Tunnel shaft lane concrete support automatic injection method

Abstract

The application discloses a tunnel and roadway concrete support automatic spraying method in the technical field of concrete support spraying, and the method realizes automatic spraying of a concrete support of a tunnel excavation face by controlling a travelling carriage chassis, a pumping mechanism, an arm support mechanism and an environment scanning mechanism through a travelling carriage computer, and when the concrete support is sprayed, a worker does not need to enter the tunnel to remotely control a concrete wet spraying machine, so that the threat of a bad environment to the health of the worker and a safety hidden danger are completely avoided, various parameters during spraying of the concrete support are adjusted according to actual conditions of the excavation face, so that the spraying process of the concrete support is accurately controlled, the forming quality of the final concrete support is improved, and rework caused by manual errors is reduced, meanwhile, continuous operation without interruption can be realized, and construction efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of concrete support spraying technology, specifically to an automatic spraying method for concrete support in tunnels and shafts. Background Technology

[0002] Shotcrete support, as an important process in tunnel and shaft support, is widely used in railways, highways, water conservancy, national defense, metallurgy and other fields. Its working principle is to use fluid power to transport pre-mixed concrete through pipelines and spray it at high speed onto the sprayed surface. A concrete layer is formed by the continuous impact and compaction of the concrete during the spraying process.

[0003] Traditional wet spraying machine operators need to operate the equipment at close range, and are exposed to dust, noise, harmful gases and the risk of collapse in the tunnel for a long time, which can easily cause respiratory diseases, hearing damage and even safety accidents. Especially as engineering equipment, it often faces harsh environments such as long and deep tunnels, high-altitude areas and extreme high and low temperature working environments. For example, the construction of high-altitude railways requires a large number of tunnel construction equipment, including rock drilling rigs and excavators. The thin air in the high-altitude environment causes construction equipment to generally face problems such as reduced power, increased energy consumption and aggravated emission pollution. This is more prominent in long-distance tunnel construction, and there are also safety hazards such as "competing with people for oxygen" and large accumulation of harmful gases.

[0004] Meanwhile, traditional wet spraying machines rely on manual adjustment of the spraying angle, distance, and speed, resulting in poor operational consistency, uneven spraying thickness, and difficulty in guaranteeing spraying quality. Furthermore, the training period for skilled wet spraying machine operators is long, labor costs are high, and fatigue can easily lead to quality fluctuations, making it difficult to guarantee the final construction quality.

[0005] Based on this, the present invention designs an automatic shotcrete method for concrete support in tunnels and shafts to solve the above problems. Summary of the Invention

[0006] To achieve the above objectives, the present invention provides the following technical solution: an automatic concrete spraying method for tunnel shaft support, wherein the concrete support is automatically sprayed using a wet concrete spraying machine, the wet concrete spraying machine including a traveling chassis, a pumping mechanism, a boom mechanism, an environmental scanning mechanism, and a traveling computer; the pumping mechanism, boom mechanism, environmental scanning mechanism, and traveling computer are all mounted on the traveling chassis.

[0007] The automatic shotcrete method for tunnel shaft concrete support includes the following steps:

[0008] S1, obtain the coordinates of the tunnel construction location and input them into the vehicle computer. The vehicle computer then controls the vehicle chassis to move to the tunnel construction location.

[0009] S2, use an environmental scanning mechanism to scan and model the tunnel outline, and calculate the thickness of the concrete sub-base based on the concrete support forming outline and the tunnel outline model.

[0010] S3, start the pumping mechanism and boom mechanism to spray the bottom layer in each scanned cloud point area. When spraying, first spray the arch foot of the tunnel excavation face to the waist. After the concrete from the arch foot to the waist has solidified, spray the waist to the top. The spraying thickness is the bottom layer thickness calculated in step S2.

[0011] S4. After the base layer has solidified, the nozzle is moved to the over-excavation point by controlling the boom mechanism to spray and fill the over-excavation point and fill the pits on the surface of the base layer.

[0012] S5 uses an environmental scanning mechanism to scan and model the surface of the substrate, and then transmits the modeled data to the vehicle computer for analysis to obtain the contour data of the substrate surface.

[0013] S6, by planning the swing speed of the boom mechanism and the spraying speed of the pumping mechanism when spraying the leveling layer using the surface contour data of the base layer, and then spraying the leveling layer on the base layer surface to obtain concrete support.

[0014] As a further aspect of the present invention, in step S1, the coordinates of the tunnel construction location are obtained through the survey report of the tunnel construction location. The starting position coordinates of the wet concrete spraying machine and the tunnel construction location coordinates are input into the vehicle computer. The cruise software in the vehicle computer controls the movement of the vehicle chassis, so that the wet concrete spraying machine moves to the tunnel construction location.

