Spraying control method and system based on sprayed concrete

Abstract

The invention discloses a spraying control method and system based on sprayed concrete, and the method comprises the steps: determining the spraying direction, the spraying speed and the position of a spraying inflection point according to the spraying starting point position of a to-be-sprayed region, the standby position of a nozzle and the current configuration parameters of the nozzle, and generating a spraying path; the spraying path comprises a plurality of spraying broken lines which are equal in spraying length and form a first included angle with the horizontal line, and the intersection point of every two adjacent spraying broken lines is the position of a spraying inflection point; and controlling the nozzle to start spraying of sprayed concrete, controlling the mechanical arm assembly to drive the nozzle to spray according to the spraying path, detecting the ground clearance of the mechanical arm assembly in real time, and controlling the mechanical arm assembly and the nozzle to stop working when the ground clearance reaches a preset height. The spraying path is in a broken line shape, a certain included angle is formed between the spraying path and the horizontal line for oblique spraying, the coverage area of sprayed concrete sprayed by the nozzle is maximum, and the spraying efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of shotcrete spraying, and in particular to a spraying control method and system based on shotcrete spraying. Background Art

[0002] Shotcrete is the most commonly used concrete in daily tunnel construction. Shotcrete has a certain fluidity and viscosity. Unlike ordinary concrete, after ordinary concrete is sprayed on the wall of the spraying area, the part in contact with the wall of the spraying area will adhere to the wall, and the excess part may fall directly on the ground. Shotcrete has good adhesion to the wall. After being sprayed on the wall, it will adhere to the wall and then flow down along the wall. However, during the current concrete spraying process, the flow of excess concrete after spraying is not considered. Instead, it is generally adopted to first select multiple spraying points in the area to be sprayed, and then control the various mechanical arms supporting the nozzle to drive the nozzle to spray along the set spraying path. This method has low spraying efficiency and high spraying waste rate. Summary of the invention

[0003] The object of the present invention is to provide a spraying control method based on shotcrete, so that the spraying path is in a broken line shape and the spraying is performed at a certain angle to the horizontal line, so that the sprayed concrete sprayed by the nozzle can cover the largest area and improve the spraying efficiency.

[0004] Based on the above objectives, this application proposes the following solutions:

[0005] A spraying control method based on shotcrete, specifically comprising the following steps:

[0006] S1, obtaining the spraying starting position of the area to be sprayed, the standby position of the nozzle, and the current configuration parameters of the nozzle, and controlling the mechanical arm assembly to drive the nozzle to move from the standby position to the spraying starting position;

[0007] S2. determining the injection direction and injection speed according to the current configuration parameters of the nozzle, wherein the configuration parameters include a direction angle and a speed mode;

[0008] S3, determining the position of the injection inflection point according to the injection starting point position, the injection direction and the injection speed, and generating an injection path according to the initial position, the injection direction, the injection speed and the position of the injection inflection point; the injection path includes a plurality of injection fold lines with equal injection lengths and a first angle with the horizontal line, and the intersection of two adjacent injection fold lines is the position of the injection inflection point;

[0009] S4. Control the nozzle to start spraying the shotcrete, and control the robotic arm assembly to drive the nozzle to spray along the spraying path, while detecting the height of the robotic arm assembly from the ground in real time. When the height from the ground reaches a preset height, control the robotic arm assembly and the nozzle to stop working.

[0010] In some specific schemes, several jet fold lines are connected end to end in sequence and have the same first angle with the horizontal line, the first angle is an acute angle, and at the position of the jet inflection point, the angle formed by the intersection of two adjacent jet fold lines is a right angle.

[0011] In some specific embodiments, the first angle is 45 degrees.

[0012] In some specific solutions, the configuration parameters also include the spray flow rate of the nozzle, the spray length of the spray line is equal, and the calculation method of the spray length L is:

[0013]

[0014] Wherein, Q represents the injection flow rate, v represents the injection speed in the current injection mode, and X represents the amount of concrete bonded to the wall per unit area of ​​the target.

