TBM tunneling without rebounding and spraying mixture

Abstract

The application discloses a TBM tunneling tunnel non-rebound spraying and mixing method, and realizes the method through a non-rebound spraying and mixing device, which comprises a supporting frame arranged on an arc track in a tunnel, a movable frame arranged on the supporting frame and capable of reciprocating along the longitudinal direction of the tunnel, a spraying and mixing mechanical arm arranged on the top of the movable frame, a curved arc template connected with the spraying and mixing mechanical arm through an adjusting mechanism, and a lower edge of the curved arc template being in contact with the surface of a sprayed and mixed concrete layer of the tunnel, and the adjusting mechanism being used for keeping a fixed distance between the curved arc template and the inner wall of the tunnel; during work, the supporting frame gradually rises along the arc track, the movable frame gradually moves along the longitudinal direction of the tunnel in each layer, and the spraying and mixing work in the range of the spraying and mixing mechanical arm is completed step by step, then the arc track is moved, and the spraying and mixing work of the whole inner wall of the tunnel is completed. The application is suitable for the support of the tunnel, solves the problems of much rebound of concrete and uneven spraying and mixing surface in the spraying and mixing process of the tunnel, improves the pouring quality of the spraying and mixing, and reduces the rebound of the concrete.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of TBM tunneling, in particular to a TBM tunneling non-rebound spraying and mixing method. BACKGROUND

[0002] In the process of tunnel excavation, in order to improve the stability, safety and waterproofness of the tunnel, concrete spraying and mixing needs to be carried out, that is, spraying and mixing. In the process of spraying and mixing, concrete is sprayed onto the inner wall of the tunnel by spraying machinery, but due to the influence of factors such as water content, additives, spraying speed, spraying angle and distance between the spraying machinery and the inner wall of the tunnel, it is inevitable that concrete rebounding and falling will occur. When the rebounding and falling concrete solidifies on the equipment or the bottom of the tunnel, it will affect the normal operation of the equipment and the normal tunneling when it accumulates to a certain extent. According to relevant specifications, the rebounding amount of the side wall should not be greater than 15%, and the rebounding amount of the top arch should not be greater than 25%, but the current conventional technical solution has a large amount of concrete rebounding, which causes material waste and leads to high economic cost.

[0003] The existing invention patent ZL202122119584.2 discloses a concrete rebounding material collecting and cleaning platform, a spraying and mixing supporting device and an open TBM, which changes the receiving area of the rebounding concrete by means of the reversible and telescopic collecting platform mechanism, thereby solving the problems of difficult cleaning and low efficiency of the rebounding concrete. The TBM spraying and mixing device and supporting method with the application number CN202311089055.X increases a curved plate below the concrete spraying head to collect the rebounding concrete, thereby recycling the recovered concrete, avoiding the solidification of the equipment caused by the spraying and falling material, and reducing the production cost. However, the above two technical solutions passively solve the problem of concrete rebounding and falling, and do not fundamentally solve the problem, which cannot meet the needs of safe, efficient and civilized construction, and seriously restricts the construction progress. SUMMARY

[0004] In order to solve the above problems, the present application provides a TBM tunneling non-rebound spraying and mixing method, which can specifically adopt the following technical scheme:

[0005] The TBM tunneling non-rebound spraying and mixing method disclosed by the present application is realized by a non-rebound spraying and mixing device, and is characterized in that: the spraying and mixing device comprises a supporting frame arranged on an arc-shaped track in the tunnel, an active frame reciprocally moving along the longitudinal direction of the tunnel is arranged on the supporting frame, a spraying and mixing mechanical arm is arranged on the top of the active frame, a curved template connected by an adjusting mechanism is further arranged on the top of the active frame, the lower edge of the curved template is connected with the surface of the sprayed concrete layer in the tunnel, and the adjusting mechanism is used to keep a fixed distance between the curved template and the inner wall of the tunnel.

[0006] The non-rebound spraying and mixing method comprises the following steps:

[0007] Firstly, the support frame is placed at the lower left and / or right end of the arc-shaped track and is moved upward along the arc-shaped track to the appropriate position, while the movable frame is adjusted to be located at the end of the support frame;

[0008] Secondly, the lower edge of the curved arc template is connected to the surface of the tunnel sprayed concrete layer, and the curved arc template is kept at a fixed distance from the tunnel inner wall by adjusting the adjusting mechanism. Then, the concrete spraying is carried out between the curved arc template and the tunnel inner wall by the spraying mechanical arm, and the spraying work at the working position of the curved arc template is completed.