[0015] As a further aspect of the present invention, during the movement of the vehicle chassis 1 in step S1, the environmental scanning mechanism scans the road surface inside the tunnel in real time and feeds back the scanning data to the vehicle computer in real time. After processing by the cruise software, real-time route planning is performed.

[0016] As a further aspect of the present invention, in step S2, the modeled data is transmitted to the vehicle computer to analyze the size of the excavation face and the locations of over-excavation and under-excavation. After removing over-excavation points and under-excavation points that exceed the preset size, the excavation face is divided into multiple scanning point areas. The concrete support forming contour is compared with the excavation face to calculate the required concrete volume and average thickness of each scanning point area. The average concrete thickness is subtracted from the leveling layer thickness to obtain the base layer thickness.

[0017] As a further aspect of the present invention, in step S2, the preset dimensions are the over-excavation depth and under-excavation thickness specified in the tunnel construction requirements. When there are no over-excavation points or / and under-excavation points exceeding the preset dimensions, the over-excavation points with the maximum depth or / and under-excavation points with the maximum thickness are removed.

[0018] As a further aspect of the present invention, in step S2, the tunnel contour is divided into multiple scanning point regions according to the spray range of the nozzle.

[0019] As a further embodiment of the present invention, the environmental scanning mechanism includes a laser scanner, a mounting platform, and a rotating platform. The rotating platform is mounted on one end of the length direction of the vehicle chassis via the mounting platform, and the laser scanner is mounted on the rotating platform so that the laser scanner has rotational degrees of freedom in the X, Y, and N axis directions.

[0020] As a further embodiment of the present invention, the mounting platform includes a base, a push rod motor, and a protective cover. The base is fixed on the chassis of the vehicle for mounting a laser scanner. The protective cover is hinged to one end of the base and has a first state that covers the laser scanner on the base and a second state that exposes the laser scanner on the base. The push rod motor is hinged to the base and the protective cover at both ends, respectively, so as to drive the protective cover to switch between the first state and the second state through the action of the push rod motor.

[0021] As a further embodiment of the present invention, the vehicle chassis includes a chassis assembly, wheels and wheel-side motors. The bottom of the chassis assembly is provided with at least two connecting bridges. Both ends of the connecting bridges are provided with wheels and wheel-side motors. The wheel-side motors at both ends of the connecting bridges are used to drive the wheels at both ends of the connecting bridges.

[0022] As a further embodiment of the present invention, the boom mechanism includes a boom traveling mechanism, a boom slewing platform, a first boom, a second boom, a third boom, and a fourth boom; the boom traveling mechanism is fixed on the chassis assembly, allowing the boom slewing platform, the first boom, the second boom, the third boom, and the fourth boom to travel as a whole along the length of the chassis assembly; the boom slewing platform is mounted on the boom traveling mechanism, giving the first boom, the second boom, the third boom, and the fourth boom rotational freedom in both the X and Y axes; the first boom is connected to the boom slewing platform via a pin and a hydraulic cylinder for pitch adjustment; the second boom is nested within the first boom via a pin and a hydraulic cylinder, allowing it to extend and retract along the length of the first boom; the third boom is connected to the end of the second boom away from the first boom via a pin and a hydraulic cylinder, for folding the boom assembly; one end of the fourth boom is nested within the end of the third boom away from the second boom via a hydraulic cylinder and a pin, allowing it to extend and retract along the length of the third boom, and the other end is connected to a nozzle via bolts.

[0023] As a further embodiment of the present invention, the nozzle includes a nozzle, a mixer, a connector, and a hydraulic motor; the nozzle, mixer, and connector are connected in sequence, the connector is used to connect to a pumping system through a delivery pipeline, the mixer has an addition hole on its side wall for allowing concrete admixture to enter, and the concrete admixture is mixed with the concrete through the mixer, the nozzle is used to atomize the concrete and spray it out; the connector is mounted on four arms through a hydraulic motor, the hydraulic motor is used to drive the connector to rotate, thereby driving the nozzle to rotate.

[0024] As a further embodiment of the present invention, a camera is fixedly installed on the chassis assembly, and the camera, boom mechanism and environmental scanning mechanism are arranged sequentially along the length direction of the chassis assembly, so as to observe the working status of the boom mechanism and environmental scanning mechanism through the camera.

[0025] The present invention has the following beneficial effects:

[0026] 1. This method uses a vehicle computer to control the vehicle chassis, pumping mechanism, boom mechanism and environmental scanning mechanism to realize automatic spraying of concrete support at the excavation face in the tunnel. When spraying concrete support, there is no need for staff to enter the tunnel to operate the concrete wet spraying machine at close range, thus completely avoiding the threat to the health and safety of staff in the harsh environment.

