Assembly type rapid filling technology for roadway top-caving area based on 3D modeling and printing

Abstract

The invention belongs to the field of coal mining, and particularly relates to a roadway top-caving area assembly type rapid filling technology based on 3D modeling and printing, and the technology comprises the following steps: S1, three-dimensional scanning modeling and positioning; s2, carrying out modular decomposition and 3D printing; s3, ground prefabrication and underground assembly are carried out; s4, remote control lifting and filling body installation; s5, fixing and supporting; s6, detecting the integrity of the filling body; s7, recording and archiving the data; s8, performing surface treatment on the filling body; s9, monitoring and maintaining the surrounding environment; and S10, recovering and maintaining the equipment. According to the assembly type rapid filling technology for the roadway top-coal-caving area based on 3D modeling and printing, remote control operation is adopted in the whole process, operators do not need to enter the dangerous area of the top-coal-caving area, and safety threats caused by risks such as roof fall and gas accumulation are effectively avoided. Meanwhile, potential safety hazards such as fire hazards caused by solidification and heat release of underground materials can be avoided through the ground prefabricated parts, the life safety of operators is guaranteed in an all-around mode, and the operation safety is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of coal mine mining, and specifically to an assembled rapid filling technology for roadway high-goaf areas based on 3D modeling and printing. Background Art

[0002] During the coal mine mining process, due to complex geological conditions (such as composite roof, soft interlayer, etc.) in the roadway roof, local roof fall accidents are prone to occur, forming high-goaf areas. High-goaf areas not only threaten the stability of the roadway, but also provide space for gas accumulation, seriously endangering the safety of underground operations.

[0003] At present, the commonly used high-goaf area treatment technologies in the industry mainly include the following two categories:

[0004] Wooden crib filling method: A false roof is formed by stacking wooden cribs to provide support for subsequent support. However, there are a large number of gaps between the wooden cribs, and the filling body has a poor fit with the roof, resulting in an insufficient filling rate (usually less than 60%). In addition, wood is flammable and needs to be manually transported, posing risks of fire and casualties.

[0005] Grouting filling method: After enclosing the high-goaf area with a formwork bag or waterproof cloth, foaming materials or concrete are injected. However, due to the influence of gravity, the grouting materials are difficult to completely fill the irregular space, and the filling rate is still not ideal. At the same time, a large amount of heat is released during the solidification process of the foaming materials, which is likely to cause an increase in underground temperature and potential gas explosion hazards.

[0006] Since the above methods all require on-site operations in the high-goaf area, the construction period is long, the efficiency is low, and the operating personnel need to be exposed to a dangerous environment. In addition, traditional filling materials and processes are difficult to meet the requirements of modern mines for safety, efficiency, and environmental protection. In view of this, we propose an assembled rapid filling technology for roadway high-goaf areas based on 3D modeling and printing. Summary of the Invention

[0007] The main object of the present invention is to provide an assembled rapid filling technology for roadway high-goaf areas based on 3D modeling and printing, which can solve the problems raised in the above background art.

[0008] To achieve the above object, the assembled rapid filling technology for roadway high-goaf areas based on 3D modeling and printing proposed by the present invention includes the following steps:

[0009] S1. Three-dimensional scanning modeling and positioning: A remotely controlled lifting platform is used to carry a high-precision three-dimensional laser scanner to conduct a full-range scan of the high-goaf area to generate a three-dimensional point cloud model with millimeter-level accuracy. During the scanning process, the parking position of the lifting platform is determined through laser positioning or wire marking to ensure the subsequent assembly accuracy. The three-dimensional model data is wirelessly transmitted to the ground control center, and professional software (such as AutoCAD, SolidWorks) is used for model optimization and segmentation;