[0009] Thirdly, the position of the movable frame is adjusted so that the curved arc template moves to the next working position along the longitudinal direction of the tunnel, and step two is repeated until the concrete spraying at the height layer of the support frame is completed.

[0010] Fourthly, the support frame is moved upward along the arc-shaped track to the next working position at the next height, and steps one to three are repeated until the concrete spraying on the left and / or right side of the tunnel inner wall within the moving range of the support frame is completed.

[0011] Fifthly, the arc-shaped track is moved to the next working position along the longitudinal direction of the arc tunnel, and steps one to four are repeated until the complete concrete spraying of the tunnel inner wall is completed.

[0012] The arc-shaped track is a rotary gear ring arranged on the support frame, the inner side of the rotary gear ring is provided with a limiting track, the support frame is provided with a rotary large gear and two rotary small gears connected with the rotary large gear, the rotary large gear is driven by a rotary motor, the rotary small gears are connected with the rotary gear ring, and a anti-falling wheel arranged in the limiting track is connected with the rotary small gears.

[0013] The support frame comprises two vertically arranged vertical plates, a horizontal guide rod and a straight rack extending along the longitudinal direction of the tunnel are arranged between the vertical plates, a rotary gear driven by a rotary motor is arranged in the movable frame, the movable frame is arranged on the horizontal guide rod, and the rotary gear is engaged with the straight rack.

[0014] The adjusting mechanism comprises a telescopic oil cylinder arranged on the top of the movable frame, a support rod perpendicular to the telescopic oil cylinder is arranged on the movable end of the telescopic oil cylinder, a connecting rod and a swing arm oil cylinder are arranged on the support rod, the connecting rod is connected with the curved arc template by hinging, and the swing arm oil cylinder is arranged above the connecting rod and connected with the curved arc template by hinging.

[0015] Telescopic sleeve rods connected with the support rod are arranged on both sides of the telescopic oil cylinder, the connecting rod is coaxially arranged with the telescopic oil cylinder, and the swing arm oil cylinder is a pair of symmetrically arranged on both sides of the connecting rod.

[0016] The end of the spraying and mixing mechanical arm is provided with an ultrasonic distance sensor.

[0017] The rebound-free spraying and mixing device provided by the application has simple structure, convenient use and low maintenance cost, and the spraying and mixing mechanical arm sprays concrete on the tunnel wall in all directions by moving the supporting frame along the arc-shaped track and moving the movable frame along the tunnel axis, the angle of the curved arc template and the distance between the curved arc template and the tunnel wall are adjusted in the process, so that the thickness of the sprayed concrete meets the standard requirements, and the rebound of the concrete is reduced due to the blocking effect of the curved arc template. The adjusting mechanism can accurately adjust the distance between the curved arc template and the tunnel wall and the included angle between the curved arc template and the tunnel wall, so that the sprayed concrete falls between the curved arc template and the tunnel wall to the maximum extent, and the sprayed concrete surface is in contact with the curved arc template surface, which helps to ensure the smoothness of the spraying and mixing surface at different positions, facilitates the erection of the synchronous lining end plugging mold in the later stage, and saves construction time.

[0018] The rebound-free spraying and mixing method for TBM tunneling provided by the application is suitable for tunnel support, solves the problems of too much rebound of concrete and uneven spraying and mixing surface in the tunnel spraying and mixing process, improves the pouring quality of spraying and mixing, reduces the rebound of concrete, avoids the phenomenon of equipment downtime caused by cleaning accumulated slag, meets the needs of safe, efficient and civilized construction, saves time for later process construction, and improves construction efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 is a structural schematic view of the rebound-free spraying and mixing device.

[0020] Figure 2 is Figure 1 a structural schematic view of the spraying and mixing device.

[0021] Figure 3 is Figure 2 a left view.

[0022] Figure 4 is Figure 3 a perspective structural schematic view of the movable frame part.

[0023] Figure 5 is Figure 2 a top view of the adjusting mechanism part.

[0024] Figure 6 is a process schematic view of the supporting frame moving step by step upwards on the left side of the arc-shaped track in the spraying and mixing process.