[0027] 2. This method uses an environmental scanning device to scan the tunnel outline to obtain the dimensions of the tunnel excavation face and the over-excavation and under-excavation situation on the excavation face. Based on the actual situation of the excavation face, various parameters during concrete support spraying are adjusted to precisely control the concrete support spraying process, improve the final concrete support forming quality, reduce rework caused by human error, and at the same time, enable continuous operation without interruption, thereby improving construction efficiency.

[0028] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0029] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0030] Figure 1 This is a left-side schematic diagram of the wet concrete spraying machine in this invention.

[0031] Figure 2 This is a right-side schematic diagram of the wet concrete spraying machine in this invention.

[0032] Figure 3 This is a left-side view of the concrete wet spraying machine after the boom mechanism has been removed in this invention.

[0033] Figure 4 This is a schematic diagram of the environmental scanning mechanism in this invention.

[0034] Figure 5 This is a schematic diagram of the mounting platform in this invention.

[0035] Figure 6 This is a schematic diagram of the wheel-side steering fixed bridge in this invention.

[0036] Figure 7 This is a schematic diagram of the wheel-side steering floating bridge in this invention.

[0037] Figure 8 This is a schematic diagram of the boom mechanism in this invention.

[0038] Figure 9 This is a schematic diagram of the nozzle structure in this invention.

[0039] Figure 10 This is a schematic diagram of the power battery structure in this invention.

[0040] Figure 11 This is a schematic diagram of the quick-release frame in this invention.

[0041] Figure 12 This is a flowchart of the present invention.

[0042] Figure 13 This is a schematic diagram of the tunnel excavation face.

[0043] Legend:

[0044] 1. Overhead chassis; 11. Chassis assembly; 12. Wheel; 13. Wheel-side motor; 141. Reduction brake box; 142. Steering cylinder; 143. Axle; 144. Motor mount; 145. Articulated rocker arm; 146. Limiting frame; 2. Pumping mechanism; 3. Boom mechanism; 31. Traveling mechanism; 32. Boom turntable; 33. First boom; 34. Second boom; 35. Third boom; 36. Fourth boom; 4. Environmental scanning mechanism; 41. Laser scanner; 42. Mounting platform; 421. Base; 422. Push rod motor; 423. Protective cover; 43. Rotary table; 5. Onboard computer; 6. Nozzle; 61. Nozzle; 62. Mixer; 63. Connector; 64. Hydraulic motor; 7. Camera; 8. Cab; 91. Power battery; 92. Charging port; 93. Quick-release frame; 94. Drum. Detailed Implementation

[0045] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered below.

[0046] Please see Figure 1-12This invention provides a technical solution: an automatic concrete spraying method for tunnel shaft support, which uses a wet concrete spraying machine for automatic concrete spraying. The wet concrete spraying machine includes a traveling chassis 1, a pumping mechanism 2, a boom mechanism 3, an environmental scanning mechanism 4, and a traveling computer 5. The traveling chassis 1 is used to travel on the road surface. The pumping mechanism 2, boom mechanism 3, environmental scanning mechanism 4, and traveling computer 5 are all mounted on the traveling chassis 1. The boom mechanism 3 is equipped with a nozzle 6, which is connected to the pumping mechanism 2 through a delivery pipeline to deliver concrete to the nozzle 6. The traveling computer 5 is electrically connected to the traveling chassis 1, pumping mechanism 2, boom mechanism 3, and environmental scanning mechanism 4 to receive data from the environmental scanning mechanism 4 and control the traveling chassis 1, pumping mechanism 2, boom mechanism 3, and environmental scanning mechanism 4.

[0047] The automatic shotcrete method for concrete support in tunnels and shafts includes the following steps:

[0048] S1. After the tunnel excavation is completed, the coordinates of the tunnel construction location are obtained through the tunnel survey report. The coordinates of the starting position of the wet concrete spraying machine and the coordinates of the tunnel construction location are input into the vehicle computer 5. The cruise software in the vehicle computer 5 controls the movement of the vehicle chassis 1, so that the wet concrete spraying machine moves to the tunnel construction location.

[0049] When construction is carried out in accordance with national construction standards, drilling and blasting, excavation, and support are all interconnected. During the tunnel construction process, surveying is carried out and a surveying report is generated. The coordinates of the excavation face that needs wet shotcrete support are obtained from the surveying report. The construction position coordinates and the initial position coordinates of the wet shotcrete machine are input into the vehicle computer 5. The navigation software automatically generates the path and drives the vehicle chassis 1 to move to the construction position.

