pre-compression concrete rapid forming device.

[0032] S34. By controlling the follow-up pre-compression spraying control system, the position of the second arm is adjusted, and then the direction of the spraying mechanical head is adjusted by controlling the spraying arm drive cylinder, thereby controlling the mutual adjustment between the spraying mechanical head and the nano-coated flexible template, so that the angle and direction of the concrete sprayed into the mold cavity by the spraying mechanical head can be adjusted.

[0033] S35. Turn on the spraying machine head and spray quick-setting concrete downwards from the opening at the top of the nano-coated flexible template to complete the pouring of the initial concrete section.

[0034] S36. After the initial concrete at the bottom of the nano-coated mold cavity has solidified, the pitch angle of the steel arch frame of the pre-compressed concrete rapid forming device is adjusted by the first arm. The tensioning device controls the contact pressure between the nano-coated flexible template and the steel arch frame, so that the device changes from being tightly attached to the steel arch frame to just being in contact with the steel arch frame. The follow-up pre-compressed spraying control system controls the lateral adaptive telescopic template to retract, and then the drive roller is started to control the nano-coated flexible template to move slowly from bottom to top, closely attached to the steel arch frame, until the current segment of mold spraying and pouring work is completed.

[0035] Based on the above technical solution, the present invention can produce at least the following technical effects:

[0036] This invention provides a TBM-driven pre-compression shotcrete rapid prototyping device and its construction method. The device integrates the TBM-driven system and the pre-compression shotcrete rapid prototyping device into a single unit via a rotating gear ring. This device, used in conjunction with TBM excavation, significantly improves the construction efficiency and quality of initial support. The initial support, once formed, exhibits a high degree of surface smoothness, eliminating the need for surface shaping. The TBM-driven pre-compression shotcrete rapid prototyping device addresses the common problems in current tunnel initial support construction, such as severe dust pollution from shotcrete construction and high rebound rate of shotcrete leading to material waste. Attached Figure Description

[0037] Figure 1 This is an overall structural diagram of the TBM-guided pre-compression shotcrete rapid prototyping device in Embodiment 1 of the present invention;

[0038] Figure 2 This is a schematic diagram of the rotary gear ring in Embodiment 1 of the present invention;

[0039] Figure 3 This is a schematic diagram of the synchronous motor installation in Embodiment 1 of the present invention;

[0040] Figure 4 This is a structural diagram of the follow-up synchronous hydraulic cylinder in Embodiment 1 of the present invention;

[0041] Figure 5 This is an overall structural diagram of the pre-stressed concrete rapid molding device in Embodiment 1 of the present invention;

[0042] Figure 6 This is a schematic diagram of the nano-coated flexible template in Embodiment 1 of the present invention;

[0043] Figure 7 This is a schematic diagram of the retractable scraper in Embodiment 1 of the present invention;

[0044] Figure 8 This is a schematic diagram of the lateral adaptive telescopic template in Embodiment 1 of the present invention;

[0045] Figure 9 This is a schematic diagram of the pre-compression forming device frame arm in Embodiment 1 of the present invention;

[0046] Figure 10 This is a schematic diagram of the second boom in Embodiment 1 of the present invention;

[0047] Figure 11 Control program diagram of the servo system in Embodiment 2 of the present invention;

[0048] Figure 12 This is a schematic diagram of the control relationship between the follow-up pre-compression spray mixing control system 3 and each component in Embodiment 2 of the present invention.