[0025] Figure 7 is Figure 6 a spraying and mixing process schematic view when the movable frame moves in sequence along the tunnel longitudinal direction in the first view.

[0026] Figure 8 isFigure 6 The second figure is a schematic diagram of the spray mixing process when the movable frame moves sequentially along the longitudinal direction of the tunnel. DETAILED DESCRIPTION

[0027] The following describes an embodiment of the present invention in detail with reference to the accompanying drawings. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process. However, the protection scope of the present invention is not limited to the following embodiment.

[0028] The rebound-free spray mixing method for TBM tunneling described in the present invention is achieved through a rebound-free spray mixing device.

[0029] like Figures 1-5 As shown, the rebound-free spray mixing device is arranged on a curved track 1 in the tunnel, including a support frame 2, a movable frame 3 that moves back and forth along the longitudinal direction of the tunnel is provided on the support frame 2, a spray mixing robot arm 4 is provided on the top of the movable frame 3, and a curved template 6 connected by an adjustment mechanism 5 is also provided on the top of the movable frame 3. The lower edge of the curved template 6 is in contact with the surface of the tunnel sprayed concrete layer 7, and the adjustment mechanism 5 is used to keep the curved template 6 at a fixed distance from the inner wall of the tunnel.

[0030] The aforementioned curved track 1 is located at the outer edge of the support frame 11 and comprises two rotating gear rings 12 arranged symmetrically along the vertical centerline of the tunnel. Spaced apart, they are spaced front to back, with a limit track 13 located on the inner side of each rotating gear ring 12. The support frame 2, whose surface is perpendicular to the tunnel's cross-section, consists of a vertical plate 21, horizontal guide rods 22, and a linear rack 23. The horizontal guide rods 22 and the linear rack 23 are parallel to each other and arranged horizontally along the longitudinal direction of the tunnel. There are two horizontal guide rods 22, one on either side of the linear rack 23. The vertical plates 21 are located at both ends of the horizontal guide rods 22 and the linear rack 23, securing them.

[0031] A rotary motor 81 is provided at each of the front and rear ends of the support frame 2. Each rotary motor 81 is connected to a large rotary gear 82, each of which is meshed with two small rotary gears 83. The large rotary gears 82 and the small rotary gears 83 are connected via a Y-shaped bracket, maintaining their relative positions. The small rotary gears 83 are meshed with the rotating ring gear 12, and each small rotary gear 83 is connected to a locking wheel 84 via a connecting rod. The locking wheel 84 is located within the limiting track 13. When the rotary motor 81 is activated, the support frame 2 can move along the rotating ring gear 12 through the transmission action of the large rotary gear 82, the small rotary gears 83, and the rotating ring gear 12.

[0032] The movable frame 3 inside the support frame 2 is provided with a rotating gear 32 driven by a rotating motor 31, which is engaged with the linear rack 23. When the rotating motor 31 is started, the rotating gear 32 moves along the linear rack 23, thereby realizing the reciprocating movement of the movable frame 3 inside the support frame 2 along the longitudinal direction of the tunnel.

[0033] The spraying and mixing mechanical arm 4 mounted on the top of the movable frame 3 can realize 360° swing rotation, and an ultrasonic distance sensor is mounted at the end thereof for detecting the distance between the sprayed concrete layer 7 and the top of the curved arc formwork 6. The adjusting device 5 for connecting the curved arc formwork 6 includes a telescopic oil cylinder 51 provided on the top of the movable frame 3, a support rod 52 provided perpendicularly to the movable end of the telescopic oil cylinder 51, a connecting rod 53 and a swing oil cylinder 54 provided on the support rod 52, wherein the connecting rod 53 is hingedly connected to the curved arc formwork 6, the swing oil cylinder 54 is located above the connecting rod 53, and the movable end of the swing oil cylinder 54 is hingedly connected to the curved arc formwork 6. Therefore, when the telescopic oil cylinder 51 works, the distance between the curved arc formwork 6 and the inner wall of the tunnel can be adjusted; when the swing oil cylinder 54 works, the included angle between the curved arc formwork 6 and the inner wall of the tunnel can be adjusted. Through the joint action of the telescopic oil cylinder 51 and the swing oil cylinder 54, the curved arc formwork 6 can be kept at a fixed distance from the inner wall of the tunnel. Further, telescopic sleeve rods 55 connected to the support rod 52 are provided on both sides of the telescopic oil cylinder 51, the connecting rod 53 is coaxially provided with the telescopic oil cylinder 51, and the swing oil cylinder 54 is a pair of swing oil cylinders symmetrically provided on both sides of the connecting rod 53, thereby improving the adjustment accuracy of the curved arc formwork 6.