[0050] S2, use the environmental scanning mechanism 4 to scan and model the tunnel outline, and transmit the modeled data to the vehicle computer 5 to analyze the size of the excavation face and the locations of over-excavation and under-excavation. After removing over-excavation and under-excavation points that exceed the preset size, the excavation face is divided into multiple scanning point areas. The concrete support forming outline is compared with the excavation face to calculate the required concrete volume and average thickness of each scanning point area. The average concrete thickness is subtracted from the leveling layer thickness to obtain the base layer thickness.

[0051] After the concrete wet spraying machine is moved to the construction position, due to the over-excavation and under-excavation of the tunnel during drilling and blasting, the excavation surface inside the tunnel will be uneven. When spraying concrete support, the thickness of the concrete spraying needs to be adjusted according to the actual tunnel outline. The tunnel outline at the working position is scanned by the environmental scanning mechanism 4, and the data of the tunnel outline model is transmitted to the vehicle computer 5 for analysis. The size of the excavation surface in the tunnel outline and the over-excavation and under-excavation positions in the excavation surface are analyzed to provide a basis for subsequent concrete spraying.

[0052] After obtaining the dimensions of the excavation face at the tunnel construction location, the required concrete volume and average thickness for shotcrete support can be calculated based on these dimensions. However, before calculating the concrete volume and average thickness, over-excavation and under-excavation areas exceeding the preset dimensions need to be removed. Firstly, over-excavation areas exceeding the preset dimensions cannot achieve the desired support effect with shotcrete support. Under-excavation areas exceeding the preset dimensions have exceeded the concrete support forming outline, making it impossible to spray concrete support onto under-excavation areas. Secondly, this will also affect the calculated average thickness, resulting in an average thickness that is too large or too small, affecting the normal spraying of subsequent concrete support. Therefore, removing over-excavation and under-excavation areas exceeding the preset dimensions allows for a more accurate calculation of the required concrete volume and average thickness for shotcrete support at the excavation face.

[0053] Meanwhile, before calculating the average thickness, the excavation face is divided into multiple scanning point areas. The required concrete volume and average thickness are calculated separately for each scanning point area. This allows for a more suitable average thickness based on the dimensions of different areas, thus making the average thickness data more accurate.

[0054] If the concrete volume and average thickness are calculated using the entire excavation face, and concrete of the average thickness is sprayed onto the excavation face, the outline of the concrete support will be consistent with the outline of the excavation face before the concrete is sprayed. However, if the excavation face is divided into multiple scanning point areas, and the required concrete volume and average thickness are calculated for each area, and concrete is sprayed onto the excavation face according to the average thickness of each scanning point area, the outline of the final concrete support can be closer to the formed outline, making the outline of the concrete support smoother.

[0055] After calculating the average thickness, the thickness of the leveling layer is subtracted from the average thickness to obtain the thickness of the base layer. The leveling layer is used to smooth the outline of the base layer and make the final concrete support surface flat. Generally, the thickness of the leveling layer is 20-50mm.

[0056] S3, start the pumping mechanism 2 and boom mechanism 3 to spray the bottom layer in each scanned cloud point area. When spraying, first spray the arch foot of the tunnel excavation face to the waist. After the concrete from the arch foot to the waist has solidified, spray the waist to the top. The spraying thickness is the bottom layer thickness calculated in step S2.

[0057] After calculating the average thickness of the base layer, concrete spraying can begin. The crane computer 5 controls the boom mechanism 3 to start, and the boom mechanism 3 moves the nozzle 6 to the spraying position and makes the nozzle 6 face the working surface to be sprayed concrete. Then, the crane computer 5 controls the pumping mechanism 2 to start, and the pumping mechanism 2 delivers concrete to the nozzle 6 through the delivery pipeline. Then, the concrete is atomized by the nozzle 6 and sprayed onto the excavation surface, thus realizing the spraying of the base layer on the excavation surface.

[0058] like Figure 13 As shown, the excavation face inside the tunnel is generally arched. Therefore, when spraying the base layer on the excavation face, the spraying starts from the arch foot on the first side of the excavation face and continues upward until it reaches the waist of the excavation face. Then, the spraying starts from the arch foot on the second side of the excavation face and continues upward until it reaches the waist of the arch. At this point, the concrete from the arch foot to the waist of the excavation face has solidified. Then, the spraying starts from the waist of the arch on the first side of the excavation face and continues upward until it reaches the top of the arch. Subsequently, the spraying starts from the waist of the arch on the second side of the excavation face and continues upward until it reaches the top of the arch. When spraying the base layer from the waist to the top of the arch, the solidified base layer from the arch foot to the waist of the arch can serve as a support to ensure that the concrete can be properly formed when spraying it from the waist to the top of the arch.