[0010] S2. Modular decomposition and 3D printing. The three-dimensional model of the high-risk area is decomposed into two types of modules. The ground prefabricated components are standardized geometric bodies (cylinders or cuboids) with concave slots set on the edges. The materials are lightweight inorganic composite materials (such as foamed ceramics or slag-based materials), which have both lightweight and high-strength characteristics. The contour printing composite components are special-shaped modules divided according to the actual contour of the high-risk area. They are printed layer by layer with lightweight organic materials (such as polyurethane foam or photosensitive resin) using an on-site 3D printer, and convex plugs matching the prefabricated components are set on the edges;

[0011] S3, ground prefabrication and underground assembly. Ground prefabricated components are mass-produced through molds, transported underground, and assembled on a movable lifting platform according to the three-dimensional model sequence. During assembly, fast splicing is achieved through mechanical engagement of slots and plugs, and the error is controlled within ±2mm. Contour printing combined components are selected for ground prefabrication or underground on-site printing according to actual needs to ensure complete fit with the surface of the high-risk area;

[0012] S4, remote control lifting and filling body installation, the lifting platform is equipped with a hydraulic drive system and a wireless remote control module, which transports the assembled filling combination module to the preset position below the high-risk area. The filling body is pushed vertically into the high-risk area through the lifting device, and the gap between the filling body and the top plate is filled with elastic sealing tape to ensure that there is no gap left;

[0013] S5. Fixation and support: After the filling body is installed, it is reinforced with anchor rods (cables) or single pillars. Prefabricated components are embedded with support holes to facilitate the rapid installation of anchor rods.

[0014] S6. Filling integrity inspection: After the fixation and support are completed, the filling body is inspected using geological radar or ultrasonic detector to ensure that there are no defects such as cavities and cracks inside the filling body to ensure the filling quality. The inspection data is transmitted to the ground control center in real time, and if any problems are found, they are repaired in time;

[0015] S7. Data recording and archiving: Detailed records of scanning data, component production data, installation data, and test data during the entire filling process are kept and archived. These data will serve as an important basis for subsequent tunnel maintenance and safety assessment, facilitating timely detection of potential safety hazards and taking corresponding measures;

[0016] S8. Surface treatment of the filling body. After the filling body is installed and fixed and has passed the inspection, the surface of the filling body is treated. If inorganic materials are used, waterproof and anti-corrosion coatings can be applied on the surface to prevent groundwater erosion and oxidation; if organic materials are used, fire retardant treatment can be performed to improve the safety of the filling body;

[0017] S9. Peripheral environment monitoring and maintenance: within a certain period after the filling operation is completed, parameters such as the displacement of the roadway surrounding rock, stress changes, and gas concentration around the gob area are monitored in real time. According to the monitoring data, the support parameters are adjusted in a timely manner or other maintenance measures are taken to ensure the long-term stable safety of the roadway;

[0018] S10. Equipment recovery and maintenance: after the filling operation is completely finished, equipment such as the remotely controlled lifting platform, 3D scanner, and 3D printer used are recovered. They are thoroughly cleaned, maintained, and repaired on the ground to prepare for the next use, extend the service life of the equipment, and reduce costs.

[0019] Preferably, in step S1, laser positioning or wire marking is used to determine the parking position of the lifting platform.

[0020] Preferably, in step S2, the module is divided into a ground prefabricated component and a contour printing combined component, and the two are connected through a slot - plug structure.

[0021] Preferably, the ground prefabricated component is a cylinder or a cuboid, and the material is slag-based foamed ceramics or other lightweight inorganic composite materials. The ground prefabricated component is designed as a cylinder or a cuboid because of its regular shape, which is convenient for mold making and mass production, and can improve production efficiency while ensuring structural strength. Selecting slag-based foamed ceramics or other lightweight inorganic composite materials is not only because of their lightweight characteristics, which can effectively reduce the burden during transportation and installation, but also because of their good compressive strength and stability, which can meet the support requirements after filling the gob area of the roadway.