[0049] In the diagram: 1. TBM follow-up system; 2. Pre-stressed concrete rapid prototyping device; 3. Follow-up pre-stressed spraying control system; 4. Rotary gear ring; 5. Synchronous platform stabilizer; 6. Follow-up synchronous cylinder; 7. TBM synchronous track; 8. TBM body; 9. TBM slewing support; 10. Synchronous motor; 11. Rotary reducer; 12. Nano-coated flexible template; 13. Tensioning device; 14. Drive roller; 15. Guide roller; 16. Limiting roller; 17. Adaptive telescopic template; 18. Side formwork fixing frame; 19. Side formwork flexible support; 20. First boom; 21. Second boom ; 2101, Sliding part; 2102, Nozzle connection part; 22, Spray mixing mechanical head; 23, Telescopic scraper; 24, Scraper bracket; 25, Scraper drive cylinder; 26, Side mold drive cylinder; 27, Nozzle swing cylinder; 28, Arm drive cylinder; 29, First steering mechanism; 30, Nozzle arm slide rail; 31, Synchronization platform; 32, Second steering mechanism; 33, Nozzle arm drive cylinder; 34, Limiting gear; 35, Overflow valve; 36, Cylinder 1; 37, Cylinder 2; 38, Control valve; 39, Synchronization valve; 40, 60° nozzle swing motor; 41, Nozzle brush motor. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0051] Example 1

[0052] Please see Figure 1A TBM-driven pre-compression shotcrete rapid molding device includes a TBM body 8, a TBM-driven system 1 connected to the TBM body 8, a pre-compression shotcrete rapid molding device 2 and a driven pre-compression shotcrete control system 3 connected to the TBM-driven system 1.

[0053] Please see Figures 1 to 2 In this embodiment, the TBM follow-up system 1 includes a synchronization platform 31, a rotary gear ring 4 disposed on the outside of the synchronization platform 31, a synchronization platform stabilizer 5 connected to the inside of the synchronization platform 31, and a follow-up synchronization cylinder 6; a TBM synchronization track 7 is provided on the TBM body 8, and the TBM follow-up system 1 is fixed on the TBM synchronization track 7 by the synchronization platform stabilizers 5 on both sides to maintain the construction stability of the TBM follow-up system 1.

[0054] Please see Figures 2 to 3 In this embodiment, the rotary gear ring 4 is arranged circumferentially along the outer side of the synchronous platform 31. By setting the rotary gear ring 4, the pre-stressed concrete rapid molding device 2 can perform circumferential operations along the toothed track of the rotary gear ring 4.

[0055] Please see Figure 4 In this embodiment, the aforementioned follow-up synchronization cylinder 6 enables the TBM follow-up system 1 to move longitudinally along the TBM synchronization track 7 on the TBM body 8. During tunnel construction, the TBM follow-up system 1 controls the synchronization platform 31 to remain relatively stationary with respect to the TBM body 8.

[0056] Please see Figures 5 to 10 In this embodiment, the pre-compressed concrete rapid molding device 2 includes a TBM rotary support 9, a synchronous motor 10, a rotary reducer 11, a first arm 20, and a concrete pre-compressing molding component connected to the first arm 20. The concrete pre-compressing molding component includes a second arm 21, which is connected to the first arm 20 via an arm drive cylinder 28 and a first steering mechanism 29. The second arm 21 includes a sliding part 2101 and a nozzle connection part 2102. The two ends of the sliding part 2101 are respectively provided with a nozzle arm drive cylinder 33, a second steering mechanism 32, and a rotary reducer 11. The rotary reducer 11 can rotate the pre-compressed concrete rapid molding device 2 slightly left and right for fine adjustment. During the sprayed concrete construction process, if the device deviates or is not aligned with the I-beam, the rotary reducer 11 can be used to dynamically adjust the device, thereby improving the overall construction efficiency and quality.

[0057] The upper end face of the sliding part 2101 is provided with a nozzle support arm slide rail 30, and the nozzle connecting part 2102 is slidably connected to the sliding part 2101 through the nozzle support arm slide rail 30; the nozzle connecting part 2102 is respectively provided with a spray mixing mechanical head 22 and a nozzle swing cylinder 27; the synchronous motor 10 meshes with the rotary gear ring 4.

[0058] In actual work, after completing a construction section, the TBM follow-up system 1 is kept stationary, and the boom drive cylinder 28 is controlled to retract the first boom 20, moving the pre-stressed concrete rapid forming device 2 to the next construction section. The first boom 20 is equipped with a first steering mechanism 29, which can control the pitch angle of the pre-stressed concrete rapid forming device 2, so that the pre-stressed concrete rapid forming device 2 can fit tightly against the steel arch frame.

[0059] In this embodiment, a belt template assembly is connected to the side of the sliding part 2101 near the rotary reducer 11; the belt template assembly includes a nano-coated flexible template (12), a side mold fixing frame 18, and a scraper bracket 24 connected to the side mold fixing frame 18.

[0060] To prevent concrete from sticking to the formwork during construction, in this embodiment, a layer of nanomaterial is sprayed onto the surface of the formwork, the size of which can be selected according to actual work needs.

[0061] The nano-coated flexible template 12 is connected to the side formwork fixing frame 18 via multiple drive rollers 14, guide rollers 15, and limiting rollers 16. The multiple drive rollers 14, guide rollers 15, and limiting rollers 16 are mounted on the side formwork fixing frame 18. The nano-coated flexible template 12 is fixed between the two side formwork fixing frames 18 via multiple drive rollers 14, guide rollers 15, and limiting rollers 16. In this embodiment, an outer shell is also provided between the nano-coated flexible template 12 and the two side formwork fixing frames 18. The outer shell is used to prevent concrete from entering the interior of the template.

[0062] The side mold fixing frame 18 is also equipped with a tensioning device 13. The follow-up pre-pressure spraying control system 3 controls the contact pressure between the nano-coated flexible template 12 and the steel arch frame through the tensioning device 13. Through multiple drive rollers 14 and guide rollers 15, the nano-coated flexible template 12 can rotate in a specified direction.

[0063] The inner side of the nano-coated flexible template 12 is provided with a limiting toothed rail 34, which meshes with the limiting roller 16. The limiting roller 16 is used to prevent the nano-coated flexible template 12 from deviating.

[0064] In actual work, some concrete is still attached to the nano-coated flexible template 12. In this embodiment, a telescopic scraper 23 and a scraper driving cylinder 25 are provided on the scraper bracket 24. The operator can control the scraper driving cylinder 25 through the follow-up pre-compression spraying control system 3 to make the telescopic scraper 23 scrape off the concrete attached to the nano-coated flexible template 12. When the telescopic scraper 23 comes into contact with the nano-coated flexible template 12, the nano-coated flexible template 12 rotates under the action of multiple driving rollers 14 and guide rollers 15. Therefore, in conjunction with the telescopic scraper 23, the concrete attached to the nano-coated flexible template 12 can be automatically scraped off.

[0065] In addition, in this embodiment, the pre-stressed concrete rapid prototyping device 2 has an overall inverted trapezoidal structure, which facilitates concrete spraying construction and also prevents the concrete from sticking to the nano-coated flexible template 12.

[0066] During the construction of the first formwork of concrete, the follow-up pre-compression spraying control system 3 controls the telescopic scraper 23 to contact the nano-coated flexible template 12. The telescopic scraper 23 can also act as the template for the first formwork, preventing concrete from flowing out from the bottom of the device during the construction of the first formwork.

[0067] Please see Figure 8 In this embodiment, adaptive telescopic template assemblies are also provided on both sides of the side formwork fixing frame 18. The adaptive telescopic template assembly includes a lateral adaptive telescopic template 17 and a side formwork driving cylinder 26. The follow-up pre-compression spraying control system 3 adjusts the pressure between the adaptive telescopic template 17 and the surrounding rock by controlling the side formwork driving cylinder 26. The extended lateral adaptive telescopic template 17 can fit well with the tunnel surrounding rock.

[0068] For different construction conditions, the lateral adaptive expansion formwork 17 can be adjusted differently for on-site construction. When constructing a tunnel without a steel arch frame, the follow-up pre-compression spraying control system 3 controls the lateral adaptive expansion formwork 17 to extend and act as a side formwork. When constructing a tunnel with a steel arch frame, the steel arch frame can be used as a side formwork, and the lateral adaptive expansion formwork 17 does not extend.

[0069] In this embodiment, a side formwork flexible support 19 is provided at one end of the adaptive expansion formwork 17 near the surrounding rock. The side formwork flexible support 19 is used to fill the small gaps between the adaptive expansion formwork 17 and the surrounding rock, preventing concrete from flowing out of the gaps during construction. The side formwork flexible support 19 can be made of a polymer elastomer material. In other embodiments, the side formwork flexible support 19 can be an inflatable pad, which is used to fill the small gaps between the adaptive expansion formwork 17 and the surrounding rock when inflated.

[0070] Example 2

[0071] Please see Figure 11 Based on Embodiment 1, this embodiment provides an exemplary working principle for the synchronous operation of the front and rear moving cylinders of the shotcrete system platform and the follow-up synchronous cylinders of the TBM propulsion system. It is based on a hydraulic system, including a hydraulic pump 35, a first cylinder 36, a second cylinder 37, hydraulic pipelines, a control valve 38, and a synchronization valve 39.

[0072] When the hydraulic pump 35 starts, the hydraulic oil is distributed to cylinder 36 and cylinder 37 through the hydraulic pipeline. The control valve 38 is used to control the flow direction and flow rate of the hydraulic oil, so that the hydraulic cylinders for moving back and forth of the shotcrete system platform and the follow-up synchronous hydraulic cylinders of the TBM propulsion system can work synchronously.

[0073] When control valve 38 is open, hydraulic oil flows into one cylinder and simultaneously exits from the other. This ensures that the pressure and volume changes in both cylinders are identical. When control valve 38 is closed, hydraulic oil no longer flows into or out of the cylinders. Due to the sealing and pressure transmission characteristics of the hydraulic system, the pressure and volume in the forward and backward movement cylinders of the shotcrete system platform and the follow-up synchronization cylinders of the TBM propulsion system remain the same. This allows the two cylinders to work synchronously and complete their respective tasks.

[0074] Specifically, the volume change of the rod cavity in cylinder 36 is: P c =V a ×A2; Change in the volume of the rodless chamber in cylinder 36: P a =V a ×A1;

[0075] Changes in the rod cavity volume of hydraulic cylinder 237: P d =V b ×A2; Change in the volume of the rodless cavity in cylinder 237: P h =V b ×A1;

[0076] Where V a For the follow-up synchronous hydraulic cylinder - 36 movement speed, P C A1 is the volume of the rod-side chamber of the 36-type synchronous hydraulic cylinder, A2 is the area of ​​the rod-side chamber, A1 is the area of ​​the rodless chamber, and P is the volume of the rod-side chamber. a For rodless cavity volume, V b For the follow-up synchronous hydraulic cylinder 2 37 movement speed, P d For the rod chamber volume of the follow-up synchronous hydraulic cylinder 2 37, P h The volume of the rodless chamber of the second synchronous hydraulic cylinder 37.

[0077] In this embodiment, cylinder 36 is the forward and backward moving cylinder of the shotcrete system, and cylinder 37 is the synchronization cylinder of the TBM propulsion system; assuming cylinder 36 extends 1 meter, the volume change of cylinder 36 is: P c =A2×1, and similarly P d =A2×Vb Since the cylinder specifications and models are the same, the area of ​​the rod chamber A2 is the same, therefore V a =V b The displacement of the two hydraulic cylinders was synchronized.

[0078] When hydraulic cylinder 1 and hydraulic cylinder 2 are controlled synchronously, the synchronization valves F1 and F2 are opened to connect hydraulic cylinder 1 and hydraulic cylinder 2 in series, thereby achieving an equivalent volume change and thus synchronizing the two hydraulic cylinders. When synchronization is not required, the synchronization valves F1 and F2 are closed to allow hydraulic cylinder 1 to be controlled independently.

[0079] In this embodiment, a safety relief valve 35 is also included to prevent the system pressure from exceeding the allowable value.

[0080] Please see Figure 12 , Figure 12 An exemplary schematic diagram of the control relationship between the follow-up pre-compression injection mixing control system 3 and its components is provided.

[0081] In this embodiment, the nozzle connection part 2102 may also be provided with a 60° nozzle swing motor and a nozzle brush motor for adjusting the spray mixing mechanical head 22; each component can be centrally controlled by the follow-up pre-compression spray mixing control system 3, and personnel can control the follow-up pre-compression spray mixing control system 3 by remote control or other means.