[0059] S4. After the base layer has solidified, the nozzle 6 is moved to the over-excavation point by the boom mechanism 3 to spray and fill the over-excavation point and fill the pits on the surface of the base layer.

[0060] After the base layer spraying is completed and solidified, the surface of the base layer will also be uneven due to the unevenness of the excavation surface. At the same time, the base layer will increase the size of the depressions, which are the over-excavation positions on the excavation surface. Since the data of the over-excavation and under-excavation positions on the excavation surface are all stored in the gantry computer 5, the gantry computer 5 can control the boom mechanism 3 to move the nozzle 6 to the over-excavation position on the excavation surface, which is the current depression position on the base layer surface, to fill the depression position on the base layer surface, so as to eliminate the depression on the base layer surface and make the base layer surface basically flat, so as to ensure the flatness of the final formed concrete support surface.

[0061] S5, the environmental scanning mechanism 4 scans and models the surface of the substrate, and transmits the modeled data to the vehicle computer 5 for analysis to obtain the contour data of the substrate surface.

[0062] After the depressions on the base layer surface are filled, the base layer surface is scanned again by the environmental scanning mechanism 4 to obtain the contour data of the base layer surface, which provides a basis for the subsequent spraying and leveling layer.

[0063] S6, by planning the swing speed of the boom mechanism 3 and the spraying speed of the pumping mechanism 2 when spraying the leveling layer using the surface contour data of the base layer, the leveling layer is then sprayed on the surface of the base layer to obtain concrete support.

[0064] After obtaining the surface contour data of the base layer, the surface contour data of the base layer is imported into the vehicle computer 5. The spraying software analyzes the flatness error of the base layer surface and calculates the error information into the leveling layer spraying process. The error information is used to plan the swing speed of the boom mechanism 3 and the spraying speed of the pumping mechanism 2 during the leveling layer spraying to ensure the flatness of the final leveling layer surface.

[0065] After obtaining the surface contour data of the base layer, when the boom mechanism 3 drives the nozzle 6 to move to the recessed position of the base layer surface, the speed of the pumping mechanism 2 can be increased to increase the spray flow of the nozzle 6, or the boom mechanism 3 can control the nozzle 6 to stay in the recessed position, thereby increasing the volume of concrete sprayed in the recessed position. Conversely, when the boom mechanism 3 drives the nozzle 6 to move to the protruding position of the base layer surface, the speed of the pumping mechanism 2 can be reduced to reduce or stop the spray flow of the nozzle 6, or the boom mechanism 3 can control the nozzle 6 to quickly pass through the protruding position, thereby reducing the volume of concrete sprayed in the protruding position. Ultimately, the effect of smoothing the base layer surface is achieved, forming a smooth concrete support on the tunnel excavation face.

[0066] This method utilizes a wet concrete spraying machine for automatic spraying of concrete support within tunnels. The traveling computer 5 controls the movement of the traveling chassis 1, enabling automatic movement of the wet concrete spraying machine. The traveling computer 5 also controls the boom mechanism 3 and the pumping mechanism 2 to achieve automatic spraying of concrete support. Simultaneously, the environmental scanning mechanism 4 scans the tunnel contour and controls the average thickness of the sprayed base layer based on the tunnel contour. It also controls the real-time pumping speed of the pumping mechanism 2 and the position of the boom mechanism 3 during the spraying of the base layer, leveling layer, and filling of grooves, thus achieving automatic spraying of concrete support within the tunnel. This eliminates the need for personnel to enter the construction site for operation and monitoring, providing a good working environment for workers. In some extreme working environments, it can effectively reduce safety hazards for workers.

[0067] Meanwhile, detailed tunnel contour data can be obtained through the scanning of the environmental scanning mechanism 4, from which the excavation face, over-excavation and under-excavation dimensions can be accurately obtained. Based on this data, the parameters of the boom mechanism 3 and the pumping mechanism 2 can be adjusted to precisely control the spraying of concrete support and increase the quality of the final concrete support.

[0068] Preferably, in step S3, when spraying the base layer on the tunnel excavation face, the spraying process adopts an N-shaped brushing motion. Since the tunnel excavation face is uneven and most of it has arches, the N-shaped spraying process can not only fill the back of the arch I-beams, but also make it easier to control the spraying profile.

[0069] Preferably, in step S6, when spraying and leveling the base layer surface, the spraying process is a figure-eight brushing motion from the arch foot to the arch top. Since the previous arch frame filling and depression filling have been completed, the base layer surface is basically flat. Using the figure-eight brushing motion will increase the scattering area of ​​the spraying ring, making the spraying amount better controlled and the sprayed surface flatter.

[0070] Pumping systems are a conventional technique in this field, and this application does not impose any restrictions on them.

