A precise grouting device and grouting method for crushed surrounding rock classification in deep mine tunnels

Abstract

The present invention discloses a precise grouting device and a grouting method for classifying broken surrounding rocks in deep tunnels of mines, which belongs to the field of mining engineering technology. The device includes a classification and identification module, a grouting module, and a pressure detection and control module. The grouting module is placed in a shell. The grouting module includes a multi-channel switching unit, a slurry storage unit, and a flow control unit. The classification and identification module is connected to the grouting module, the grouting module is connected to the pressure detection and control module, the pressure detection and control module is connected to the multi-channel switching unit, and the multi-channel switching unit is connected to the slurry storage unit. The present invention adopts the above-mentioned precise grouting device and a grouting method for classifying broken surrounding rocks in deep tunnels of mines, and realizes precise classification of broken surrounding rocks, dynamic switching of slurries, and real-time stable control of grouting pressure through the coordinated work of the classification and identification module, the grouting module, and the pressure monitoring and control module, combined with intelligent control technology and a visual monitoring terminal.

Description

Technical Field

[0001] The present invention relates to the technical field of mining engineering, and in particular to a precise grouting device and a grouting method for classified broken surrounding rocks in deep mine tunnels. Background Art

[0002] Broken surrounding rock in mine tunnels is a common and difficult problem to solve during mining. Causes of this problem include ground stress release, mining vibration, and blasting shock. This type of surrounding rock typically has a high crack rate and low stability, which can easily lead to tunnel deformation and collapse, endangering operational safety. Therefore, grouting technology is widely used to reinforce broken surrounding rock. Grouting is injected into the cracks of the surrounding rock to fill the voids and enhance the strength of the rock mass, thereby improving the stability of the surrounding rock. However, existing grouting devices have the following significant deficiencies in practical applications:

[0003] First, traditional grouting equipment lacks the ability to classify and identify surrounding rock, making it difficult to select the appropriate grouting fluid based on the size and distribution of surrounding rock fissures. Injecting low-viscosity grout into areas with wide fissures can easily lead to material waste, while high-viscosity grout lacks fluidity in microcracks, potentially resulting in incomplete filling and reduced grouting effectiveness. This "one-size-fits-all" grouting approach often fails to precisely match grouting properties with fissure characteristics, compromising reinforcement quality.

[0004] Secondly, grouting pressure control technology is still imperfect, making real-time monitoring and dynamic adjustment difficult. In complex deep rock environments, the stress state, crack distribution, and permeability of the surrounding rock constantly change as operations proceed. If the grouting pressure is too high, it may cause secondary fractures in the surrounding rock; if the pressure is too low, the slurry cannot be guaranteed to fill deep into the cracks, thus affecting the reinforcement effect. Existing grouting devices typically use fixed pressure settings and lack closed-loop control mechanisms. This makes it difficult to adapt to dynamic changes in the surrounding rock state, resulting in low grouting efficiency.

[0005] Furthermore, traditional grouting equipment has poor adaptability in complex environments. Deep mine tunnels often experience extreme conditions such as high humidity, high dust levels, and high temperatures. Long-term use can easily cause equipment sensors to malfunction or become clogged, impacting data collection and equipment performance. Furthermore, traditional equipment lacks visual monitoring capabilities, making it difficult for operators to monitor the dynamic status of the grouting process, leading to blind spots in construction management and effectiveness evaluation. Summary of the Invention

[0006] The purpose of the present invention is to provide a precise grouting device and grouting method for classifying broken surrounding rocks in deep mine tunnels. Through the coordinated work of the classification and identification module, the grouting module and the pressure monitoring and control module, combined with intelligent control technology and a visual monitoring terminal, the precise classification of broken surrounding rocks, the dynamic switching of slurry and the real-time stable control of grouting pressure can be achieved.

[0007] To achieve the above-mentioned objectives, the present invention provides a precise grouting device for classifying broken surrounding rocks in deep mine tunnels, comprising a classification and identification module, a grouting module, and a pressure detection and control module. The grouting module is placed in a shell, and the grouting module includes a multi-channel switching unit, a slurry storage unit, and a flow control unit. The classification and identification module is connected to the grouting module through a grouting pipeline, the grouting module is connected to the pressure detection and control module, the pressure detection and control module is connected to the multi-channel switching unit, and the multi-channel switching unit is connected to the slurry storage unit.

[0008] Preferably, the classification and identification module is fixedly connected to the porous grouting head through a metal flange, and the porous grouting head is fixedly connected to the grouting pipeline. A multi-layer sealing gasket is provided at the rear end of the classification and identification module. The outer shell is made of high-strength corrosion-resistant material and is covered with a waterproof and dust-proof coating. A shock-absorbing device is installed outside the classification and identification module.

[0009] Preferably, the classification and identification module includes a multifunctional sensor array, a signal processing unit, an embedded AI analysis system, a module self-cleaning system and a porous grouting head, wherein the multifunctional sensor array includes an acoustic wave detection unit, a resistivity detection unit and a pressure sensing unit, the multifunctional sensor array is connected to the signal processing unit, the acoustic wave detection unit, the resistivity detection unit and the pressure sensing unit are connected to the signal processing unit through electrical signals, and the signal processing unit is connected to the AI analysis system through electrical signals.