[0022] Preferably, the contour printing combined component is segmented according to the contour of the gob area, and the material is lightweight organic materials such as polyurethane foam or photosensitive resin. The contour printing combined component segmented according to the contour of the gob area can accurately fit the irregular surface of the gob area to achieve efficient filling. Using lightweight organic materials such as polyurethane foam or photosensitive resin is because these materials have good fluidity, are suitable for 3D printing technology, can be quickly formed, and have a certain elasticity after curing, which can better adapt to the minor deformation of the gob area. At the same time, their lightweight characteristics also help to reduce the overall filling weight.

[0023] Preferably, in step S4, the lifting platform is equipped with a hydraulic drive system and a wireless remote control module. The lifting platform equipped with a hydraulic drive system has the characteristics of strong power and stable operation compared with other drive methods. It can accurately control the lifting height and speed to ensure that the filling combined module is accurately transported to the preset position below the gob area. The wireless remote control module enables the operator to operate in a safe area away from the gob area, avoiding personnel exposure to dangerous environments and greatly improving the operation safety.

[0024] Preferably, in step S5, bolting or single props are used for support. Support holes are pre-embedded in the precast components. Using bolting or single props for support can effectively enhance the connection stability between the filling body and the surrounding rock of the roadway, preventing the displacement or collapse of the filling body. The pre-embedded support holes in the precast components not only facilitate the rapid installation of bolts, improve the construction efficiency, but also ensure the accuracy of the bolt installation position, ensuring the reliability of the support effect.

[0025] Preferably, in step S6, a ground penetrating radar or an ultrasonic detector is used to detect the integrity of the filling body. Using a ground penetrating radar or an ultrasonic detector to detect the integrity of the filling body, these two detection methods have the characteristics of non-contact and non-destructive testing, and can quickly and accurately detect whether there are defects such as cavities and cracks inside the filling body. The detection data is transmitted to the ground control center in real time, which is convenient for technicians to analyze and process in a timely manner. If problems are found, repair measures can be taken immediately to ensure the filling quality and the safety of the roadway.

[0026] Preferably, in step S8, a waterproof and anti-corrosion coating is applied to the surface of the inorganic material filling body, and a fireproof and flame-retardant treatment is carried out on the organic material filling body. Applying a waterproof and anti-corrosion coating to the surface of the inorganic material filling body can effectively prevent the erosion of groundwater and corrosive gases in the mine on the filling body, extend the service life of the filling body, and ensure its long-term stable performance. Carrying out a fireproof and flame-retardant treatment on the organic material filling body is considered because there are fire hazards in the mine. Improving the fireproof performance of the organic material can reduce the harm degree during a fire and ensure the safety of underground operations.

[0027] Preferably, in step S9, the displacement, stress change and gas concentration of the surrounding rock of the roadway around the gob area are monitored in real time, which can timely master the stability of the surrounding rock of the roadway and the gas condition. Once abnormal displacement of the surrounding rock, sudden stress change or gas concentration exceeding the standard are found, corresponding measures can be taken quickly, such as strengthening support, adjusting the ventilation system, etc., to ensure the long-term stable safety of the roadway and avoid accidents.

[0028] The present invention provides a 3D modeling and printing-based rapid assembly filling technology for roadway gob areas. It has the following beneficial effects:

[0029] (1) The 3D modeling and printing-based rapid assembly filling technology for roadway gob areas adopts remote control operation throughout the process. The operators do not need to enter the dangerous gob area, effectively avoiding the safety threats brought by risks such as roof fall and gas accumulation. At the same time, the method of precast components on the ground can avoid safety hazards caused by the heat release of material solidification underground, such as fires and gas explosions, comprehensively protecting the lives of the operators and greatly improving the operation safety.