[0071] Specifically, during step S1, when the vehicle chassis 1 is moving, the environmental scanning mechanism 4 scans the road surface inside the tunnel in real time and feeds back the scan data to the vehicle computer 5 in real time. After processing by the cruise software, real-time route planning is performed.

[0072] The environmental scanning mechanism 4 can not only scan the tunnel outline after the wet concrete spraying machine arrives at the construction position, but also scan the road surface conditions inside the tunnel in real time during the process of the wet concrete spraying machine moving from the initial position to the construction position. The environmental scanning mechanism 4 also feeds back the scanned road surface conditions to the vehicle computer 5 in real time. After processing by the cruise software in the vehicle computer 5, the driving route is planned in real time, so that the wet concrete spraying machine can avoid obstacles in the tunnel and move smoothly from the initial position to the construction position.

[0073] Specifically, in step S2, the preset dimensions are the over-excavation depth and under-excavation thickness specified in the tunnel construction requirements. When there are no over-excavation points or / and under-excavation points exceeding the preset dimensions, the over-excavation points with the maximum depth or / and under-excavation points with the maximum thickness are removed.

[0074] Before tunnel construction, requirements are set for the dimensions of the tunnel excavation face, as well as the dimensions of over-excavation and under-excavation. The tunnel excavation face has a theoretical outline; however, drill-and-blast excavation cannot guarantee excavation accuracy, inevitably leading to over-excavation and under-excavation. Areas that do not reach the theoretical outline will protrude beyond it; these are considered under-excavated. Conversely, areas that exceed the theoretical outline will be recessed below it; these are considered over-excavated. Since concrete support also has a theoretical outline, if an under-excavated area exceeds this theoretical outline, it is directly determined that shotcrete support cannot be applied to that under-excavated area. Of course, in actual construction, under-excavated areas are not... Since the theoretical outline of the concrete support is close to that of the tunnel, it is impossible to spray concrete on its surface. Therefore, a preset size needs to be set according to the actual thickness of the concrete support. When the height of the under-excavation position exceeds the preset size, it is directly removed from the tunnel excavation face. Similarly, when the over-excavation depth is too large, it is impossible to achieve support by spraying concrete. Therefore, a preset size needs to be set according to the size of the tunnel excavation face. When the depth of the over-excavation position exceeds the preset size, it is directly removed from the tunnel excavation face and is not included in the calculation of the average thickness of the bottom layer or the subsequent spraying of the bottom layer and the leveling layer. The removed over-excavation position and under-excavation position are processed separately after the concrete support is sprayed.

[0075] In actual construction, the dimensions of over-excavation and under-excavation locations on the excavation face generally do not exceed the preset dimensions. In this case, the over-excavation location with the largest depth is selected from multiple over-excavation locations, and the under-excavation location with the largest height is selected from several under-excavation locations. After removing the largest over-excavation location and the largest under-excavation location, the concrete volume and average thickness required for shotcrete support are calculated to eliminate the interference of extreme values ​​and better reflect the central trend of most data.

[0076] Specifically, in step S2, the tunnel contour is divided into multiple scanning point regions according to the spray range of the nozzle 6;

[0077] When the excavation face is divided into multiple scanning point areas, the length of the scanning point area in the tunnel length direction is controlled according to the spraying range of nozzle 6. During the spraying process by the concrete wet spraying machine, the concrete sprayed by nozzle 6 can just cover the scanning point area in the tunnel length direction, and the entire scanning point area is covered by the brushing of nozzle 6. The full spraying of concrete in the scanning point area can be completed by the brushing of nozzle 6, which makes the movement path of the swing arm in the base layer spraying process simpler, and at the same time makes the final base layer smoother.

[0078] Specifically, such as Figure 4 As shown, the environmental scanning mechanism 4 includes a laser scanner 41, a mounting platform 42, and a rotating platform 43. The rotating platform 43 is mounted on one end of the length direction of the vehicle chassis 1 via the mounting platform 42. The laser scanner 41 is mounted on the rotating platform 43 so that the laser scanner 41 has rotational degrees of freedom in the X, Y, and N axis directions.

[0079] During operation, the laser scanner 41 is rotated by the rotary table 43, which can scan the tunnel from all directions to obtain the excavation surface and road surface outline. The rotary table 43 is installed at one end of the length direction of the vehicle chassis 1 through the mounting platform 42, which reduces the side obstruction range of the measuring beam of the laser scanner 41, so that the laser scanner 41 can obtain a good measuring angle when measuring the road surface.