[0010] Preferably, the front end of the classification and identification module is a grooved planar structure, and working ports of a multi-functional sensor array are arranged around the groove. The working ports include an acoustic wave probe, a multi-point electrode contact point and a pressure sensing contact surface, wherein the acoustic wave probe is connected to the acoustic wave detection unit, the multi-point electrode contact point is connected to the resistivity detection unit, and the pressure sensing contact surface is connected to the pressure sensing unit.

[0011] Preferably, the module self-cleaning system includes an airflow cleaning unit, which includes an air pump, a nozzle system and an airflow control valve. The nozzle is connected to the rear end of the classification and identification module, and the other end is connected to the nozzle system. The nozzle system is distributed at the working port of the multi-functional sensor array. The airflow control valve is electrically connected to the AI analysis system, and the airflow control valve is placed on the connecting pipe between the nozzle and the air pump.

[0012] Preferably, the grouting module is a frame structure, its shell is made of high-strength corrosion-resistant material, and the surface is covered with a wear-resistant coating. The slurry storage unit is placed in the top area of the grouting module, and the slurry storage unit includes a high-viscosity slurry storage tank, a low-viscosity slurry storage tank, and an ultra-low-viscosity slurry storage tank.

[0013] Preferably, a multi-channel switching unit is provided between the slurry storage unit and the grouting pump, the multi-channel switching unit comprising an input pipeline, an output pipeline, a support structure and an electronically controlled valve system, the output pipeline being connected to the grouting pump, an input pipeline being connected between the slurry storage unit and the multi-channel switching unit, the input pipeline being equipped with an electronically controlled valve system, the electronically controlled valve system comprising a valve body, a coil and a feedback sensor;

[0014] The grouting pump and flow control unit are placed in the bottom area of the grouting module. The grouting pump is a high-precision plunger pump, and the flow control unit includes a flow sensor and a control valve.

[0015] Preferably, a grouting effect dynamic monitoring and control module is provided on one side of the shell, and a control and visualization monitoring terminal is provided on the other side. The grouting effect dynamic monitoring and control module is a rectangular chassis structure, and its shell is made of high-strength corrosion-resistant alloy material, and the surface is sprayed with an anti-corrosion coating. The grouting effect dynamic monitoring and control module includes a flow sensor unit, a control system unit, a fault warning unit and a closed-loop control system, and the closed-loop control system is electrically connected to the grouting module.

[0016] Preferably, the control and visual monitoring terminal includes a visual liquid crystal panel, a central processing unit, a communication module, a data storage unit and a graphics rendering system, and the visual liquid crystal panel, the central processing unit, the communication module, the data storage unit and the graphics rendering system are all electrically connected to each other.

[0017] The present invention also provides a method for accurately grouting broken surrounding rocks by classification in deep mine tunnels, which uses the above-mentioned accurate grouting device for accurately grouting broken surrounding rocks by classification in deep mine tunnels, including the following steps:

[0018] Step 1: Device installation: Deploy the device in the deep tunnel area of the mine to be grouting. The classification and identification module is fixedly connected to the porous grouting head through a metal flange. The porous grouting head is fixedly connected to the grouting pipeline. The other end of the grouting pipeline is connected to the grouting pump. The grouting module is also connected to the pressure detection control module through a flange.

[0019] Step 2: Classification and identification of surrounding rock: The acoustic wave detection unit, resistivity detection unit, and pressure sensing unit of the classification and identification module are activated. The acoustic wave detection unit assesses the width of the crack by monitoring the propagation speed of the sound wave. The resistivity detection unit determines the water content of the crack by measuring the electrical conductivity of the surrounding rock. The pressure sensing unit is used to capture the stress changes of the local surrounding rock. The obtained physical parameter data is transmitted to the AI analysis system through the signal processing unit for fusion analysis, and finally the crack category is output;

[0020] Step 3: Slurry switching and grouting operation: Based on the classification results, the classification recognition module outputs "crack" information and transmits it to the grouting module. The multi-channel switching unit in the grouting module automatically selects a slurry storage tank suitable for this type of crack and starts the grouting pump. The slurry is injected into the grouting pipeline through the grouting pump and then injected into the crack area through the porous grouting head. When the grouting is completed, the grouting pump automatically shuts down and prepares to switch to the next area.

[0021] Step 4: Real-time pressure monitoring and control: During the grouting process, the grouting effect dynamic monitoring and control module monitors the injection status of the slurry in real time through pressure sensors and flow sensors, and feeds back the monitoring data to the grouting module through a closed-loop control system. When the pressure deviates from the preset range, the closed-loop system automatically adjusts the output parameters of the grouting pump to maintain stable grouting pressure;

[0022] Step 5: Self-cleaning and equipment maintenance: After grouting is completed, the classification and recognition module activates the self-cleaning function, and high-pressure air flows through the nozzles in the air cleaning unit to clean the mineral powder and slurry residue on the surface of the sensor array;

[0023] Step 6: Grouting reinforcement of micro-cracked surrounding rock: For micro-cracks, the grouting module automatically switches to the ultra-low viscosity slurry storage tank and injects ultra-low viscosity slurry into the micro-cracks at a lower flow rate;

[0024] Step 7. Pressure monitoring and control of micro-crack grouting: For micro-crack types, the pressure monitoring and control module sets a lower pressure threshold and adjusts the grouting pressure through a closed-loop control system.

[0025] Therefore, the present invention adopts the above-mentioned precise grouting device and grouting method for classification of broken surrounding rock in deep mine tunnels, which has the following beneficial effects:

[0026] (1) Intelligent classification and identification: Multi-physical parameter fusion and AI algorithm analysis improve the accuracy and efficiency of surrounding rock classification;

[0027] (2) Dynamic slurry switching: achieving precise matching of slurries for different fracture types, significantly reducing waste;

[0028] (3) Closed-loop pressure control: Real-time monitoring and dynamic adjustment significantly improve the safety and stability of grouting construction;

[0029] (4) Visualization and remote control: Visual UI and remote control technology significantly improve construction management and adaptability.

[0030] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1This is a schematic diagram of the overall structure of an embodiment of a precise grouting device and grouting method for crushed surrounding rock classification in a deep mine tunnel according to the present invention;

[0032] Figure 2 This is a structural diagram of a classification and identification module of an embodiment of a device and method for accurately classifying and accurately grouting broken surrounding rocks in a deep mine tunnel according to the present invention;

[0033] Figure 3 This is a schematic diagram of the grouting module structure of an embodiment of a device and method for accurately grouting broken surrounding rock classification in a deep mine tunnel according to the present invention;

[0034] Figure 4 It is a structural schematic diagram of a dynamic monitoring control module for grouting effect of an embodiment of a precise grouting device and a grouting method for classification of broken surrounding rocks in deep mine tunnels of the present invention.

[0035] Reference numerals

[0036] 1. Classification and identification module; 11. Multi-function sensor array; 12. Metal flange; 13. Acoustic wave detection unit; 14. Resistivity detection unit; 15. Pressure sensing unit; 16. Signal processing unit; 17. Multi-porous grouting head; 2. Grouting effect dynamic monitoring and control module; 21. Pressure sensor; 22. Flow sensor; 23. Control system unit; 24. Closed-loop control system; 3. Visual LCD panel; 4. Multi-channel switching unit; 41. Slurry storage unit; 5. High-viscosity slurry storage tank; 6. Grouting pipeline; 7. Pressure detection control module; 8. Grouting pump; 9. Low-viscosity slurry storage tank; 10. Ultra-low viscosity slurry storage tank. DETAILED DESCRIPTION

[0037] The technical solution of the present invention is further described below with reference to the accompanying drawings and embodiments.

[0038] Unless otherwise defined, the technical or scientific terms used in the present invention shall have the usual meanings understood by persons of ordinary skill in the field to which the present invention belongs. The words "first", "second" and similar terms used in the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. Words such as "include" or "comprise" mean that the elements or objects preceding the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects. Words such as "connect" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0039] Example 1

[0040] like Figure 1 As shown, the present invention provides a precise grouting device for classifying broken surrounding rocks in deep tunnels of mines, including a classification and identification module 1, a grouting module, and a pressure detection control module 7. The grouting module is placed in a shell, and the grouting module includes a multi-channel switching unit 4, a slurry storage unit 41 and a flow control unit. The classification and identification module 1 is connected to the grouting module, the grouting module is connected to the pressure detection control module 7, the pressure detection control module 7 is connected to the multi-channel switching unit 4, and the multi-channel switching unit 4 is connected to the slurry storage unit 41.

[0041] The classification and identification module 1 is connected to the grouting pipeline 6 through a metal flange 12 and is installed at the front end of the grouting pipeline 6. Its overall shape is an integrated cylindrical module, and its shape matches the grouting pipeline 6, which can ensure the stability of the installation and facilitate operation and maintenance in a mining environment. A multi-layer sealing gasket is provided at its rear end to ensure the airtightness between the classification and identification module 1 and the grouting pipeline 6 to prevent slurry leakage during grouting operations. The outer shell is made of high-strength corrosion-resistant material and is covered with a waterproof and dust-proof coating to adapt to high-humidity and high-dust mining environments. A shock-absorbing device is installed on the outside of the classification and identification module 1 to buffer the vibrations that may be generated during the grouting operation and ensure the normal operation of the multi-functional sensor array 11.

[0042] like Figure 2 As shown, the classification and recognition module 1 includes a multifunctional sensor array 11, a signal processing unit 16, an embedded AI analysis system, a module self-cleaning system and a porous grouting head 17, wherein the multifunctional sensor array 11 includes an acoustic wave detection unit 13, a resistivity detection unit 14 and a pressure sensing unit 15, the multifunctional sensor array 11 is connected to the signal processing unit 16, the acoustic wave detection unit 13, the resistivity detection unit 14 and the pressure sensing unit 15 are connected to the signal processing unit 16 through electrical signals, and the signal processing unit 16 is connected to the AI analysis system through electrical signals.

[0043] The module's embedded AI analysis system is integrated into the internal signal processing unit 16. Its hardware includes an embedded computing chip and a data storage unit, and it uses edge computing technology to run a pre-trained machine learning model. Data collected by the sensors is preprocessed by the signal processing unit 16. After filtering and feature value extraction, it is transmitted to the AI analysis system for multimodal fusion analysis. The system can determine the fracture type of the surrounding rock in real time and output three classification results: cracks (wide cracks), small cracks, and microcracks. These classification results are transmitted to the grouting module via the module's communication interface, providing an accurate basis for subsequent operations.

[0044] The front end of the classification and identification module 1 features a grooved, planar structure. The groove is surrounded by the working ports of a multifunctional sensor array 11, which includes an acoustic probe, multi-point electrode contacts, and a pressure-sensing contact surface. The acoustic probe is connected to an acoustic detection unit 13, the multi-point electrode contacts are connected to a resistivity detection unit 14, and the pressure-sensing contact surface is connected to a pressure-sensing unit 15. Each working port has been treated to resist wear and tear, ensuring long-term resistance to the abrasive pressures of a mining operating environment. An automatic closing mechanism protects the sensor when not in operation, preventing slurry backflow from damaging the detection equipment.

[0045] The interior of the module is designed with functional zoning, and multiple layers of partitions are set inside the cylinder to rationally arrange the functional units. A multifunctional sensor array 11 is arranged in the area near the contact surface at the front end. The acoustic wave detection unit 13 directly contacts the surface of the surrounding rock through a contact probe, and uses highly sensitive piezoelectric materials to monitor the propagation speed of the acoustic wave in real time, accurately reflecting the width and distribution characteristics of the cracks. The resistivity detection unit 14 is arranged on the periphery of the contact surface using an annular multi-point electrode. By collecting the resistivity gradient changes of the surrounding rock, the water content and saturation of the cracks are determined. The pressure sensing unit 15 is arranged behind the contact panel and fixed by a high-pressure resistant support seat. The local stress distribution on the surface of the surrounding rock is measured in real time using a micro piezoresistive sensor.

[0046] The module self-cleaning system is implemented through an airflow cleaning unit. The rear end of the classification and identification module 1 is connected to an air pump, which delivers high-pressure airflow to the sensor array area through an airflow pipeline. The module self-cleaning system includes an airflow cleaning unit, which includes an air pump, a nozzle system, and an airflow control valve. The nozzle is connected to the rear end of the classification and identification module 1, and the other end is connected to the nozzle system. The nozzle system is distributed at the working port of the multifunctional sensor array 11. The airflow control valve is electrically connected to the AI analysis system and is placed on the connecting pipe between the nozzle and the air pump. The cleaning function can be automatically triggered according to the set cleaning cycle or changes in the sensitivity of the sensor signal to ensure the stability of the sensor during long-term use.

[0047] Classification and Identification Module 1's cylindrical design ensures stability and compactness in high-pressure environments. Its high-precision sensor array can collect multiple physical parameters in real time. Combined with an embedded AI analysis system, it enables accurate classification of surrounding rock fracture types. A self-cleaning function significantly improves Classification and Identification Module 1's long-term operational capabilities in complex environments, avoiding detection errors caused by decreased sensor sensitivity. The synergistic effect of Classification and Identification Module 1 significantly improves the efficiency and reliability of grouting operations, providing efficient and intelligent technical support for the reinforcement of broken surrounding rock in deep mine tunnels.

[0048] like Figure 3As shown, the grouting module features an integrated frame structure with an outer shell made of high-strength, corrosion-resistant material and a wear-resistant coating to withstand the high humidity and dust conditions of complex mining environments. The grouting module is divided into functional areas, with a slurry storage unit 41, a multi-channel switching unit 4, a grouting pump 8, and a flow control unit strategically arranged to ensure a compact and efficient structure. The slurry storage unit 41 is located at the top of the grouting module and utilizes a cylindrical tank design. Three groups of tanks are provided, one for storing high-viscosity slurries (such as cement-based polymers), one for storing low-viscosity slurries (such as modified epoxy resins), and one for storing ultra-low-viscosity slurries (such as nanosilicon slurries). The slurry storage unit 41 includes a high-viscosity slurry storage tank 5, a low-viscosity slurry storage tank 9, and an ultra-low-viscosity slurry storage tank 10. The capacity of each tank is adjusted based on actual construction requirements. The outer shell is made of high-strength polymer or corrosion-resistant metal, and the inner wall is coated with an anti-stick coating to prevent slurry from clumping or sticking after prolonged storage. The top of the storage tank is equipped with a sealing cover and a pressure relief device to ensure the safety of the slurry under high pressure. Each storage tank is equipped with a separate outlet pipe at the bottom, which is connected to the multi-channel switching unit 4.

[0049] A multi-channel switching unit 4 is located between the slurry storage unit 41 and the grouting pump 8. This unit comprises an input pipeline, an output pipeline, a support structure, and an electrically controlled valve system. The output pipeline is connected to the grouting pump 8. An input pipeline is connected between the slurry storage unit 41 and the multi-channel switching unit 4. The input pipeline is equipped with an electrically controlled valve system. This system comprises a valve body, a coil, and a feedback sensor. When the coil is energized, it generates a magnetic field, driving the valve core to move, thereby opening or closing the channel. The control unit receives the fracture classification signal (e.g., wide fractures, small fractures, micro fractures) sent by the classification and recognition module 1 using a preset algorithm and matches the corresponding valve command. For example, if the surrounding rock is detected to have wide fractures, the control unit triggers the valve of the high-viscosity slurry storage tank, while the valves of the other tanks remain closed, ensuring that the slurry flows along a unique path to the grouting pump 8.

[0050] The grouting pump 8 and flow control unit are located in the bottom area of the grouting module. The grouting pump 8 is a high-precision plunger pump that can provide a stable flow rate and adjustable pressure to ensure that the slurry is evenly injected deep into the cracks. The flow control unit includes a flow sensor 22 and a control valve, which can monitor the slurry flow in real time and adjust the output parameters as needed to meet the filling requirements of different crack types. The module supports a staged grouting mode, which uses a preset program to fill large cracks first and then small cracks, achieving layered reinforcement and optimizing slurry utilization.

[0051] The grouting module achieves high efficiency and adaptability during the grouting process through its compact rectangular frame design, scientific internal functional zoning, and intelligent multi-channel switching unit 4. The corrosion-resistant design and anti-stick coating of the slurry storage unit 41 extend the equipment's service life. The electronically controlled valve system of the multi-channel switching unit 4 responds quickly based on the classification results, ensuring a precise match between the slurry type and the surrounding rock characteristics. The dynamic adjustment function of the grouting pump 8 and the flow control unit ensures that the slurry uniformly fills the cracks, significantly improving the overall reinforcement effect of the surrounding rock. The module's high dynamic response capability effectively shortens the construction period, reduces slurry waste, optimizes resource utilization, and provides efficient and reliable technical support for grouting operations in complex mining environments.

[0052] like Figure 1 As shown, a dynamic monitoring control module 2 for grouting effect is provided on one side of the shell, and a control and visual monitoring terminal is provided on the other side. Figure 4 As shown, the grouting effect dynamic monitoring and control module 2 is a rectangular chassis structure. Its outer shell is made of a high-strength, corrosion-resistant alloy material and is sprayed with an anti-corrosion coating to adapt to the high humidity and high dust environment of the mine. The grouting effect dynamic monitoring and control module 2 includes a flow sensor 22, a control system unit 23, a fault warning unit, and a closed-loop control system 24, which is electrically connected to the grouting module. The entire module is compactly designed for easy installation and maintenance, while ensuring efficient and coordinated functions of its components.

[0053] The real-time monitoring function of the grouting effect dynamic monitoring control module 2 relies on the precise coordination of the pressure sensor 21 and the flow sensor 22. The pressure sensor 21 uses a high-precision piezoresistive sensor to collect real-time pressure data in the grouting pipeline 6. The pressure sensor 21 outputs a corresponding electrical signal based on the pressure changes of the measured medium (slurry), which is transmitted to the control system after analog-to-digital conversion. The flow sensor 22 uses an ultrasonic flowmeter or an electromagnetic flowmeter to monitor the flow rate of the slurry in real time. The flow sensor 22 detects the slurry flow rate by measuring the conductivity of the fluid or the propagation speed of sound waves, ensuring that the flow data is accurately transmitted to the control system. The pressure and flow data are continuously fed back to the control unit as a basis for subsequent dynamic adjustments.

[0054] The dynamic adjustment function is the core of this module and is implemented by the closed-loop control system 24. The core of the closed-loop control system 24 is the microprocessor unit, which automatically calculates whether the current grouting pressure deviates from the set range based on the data returned by the pressure sensor 21 and the flow sensor 22, and automatically adjusts the output parameters (including pressure and flow) of the grouting pump 8 based on the classification results. The specific implementation method is as follows:

[0055] Pressure Regulation: Pressure sensor 21 monitors the pressure in the grouting pipeline in real time, and the microprocessor unit compares it to a set pressure threshold. If the pressure exceeds the set range, the control system immediately issues an adjustment signal to adjust the output power of grouting pump 8, reducing or increasing the pressure to ensure it remains within a safe range. This regulation process uses a stepper motor-driven pressure regulating valve, which adjusts the valve opening electronically to adjust the pressure.

[0056] Flow Control: Flow sensor 22 monitors the slurry flow rate in real time and feeds this data back to the microprocessor. If the flow rate is abnormal (e.g., too low, indicating a possible pipe blockage or slurry flow obstruction), the control system adjusts the flow rate output via the flow control valve to ensure a smooth and uniform grouting flow.

[0057] The dynamic adjustment function of this module can control the pressure and flow accuracy during the grouting process to within 0.1MPa, ensuring that the slurry can accurately fill every area of the crack and improve the grouting effect.

[0058] The fault warning unit consists of an anomaly detection system and an alarm system. The anomaly detection system continuously compares the real-time collected pressure and flow data to detect whether any abnormal situation has occurred. Its main working principle is:

[0059] Abnormal pressure detection: If the pressure exceeds the preset upper limit or falls below the lower limit during grouting, the abnormality detection system will immediately identify this change and trigger the alarm system. At this time, the control system will stop the grouting operation by closing the valve and switch to standby mode.

[0060] Abnormal flow rate detection: A low flow rate may indicate a pipe blockage or slurry flow obstruction. When the flow sensor 22 detects an abnormal drop in flow rate, the fault warning unit will issue an alarm signal and adjust the working state of the grouting system to avoid further problems.

[0061] The alarm system includes an audible and visual alarm device and a digital display alarm interface, which can display the fault location, fault type and severity in real time, helping operators to quickly locate the problem and deal with it in a timely manner.

[0062] The grouting effect dynamic monitoring and control module 2 achieves precise pressure control and flow regulation by real-time monitoring of pressure and flow changes during the grouting process. This effectively prevents secondary damage to the surrounding rock caused by excessive pressure and ensures that the slurry evenly and fully fills the cracks. The closed-loop control system 24 improves the automation level of operations, reduces manual intervention, and makes the grouting process more intelligent and refined. In addition, the alarm system can promptly issue an alarm when an abnormal situation occurs, preventing equipment damage or poor grouting results, further improving the safety and stability of grouting construction.

[0063] The control and visual monitoring terminal includes a visual LCD panel 3, a central processing unit, a communication module, a data storage unit, and a graphics rendering system. These three components are electrically connected. The terminal's high-resolution touchscreen displays construction data in real time. A graphical interface presents surrounding rock classification, grouting progress, and pressure changes in three dimensions. Operators can intuitively view the progress and status of each grouting operation and adjust equipment parameters based on the displayed information. The screen design supports multi-touch operation, ensuring convenient and precise control.

[0064] The central processing unit (CPU) handles data processing, calculation, and analysis, receiving real-time data from various sensors and equipment modules and calculating optimized parameters for the grouting process based on predefined algorithms. This processing unit exchanges data with other terminal modules (such as graphics rendering and remote communications) via a high-speed bus to ensure efficient system operation.

[0065] The communication module enables remote data transmission and control between the control terminal and the remote monitoring center. Through Wi-Fi, 4G, or 5G networks, operators can remotely access the control terminal to monitor construction progress and adjust equipment. This feature is particularly useful in complex mining environments. Remote operation avoids the risks and inconvenience of on-site operations while enabling timely response to emergencies and ensuring smooth construction operations.

[0066] The data storage unit is responsible for recording and storing classification results, grouting parameters, and other data from the entire construction process. This data can be uploaded to a cloud database in real time for long-term storage and further analysis. Detailed construction reports are also generated, providing a scientific basis for subsequent construction optimization. Data storage and management also facilitates the accumulation of historical data on mining operations, facilitating future traceability and evaluation.

[0067] The control and visual monitoring terminal greatly enhances the intuitiveness of the operation process through a graphical UI interface and three-dimensional visual display. Operators can monitor the status of grouting operations in real time, promptly identify problems, and adjust parameters to ensure optimal grouting results. The introduction of remote control functions reduces the need for on-site personnel and improves construction management efficiency. Operators can conveniently adjust equipment, monitor construction progress, and respond quickly to emergencies from the remote monitoring center. In addition, data recording and analysis functions provide accurate construction references for subsequent mine reinforcement operations. By accumulating and analyzing historical data, a digital experience library is formed, promoting the optimization of construction plans and improving operational efficiency.

[0068] The present invention also provides a method for precise grouting of broken surrounding rock classification in deep mine tunnels, comprising the following steps:

[0069] Step 1, device installation: Deploy the device in the deep tunnel of the mine to be grouting. The classification and identification module 1 is fixedly connected to the porous grouting head 17 through the metal flange 12. The porous grouting head 17 is fixedly connected to the grouting pipeline 6. The other end of the grouting pipeline 6 is connected to the grouting pump. The sealing of the classification and identification module is ensured, and the multifunctional sensor array 11 is ensured to be in close contact with the surrounding rock surface. This installation position can ensure that the sensor collects accurate physical signals from the surrounding rock surface and provides accurate data input for subsequent operations. The grouting module is also connected to the pressure detection control module 7 through the flange and maintained in a stable connection with the grouting pipeline 6. All modules are precisely positioned to ensure the smooth progress of the grouting operation.

[0070] Step 2, classification and identification of surrounding rock: Start the acoustic wave detection unit 13, resistivity detection unit 14 and pressure sensing unit 15 of the classification and identification module 1. The acoustic wave detection unit 13 evaluates the width of the crack by monitoring the propagation speed of the sound wave. The resistivity detection unit 14 determines the water content of the crack by measuring the electrical conductivity of the surrounding rock. The pressure sensing unit 15 is used to capture the stress changes of the local surrounding rock. The obtained physical parameter data is transmitted to the AI analysis system through the signal processing unit 16 for fusion analysis, and finally the category of the crack is output. For example, the classification result is "wide crack". Through the classification and identification module 1, the crack characteristics of the surrounding rock can be accurately identified, providing reliable basic data for subsequent grouting operations. This data will be used to optimize slurry selection and grouting parameters.

[0071] Step 3, slurry switching and grouting operation: According to the classification results, the classification and identification module 1 outputs the "crack" information and transmits it to the grouting module. The multi-channel switching unit 4 in the grouting module automatically selects the slurry storage tank suitable for this type of crack and turns on the grouting pump 8. The slurry is injected into the crack area through the grouting pump 8. The flow rate and pressure of the grouting process can be adjusted according to the settings to ensure that the slurry can fully fill the crack. The slurry is injected into the grouting pipeline 6 through the grouting pump 8 and then injected into the crack area through the porous grouting head 17. When the grouting is completed, the grouting pump 8 automatically shuts down and prepares to switch to the next area. During this process, the automated control ensures the accurate injection of high-viscosity slurry, prevents slurry waste, and ensures that the crack area is fully reinforced.

[0072] Step 4: Real-time pressure monitoring and regulation: During the grouting process, the grouting effect dynamic monitoring control module 2 monitors the injection status of the slurry in real time through the pressure sensor 21 and the flow sensor 22, and feeds back the monitoring data to the grouting module through the closed-loop control system 24. When the pressure deviates from the preset range, the closed-loop system automatically adjusts the output parameters of the grouting pump 8 to keep the grouting pressure stable.

[0073] Real-time pressure and flow monitoring ensures a smooth grouting process, preventing excessive grouting pressure from causing secondary damage to the surrounding rock or insufficient grout filling. This closed-loop regulation system effectively guarantees the quality and safety of grouting.

[0074] Step 5: Self-cleaning and equipment maintenance: After grouting is completed, the classification and recognition module 1 starts the self-cleaning function, and high-pressure airflow passes through the nozzle in the classification and recognition module 1 to clean the mineral powder and slurry residue on the surface of the multifunctional sensor array 11.

[0075] Regular cleaning ensures that the sensor's sensitivity remains unchanged over time, preventing classification errors caused by sensor clogging. The self-cleaning function extends the life of the device and improves the long-term reliability of the system, ensuring efficient operation every time.

[0076] Step 6. Grouting reinforcement of micro-cracked surrounding rock: In another type of tunnel, the surrounding rock is less fragmented and the cracks are smaller. The classification and identification module 1 accurately identifies the cracks as "micro-cracks" through the significant reduction in the speed of sound wave propagation and the change in resistivity data. This identification result can adapt to different surrounding rock conditions and improve the applicability of classification and identification. For micro-crack types, the grouting module automatically switches to the ultra-low viscosity slurry storage tank 10 and injects ultra-low viscosity slurry into the micro-cracks at a lower flow rate. Low-flow grouting ensures that the slurry can be evenly distributed deep into the micro-cracks, avoiding the problem of incomplete grouting.

[0077] Step 7: Pressure Monitoring and Control for Microcrack Grouting: For microcracks, the pressure monitoring and control module sets a low pressure threshold and regulates the grouting pressure through a closed-loop control system 24 to prevent excessive grouting pressure from causing slurry leakage or further damage to the surrounding rock. This measure optimizes parameters based on the characteristics of microcracks, ensuring a safer and more efficient grouting process.

[0078] Therefore, the present invention adopts the above-mentioned precise grouting device and grouting method for classifying broken surrounding rocks in deep mine tunnels. Through the coordinated work of the classification and identification module, the grouting module and the pressure monitoring and control module, combined with intelligent control technology and a visual monitoring terminal, it realizes the precise classification of broken surrounding rocks, dynamic switching of slurry and real-time stable control of grouting pressure.

[0079] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit the same. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that they can still modify or replace the technical solutions of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A precise grouting device for crushed surrounding rock classification in deep mine tunnels, characterized by: It includes a classification and identification module, a grouting module, and a pressure detection and control module. The grouting module is placed in the shell. The grouting module includes a multi-channel switching unit, a slurry storage unit and a flow control unit. The classification and identification module is connected to the grouting module through a grouting pipeline. The grouting module is connected to the pressure detection and control module. The pressure detection and control module is connected to the multi-channel switching unit. The multi-channel switching unit is connected to the slurry storage unit. The grouting module is a frame structure with a shell made of high-strength corrosion-resistant material and a wear-resistant coating on the surface. The slurry storage unit is placed on the top area of the grouting module. The slurry storage unit includes a high-viscosity slurry storage tank, a low-viscosity slurry storage tank, and an ultra-low-viscosity slurry storage tank. A multi-channel switching unit is provided between the slurry storage unit and the grouting pump. The multi-channel switching unit includes an input pipeline, an output pipeline, a support structure and an electric control valve system. The output pipeline is connected to the grouting pump. An input pipeline is connected between the slurry storage unit and the multi-channel switching unit. The input pipeline is equipped with an electric control valve system. The electric control valve system includes a valve body, a coil and a feedback sensor. The grouting pump and flow control unit are placed in the bottom area of the grouting module. The grouting pump is a high-precision plunger pump, and the flow control unit includes a flow sensor and a control valve.

2. The device for accurate grouting of broken surrounding rock in deep mine tunnels according to claim 1 is characterized by: The classification and identification module is fixedly connected to the porous grouting head through a metal flange, and the porous grouting head is fixedly connected to the grouting pipeline. A multi-layer sealing gasket is provided at the rear end of the classification and identification module. The outer shell is made of high-strength corrosion-resistant material and is covered with a waterproof and dust-proof coating. A shock-absorbing device is installed on the outside of the classification and identification module.

3. The device for accurate grouting of broken surrounding rock in deep mine tunnels according to claim 1 is characterized by: The classification and identification module includes a multifunctional sensor array, a signal processing unit, an embedded AI analysis system, and a module self-cleaning system. The multifunctional sensor array includes an acoustic wave detection unit, a resistivity detection unit, and a pressure sensing unit. The multifunctional sensor array is connected to the signal processing unit. The acoustic wave detection unit, the resistivity detection unit, and the pressure sensing unit are connected to the signal processing unit through electrical signals. The signal processing unit is connected to the AI analysis system through electrical signals.

4. The device for precise grouting of broken surrounding rock in deep mine tunnels according to claim 3 is characterized by: The front end of the classification and identification module is a grooved planar structure, and the working ports of the multi-functional sensor array are arranged around the groove. The working ports include an acoustic wave probe, a multi-point electrode contact point and a pressure sensing contact surface. The acoustic wave probe is connected to the acoustic wave detection unit, the multi-point electrode contact point is connected to the resistivity detection unit, and the pressure sensing contact surface is connected to the pressure sensing unit.

5. The device for precise grouting of broken surrounding rock in deep mine tunnels according to claim 3 is characterized by: The modular self-cleaning system includes an airflow cleaning unit, which includes an air pump, a nozzle system and an airflow control valve. The nozzle is connected to the rear end of the classification and identification module, and the other end is connected to the nozzle system. The nozzle system is distributed at the working port of the multi-function sensor array. The airflow control valve is electrically connected to the AI analysis system, and the airflow control valve is placed on the connecting pipe between the nozzle and the air pump.

6. The device for precise grouting of broken surrounding rock in deep mine tunnels according to claim 1, characterized in that: A grouting effect dynamic monitoring and control module is provided on one side of the shell, and a control and visualization monitoring terminal is provided on the other side. The grouting effect dynamic monitoring and control module has a rectangular chassis structure, and its shell is made of high-strength corrosion-resistant alloy material with an anti-corrosion coating sprayed on the surface. The grouting effect dynamic monitoring and control module includes a flow sensor unit, a control system unit, a fault warning unit and a closed-loop control system. The closed-loop control system is electrically connected to the grouting module.

7. The device for accurate grouting of broken surrounding rock in deep mine tunnels according to claim 6, characterized in that: The control and visual monitoring terminal includes a visual LCD panel, a central processing unit, a communication module, a data storage unit and a graphic rendering system, and the visual LCD panel, the central processing unit, the communication module, the data storage unit and the graphic rendering system are all electrically connected to each other.

8. A method for accurately grouting broken surrounding rock in deep mine tunnels by classification, using the device for accurately grouting broken surrounding rock in deep mine tunnels according to any one of claims 1 to 7, characterized in that: The following steps are involved: Step 1: Device installation: Deploy the device in the deep tunnel area of the mine to be grouting. The classification and identification module is fixedly connected to the porous grouting head through a metal flange. The porous grouting head is fixedly connected to the grouting pipeline. The other end of the grouting pipeline is connected to the grouting pump. The grouting module is also connected to the pressure detection control module through a flange. Step 2: Classification and identification of surrounding rock: The acoustic wave detection unit, resistivity detection unit, and pressure sensing unit of the classification and identification module are activated. The acoustic wave detection unit assesses the width of the crack by monitoring the propagation speed of the sound wave. The resistivity detection unit determines the water content of the crack by measuring the electrical conductivity of the surrounding rock. The pressure sensing unit is used to capture the stress changes of the local surrounding rock. The obtained physical parameter data is transmitted to the AI analysis system through the signal processing unit for fusion analysis, and finally the crack category is output; Step 3: Slurry switching and grouting operation: Based on the classification results, the classification recognition module outputs "crack" information and transmits it to the grouting module. The multi-channel switching unit in the grouting module automatically selects a slurry storage tank suitable for this type of crack and starts the grouting pump. The slurry is injected into the grouting pipeline through the grouting pump and then injected into the crack area through the porous grouting head. When the grouting is completed, the grouting pump automatically shuts down and prepares to switch to the next area. Step 4: Real-time pressure monitoring and control: During the grouting process, the grouting effect dynamic monitoring and control module monitors the injection status of the slurry in real time through pressure sensors and flow sensors, and feeds back the monitoring data to the grouting module through a closed-loop control system. When the pressure deviates from the preset range, the closed-loop system automatically adjusts the output parameters of the grouting pump to maintain stable grouting pressure; Step 5: Self-cleaning and equipment maintenance: After grouting is completed, the classification and recognition module activates the self-cleaning function, and high-pressure air flows through the nozzles in the air cleaning unit to clean the mineral powder and slurry residue on the surface of the sensor array; Step 6: Grouting reinforcement of micro-cracked surrounding rock: For micro-cracks, the grouting module automatically switches to the ultra-low viscosity slurry storage tank and injects ultra-low viscosity slurry into the micro-cracks at a lower flow rate; Step 7. Pressure monitoring and control of micro-crack grouting: For micro-crack types, the pressure monitoring and control module sets a lower pressure threshold and adjusts the grouting pressure through a closed-loop control system.

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