[0015] In some specific schemes, a number of injection fold lines form a number of injection inflection points, and the formed injection inflection points are numbered, wherein the positions of the injection inflection points numbered with odd numbers are all on a first vertical straight line perpendicular to the horizontal line, and the positions of the injection inflection points numbered with even numbers are all on a second vertical straight line parallel to the first vertical straight line.

[0016] In some specific solutions, when the robot arm assembly is controlled to drive the nozzle to spray according to the spray path, the specific process is as follows:

[0017] S41, controlling the mechanical arm assembly to drive the nozzle to adjust the direction angle of the nozzle to a first angle with the horizontal plane;

[0018] S42, controlling the mechanical arm assembly to drive the nozzle to move from the injection starting point position along the injection fold line to the injection inflection point position after the injection length;

[0019] S43, controlling the mechanical arm assembly to rotate 90 degrees, and continuing to move along the next injection fold line to reach the position of the next injection inflection point after the injection length;

[0020] S44, repeat step S43 until the height of the robotic arm assembly from the ground reaches a preset height, and then control the robotic arm assembly and the nozzle to stop working.

[0021] In some specific embodiments, the nozzle is kept perpendicular to the spraying wall of the area to be sprayed during the spraying process.

[0022] In a second aspect, the present application provides a spraying control system based on shotcrete, comprising a main control module, a robotic arm assembly and a nozzle, wherein:

[0023] The nozzle pipe is pre-filled with shotcrete, and the robot arm is used to hold the nozzle and is controlled by the main control module to drive the nozzle to move and rotate;

[0024] The main control module is used to obtain the spraying starting position of the area to be sprayed, the standby position of the nozzle, and the current configuration parameters of the nozzle, and control the mechanical arm assembly to drive the nozzle to move from the standby position to the spraying starting position;

[0025] Determine the spray direction and spray speed according to the current configuration parameters of the nozzle, the configuration parameters including the direction angle and the speed mode;

[0026] Determine the position of the injection inflection point according to the injection starting point position, the injection direction and the injection speed, and generate an injection path according to the initial position, the injection direction, the injection speed and the position of the injection inflection point; the injection path includes a plurality of injection fold lines with equal injection lengths and a first angle with the horizontal line, and the intersection of two adjacent injection fold lines is the injection inflection point;

[0027] The nozzle is controlled to start spraying the shotcrete, and the robotic arm assembly is controlled to drive the nozzle to spray according to the spraying path. At the same time, the height of the robotic arm assembly from the ground is detected in real time. When the height from the ground reaches a preset height, the robotic arm assembly and the nozzle are controlled to stop working.

[0028] In some specific solutions, the configuration parameters also include the spray flow rate of the nozzle, the spray length of the spray line is equal, and the calculation method of the spray length L is:

[0029]

[0030] Wherein, Q represents the injection flow rate, v represents the injection speed in the current injection mode, and X represents the amount of concrete bonded to the wall per unit area of ​​the target.

[0031] The inventive concept of this application is:

[0032] Most of the existing ordinary concrete spraying adopts the method of setting multiple spraying points to form a spraying path parallel to the horizontal plane. This spraying method often has a vertical spraying path after reaching the inflection point. With the emergence of shotcrete, the surface area of ​​shotcrete after being sprayed on the wall is large, and the bonding area with the wall is large. The particle size distribution of cementitious materials in shotcrete is uniform, and fine aggregate is mainly used, making the concrete itself relatively uniform. After the shotcrete is sprayed on the wall, it will flow down along the wall due to gravity. If it is sprayed horizontally, the vertical spraying path between the two spraying inflection points will be covered with excess shotcrete, resulting in waste of concrete.

[0033] The present application proposes a new spraying path, which is composed of a plurality of spraying fold lines with equal spraying lengths and a first angle with the horizontal line, so that the spraying path is no longer spraying in the horizontal direction and the vertical direction, and the spraying path becomes an oblique spraying, so that the length of the sprayed concrete flowing downward along each spraying fold line is the same, and the obtained coverage area is also the largest, and the intersection of two adjacent spraying fold lines is the spraying inflection point, which can reduce the number of existing inflection points from horizontal spraying to vertical spraying and then to horizontal spraying, improve the spraying efficiency and reduce the waste of sprayed concrete.

[0034] The present invention has the beneficial effects:

[0035] The present application controls the nozzle to spray according to a spray path composed of a plurality of spray fold lines of equal spray length and having a first angle with the horizontal line. This spray path is composed only of spray fold lines, and the spray fold lines all have a first angle with the horizontal line. The intersection of two adjacent spray fold lines is the position of the spray inflection point. According to this spray path, the maximum coverage area can be obtained, and the spray efficiency is high. And for the movement of the robot arm, the spray inflection point of the spray path of the present application is obtained by the intersection of two adjacent spray fold lines of the same length, which is easier to operate and improves the spray efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 A flow chart of the spraying control method based on shotcrete provided by the present invention;

[0037] Figure 2 A schematic diagram of the concrete provided by the present invention when sprayed according to the spraying path;

[0038] Figure 3 The present invention provides the shotcrete content at each point in the area surrounded by the shot path at different shot speeds. DETAILED DESCRIPTION

[0039] 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, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. 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.

[0040] Example 1

[0041] like Figure 1 As shown, this embodiment provides a spraying control method based on shotcrete, which specifically includes the following steps:

[0042] S1, obtaining the spraying starting position of the area to be sprayed, the standby position of the nozzle, and the current configuration parameters of the nozzle, and controlling the mechanical arm assembly to drive the nozzle to move from the standby position to the spraying starting position;

[0043] S2. determining the injection direction and injection speed according to the current configuration parameters of the nozzle, wherein the configuration parameters include a direction angle and a speed mode;

[0044] S3, determining the position of the injection inflection point according to the injection starting point position, the injection direction and the injection speed, and generating an injection path according to the initial position, the injection direction, the injection speed and the position of the injection inflection point; the injection path includes a plurality of injection fold lines with equal injection lengths and a first angle with the horizontal line, and the intersection of two adjacent injection fold lines is the position of the injection inflection point;

[0045] Specifically, Figure 2 As shown, several jet fold lines are connected end to end in sequence, and have the same first angle with the horizontal line, the first angle is an acute angle, the first angle is 45 degrees, and at the position of the jet inflection point, the angle formed by the intersection of two adjacent jet fold lines is a right angle.

[0046] Several injection fold lines form several injection inflection points, and the formed injection inflection points are labeled, wherein the positions of the injection inflection points labeled with odd numbers are all on the first vertical line perpendicular to the horizontal line, and the positions of the injection inflection points labeled with even numbers are all on the second vertical line parallel to the first vertical line. Specifically, the linear distance between the first vertical line and the second vertical line is In this way, when the positions of various injection inflection points are determined, the injection path can be obtained.

[0047] The configuration parameters also include the spray flow rate of the nozzle, the spray length of the spray line is equal, and the calculation method of the spray length L is:

[0048]

[0049] Wherein, Q represents the injection flow rate, v represents the injection speed in the current injection mode, and X represents the amount of concrete bonded to the wall per unit area of ​​the target.

[0050] S4, control the nozzle to start spraying the shotcrete, and control the mechanical arm assembly to adjust the motion parameters to drive the nozzle to spray according to the spray path, and at the same time detect the height of the mechanical arm assembly from the ground in real time, and control the mechanical arm assembly and the nozzle to stop working when the height from the ground reaches a preset height. The motion parameters include the rotation angle, motion direction and coordinates of the mechanical arm assembly.

[0051] Specifically, when the robot arm assembly is controlled to drive the nozzle to spray according to the spray path, the specific process is as follows:

[0052] S41, controlling the mechanical arm assembly to drive the nozzle to adjust the direction angle of the nozzle to a first angle with the horizontal plane;

[0053] S42, controlling the mechanical arm assembly to drive the nozzle to move from the injection starting point position along the injection fold line to the injection inflection point position after the injection length;

[0054] S43, controlling the mechanical arm assembly to rotate 90 degrees, and continuing to move along the next injection fold line to reach the position of the next injection inflection point after the injection length;

[0055] S44, repeat step S43 until the height of the robotic arm assembly from the ground reaches a preset height, and then control the robotic arm assembly and the nozzle to stop working.

[0056] In some specific embodiments, the nozzle is kept perpendicular to the spray wall of the area to be sprayed during the spraying process.

[0057] In order to better illustrate the advantages of the injection path of the present application, a detailed derivation process is given below:

[0058] like Figure 2 As shown in the figure, after the shotcrete is sprayed onto the wall, it will slide down due to its own gravity. The parts of the wall wrapped by the adjacent spray fold lines shown in the figure will be bonded with the concrete flowing down from the vertical upward spray fold lines. After the spraying of the spray fold lines is completed, all areas that can be bonded with concrete are defined as the coverage area. Taking one of the coverage areas △BCD as an example, when the nozzle moves along the spray fold line AB at a constant speed with the robotic arm assembly, the shotcrete in the nozzle is sprayed on the wall along the AB line segment. Assuming that the shotcrete can flow down along the AB line segment to fit the wall for a distance of 2r, after exceeding 2r, it will almost stop flowing. In this way, any section in the middle area, such as every point on the coverage area BCD, receives the concrete flowing down from the AB section, and the concrete can be evenly distributed here. For the shotcrete, the part in contact with the wall will have a strong bonding force due to its ultra-fine cement completely embedded in the pores of the wall. In this way, the part of the concrete in contact with the wall will be firmly bonded to the wall, and the other part will continue to flow downward.

[0059] Assuming that the unit bonding amount of the coverage area is X, the spray flow rate of the nozzle is Q, and the spray velocity is v, then for the coverage area BCD, the concrete uniformly sprayed on the spray fold line AB and the concrete sprayed on the spray fold line BC will flow down to the coverage area BCD. Since the length of the spray fold line AB is equal to the length of the spray fold line BC, assuming it is L, the distance that the sprayed concrete can flow down along the wall is 2r. For the coverage area BCD, the amount of concrete sprayed from the AB segment is The amount of concrete sprayed under the BC section flow is also The total amount of concrete sprayed in the coverage area BCD is

[0060] Assuming that the unit area bonding amount of the coverage area BCD is X, we can know that the total amount of bonding concrete in this area is 2r*r*0.5*X=r 2 *X

[0061] Easy to know:

[0062]

[0063] It can be deduced that the distance the shotcrete can flow down the wall is: The injection length of the injection line can also be derived It can be seen that r can be kept fixed by varying the values ​​of Q and v. In particular, r depends on the bonding properties of the concrete itself to the wall.

[0064] from Figure 2 It can also be seen that the injection path formed by the present application ensures uniform injection. Except for the boundary, any column drawn on the injection fold line has the same number of intersections with the injection fold line. Since the nozzle moves at a uniform speed throughout the entire process, this ensures that the amount of concrete that can be bonded to each thin column is the same. The two columns at the left and right end points of the injection fold line pass through the position of the injection inflection point, and the position of the injection inflection point is the intersection of two adjacent injection fold lines.

[0065] In order to prove that the spraying path of this application is reasonable, the whole process is simulated by using the discrete element simulation method of PFC software. First, a sprayed concrete model is constructed according to the components of the sprayed concrete. For each spraying unit, the speed at which they are sprayed from the nozzle is set to v, the cross-sectional area of ​​the sprayed fluid is fixed to S, and the spraying direction is perpendicular to the wall and the distance from the wall is l. The wall is vertical and the area is large enough. The force field setting for the whole process only sets the gravity field. Spray according to the above-mentioned spraying path, move continuously from a certain point, and stop the nozzle spraying after turning 100 times. After the concrete sprayed on the wall stops moving, calculate the sprayed concrete content at each point in the area surrounded by the spraying path. Record the ratio of the maximum value to the minimum value q1.

[0066] Change the injection speed to 2v, 3v, 4v...10v, repeat the above experiment, and get q2, q3,...q10. The numbers from q1 to q10 are as follows Figure 3 As shown, it can be found that the ratios of the ten sets of data are all below 1.1, indicating that the concrete sprayed on the wall is evenly distributed, and these ten data do not show that the uneven distribution of the sprayed concrete increases with the increase of the spraying speed (i.e., the increase of the spraying amount). All these indicate that the above-mentioned spraying path is reasonable.