[0080] Specifically, such as Figure 5 As shown, the mounting platform 42 includes a base 421, a push rod motor 422, and a protective cover 423. The base 421 is fixed on the vehicle chassis 1 for mounting the laser scanner 41. The protective cover 423 is hinged to one end of the base 421 and has a first state that covers the laser scanner 41 on the base 421 and a second state that exposes the laser scanner 41 on the base 421. The push rod motor 422 is hinged to the base 421 and the protective cover 423 at both ends, so that the protective cover 423 can be switched between the first state and the second state by the action of the push rod motor 422.

[0081] In the first state, the open end of the protective cover 423 is tightly attached to the top surface of the base 421. The protective cover 423 can cover the laser scanner 41, which is also installed on the top surface of the base 421, inside it. The protective cover 423 can prevent the laser scanner 41 from being rained on or subjected to external impact, ensuring the safety of the laser scanner 41. When it is necessary to scan the tunnel contour through the laser scanner 41, the output shaft of the push rod motor 422 can extend to push the protective cover 423 away from the top surface of the base 421, so that the protective cover 423 switches from the first state to the second state, exposing the laser scanner 41 installed on the top surface of the base 421. When switching from the second state to the first state, the output shaft of the push rod motor 422 only needs to retract to drive the protective cover 423 to flip. The first state of the protective cover 423 protects the laser scanner 41. When the laser scanner 41 is not used, it can prevent the laser scanner 41 from being rained on or subjected to external impact, ensuring the safety of the laser scanner 41.

[0082] Specifically, such as Figure 2 and Figure 6 As shown, the vehicle chassis 1 includes a chassis assembly 11, wheels 12 and wheel-side motors 13. The chassis assembly 11 has at least two connecting bridges at its bottom. Both ends of the connecting bridges are provided with wheels 12 and wheel-side motors 13. The wheel-side motors 13 at both ends of the connecting bridges are used to drive the wheels 12 at both ends of the connecting bridges.

[0083] like Figure 2-7 As shown, in this example, the chassis assembly 11 has two connecting bridges at the bottom. Both ends of the two connecting bridges are equipped with wheels 12 and wheel-side motors 13. The wheel-side motors 13 are used to drive the wheels 12 to rotate, so as to realize the movement of the vehicle chassis 1. Each wheel 12 is driven by a wheel-side motor 13, and the power of each wheel 12 can be controlled separately. When the concrete wet spraying machine is traveling in the tunnel, the road surface environment in the tunnel is scanned by the laser scanner 41. After the road surface environment is imported into the vehicle computer 5, the power of each wheel 12 is controlled separately by the cruise software, which improves the passability of the vehicle chassis 1 in complex road environment and ensures that the concrete wet spraying machine can reach the construction position smoothly.

[0084] like Figure 6-7 As shown, in this example, the chassis assembly 11 has a wheel-side steering fixed axle and a wheel-side steering floating axle at its bottom;

[0085] like Figure 6As shown, the wheel-side steering fixed axle includes a reduction brake box 141, a steering cylinder 142, an axle body 143, and a motor mount 144. The wheel 12 is fixedly mounted on the reduction brake box 141. The reduction brake box 141 and the wheel-side motor 13 are both fixed on the motor mount 144. The wheel-side motor 13 is connected to the reduction brake box 141 through a coupling, which is used to output torque to the reduction brake box 141 to drive the wheel 12 to rotate. The steering cylinder 142 has piston rods at both ends. The two piston rods are respectively hinged to the motor mounts 144 at both ends of the axle body 143 through pins. The two motor mounts 144 are also hinged to both ends of the axle body 143 through pins. By contracting the piston rods at both ends of the steering cylinder 142, the motor mounts 144 at both ends of the axle body 143 are rotated to adjust the angle of the wheel 12 and achieve the steering effect of the concrete wet spraying machine.

[0086] like Figure 7 As shown, the wheel-side steering floating axle includes a reduction brake box 141, a motor base 144, a steering cylinder 142, a hinged rocker arm 145, a limiting frame 146, and an axle body 143. Unlike the steering fixed axle, the wheel-side floating axle is provided with a hinged rocker arm 145 and a limiting frame 146 between it and the chassis assembly 11. The hinged rocker arm 145 is connected to the axle body 143 through a pin in the middle, which is used for the floating of the wheel-side steering floating axle to adapt to the floating of the vehicle in complex road conditions. The limiting frame 146 is fixed to the chassis assembly 11 by welding, which is used to limit the floating angle of the wheel-side steering floating axle, so that the concrete wet spraying machine can adapt to complex and changing environments and increase the passability of the vehicle chassis 1.

[0087] Specifically, the boom mechanism 3 is a conventional technical means in this field, and this application does not impose any restrictions on it.

[0088] Figure 8 An example of a boom mechanism 3 is shown, in which boom mechanism 3 includes boom traveling mechanism 31, boom turntable 32, one boom 33, two booms 34, three booms 35 and four booms 36;

[0089] The boom traveling mechanism 31 is fixed on the chassis assembly 11, so that the boom turntable 32, the first boom 33, the second boom 34, the third boom 35 and the fourth boom 36 can travel as a whole along the length of the chassis assembly 11.

[0090] The boom slewing table 32 is mounted on the boom traveling mechanism 31, giving the first boom 33, second boom 34, third boom 35 and fourth boom 36 rotational degrees of freedom in the X and Y directions.

[0091] One arm 33 is connected to the boom slewing table 32 via a pin and a hydraulic cylinder to achieve pitch adjustment;

[0092] The second arm 34 is nested within the first arm 33 via a pin and a hydraulic cylinder, and can extend and retract along the length of the first arm 33.

[0093] The third arm 35 is connected to the end of the second arm 34 away from the first arm 33 by a pin and a hydraulic cylinder, and is used for folding the boom assembly. The mechanism is similar to a scissor frame structure (not shown in the figure), which is a conventional technical means in this field.

[0094] One end of the four-arm 36 is nested in the end of the three-arm 35 away from the second arm 34 by a hydraulic cylinder and a pin, and can extend and retract along the length of the three-arm 35. The other end is connected to the nozzle 6 by a bolt.

[0095] like Figure 8 As shown, the position of the nozzle 6 can be adjusted by the cooperation of one arm 33, two arms 34, three arms 35 and four arms 36. At the same time, the adjustment is very flexible and the position of the nozzle 6 can be precisely controlled.

[0096] Specifically, the nozzle 6 is a conventional technical means in this field, and this application does not impose any restrictions on it;

[0097] Figure 9 An example of a nozzle 6 is shown, in which nozzle 6 includes a nozzle 61, a mixer 62, a connector 63 and a hydraulic motor 64;

[0098] Nozzle 61, mixer 62 and connector 63 are connected in sequence. Connector 63 is used to connect to pumping system through delivery pipeline. Mixer 62 has an addition hole on its side wall for concrete admixture to enter and mixes concrete admixture with concrete through mixer 62. Nozzle 61 is used to atomize concrete and spray it out.

[0099] When spraying concrete onto the excavation face inside the tunnel, concrete admixtures, such as quick-setting agents, can be added to the concrete through the addition holes opened on the side wall of the mixer 62. This can accelerate the setting speed of the concrete after it is sprayed onto the excavation face and help the concrete support to take shape.

[0100] The connector 63 is mounted on the four arms 36 via a hydraulic motor 64. The hydraulic motor 64 is used to drive the connector 63 to rotate, thereby driving the nozzle 61 to rotate.

[0101] When spraying concrete into the tunnel excavation face through nozzle 61, the nozzle 61 is driven to swing back and forth by hydraulic motor 64, thereby achieving the brushing motion of nozzle 61.

[0102] like Figure 2-3 As shown, in some examples, a camera 7 is fixedly installed on the chassis assembly 11. The camera 7, the boom mechanism 3, and the environmental scanning mechanism 4 are arranged sequentially along the length of the chassis assembly 11 so as to observe the working status of the boom mechanism 3 and the environmental scanning mechanism 4 through the camera 7.

[0103] When the wet concrete spraying machine is working, the staff can remotely observe the working status of the wet concrete spraying machine through camera 7, so that the wet concrete spraying machine can be shut down in time if a malfunction occurs, ensuring the safe operation of the wet concrete spraying machine.

[0104] like Figure 1-3 As shown, a cab 8 is also provided on the chassis 1. When the wet concrete spraying machine needs to be moved when it is not working, it can be moved by manual driving, providing multiple driving modes for the wet concrete spraying machine.

[0105] Furthermore, the cab 8 is installed at the end of the vehicle chassis 1 away from the environmental scanning mechanism 4, so as not to obstruct the laser scanner 41. At the same time, the camera 7 is fixed at the top of the cab 8 on the side facing the boom mechanism 3, so that the camera 7 can obtain a good field of view and facilitate the observation of the working status of the boom mechanism 3 and the environmental scanning mechanism 4.

[0106] like Figure 10 As shown, the chassis assembly 11 is equipped with a power supply system for providing electrical power to the entire concrete wet spraying machine. The power supply system includes a power battery 91 and cables.

[0107] The power battery 91 can provide the necessary electrical energy for the operation of the concrete wet spraying machine, and a charging port 92 is provided on the chassis 1. The power battery 91 can be recharged by connecting an external charging gun. At the same time, the power battery 91 is mounted on the chassis 1 through a quick-release frame 93. The quick-release frame 93 can be used to quickly remove and replace the power battery 91, and can quickly recharge when the power battery 91 is low on power.

[0108] