Construction equipment and method for tunnel fallen block over-excavation composite support

Abstract

The invention discloses construction equipment and method for a tunnel chipping and overexcavation composite support, solves the problems that in the prior art, a tunnel overexcavation concave cavity is poor in stability and poor in stability after repair, and has the beneficial effect of being beneficial to improving the stability of a tunnel, and according to the specific scheme, the construction equipment for the tunnel chipping and overexcavation composite support comprises a frame, the frame is movable and supports the first mechanical arm and the second mechanical arm, the first mechanical arm is telescopic, the telescopic end of the first mechanical arm is connected with the grouting mechanism and the dust removal mechanism, the grouting mechanism and the dust removal mechanism are integrally arranged, dust removal is conducted on a tunnel over-excavation cavity through the dust removal mechanism, and grouting is conducted on the surface of the over-excavation cavity through the grouting mechanism. The second mechanical arm has multiple degrees of freedom, a supporting piece is arranged at the movable end of the second mechanical arm and supports the drilling mechanism and the anchor rod mechanism, the drilling mechanism is used for drilling holes in the over-excavation concave cavity, and the anchor rod mechanism is used for construction of anchor rods in the over-excavation concave cavity.

Description

Technical Field

[0001] The invention relates to the technical field of coordinated repair of tunnel collapsed, defective and sunken block systems, and in particular to equipment and a method for constructing composite support for tunnel block fall and over-excavation. Background Art

[0002] The statements in this section merely provide background information related to the present invention and do not necessarily constitute prior art.

[0003] At present, drilling and blasting is still the main method of tunnel excavation, and over-excavation is a common problem in tunnel blasting and excavation. Over-excavation refers to the excavation depth that exceeds the design requirements during the construction process. Its occurrence is often related to design factors, unreasonable construction plans, geological conditions, etc. For example, improper control of excavation progress and equipment operation, insufficient precision of drilling operations and control mostly relying on manual experience and improper control of explosives in blasting operations, etc., will cause over-excavation. In addition, the complexity of geological conditions is also one of the reasons for over-excavation. If appropriate repair and control measures are not applied, it is very easy to induce large-scale collapse and instability and other engineering disasters.

[0004] Tunnel over-excavation will significantly reduce the stability of the tunnel structure. The tunnel section originally excavated according to the design requirements will form irregular cavities after over-excavation. These cavities will weaken the overall bearing capacity of the tunnel and easily lead to risks such as falling and collapse. The traditional repair method has the following problems:

[0005] There is no unified repair equipment. It is necessary to use excavators, bolters, grouting equipment and other equipment to operate in sequence or in coordination with each other. Moreover, each equipment needs to be put into operation several times, which makes the work efficiency low.

[0006] During the operation of each device, each machine needs to be operated manually on site, which poses a safety risk;

[0007] During the operation of the equipment, dust removal is impossible and the working environment is relatively harsh;

[0008] There is no unified technical standard for repairing over-excavated cavities, and the repair results have the problem of poor stability. Summary of the invention

[0009] In view of the deficiencies in the prior art, the object of the present invention is to provide a device for constructing composite support for over-excavation in tunnels, which can effectively repair over-excavation cavities in tunnels.

[0010] In order to achieve the above object, the present invention is implemented through the following technical solutions:

[0011] A construction equipment for tunnel block fall and over-excavation composite support, comprising a frame, the frame is movable, the frame supports a first mechanical arm and a second mechanical arm, the first mechanical arm is retractable, the retractable end of the first mechanical arm is connected to a grouting mechanism and a dust removal mechanism, the grouting mechanism and the dust removal mechanism are integrated, the dust removal mechanism is used to remove dust from the over-excavation cavity of the tunnel, and the grouting mechanism is used to grout the surface of the over-excavation cavity, the second mechanical arm has multiple degrees of freedom, and a support is set at the movable end of the second mechanical arm, the support supports both a drilling mechanism and an anchor mechanism, the drilling mechanism is used to drill holes at the over-excavation cavity, the anchor mechanism is used to construct anchors at the over-excavation cavity, the grouting mechanism can also grout the holes drilled at the over-excavation cavity to inject slurry into the over-excavation cavity, and can perform grouting operations on the anchors after the anchors are driven in.

[0012] In the equipment for constructing composite support for over-excavation of tunnel blocks as described above, the telescopic end of the first mechanical arm is connected to the connecting piece, the connecting piece is hollow, a detachable concrete nozzle is arranged at one end of the connecting piece, and the other end is connected to the concrete box, the side of the connecting piece supports the dust removal mechanism, and the first mechanical arm and the second mechanical arm are arranged on both sides of the frame opposite to each other.

[0013] As described above, a tunnel block falling and over-excavation composite support construction equipment, the dust removal mechanism includes a dust removal component and a water outlet nozzle, support rods are respectively arranged on both sides of the connecting piece, the support rod on one side clamps the dust removal component through a first clamping piece, and the dust removal component is connected to the dust collecting box, the support rod on the other side clamps the water outlet nozzle through a second clamping piece, and the water outlet nozzle is connected to the water tank.

[0014] In the above-mentioned tunnel block falling and over-excavation composite support construction equipment, the first mechanical arm, the second mechanical arm, the grouting mechanism, the dust removal mechanism, the drilling mechanism, and the anchor mechanism are respectively connected to the controller;

[0015] The frame is provided with a running mechanism, the running mechanism is connected to a controller, and the controller is remotely connected to a remote controller.

[0016] As described above, a tunnel block falling and over-excavation composite support construction equipment, the first mechanical arm is installed on the frame through the first support seat, the second mechanical arm is fixed to the frame through the second support seat, a first auxiliary arm is arranged between the shell of the second mechanical arm and the second support seat, the first auxiliary arm is retractable, a second auxiliary arm is arranged between the shell of the second mechanical arm and the movable mounting block, the second auxiliary arm includes multiple connecting rods, two adjacent connecting rods are movably connected, the telescopic end of the second mechanical arm is connected to the movable mounting block, and the movable mounting block is connected to the support member.

[0017] The above-mentioned tunnel block falling over-excavation composite support construction equipment, wherein the end of the support member away from the second mechanical arm is connected to the net hanging mechanism;

[0018] The mesh hanging mechanism includes a grid for supporting the steel mesh, the grid includes two vertical plates, a connecting block is arranged at one end of the support, the connecting block supports the first linear drive component, the movable end of the first linear drive component is connected to the vertical plate, and the vertical plate is arranged to support the convex part of the steel mesh.

[0019] The above-mentioned tunnel block falling over-excavation composite support construction equipment, wherein the support member is connected to the second mechanical arm through a turntable, the turntable is rotatable relative to the second mechanical arm, the drilling mechanism is located on one side of the support member, and the anchor mechanism is fixed to the other side of the support member;

[0020] The drilling mechanism includes a first driving power source, which is connected to a drill bit. A support member supports a vertical beam. The drill bit is arranged to pass through the vertical beam. Driven by the first driving power source, the drill bit realizes telescopic and rotational movement relative to the vertical beam. The drill bit can pass through the space between the two vertical plates of the grid.

[0021] As described above, in the construction equipment for composite support of tunnel block fall and over-excavation, the anchor rod mechanism includes a clamping arm, which is supported by a connecting plate. The clamping arm includes a first clamping plate and a second clamping plate. The second clamping plate is connected to the second linear drive component to clamp the anchor rod. The connecting plate is connected to the second driving power source. The anchor rod can be set through the space between the two vertical plates of the frame.

[0022] In a second aspect, the present invention further provides a tunnel block falling over-excavation composite support method, which uses the tunnel block falling over-excavation composite support construction equipment, including the following contents:

[0023] The over-excavated cavity of the tunnel is sprayed with mesh to form a shell: loose rocks in the over-excavated cavity are removed, the construction equipment is moved to the tunnel, the over-excavated cavity is dusted by the dust removal mechanism, and the over-excavated cavity is sprayed with concrete for the first time by the grouting mechanism to form a layer of concrete protective shell on the surface of the over-excavated cavity;

[0024] The over-excavated cavity of the tunnel is grout-filled: the second mechanical arm moves so that the drilling mechanism is aligned with the over-excavated cavity, and the drilling mechanism drills holes at the over-excavated cavity to form grouting holes. A grouting pressure box is buried at the grouting hole, and a pressure sensor is arranged in the grouting pressure box. The pressure sensor is connected to the controller, and the grouting hole is grouted through the grouting mechanism;

[0025] Targeted anchoring operation is performed on the over-excavated cavity of the tunnel: the second robotic arm moves to align the drilling mechanism with the over-excavated cavity, the drilling mechanism drills a hole in the over-excavated cavity, the anchor mechanism clamps the anchor and sends the anchor into the corresponding borehole, and the grouting mechanism injects concrete slurry into the corresponding borehole.

[0026] The above-mentioned tunnel block falling over-excavation composite support method further includes the following contents before the initial injection of concrete into the over-excavation cavity by the grouting mechanism:

[0027] Determine the actual contour of the over-excavated cavity to determine the area for hanging the net;

[0028] Drill holes and drive expansion bolts where the over-excavation cavity opening extends to the tunnel contour;

[0029] Fix the hanging net with expansion bolts.

[0030] The beneficial effects of the present invention are as follows:

[0031] 1) The present invention integrates multiple functions, including grouting, drilling and anchor installation, through the provision of construction equipment. The first mechanical arm is used to support the grouting mechanism and the dust removal mechanism, which can remove dust during the operation. The second mechanical arm is used to support the drilling mechanism and the anchor mechanism, so that the over-excavated cavity can be drilled and grouted, and the anchor can be installed after drilling. After the anchor is installed, grouting can be performed. There is no need to frequently switch equipment, which simplifies the operation process and improves the construction speed and efficiency. The equipment is reasonably designed and easy to operate, which reduces the construction difficulty and the work intensity of the operator.

[0032] 2) The present invention is provided with a mesh hanging mechanism, which includes a mesh frame, and the mesh frame can support the steel mesh, so that the steel mesh can be conveniently hung in the over-excavated cavity of the tunnel, facilitating the smooth implementation of the mesh spraying shell operation.

[0033] 3) In the present invention, the first robotic arm is retractable, and the second robotic arm has multiple degrees of freedom, and can flexibly perform various operations to meet the needs of repairing over-excavated cavities of different shapes and sizes. At the same time, through modular designs such as connectors and mounting plates, different equipment can be easily replaced, thereby improving the versatility and flexibility of the equipment. The operating equipment is remotely connected to the remote control, and there is no need for workers to enter for each process, thereby ensuring operational safety.

[0034] 4) The present invention provides a support method and forms a systematic composite support method through the coordinated application of three technologies: mesh spraying shelling, grouting filling and targeted anchoring. The three technologies complement each other and jointly improve the stability and safety of tunnel over-excavation cavity support, effectively solving the problem that tunnel over-excavation cavity is difficult to effectively repair; specifically, a series of steps such as cleaning the working surface, precise measurement, mesh spraying, grouting filling and targeted anchoring are used to ensure the support effect; and real-time monitoring and data analysis by the controller provide a basis for construction decision-making and optimization. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0036] Figure 1 It is a schematic diagram of an equipment for constructing a tunnel block falling and over-excavation composite support according to one or more embodiments of the present invention.

[0037] Figure 2 It is a schematic diagram of a grouting mechanism and a dust removal mechanism in an installation device for a tunnel block falling and over-excavation composite support according to one or more embodiments of the present invention.

[0038] Figure 3 It is a schematic diagram of a clamping member in an installation device for composite support for falling blocks and over-excavation in a tunnel according to one or more embodiments of the present invention.

[0039] Figure 4 It is an enlarged schematic diagram of part of the structure of a tunnel block falling and over-excavation composite support construction device according to one or more embodiments of the present invention.

[0040] Figure 5 It is a comparison diagram of tunnel over-excavation cavity support before and after using a tunnel block falling over-excavation composite support construction equipment according to one or more embodiments of the present invention.

[0041] Figure 6 It is a flow chart of a tunnel block falling and over-excavation composite support method according to one or more embodiments of the present invention.

[0042] Figure 7 It is a flow chart of mesh spraying shell in a tunnel block falling and over-excavation composite support method according to one or more embodiments of the present invention.

[0043] Figure 8 It is a flow chart of grouting filling in a tunnel block falling and over-excavation composite support method according to one or more embodiments of the present invention.

[0044] Fig. 9 It is a flow chart of targeted anchoring in a tunnel block falling and over-excavation composite support method according to one or more embodiments of the present invention.

[0045] In the figure: the distances or sizes between parts are exaggerated to show the positions of various parts, and the schematic diagram is for reference only.

[0046] Among them: 1. Base; 2. Frame; 3. Dust removal fan; 4. Concrete box; 5. First mechanical arm; 6. Second mechanical arm; 7. First auxiliary arm; 8. Second auxiliary arm; 9. Movable mounting block; 10. Oil cylinder;

[0047] 121, first support base; 122, second support base;

[0048] 31. Ash collecting box;

[0049] 51. Connecting piece; 52. Concrete nozzle; 53. Clamping piece; 54. Dust removal assembly; 55. Water nozzle; 511. Mounting plate; 521. Splash shield; 531. First clamping piece; 532. Second clamping piece; 533. Fixing plate; 534. Lifting block; 535. Clamping plate; 536. Screw; 541. Delivery hose; 551. Water nozzle; 552. Water pipe;

[0050] 61. Turntable; 62. Drilling mechanism; 63. Anchor mechanism; 64. Net hanging mechanism; 65. Vertical beam; 66. Support member; 621. First driving power source; 622. Drill bit; 631. Clamping arm; 632. Second driving power source; 633. Anchor; 641. Grid; 642. Vertical plate; 643. Protrusion. DETAILED DESCRIPTION

[0051] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.

[0052] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless otherwise explicitly stated in the present invention, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "include" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof;

[0053] As introduced in the background technology, the prior art has the problem of poor stability of tunnel over-excavation cavity and poor stability after repair. In order to solve the above technical problems, the present invention proposes a construction equipment for tunnel block falling over-excavation composite support.

[0054] Embodiment 1

[0055] In a typical embodiment of the present invention, reference is made to Figure 1As shown, a construction equipment for composite support of tunnel block fall and over-excavation includes a frame 2, the frame 2 is movable, the frame 2 supports a first mechanical arm 5 and a second mechanical arm 6, the first mechanical arm 5 is retractable, the retractable end of the first mechanical arm 5 is connected to a grouting mechanism and a dust removal mechanism, the grouting mechanism and the dust removal mechanism are integrated, the dust removal mechanism is used to remove dust from the over-excavation cavity of the tunnel, and the grouting mechanism is used to grout the surface of the over-excavation cavity, the second mechanical arm 6 has multiple degrees of freedom, and a support is set at the movable end of the second mechanical arm 6, the support supports both the drilling mechanism and the anchor mechanism, the drilling mechanism is used to drill holes in the over-excavation cavity, the anchor mechanism is used to construct anchors in the over-excavation cavity, the grouting mechanism can also grout the holes drilled in the over-excavation cavity to inject slurry into the over-excavation cavity, and can grout the anchors after the anchors are driven in.

[0056] In this embodiment, the frame 2 supports the base 1, the water tank is installed on the left side of the rear part of the frame 2, the dust removal fan 3 is installed on the right side of the rear part of the frame 2, and a dust collecting box 31 is provided at the lower part, the dust removal fan 3 is connected to the dust collecting box 31, and the base 1 is installed with a first support seat 121, a second support seat 122 and a concrete box 4, the concrete box 4 is located in the middle of the base 1, and the concrete box 4 supplies concrete to the first mechanical arm 5. The first support seat 121 and the second support seat 122 are located on both sides of the concrete box 4, so that the second mechanical arm 6 is on the front side of the frame and the first mechanical arm 5 is on the rear side of the frame.

[0057] The telescopic end of the first robotic arm is connected to the connecting piece 51, the connecting piece 51 is hollow, a detachable concrete nozzle 52 is provided at one end of the connecting piece 51, and the other end is connected to the concrete box 4. The side of the connecting piece 51 supports the dust removal mechanism, and the fixed end of the first robotic arm is installed at the first support seat 121.

[0058] Specifically, the first mechanical arm 5 can be a telescopic cylinder, see Figure 2 As shown, a mounting plate 511 is provided at one end of the connecting piece 51, and the mounting plate is hollow. The mounting plate 511 is detachably connected to the concrete nozzle 52. After the concrete nozzle is disassembled, the grouting pipe can be installed through the mounting plate 511, and the grouting pipe and the mounting plate 511 can be connected through a threaded structure. A splash shield 521 is installed on the outside of the concrete nozzle 52. The splash shield 521 is trumpet-shaped to reduce the splashing and dispersion of cement slurry, protect the health of construction workers, and facilitate operation and subsequent cleaning by workers; the tail end of the connecting piece 51 is connected to the concrete box 4 through a concrete conveying pipe, one side of the connecting piece 51 is connected to the water outlet nozzle 55 through a clamping piece, and the other side of the connecting piece clamps the dust removal component 54 through a clamping piece 53.

[0059] Wherein, the connecting member 51 is a connecting pipe;

[0060] It is easy to understand that the clamping member 53 includes a first clamping member 531 and a second clamping member 532. One side of the connecting member clamps the water outlet nozzle 55 through the second clamping member 532, and the other side of the connecting member clamps the dust removal assembly 54 through the first clamping member 531.

[0061] refer to Figure 3 As shown, the first clamping member 531 and the second clamping member 532 respectively include a fixing plate 533, and the fixing plates 533 are respectively installed on both sides of the connecting member 51 through support rods, and the lifting blocks 534 are installed on the upper and lower ends of the fixing plates 533. The clamping plate 535 is installed on the lifting block 534, and the clamping plate 535 is L-shaped. The screw 536 is located on the right side of the fixing plate 533. The lifting block 534 can be moved up and down by rotating the screw 536, so as to drive the clamping plate 535 to tightly engage and fix the dust removal component 54 and the water outlet nozzle 55.

[0062] It should be noted that the clamping plate 535 is hollow, the part of the lifting block 534 located inside the clamping plate 535 is provided with a rack, the part of the screw 536 located inside the fixed plate is connected to the gear, the gear and the rack cooperate to drive the lifting block to move up and down relative to the fixed plate, and the screw corresponds to the lifting block one by one;

[0063] In other examples, the first clamping member and the second clamping member are clamping cylinders respectively, and the fixed sections of the clamping cylinders are connected to the support rods on both sides of the connecting member 51 .

[0064] In this embodiment, the dust removal assembly 54 is used to blow away or absorb dust on the working surface. The dust removal assembly 54 includes a dust removal nozzle clamped by a first clamping member. A conveying hose 541 is installed at the tail of the dust removal nozzle. The other end of the conveying hose 541 is connected to the top connection port of the dust removal fan 3.

[0065] It is easy to understand that the water outlet nozzle 55 includes a water outlet pipe clamped by the second clamping member 532, and the water outlet pipe is provided with a plurality of water outlet nozzles 551, and the water outlet nozzles 551 are existing atomizing nozzles, and the water outlet nozzles 551 are arranged in a circle, and the tail of the water outlet nozzle is connected to the water pipe 552, and the water pipe 552 is connected to the water tank;

[0066] refer to Figure 1 and Figure 4 As shown, the second robotic arm 6 has multiple degrees of freedom. The lower end of the second robotic arm 6 is mounted on the second support seat 122 . The second robotic arm 6 includes a turntable 61 , a drilling mechanism 62 , an anchor mechanism 63 , a net grabbing mechanism 64 and a main beam 65 .

[0067] In some examples, the second mechanical arm 6 is specifically a telescopic oil cylinder, a movable mounting block 9 is provided at the telescopic end of the second mechanical arm 6, and the shape of the movable mounting block is not limited. A first auxiliary arm 7 is provided between the second mechanical arm 6 and the second support seat 122, and the first auxiliary arm is a telescopic oil cylinder. The telescopic end of the first auxiliary arm is fixed to the sleeve of the second mechanical arm 6, and a second auxiliary arm 8 is provided between the sleeve of the second mechanical arm 6 and the movable mounting block 9. The second auxiliary arm specifically includes two connecting rods, the two connecting rods are hingedly connected, and the connecting end is hingedly connected to the second mechanical arm 6 and the movable mounting block 9;

[0068] In this embodiment, the movable mounting block 9 is connected to the turntable 61, and the turntable 61 can rotate relative to the movable mounting block 9. Specifically, a rotating motor is arranged at the movable mounting block 9, and the rotating motor is connected to the turntable 61, so that the turntable can rotate relative to the movable mounting block 9. The turntable 61 is connected to the support member 66, and the support member can be a support plate. The turntable 61 realizes the functional switching of the drilling mechanism and the anchor mechanism by rotating.

[0069] In order to realize the hanging of the steel mesh, the end of the support member away from the second mechanical arm 6 is connected to the hanging mechanism; the hanging mechanism 64 includes a grid 641 for supporting the steel mesh, the grid 641 includes two vertical plates, a connecting block is set at one end of the support member, and the vertical plates 642 are respectively connected to the connecting blocks. Specifically, a linear drive motor is set at the connecting block, and the movable end of the linear drive motor is connected to the vertical plate 642, and the linear drive motor is connected to the controller, so as to control the opening and closing movement of the two vertical plates. A plurality of protrusions 643 are set on the side of the vertical plate 642 away from the other vertical plate. The protrusion 643 is specifically a hook-shaped protrusion. The two adjacent protrusions of the vertical plate 642 are set at a distance. The setting of the protrusion is conducive to the hanging of the steel mesh on the grid.

[0070] It should be noted that the support member 66 supports the vertical beam 65, the drill bit 622 is arranged through the vertical beam 65, and the drilling mechanism 62 includes a first driving power source 621, which is connected to the drill bit 622. The first driving power source 621 is an existing driving device for the drill bit. The first driving power source 621 drives the drill bit 622 to move along the main beam 65 to achieve drilling operations. The drill bit can be arranged through the space between the two vertical plates of the grid.

[0071] Among them, the anchor rod mechanism 63 includes a clamping arm 631, a second driving power source 632 and an anchor rod 633. The clamping arm 631 is supported by a connecting plate. The clamping arm 631 includes a first clamping plate and a second clamping plate. The second clamping plate is connected to a second linear driving component. The second linear driving component drives the second clamping plate to move relative to the first clamping plate. The first clamping plate and the second clamping plate are used to clamp the anchor rod 633. The second linear driving component can be a telescopic cylinder. The connecting plate is connected to the second driving power source 632. The anchor rod 633 can be set through the space between the two vertical plates of the truss. The second driving power source 632 drives the anchor rod 633 to move along the main beam 65 to realize the installation operation of the anchor rod 633. The second driving power source is an existing anchor rod driving device.

[0072] It is easy to understand that the first robotic arm 5, the second robotic arm 6, the grouting mechanism, the dust removal mechanism, the drilling mechanism, and the anchor mechanism are respectively connected to the controller; specifically, the concrete delivery pipe is provided with a first valve, the delivery hose 541 is provided with a second valve, and the water pipe 552 is provided with a third valve, and each valve is separately connected to the controller, the frame 2 is provided with a traveling mechanism, the traveling mechanism is connected to the controller, and the controller is remotely connected to the remote control. The controller can be a PLC controller, the controller is provided in a control box, the control box is installed on the base, the remote control is provided with corresponding operation buttons, and the remote control is used to control the remote operation of each component.

[0073] Embodiment 2

[0074] A composite support method for tunnel block fall and over-excavation, reference Figure 5 , Figure 6 As shown, including the following:

[0075] S1. Carry out shell forming operation on the over-excavated cavity of the tunnel;

[0076] S2. Carry out grouting and filling operation on the over-excavated cavity of the tunnel;

[0077] S3. Carry out targeted anchoring operations on the tunnel over-excavation cavity;

[0078] The over-excavated cavity of the tunnel is sprayed with mesh to form a shell. Figure 7 As shown, including the following:

[0079] S11. Thoroughly clean the over-excavated cavity of the tunnel. Considering the safety of personnel, firstly, remove the loose rocks, soil and other debris on the surface by using the bucket of the excavator and other equipment and transport them away. Then, control the construction equipment to enter the site by remote control. The water nozzle 55 and the dust removal component 54 on the first mechanical arm of the construction equipment are remotely controlled to spray water and remove dust on the exposed surface of the over-excavated cavity to ensure that the working surface is clean and flat.

[0080] S12. After the work surface cleaning work is completed, the concrete box 4 supplies concrete to the concrete nozzle 52, and the concrete nozzle 52 on the first mechanical arm 5 performs the initial spraying of concrete on the exposed over-excavated cavity surrounding rock, that is, C25 concrete is sprayed with a set thickness to close the exposed rock surface, so that a layer of concrete protective shell is formed on the surface of the over-excavated cavity to initially stabilize the over-excavated cavity surrounding rock;

[0081] S13. Accurately measure the shape and size of the over-excavated cavity by using high-precision measuring equipment such as a laser tunnel section detector. Place the measuring equipment at a suitable location. The laser beam it emits will scan the over-excavated cavity at a preset angle and range and record the coordinate information of each measuring point. This will calculate the actual contour line and size of the over-excavated cavity, and then mark the area at the opening of the over-excavated cavity where the hanging net needs to be laid;

[0082] S14. According to the measurement and marking results, the steel mesh is cut, and holes are drilled at the predetermined positions and intervals from the opening of the over-excavated cavity to the tunnel contour by using equipment such as impact drills, and expansion bolts are driven in. The steel mesh can generally be a third-level steel mesh with a diameter of 22 mm and a mesh size of 20×20 mm;

[0083] S15. Fix the cut steel mesh to the mesh frame of the mesh mechanism on the construction equipment, control the second mechanical arm 6 of the construction equipment to move to the mesh position, lay the steel mesh at the marked position of the opening of the over-excavated cavity through the mesh grasping mechanism 64, ensure that the mesh holes correspond to the positions of the expansion bolts, tighten the nuts to expand the expansion bolts to achieve tight fixation of the mesh;

[0084] S16. Weld or tie the mesh in each area to form an integral structure;

[0085] S17. Adjust the construction equipment to move the first mechanical arm 5 to the super-excavated cavity working surface, open the concrete box again and use the concrete nozzle 52 of the first mechanical arm 5 to perform secondary concrete spraying to ensure that the concrete is evenly sprayed on the hanging net, and finally form a solid protective shell at the opening of the super-excavated cavity, further improving the stability of the super-excavated cavity;

[0086] S18. After the mesh spraying and mixing construction is completed, on-site monitoring tests are carried out, including displacement measurement of the mesh spraying shell, that is, measurement points are arranged at key positions of the mesh spraying shell, such as edges and hanging corners, and the initial coordinates of the measurement points are measured using a total station. In addition, the three-dimensional coordinate changes of the measurement points are measured regularly during the construction process, and the measurement data are recorded for comparative analysis, so as to timely discover deformation and damage of the repaired structure, protect the stability of the structure, and improve construction efficiency and quality.

[0087] It should be noted that reference Figure 8As shown in the figure, the grouting filling operation is carried out on the over-excavated cavity of the tunnel, including the following contents:

[0088] S21. Determine the number and location of grouting holes required based on the size of the over-excavated cavity, the thickness of the concrete protective shell formed by the mesh spraying, and other actual conditions;

[0089] S22. Control the second mechanical arm 6 of the construction equipment to move to a suitable position so that the drilling mechanism 62 is aligned with the over-excavated cavity working surface, and drive the drill bit 622 to move forward along the main beam 65 through the first driving power source 621 to perform a drilling operation on the protective shell formed by the sprayed shell at the opening of the collapsed over-excavated cavity in step S1, so as to subsequently inject the grouting material into the over-excavated cavity area;

[0090] S23. After the drilling operation in step S22 is completed, the grouting pressure box is buried through the grouting hole. A pressure sensor is arranged in the grouting pressure box. The pressure sensor is connected to the controller. The controller is connected to the computer. The computer has a display screen for monitoring. The grouting pressure box can be fixed with materials such as sealant to ensure that the sensing surface of the grouting pressure box is in close contact with the tunnel wall and will not be displaced or damaged due to the pressure during the grouting process. The grouting pressure box is preliminarily tested to ensure its normal operation.

[0091] S24. Insert the grouting pipe into the drilled hole for grouting. The grouting pressure can be monitored by the grouting pressure box to observe the grouting pressure and whether there is concrete slurry loss at any time. At the same time, a slurry pressure stabilizing component is set between the connecting piece and the concrete box 4 to ensure that the concrete slurry evenly and fully fills the over-excavated cavity and finally solidifies. During the grouting work, the concrete nozzle 52 at the mounting plate 511 at the front end of the connecting piece 51 on the first mechanical arm 5 of the construction equipment is removed, and the grouting pipe is installed in the mounting plate 511 to realize the convenient replacement of the equipment and improve the work efficiency;

[0092] S25. Use sealing materials to seal the holes to ensure that there is no slurry leakage in the holes.

[0093] Wherein, in step S24, the slurry pressure stabilizing component includes a valve arranged on the pipeline, a flow meter and a pressure sensor are arranged on the pipeline, the flow meter, the pressure sensor and the valve are all connected to the controller, the controller controls the opening size of the valve according to the signals fed back by the flow meter and the pressure sensor, and the grouting pressure and flow are stabilized by the setting of the slurry pressure stabilizing component, so that the slurry can evenly fill the over-excavated cavity, and maintain the set pressure after the grouting amount reaches the requirement, and stabilize for a period of time to ensure that the slurry fully fills the over-excavated cavity and solidifies;

[0094] In step S25, the sealing operation includes: first, using the dust removal component of the application equipment to clean the grouting hole to remove the residual slurry and debris in the hole; then injecting the existing sealing material into the hole; finally, maintaining the pressure and curing, that is, continuously maintaining the set pressure so that the sealing material can be fully cured and reach the set strength;

[0095] Targeted anchoring of tunnel overcut cavity, reference Fig. 9 As shown, including the following:

[0096] S31. Based on the numerical simulation results of targeted anchor bolt placement, the drilling mechanism 62 of the second mechanical arm 6 on the construction equipment is used to perform precise drilling operations on the tunnel over-excavation cavity, and at the same time, attention is paid to controlling the drilling speed and drilling pressure to prevent damage to the surrounding structure. The numerical simulation of targeted anchor bolt placement can be achieved through 3DEC (three-dimensional discrete element method program) in the computer, and the stress distribution and deformation of the surrounding rock can be accurately obtained to determine the placement position and depth of the anchor bolt, etc., and the anchor bolt placement plan can be optimized to further guide the drilling operation;

[0097] S32. Use the water nozzle 55 and dust removal component 54 of the first mechanical arm of the construction equipment to clean the hole for the subsequent installation and grouting of the anchor rod 633. The hole cleaning operation is to move the first mechanical arm 5 of the construction equipment to a suitable position, turn on the water tank and the dust removal fan, and first use the dust removal component 54 to clean the dust. At the same time, the water nozzle 551 installed on the outer ring of the water nozzle sprays atomized water vapor to increase the dust reduction effect and also play a role in air purification. After that, the water nozzle 55 can be selected to perform further cleaning operations according to the situation in the hole;

[0098] S33. Use the anchor mechanism 63 of the second mechanical arm on the construction equipment to perform targeted anchor installation operations on the tunnel over-excavation cavity. The anchor installation operation is to move the second mechanical arm 6 to a suitable position, and the clamping arm 631 takes the anchor from the anchor library and clamps the anchor. The second driving power source 632 drives the anchor 633 to move forward along the main beam 65 to complete the anchor installation operation. The anchor can generally be a third-level mortar anchor with a diameter of 22mm. The length of the anchor embedded in the rock mass should be greater than 1.5m;

[0099] S34. Install the grouting pipe on the construction equipment, connect and open the grouting pump to perform anchor grouting operations, the installation of the grouting pipe is to remove the concrete nozzle 52 on the first robotic arm mounting plate, snap-fit ​​the grouting pipe, and connect the grouting pipe to the grouting pump;

[0100] S35. After the anchor grouting operation in step S34 is completed, the duct is sealed to prevent the loss of slurry and improve the anchoring effect, and to prevent interference from external factors to maintain the performance of the grouting material and extend its service life. The material for sealing the duct can be cement or sealant;

[0101] S36. After the targeted anchor placement work is completed, field tests of grouting pressure monitoring and data collection are carried out to evaluate the stability of the repaired structure. This also provides certain guidance for the construction and design optimization of the tunnel, which helps prevent tunnel safety accidents.

[0102] In this way, the concave cavity working surface is efficiently cleaned and pretreated before the mesh spraying shell operation, including thorough cleaning and water spraying cleaning through professional equipment and robotic arms to ensure that the working surface is clean and flat, laying a good foundation for subsequent operations; during and after the repair process, assisted by real-time on-site monitoring tests and evaluation work, such as displacement measurement and grouting pressure monitoring, deformation and damage of the repaired structure can be discovered in time to ensure structural stability; grouting technology is optimized through pressure stabilization and sealing methods to ensure that the grouting slurry evenly and fully fills the concave cavity and finally solidifies, thereby improving the grouting effect; based on the numerical simulation results of targeted anchor layout, precise drilling and anchor installation operations are carried out to optimize the construction process and improve construction quality and efficiency.

[0103] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A tunnel block falling over-excavation composite support construction equipment, characterized in that: The invention comprises a frame, which is movable and supports a first mechanical arm and a second mechanical arm. The first mechanical arm is retractable and the retractable end of the first mechanical arm is connected to a grouting mechanism and a dust removing mechanism. The grouting mechanism and the dust removing mechanism are arranged integrally. The over-excavated cavity of the tunnel is dusted by the dust removing mechanism, and the grouting mechanism performs grouting on the surface of the over-excavated cavity. The second mechanical arm has multiple degrees of freedom. A support is arranged at the movable end of the second mechanical arm. The support supports both a drilling mechanism and an anchor mechanism. The drilling mechanism is used for drilling holes at the over-excavated cavity, and the anchor mechanism is used for constructing anchors at the over-excavated cavity. The grouting mechanism can also perform grouting on the holes drilled at the over-excavated cavity to inject slurry into the over-excavated cavity, and can perform grouting on the anchors after the anchors are driven in.

2. The equipment for constructing composite support for tunnel block fall and over-excavation according to claim 1 is characterized in that: The telescopic end of the first mechanical arm is connected to the connecting piece, the connecting piece is hollow, a detachable concrete nozzle is arranged at one end of the connecting piece, and the other end is connected to the concrete box, the side of the connecting piece supports the dust removal mechanism, and the first mechanical arm and the second mechanical arm are arranged on both sides of the frame opposite to each other.

3. The equipment for constructing composite support for tunnel block fall and over-excavation according to claim 2 is characterized in that: The dust removal mechanism includes a dust removal component and a water outlet nozzle. Support rods are respectively arranged on both sides of the connecting member. The support rod on one side clamps the dust removal component through a first clamping member, and the dust removal component is connected to the dust collecting box. The support rod on the other side clamps the water outlet nozzle through a second clamping member, and the water outlet nozzle is connected to the water tank.

4. The construction equipment for tunnel block fall and over-excavation composite support according to claim 1 is characterized in that: The first mechanical arm, the second mechanical arm, the grouting mechanism, the dust removal mechanism, the drilling mechanism, and the anchor mechanism are respectively connected to the controller; The frame is provided with a running mechanism, the running mechanism is connected to a controller, and the controller is remotely connected to a remote controller.

5. The equipment for constructing composite support for tunnel block fall and over-excavation according to claim 1 is characterized in that: The first mechanical arm is installed on the frame through a first support seat, and the second mechanical arm is fixed to the frame through a second support seat. A first auxiliary arm is arranged between the shell of the second mechanical arm and the second support seat, and the first auxiliary arm is retractable. A second auxiliary arm is arranged between the shell of the second mechanical arm and the movable mounting block, and the second auxiliary arm includes multiple connecting rods, and two adjacent connecting rods are movably connected. The telescopic end of the second mechanical arm is connected to the movable mounting block, and the movable mounting block is connected to the support member.

6. The equipment for constructing composite support for tunnel block fall and over-excavation according to claim 1 is characterized in that: One end of the support member away from the second mechanical arm is connected to the net hanging mechanism; The mesh hanging mechanism includes a grid for supporting the steel mesh, the grid includes two vertical plates, a connecting block is arranged at one end of the support, the connecting block supports the first linear drive component, the movable end of the first linear drive component is connected to the vertical plate, and the vertical plate is arranged to support the convex part of the steel mesh.

7. The equipment for constructing composite support for tunnel block fall and over-excavation according to claim 6 is characterized in that: The support is connected to the second mechanical arm via a turntable, the turntable is rotatable relative to the second mechanical arm, the drilling mechanism is located on one side of the support, and the anchor mechanism is fixed to the other side of the support; The drilling mechanism includes a first driving power source, which is connected to a drill bit. A support member supports a vertical beam. The drill bit is arranged to pass through the vertical beam. Driven by the first driving power source, the drill bit realizes telescopic and rotational movement relative to the vertical beam. The drill bit can pass through the space between the two vertical plates of the grid.

8. The equipment for constructing composite support for tunnel block fall and over-excavation according to claim 6 is characterized in that: The anchor rod mechanism includes a clamping arm, which is supported by a connecting plate. The clamping arm includes a first clamping plate and a second clamping plate. The second clamping plate is connected to the second linear drive component to clamp the anchor rod. The connecting plate is connected to the second driving power source. The anchor rod can be set through the space between the two vertical plates of the frame.

9. A tunnel block falling over-excavation composite support method, characterized in that: The equipment for constructing a tunnel block-falling over-excavation composite support according to any one of claims 1 to 8 comprises the following contents: The over-excavated cavity of the tunnel is sprayed with mesh to form a shell: loose rocks in the over-excavated cavity are removed, the construction equipment is moved to the tunnel, the over-excavated cavity is dusted by the dust removal mechanism, and the over-excavated cavity is sprayed with concrete for the first time by the grouting mechanism to form a layer of concrete protective shell on the surface of the over-excavated cavity; The over-excavated cavity of the tunnel is grout-filled: the second mechanical arm moves so that the drilling mechanism is aligned with the over-excavated cavity, and the drilling mechanism drills holes at the over-excavated cavity to form grouting holes. A grouting pressure box is buried at the grouting hole, and a pressure sensor is arranged in the grouting pressure box. The pressure sensor is connected to the controller, and the grouting hole is grouted through the grouting mechanism; Targeted anchoring operation is performed on the over-excavated cavity of the tunnel: the second robotic arm moves to align the drilling mechanism with the over-excavated cavity, the drilling mechanism drills a hole in the over-excavated cavity, the anchor mechanism clamps the anchor and sends the anchor into the corresponding borehole, and the grouting mechanism injects concrete slurry into the corresponding borehole.

10. A tunnel block falling and over-excavation composite support method according to claim 9, characterized in that: Before the initial injection of concrete into the over-excavated cavity by the grouting mechanism, the following contents are also included: Determine the actual contour of the over-excavated cavity to determine the area for hanging the net; Drill holes and drive expansion bolts where the over-excavation cavity opening extends to the tunnel contour; fix the hanging net with the expansion bolts.

Images