[0067] After obtaining the injection starting point position, injection length and injection inflection point position, when generating the injection path, the position coordinates of the injection inflection point formed between the injection fold lines can be determined, and then the angle and direction of the mechanical arm assembly can be set, so that the nozzle can be driven to spray uniformly from the position of one injection inflection point along the set direction to the position of another injection inflection point. The injection route formed between the positions of the two injection inflection points is the injection fold line. The positions of the two adjacent injection inflection points are staggered. The two injection inflection points are respectively located at the diagonal lines of the quadrilateral formed by the two adjacent injection inflection points. The straight-line distance between the two adjacent injection inflection points is the injection length. When the mechanical arm assembly is in motion, the nozzle is first moved to the injection starting point position, and then the movement direction of the mechanical arm assembly is adjusted, that is, the nozzle is adjusted to move to the right in a straight line at a 45-degree angle to the horizontal line with the injection starting point as the origin to the position of the injection inflection point. At the position of the injection inflection point, the mechanical arm assembly is controlled to rotate 90 degrees, and the direction is adjusted to move to the left in a straight line at a 45-degree angle to the horizontal line to the position of the next adjacent injection inflection point.

[0068] Example 2

[0069] This embodiment provides a spraying control system based on shotcrete, including a main control module, a mechanical arm assembly and a nozzle, wherein:

[0070] The nozzle pipe is pre-filled with shotcrete, and the robotic arm assembly is used to hold the nozzle and is controlled by the main control module to drive the nozzle to move and rotate;

[0071] An angle encoder can be set on the robot arm assembly to detect the rotation angle of the rotating mechanism in the robot arm assembly, and then determine the orientation angle of the nozzle. A regulating valve can also be set on the nozzle to adjust the outlet pressure and flow of the nozzle by changing the opening of the regulating valve, thereby controlling the nozzle flow rate and flow size. The regulating valve is connected to the main control module, receives the opening control signal sent by the main control module, and changes the opening of the regulating valve to change the nozzle flow rate and flow size.

[0072] The main control module is used to obtain the spraying starting position of the area to be sprayed, the standby position of the nozzle, and the current configuration parameters of the nozzle, and control the mechanical arm assembly to drive the nozzle to move from the standby position to the spraying starting position;

[0073] Determine the spray direction and spray speed according to the current configuration parameters of the nozzle, the configuration parameters including the direction angle and the speed mode;

[0074] The position of the injection inflection point is determined according to the injection starting point position, the injection direction and the injection speed, and the injection path is generated according to the initial position, the injection direction, the injection speed and the position of the injection inflection point; the injection path includes a plurality of injection fold lines with equal injection lengths and a first angle with the horizontal line, and the intersection of two adjacent injection fold lines is the injection inflection point; the injection length L is calculated as follows:

[0075]

[0076] Wherein, Q represents the injection flow rate, v represents the injection speed in the current injection mode, and X represents the amount of concrete bonded to the wall per unit area of ​​the target.

[0077] The nozzle is controlled to start spraying the shotcrete, and the robotic arm assembly is controlled to drive the nozzle to spray according to the spraying path. At the same time, the height of the robotic arm assembly from the ground is detected in real time. When the height from the ground reaches a preset height, the robotic arm assembly and the nozzle are controlled to stop working.

[0078] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. According to the technical essence of the present invention, within the spirit and principles of the present invention, any simple modification, equivalent replacement and improvement made to the above embodiment still falls within the protection scope of the technical solution of the present invention.

Claims

1. A spraying control method based on shotcrete, characterized in that: The specific steps include: S1, obtaining the spraying starting position of the area to be sprayed, the standby position of the nozzle, and the current configuration parameters of the nozzle, and controlling the mechanical arm assembly to drive the nozzle to move from the standby position to the spraying starting position; S2. determining the injection direction and injection speed according to the current configuration parameters of the nozzle, wherein the configuration parameters include a direction angle and a speed mode; S3, determining the position of the injection inflection point according to the injection starting point position, the injection direction and the injection speed, and generating the injection path according to the initial position, the injection direction, the injection speed and the position of the injection inflection point; The jet path includes a plurality of jet fold lines with equal jet lengths and a first angle with the horizontal line, and the intersection of two adjacent jet fold lines is a jet inflection point; S4. Control the nozzle to start spraying the shotcrete, and control the robotic arm assembly to drive the nozzle to spray along the spraying path, while detecting the height of the robotic arm assembly from the ground in real time. When the height from the ground reaches a preset height, control the robotic arm assembly and the nozzle to stop working.