[0082] Example 3

[0083] Based on Example 1, this embodiment provides a rapid prototyping construction method for TBM-driven pre-compression shotcrete, including the following steps:

[0084] S1. Start the TBM follow-up system 1, and control the synchronization platform 31 and the TBM body 8 to maintain relative stillness through the TBM follow-up system 1;

[0085] S2. Select the number of pre-stressed concrete rapid forming devices 2 according to actual work needs. The pre-stressed concrete rapid forming devices 2 can be set on one or both sides of the excavation face.

[0086] When the pre-stressed concrete rapid forming device 2 is set on both sides of the excavation face, the shotcrete construction method is as follows: under the control of the synchronous motor 10, the pre-stressed concrete rapid forming device 2 on the left and right sides of the excavation face slowly moves from bottom to top along the steel arch frame and simultaneously performs shotcrete construction on the top of the excavation face; after reaching the top of the excavation face, one side of the pre-stressed concrete rapid forming device 2 is closed, and the other side of the pre-stressed concrete rapid forming device 2 is used to perform shotcrete construction on the top of the excavation face.

[0087] When the pre-stressed concrete rapid forming device 2 is set on one side of the excavation face, the first arm 20 on the opposite side is retracted by the follow-up pre-stressed sprayed concrete control system 3, thereby retracting the pre-stressed concrete rapid forming device 2 on the opposite side and avoiding mutual interference between the two pre-stressed concrete rapid forming devices 2; under the control of the synchronous motor 10, the single-sided pre-stressed concrete rapid forming device 2 slowly moves from bottom to top along the steel arch frame to perform sprayed concrete construction towards the top of the excavation face. After construction reaches the top of the arch, the follow-up pre-stressed sprayed concrete control system 3 controls the retraction of the first arm 20 on the opposite side. The first side arm 20 moves the device away from the steel arch and to the opposite corner. Since the second arm 21 is equipped with a nozzle arm drive cylinder 33, the nozzle arm drive cylinder 33 is controlled to move the nozzle connection part 2102 along the nozzle arm slide rail 30 to the end of the second arm 21. The second steering mechanism 32 is started to rotate the nozzle connection frame 31. Then the pre-compression concrete rapid forming device 2 is started to construct from the corner to the arch top, and after filling and smoothing at the overlap, the support of the tunnel outline of the section is completed.

[0088] S3. The pre-compression concrete rapid forming device 2 is controlled to move from bottom to top along the steel arch frame by the follow-up pre-compression spraying control system 3, and sprayed concrete is carried out on the top of the excavation face through the concrete pre-compression forming component.

[0089] Specifically, the method of applying shotcrete to the top of the excavation face using pre-compressed concrete components includes the following steps:

[0090] S31. The first arm 20 is adjusted by the follow-up pre-compression spraying control system 3 to control the pitch angle of the pre-compression concrete rapid forming device 2 so that the nano-coated flexible template 12 just contacts the steel arch frame. Then, the tensioning device 13 is adjusted by the follow-up pre-compression spraying control system 3 to control the contact pressure between the nano-coated flexible template 12 and the steel arch frame.

[0091] S32. During the construction of a tunnel without a steel arch frame, the side formwork drive cylinder 26 is controlled by the follow-up pre-compression spraying control system 3 to extend the lateral adaptive telescopic formwork 17 to the side of the surrounding rock. At the same time, the side formwork flexible support 19 is tightly attached to the surrounding rock, reducing the small gaps between the lateral adaptive telescopic formwork 17 and the surrounding rock, and preventing concrete from flowing out of the gaps during spraying.

[0092] When constructing a tunnel with a steel arch frame, the steel arch frame can be used as a side formwork. The adaptive telescopic formwork 17 is controlled to not extend by the follow-up pre-compression spraying control system 3.

[0093] S33. When the adaptive telescopic template 17 extends, the telescopic scraper 23 is controlled to contact the nano-coated flexible template 12 by the follow-up pre-compression spraying control system 3. It can be used as a bottom formwork when constructing the first formwork of concrete to prevent the first formwork of concrete from flowing out from the bottom of the pre-compression concrete rapid forming device 2.

[0094] S34. By controlling the follow-up pre-compression spraying control system 3, the position of the second arm 21 is adjusted, and the direction of the spraying mechanical head 22 is adjusted by controlling the spraying arm drive cylinder 33, thereby controlling the mutual adjustment between the spraying mechanical head 22 and the nano-coated flexible template 12, so that the angle and direction of the concrete sprayed into the mold cavity by the spraying mechanical head 22 can be adjusted.

[0095] S35. Start the spraying machine head 22 and spray quick-setting concrete downward from the opening at the top of the nano-coated flexible template 12 to complete the pouring of the initial concrete.

[0096] S36. After the initial concrete at the bottom of the nano-coated mold cavity has solidified, the pitch angle of the steel arch frame of the pre-compressed concrete rapid forming device 2 is adjusted by the first arm 20. The tensioning device 13 controls the contact pressure between the nano-coated flexible template 12 and the steel arch frame, so that the device changes from being tightly attached to the steel arch frame to just being in contact with the steel arch frame. The follow-up pre-compressed spraying control system 3 controls the lateral adaptive telescopic template 17 to retract. Then, the drive roller 14 is started to control the nano-coated flexible template 12 to move slowly from bottom to top, closely attached to the steel arch frame, until the current segment of mold spraying and pouring work is completed.

[0097] S4. After completing the current section of the jet grouting work, the first boom 20 is adjusted to leave the steel arch frame by controlling the follow-up pre-compression jet grouting control system 3. At the same time, the TBM follow-up system 1 moves in the tunneling direction and moves to the adjacent steel arch frame to prepare for the tunnel outline support of the next section.

[0098] S5. Repeat steps S1 to S4 until the initial support construction of the entire tunnel is completed.

[0099] It should be noted that the concrete selected for the pre-compressed concrete rapid prototyping device must meet the following conditions: it should be fluid within 30 seconds after spraying, and should be able to solidify within 30-120 seconds. Within the compression length of the nano-coated flexible template 12, the concrete should not peel off from the surrounding rock after being removed from the nano-coated flexible template 12 for 2-5 minutes.

[0100] The strength of the concrete after setting and its later strength must meet or exceed the strength requirements specified for shotcrete; it must have the workability for concrete pumping to ensure sufficient compaction within the specified lining thickness without producing pitting.

[0101] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0102] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A TBM-driven pre-compression shotcrete rapid forming device, characterized in that, It includes a TBM body (8), a TBM follow-up system (1) connected to the TBM body (8), a pre-compressed concrete rapid molding device (2) and a follow-up pre-compressed spraying control system (3) connected to the TBM follow-up system (1). The TBM follow-up system (1) includes a synchronization platform (31), a rotary gear ring (4) disposed on the outside of the synchronization platform (31), and a synchronization platform stabilizer (5) and a follow-up synchronization cylinder (6) connected to the inside of the synchronization platform (31); a TBM synchronization track (7) is provided on the TBM body (8), and the TBM follow-up system (1) is movably connected to the TBM synchronization track (7) through the synchronization platform stabilizer (5); the pre-compressed concrete rapid molding device (2) is connected to the rotary gear ring (4) through the TBM rotary support (9); The pre-compression concrete rapid molding device (2) includes a TBM rotary support (9), a synchronous motor (10), a rotary reducer (11), a first arm (20), and a concrete pre-compression molding component connected to the first arm (20). The concrete pre-compression molding assembly includes a second arm (21), which is connected to the first arm (20) via an arm drive cylinder (28) and a first steering mechanism (29). The second arm (21) includes a sliding part (2101) and a nozzle connection part (2102). The two ends of the sliding part (2101) are respectively provided with a nozzle arm drive cylinder (33), a second steering mechanism (32), and a rotary reducer (11). The upper end face of the sliding part (2101) is provided with a nozzle arm slide rail (30). The nozzle connection part (2102) is slidably connected to the sliding part (2101) via the nozzle arm slide rail (30). The nozzle connection part (2102) is respectively provided with a spray mixing mechanical head (22) and a nozzle swing cylinder (27); the synchronous motor (10) meshes with the rotary gear ring (4); The sliding part (2101) is connected to a belt template assembly on the side near the rotary reducer (11); The belt template assembly includes a nano-coated flexible template (12), a side mold fixing frame (18), and a scraper bracket (24) connected to the side mold fixing frame (18). The nano-coated flexible template (12) is connected to the side mold fixing frame (18) through multiple drive rollers (14), guide rollers (15) and limiting rollers (16). The side mold fixing frame (18) is also provided with a tensioning device (13). The follow-up pre-pressure spray mixing control system (3) controls the contact pressure between the nano-coated flexible template (12) and the steel arch frame through the tensioning device (13). The inner side of the nano-coated flexible template (12) is provided with a limiting toothed rail (34), which meshes with the limiting roller (16). The limiting roller (16) is used to prevent the nano-coated flexible template (12) from deviating.

2. The TBM-guided pre-compression shotcrete rapid forming device according to claim 1, characterized in that, The scraper bracket (24) is provided with a retractable scraper (23) and a scraper drive cylinder (25). The follow-up pre-compression spraying control system (3) controls the scraper drive cylinder (25) to make the retractable scraper (23) scrape off the concrete attached to the nano-coated flexible template (12).

3. The TBM-guided pre-compression shotcrete rapid forming device according to claim 2, characterized in that, The side formwork fixing frame (18) is also provided with adaptive telescopic template assemblies on both sides. The adaptive telescopic template assembly includes a lateral adaptive telescopic template (17) and a side formwork driving cylinder (26). The follow-up pre-compression spraying control system (3) adjusts the pressure between the adaptive telescopic template (17) and the surrounding rock by controlling the side formwork driving cylinder (26). The adaptive expansion formwork (17) is provided with a side formwork flexible support (19) at one end near the surrounding rock. The side formwork flexible support (19) is used to fill the small gap between the adaptive expansion formwork (17) and the surrounding rock to prevent concrete from flowing out of the gap during construction.

4. The TBM-guided pre-compression shotcrete rapid forming device according to claim 1, characterized in that, The pre-stressed concrete rapid prototyping device (2) has an overall inverted trapezoidal structure, which is used to facilitate concrete spraying construction and avoid concrete from sticking to the nano-coated flexible template (12).

5. A rapid prototyping construction method for TBM-driven pre-compression shotcrete, characterized in that, The TBM-guided pre-compression shotcrete rapid prototyping device according to any one of claims 1-4 includes the following steps: S1. Start the TBM servo system (1) and control the synchronization platform (31) and the TBM body (8) to remain relatively stationary. S2. Select the number of pre-stressed concrete rapid forming devices (2) according to actual work needs. The pre-stressed concrete rapid forming devices (2) are set on one or both sides of the excavation face. S3. The pre-compression concrete rapid forming device (2) is controlled to move from bottom to top along the steel arch frame by the follow-up pre-compression spraying control system (3), and the concrete pre-compression forming component is used to spray concrete onto the top of the excavation face. S4. After completing the current section of the mold spraying and pouring work, the first boom (20) is adjusted to leave the steel arch frame by controlling the follow-up pre-compression spraying control system (3). At the same time, the TBM follow-up system (1) moves in the direction of excavation and moves to the adjacent steel arch frame to prepare for the tunnel outline support of the next section. S5. Repeat steps S1 to S4 until the initial support construction of the entire tunnel is completed.

6. The TBM-guided pre-compression shotcrete rapid prototyping construction method according to claim 5, characterized in that, When the pre-stressed concrete rapid prototyping device (2) in S2 is set on both sides of the excavation face, the sprayed concrete construction method is as follows: under the control of the synchronous motor (10), the pre-stressed concrete rapid prototyping device (2) on the left and right sides of the excavation face moves slowly from bottom to top along the steel arch frame and sprayed concrete construction is carried out synchronously towards the top of the excavation face; after reaching the top of the excavation face, the pre-stressed concrete rapid prototyping device (2) on one side is closed, and sprayed concrete construction is carried out on the top of the excavation face through the pre-stressed concrete rapid prototyping device (2) on the other side.

7. The TBM-guided pre-compression shotcrete rapid prototyping construction method according to claim 5, characterized in that, When the pre-stressed concrete rapid forming device (2) in S2 is set on one side of the excavation face, the first arm (20) on the opposite side is controlled to retract by the follow-up pre-stressed spraying control system (3), thereby retracting the pre-stressed concrete rapid forming device (2) on the opposite side and avoiding mutual interference between the two pre-stressed concrete rapid forming devices (2); under the control of the synchronous motor (10), the single-sided pre-stressed concrete rapid forming device (2) slowly moves from bottom to top along the steel arch frame to carry out sprayed concrete construction to the top of the excavation face. After construction to the top of the arch, the first arm (20) on the opposite side is controlled by the follow-up pre-stressed spraying control system (3). One arm (20) moves the device away from the steel arch and moves it to the opposite corner. Since the second arm (21) is equipped with a nozzle arm drive cylinder (33), the nozzle arm drive cylinder (33) is controlled to move the nozzle connection part (2102) along the nozzle arm slide rail (30) to the end of the second arm (21). The second steering mechanism (32) is started to rotate the nozzle connection part (2102). Then the pre-compression concrete rapid forming device (2) is started to construct from the corner to the arch top, and after filling the overlap, it is smoothed to complete the support of the tunnel outline of the section.

8. The TBM-guided pre-compression shotcrete rapid prototyping construction method according to claim 5, characterized in that, The method for applying shotcrete to the top of the excavation face using a pre-compressed concrete molding assembly in S3 includes the following steps: S31. Adjust the first arm (20) through the follow-up pre-compression spraying control system (3) to control the pitch angle of the pre-compression concrete rapid forming device (2) so that the nano-coated flexible template (12) just contacts the steel arch frame. Then adjust the tensioning device (13) through the follow-up pre-compression spraying control system (3) to control the contact pressure between the nano-coated flexible template (12) and the steel arch frame. S32. During the construction of a tunnel without steel arch frame, the side formwork drive cylinder (26) is controlled by the follow-up pre-compression spraying control system (3) to make the lateral adaptive telescopic formwork (17) extend to the side of the surrounding rock. At the same time, the side formwork flexible support (19) is tightly attached to the surrounding rock, reducing the small gap between the lateral adaptive telescopic formwork (17) and the surrounding rock, and preventing concrete from flowing out of the gap during spraying. When constructing a tunnel with a steel arch frame, the steel arch frame can be used as a side formwork. The adaptive telescopic formwork (17) is controlled not to extend by the follow-up pre-compression spraying control system (3). S33. When the adaptive telescopic template (17) extends, the telescopic scraper (23) is controlled to contact the nano-coated flexible template (12) through the follow-up pre-compression spraying control system (3). When constructing the first formwork concrete, the bottom formwork can be made to prevent the concrete from flowing out from the bottom of the pre-compression concrete rapid forming device (2) during the construction of the first formwork concrete. S34. By controlling the follow-up pre-compression spraying control system (3), the position of the second arm (21) is adjusted, and the direction of the spraying mechanical head (22) is adjusted by controlling the spraying arm drive cylinder (33), thereby controlling the mutual adjustment between the spraying mechanical head (22) and the nano-coated flexible template (12), so that the angle and direction of the concrete sprayed into the mold cavity by the spraying mechanical head (22) can be adjusted. S35. Turn on the spray mixing machine head (22) and spray quick-setting concrete downward from the opening at the top of the nano-coated flexible template (12) to complete the pouring of the initial concrete. S36. After the initial concrete at the bottom of the nano-coated mold cavity has solidified, the pitch angle of the steel arch frame of the pre-compressed concrete rapid forming device (2) is adjusted by the first arm (20). The tensioning device (13) controls the contact pressure between the nano-coated flexible template (12) and the steel arch frame, so that the device changes from being close to the steel arch frame to just being in contact with the steel arch frame. The follow-up pre-compressed spraying control system (3) controls the lateral adaptive telescopic template (17) to retract. Then, the drive roller (14) is started to control the nano-coated flexible template (12) to move slowly from bottom to top close to the steel arch frame until the current section of mold spraying and pouring work is completed.

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