[0034] When the non-rebound spraying and mixing device works, first, the rotating motor 81 is started to move the support frame 2 along the rotating gear ring 12. Generally, the support frame 2 gradually moves from the lower part of the left and / or right side of the tunnel to the top center. During the spraying of concrete, the curved arc formwork 6 is located inside the tunnel wall and used as a formwork (which can constrain the smoothness of the sprayed concrete layer 7 and the consistency at different positions, thereby improving the spraying quality). Due to the height limitation of the curved arc formwork 6, the support frame 2 needs to be moved in a stepped manner on the rotating gear ring 12 (see Figure 6 ). At each predetermined position, the rotating motor 81 stops rotating, so that the support frame 2 and the rotating gear ring 12 remain relatively stationary. At this time, through the adjusting action of the telescopic oil cylinder 51 and the swing oil cylinder 54, the lower edge of the curved arc formwork 6 is connected to the surface of the sprayed concrete layer 7 of the tunnel, and the curved arc formwork 6 is kept at a fixed distance from the inner wall of the tunnel. Then, the spraying and mixing mechanical arm 4 is operated to spray concrete between the curved arc formwork 6 and the inner wall of the tunnel. In order to maximize the spraying efficiency, the actual operating range of the spraying and mixing mechanical arm 4 is greater than the width of the curved arc formwork 6. During the spraying process, the spraying and mixing mechanical arm 4 can be moved along the curved arc formwork 6, and the spraying and mixing mechanical arm 4 can also be moved along the inner wall of the tunnel. Figure 7As shown, the spraying and mixing mechanical arm 4 swings left and right, and swings back after hitting the left and right ends of the curved arc formwork 6 (i.e. the spraying is limited by the width of the curved arc formwork 6); and, the distance between the upper surface of the sprayed concrete layer 7 and the top of the curved arc formwork 6 is detected in real time during spraying, and the spraying is stopped when the distance is 30 mm or the required value; then, the rotating motor 31 is started to move the movable frame 3 and the spraying and mixing mechanical arm 4 and the curved arc formwork 6 on the movable frame 3 along the tunnel axis to continue the concrete spraying and mixing until the sprayed concrete layer 7 at the height range is completely constructed. Then, the support frame 2 is moved to the next height, and the above operations are repeated (see Figure 8 ) to complete the construction of the sprayed concrete layer 7 at the next height range. The above operations are repeated until the construction of the sprayed concrete layer 7 at the left and / or right sides of the tunnel is completed.

[0035] In this embodiment, one non-rebound spraying and mixing device is used to perform the spraying and mixing work, and the left side of the tunnel is first sprayed and mixed, and after the completion, the support frame 2 is moved to the other side of the curved arc track 6, and the spraying and mixing work on the right side of the tunnel is performed according to the spraying and mixing steps on the left side of the tunnel. Of course, two non-rebound spraying and mixing devices can also be used to simultaneously perform the spraying and mixing work on the left and right sides of the tunnel.

[0036] The steps of the spraying and mixing work on the left side of the tunnel are described in detail as follows:

[0037] Firstly, the support frame 2 is placed at the lower left end of the curved arc track 1, and is moved upward along the curved arc track 1 to an appropriate position, and the position of the movable frame 3 is adjusted so as to be located at the end of the support frame 2;

[0038] Secondly, the lower edge of the curved arc formwork 6 is brought into contact with the surface of the sprayed concrete layer 7 of the tunnel, and the curved arc formwork 6 is kept at a fixed distance from the inner wall of the tunnel by the adjusting mechanism 5, and then the spraying and mixing mechanical arm 4 sprays the concrete between the curved arc formwork 6 and the inner wall of the tunnel to complete the spraying and mixing work at the working position of the curved arc formwork 6;

[0039] Thirdly, the position of the movable frame 3 is adjusted so as to move the curved arc formwork 6 to the next working position along the longitudinal direction of the tunnel, and the step two is repeated until the concrete spraying at the height of the support frame 2 is completed;

[0040] Fourthly, the support frame 2 is moved upward along the curved arc track 6 to the next working position at the height, and the steps one to three are repeated until the concrete spraying at the left side of the inner wall of the tunnel within the moving range of the support frame 2 is completed;

[0041] Fifthly, the curved arc track 1 is moved to the next working position along the longitudinal direction of the tunnel, and the steps one to four are repeated until the concrete spraying at the inner wall of the left side of the tunnel is completed.

[0042] It should be noted that in the description of the present application, the terms indicating the orientation or positional relationship such as "front", "back", "left", "right", "vertical", "horizontal", "inner", "outer" and the like are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

Claims

1. A rebound-free spray mixing method for TBM tunneling, achieved by a rebound-free spray mixing device, characterized by: The spray-mixing device includes a support frame arranged on a curved track in the tunnel, a movable frame that moves back and forth in the longitudinal direction of the tunnel is provided on the support frame, a spray-mixing mechanical arm is provided on the top of the movable frame, and a curved template connected by an adjustment mechanism is also provided on the top of the movable frame, the lower edge of the curved template is in contact with the surface of the sprayed concrete layer in the tunnel, and the adjustment mechanism is used to maintain a fixed distance between the curved template and the inner wall of the tunnel; The rebound-free spray mixing method comprises the following steps: The first step is to place the support frame at the lower left end and / or lower right end of the curved track and move it upward along the curved track to an appropriate position, while adjusting the position of the movable frame so that it is located at the end of the support frame; The second step is to make the lower edge of the curved formwork contact the surface of the tunnel's sprayed concrete layer, and use an adjustment mechanism to maintain a fixed distance between the curved formwork and the tunnel inner wall. Then, the spray-mixing robot arm sprays concrete between the curved formwork and the tunnel inner wall, completing the spray-mixing operation at the curved formwork station. The third step is to adjust the position of the movable frame so that the curved template moves to the next work station along the longitudinal direction of the tunnel, and repeat step 2 until the concrete spraying at the height layer where the support frame is located is completed; Step 4: Move the support frame upward along the curved track to the next height position, and repeat steps 1 to 3 until the concrete spraying on the left and / or right side of the tunnel inner wall within the support frame's movement range is completed. The fifth step is to move the curved track to the next work station along the longitudinal direction of the tunnel and repeat steps one to four until all the concrete spraying on the inner wall of the tunnel is completed.

2. The rebound-free spray-mixing method for TBM tunneling according to claim 1 is characterized in that: The arc track is a rotating ring gear arranged on the support frame, a limiting track is arranged on the inner side of the rotating ring gear, a rotating large gear and two rotating small gears meshing with it are arranged on the support frame, the rotating large gear is driven by a rotating motor, the rotating small gear is meshed with the rotating ring gear, and the rotating small gear is connected to an anti-slip wheel arranged in the limiting track.

3. The rebound-free spray-mixing method for TBM tunneling according to claim 1 is characterized in that: The support frame includes two vertical plates arranged at intervals, and a horizontal guide rod and a linear rack extending longitudinally along the tunnel are arranged between the vertical plates. A rotating gear driven by a rotating motor is arranged in the movable frame, and the movable frame is passed through the horizontal guide rod, and the rotating gear is engaged with the linear rack.

4. The rebound-free spray-mixing method for TBM tunneling according to claim 1 is characterized in that: The adjustment mechanism includes a telescopic cylinder arranged on the top of the movable frame, the movable end of the telescopic cylinder is provided with a support rod perpendicular to it, the support rod is provided with a connecting rod and a swing arm cylinder, the connecting rod is hingedly connected to the bending template, the swing arm cylinder is arranged above the connecting rod, and the movable end of the swing arm cylinder is hingedly connected to the bending template.

5. The rebound-free spray-mixing method for TBM tunneling according to claim 4 is characterized in that: Telescopic sleeve rods connected to the support rod are provided on both sides of the telescopic oil cylinder. The connecting rod is coaxially arranged with the telescopic oil cylinder. The swing arm oil cylinder is a pair and is symmetrically arranged on both sides of the connecting rod.

6. The rebound-free spray-mixing method for TBM tunneling according to claim 1, characterized in that: An ultrasonic distance sensor is provided at the end of the spray-mixing robot arm.

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