[0030] (2) The assembled rapid filling technology for high goaf areas based on 3D modeling and printing generates an accurate model of the high goaf area through high-precision three-dimensional scanning, and modularizes and 3D prints based on this model. The prefabricated components on the ground and the profile printing combined components cooperate with each other, can fit well with the surface of the high goaf area, making the filling rate of the filling body reach more than 95%, significantly reducing the gas accumulation space, greatly improving the filling quality, and enhancing the stability of the roadway roof.

[0031] (3) The assembled rapid filling technology for high goaf areas based on 3D modeling and printing adopts a parallel operation mode of ground prefabrication and underground assembly, greatly shortening the construction period. Compared with the traditional wooden crib filling method and grouting filling method, the single filling operation time is shortened to 1 / 3 of the original. For example, in the embodiment, the underground assembly and filling operations can be quickly completed, effectively improving the efficiency of dealing with high goaf areas during coal mining and reducing the impact on normal production. Description of the Drawings

[0032] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on the structures shown in these drawings.

[0033] Figure 1 It is a schematic diagram of the overall process of the present invention;

[0034] Figure 2 It is a schematic diagram of three-dimensional scanning and modeling of the high goaf area profile of the present invention;

[0035] Figure 3 It is a schematic diagram of the working of the filling device of the present invention;

[0036] Figure 4 It is a schematic diagram of assembling the filling parts of the present invention;

[0037] Figure 5 It is a schematic diagram of the process of some steps of the present invention Figure 1 ;

[0038] Figure 6 It is a schematic diagram of the process of some steps of the present invention Figure 2 .

[0039] Explanation of the reference numerals in the drawings: 1, chassis; 2, wheels; 3, lifting device; 4, installation platform; 5, three-dimensional scanner; 6, high goaf area; 7, 3D model assembly; 7a, cylindrical or cuboid prefabricated component; 7b, profile printing combined component; 7c, concave slot and convex rod.

[0040] The realization, functional features and advantages of the present invention will be further described in conjunction with embodiments with reference to the accompanying drawings. Detailed implementation manners

[0041] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0042] Embodiment 1: A case of backfilling in the gob area of a coal mine

[0043] Please refer to Figure 1 - Figure 6 , the present invention provides an assembled rapid backfilling technology for roadway gob areas based on 3D modeling and printing, including the following steps:

[0044] S1. Scanning and modeling: Use a FARO Focus S 350 three-dimensional laser scanner to scan the gob area 6, adjust the position of the scanner through a remotely controlled lifting platform to ensure full coverage of the gob area 6, and generate a point cloud model with an accuracy of 0.1 mm. Use laser positioning to determine the parking position of the lifting platform, and wirelessly transmit the scanned three-dimensional model data to the ground control center. At the ground control center, use Geomagic Wrap software to optimize the model, remove noise points, and then divide the model into 12 prefabricated components and 8 contour printing components according to the shape characteristics of the gob area 6.

[0045] S2. Component production: The ground prefabricated components use slag-based foaming materials (density 0.8 g / cm3, compressive strength 15 MPa), and are batch-cast and formed through molds in a ground factory. During the production process, strictly control the dimensional accuracy of the molds to ensure that the dimensional error of the concave slots at the edges of the prefabricated components is within the allowable range. The contour printing components use polyurethane foam (curing time 30 minutes) and are made on-site in the mine through a KUKA robotic arm 3D printer. According to the divided model data, the 3D printer layer-by-layer prints the contour printing combined component 7b to ensure that the convex insertion rods at its edges are precisely matched with the concave slots of the prefabricated components.

[0046] S3. Underground assembly: Build a movable lifting platform 20 m away from the gob area 6, transport the prefabricated components on the ground to the underground. Assemble them on the lifting platform according to the assembly sequence of the three-dimensional model. First, place the prefabricated components, and then insert the contour printing combined component 7b into the concave slots of the prefabricated components through the convex insertion rods to achieve rapid splicing. The entire assembly process takes 2 hours, and the splicing error is controlled within ±2 mm.