2. A spraying control method based on shotcrete according to claim 1, characterized in that: A plurality of jet fold lines are connected end to end in sequence and have the same first angle with the horizontal line, the first angle is an acute angle, and at the jet inflection point, the angle formed by the intersection of two adjacent jet fold lines is a right angle.

3. A spraying control method based on shotcrete according to claim 2, characterized in that: The first angle is 45 degrees.

4. The spraying control method based on shotcrete according to claim 1 is characterized in that: The configuration parameters also include the spray flow rate of the nozzle, the spray length of the spray line is equal, and the calculation method of the spray length L is: Wherein, Q represents the injection flow rate, v represents the injection speed in the current injection mode, and X represents the amount of concrete bonded to the wall per unit area of ​​the target.

5. The spraying control method based on shotcrete according to claim 1 is characterized in that: A plurality of injection fold lines form a plurality of injection inflection points, and the formed plurality of injection inflection points are numbered, wherein the positions of the injection inflection points numbered odd are all on a first vertical line perpendicular to the horizontal line, and the positions of the injection inflection points numbered even are all on a second vertical line parallel to the first vertical line.

6. A spraying control method based on shotcrete according to claim 5, characterized in that: When the control robot assembly drives the nozzle to spray according to the spray path, the specific process is as follows: S41, controlling the mechanical arm assembly to drive the nozzle to adjust the direction angle of the nozzle to a first angle with the horizontal plane; S42, controlling the mechanical arm assembly to drive the nozzle to move from the injection starting point position along the injection fold line to the injection length and then reach the injection inflection point position; S43, controlling the mechanical arm assembly to rotate 90 degrees, and continuing to move along the next injection fold line to reach the position of the next injection inflection point after the injection length; S44, repeat step S43 until the height of the robotic arm assembly from the ground reaches a preset height, and then control the robotic arm assembly and the nozzle to stop working.

7. The spraying control method based on shotcrete according to claim 1 is characterized in that: During the spraying process, the nozzle is kept vertical to the spraying wall of the spraying area.

8. A spraying control system based on shotcrete, characterized in that: It includes a main control module, a robotic arm assembly and a nozzle, wherein: The nozzle pipe is pre-filled with shotcrete, and the robot arm is used to hold the nozzle and is controlled by the main control module to drive the nozzle to move and rotate; The main control module is used to obtain the spraying starting position of the area to be sprayed, the standby position of the nozzle, and the current configuration parameters of the nozzle, and control the mechanical arm assembly to drive the nozzle to move from the standby position to the spraying starting position; Determine the spray direction and spray speed according to the current configuration parameters of the nozzle, the configuration parameters including the direction angle and the speed mode; Determine the position of the injection inflection point according to the injection starting point position, the injection direction and the injection speed, and generate an injection path according to the initial position, the injection direction, the injection speed and the position of the injection inflection point; the injection path includes a plurality of injection fold lines with equal injection lengths and a first angle with the horizontal line, and the intersection of two adjacent injection fold lines is the injection inflection point; The nozzle is controlled to start spraying the shotcrete, and the robotic arm assembly is controlled to drive the nozzle to spray according to the spraying path. At the same time, the height of the robotic arm assembly from the ground is detected in real time. When the height from the ground reaches a preset height, the robotic arm assembly and the nozzle are controlled to stop working.

9. The spraying control system based on shotcrete according to claim 8, characterized in that: The configuration parameters also include the spray flow rate of the nozzle, the spray length of the spray line is equal, and the calculation method of the spray length L is: Wherein, Q represents the injection flow rate, v represents the injection speed in the current injection mode, and X represents the amount of concrete bonded to the wall per unit area of ​​the target.

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