[0047] S4. Remote control lifting and filling body installation: The lifting platform is equipped with a hydraulic drive system and a wireless remote control module. The operator transports the assembled filling combination module to the preset position below the high-goaf area 6 through the remote control in a safe area. Start the lifting device 3, and vertically and slowly push the filling body into the high-goaf area 6. At the contact part between the filling body and the roof, an elastic sealing tape is pasted in advance to ensure that there is no void residue after filling.

[0048] S5. Fixing and support: After the filling body is installed, support is carried out using Φ22mm full-thread anchor bolts (length 2.5m). Since the support holes are pre-buried inside the precast components, the anchor bolts are directly installed in the support holes, and a pre-tightening force is applied using the supporting tools to make the pre-tightening force reach 50kN to ensure the stability of the filling body.

[0049] S6. Integrity detection of the filling body: Use ground-penetrating radar to comprehensively scan the filling body to detect whether there are defects such as cavities and cracks inside the filling body. The scanning data is transmitted to the ground control center in real time. After analysis and processing, no obvious defects are found, and it is confirmed that the integrity of the filling body is good.

[0050] S7. Data recording and archiving: The original data of the high-goaf area 6 obtained by scanning, the data of the model optimization and segmentation process, the production parameters of the components, the underground assembly records, the filling body installation data, and the ground-penetrating radar detection data are recorded in detail and sorted into electronic documents and paper documents for classified archiving and storage.

[0051] S8. Surface treatment of the filling body: Since inorganic materials are used, a waterproof and anti-corrosion coating is evenly applied on the surface of the filling body to enhance the durability of the filling body.

[0052] S9. Peripheral environment monitoring and maintenance: Within one week after the filling operation is completed, displacement monitoring points, stress sensors, and gas concentration monitors are arranged around the high-goaf area 6. The displacement, stress changes of the roadway surrounding rock, and gas concentration are monitored in real time. The monitoring data shows that all parameters are within the safe range, and no additional support parameters need to be adjusted.

[0053] S10. Equipment recovery and maintenance: After all the filling operations are completed, equipment such as the remote control lifting platform, 3D laser scanner, and 3D printer are recovered from the underground to the ground. The equipment is thoroughly cleaned, the wear conditions of each component are checked, the vulnerable parts are replaced, the mechanical parts are lubricated and maintained, and the electrical components are tested and debugged for performance to ensure that the equipment is in good condition and ready for the next use. After actual measurement, the filling rate after this filling is 97.3%.

[0054] Example 2: Comparison cases of filling in high-goaf areas of different coal mines

[0055] Please refer to Figure 1 - Figure 6, the present invention proposes an assembled rapid filling technology for roadway high goaf areas based on 3D modeling and printing, including the following steps:

[0056] S1. Scanning and Modeling: Select the high goaf area 6 of another coal mine, scan it using a Leica ScanStation P40 3D laser scanner, determine the parking position of the lifting platform using wire marking, and generate a 3D point cloud model with an accuracy of 0.15 mm. After optimizing the model through PolyWorks software, it is divided into 15 prefabricated components and 10 profile printing components.

[0057] S2. Component Production: The ground prefabricated components use foamed ceramic materials (density 0.9 g / cm3, compressive strength 18 MPa) and are prefabricated in a ground factory. The profile printing composite component 7b selects photosensitive resin materials and is printed on-site underground using an industrial-grade 3D printer. The printing process strictly controls the thickness of each layer and the curing time.

[0058] S3. Underground Assembly: Build a movable lifting platform 25 m away from the high goaf area 6, assemble the components in the model order, with an assembly time of 2.5 hours and the splicing error controlled within ±1.5 mm.

[0059] S4. Remote Control Lifting and Filling Body Installation: Through the lifting platform equipped with a hydraulic drive and a wireless remote control module, transport the filling composite module to below the high goaf area 6, slowly lift the filling body for installation, and use elastic sealing tape to fill the gap.

[0060] S5. Fixing and Support: Use single props for support, reasonably arrange the prop positions according to the on-site situation to ensure the stability of the filling body.

[0061] S6. Detection of Filling Body Integrity: Use an ultrasonic detector to detect the filling body. The detection results show that the inside of the filling body is dense and there are no obvious defects.

[0062] S7. Data Recording and Archiving: Detail all process data such as scanning, production, assembly, installation, and detection, and establish a database for archival management.

[0063] S8. Surface Treatment of Filling Body: Conduct fire and flame retardant treatment on the surface of the filling body to improve safety.

[0064] S9. Peripheral Environment Monitoring and Maintenance: Continuously monitor the peripheral environment parameters of the high goaf area 6 within 10 days after filling, and fine-tune the support according to the monitoring results to ensure the stability of the roadway.

[0065] S10. Equipment Recovery and Maintenance: Recover the equipment after the operation and conduct comprehensive maintenance on the ground to provide guarantee for subsequent use. After detection, the filling rate of this filling reaches 96.5%.

[0066] The above are only the preferred embodiments of the present invention, and do not limit the patent scope of the present invention accordingly. Any equivalent structural transformation made under the inventive concept of the present invention by using the content of the specification and drawings of the present invention, or any direct / indirect application in other related technical fields shall be included within the patent protection scope of the present invention.

Claims

1. An assembled and rapid filling technology for roadway high-goaf areas based on 3D modeling and printing, characterized in that: The following steps are involved: S1, 3D scanning modeling and positioning; S2, modular decomposition and 3D printing; S3, ground prefabrication and underground assembly; S4, remote control lifting and filling body installation; S5, Fixing and support; S6. Filling integrity test; S7, data recording and archiving; S8, filling surface treatment; S9, monitoring and maintenance of surrounding environment; S10. Equipment recovery and maintenance.

2. The assembled and rapid filling technology for roadway high-goaf areas based on 3D modeling and printing according to claim 1, characterized in that: In step S1, the parking position of the lifting platform is determined by laser positioning or wire marking.

3. A rapid assembly filling technology for high goaf areas in roadways based on 3D modeling and printing according to claim 1, characterized in that: In step S2, the module is divided into a ground prefabricated component and a contour printing combined component, which are connected by a slot-rod structure.

4. A rapid assembly filling technology for roadway high-goaf areas based on 3D modeling and printing according to claim 1, characterized in that: The ground prefabricated component is a cylinder or a cuboid, and the material is slag-based foamed ceramic or other lightweight inorganic composite materials.

5. The prefabricated rapid filling technology for roadway high goaf areas based on 3D modeling and printing according to claim 1, characterized in that: The outline printing combined components are divided according to the outline of the high-risk area, and the material is a light organic material such as polyurethane foam or photosensitive resin.

6. A rapid assembly filling technology for roadway high-goaf areas based on 3D modeling and printing according to claim 1, characterized in that: In step S4, the lifting platform is equipped with a hydraulic drive system and a wireless remote control module.

7. A rapid assembly filling technology for high goaf areas in roadways based on 3D modeling and printing, characterized in that: In step S5, anchor rods or single pillars are used for support, and support holes are embedded in the prefabricated components.

8. A rapid assembly filling technology for high-goaf areas in roadways based on 3D modeling and printing according to claim 1, characterized in that: In step S6, a geological radar or an ultrasonic detector is used to perform integrity detection on the filling body.

9. A rapid assembly filling technology for high-goaf areas in roadways based on 3D modeling and printing according to claim 1, characterized in that: In step S8, a waterproof and anti-corrosion coating is applied to the surface of the inorganic material filling body, and a fire-retardant treatment is performed on the surface of the organic material filling body.

10. A rapid assembly filling technology for high-goaf areas in roadways based on 3D modeling and printing, characterized in that: In step S9, the displacement, stress change and gas concentration of the surrounding rock of the tunnels around the high-risk area are monitored in real time.

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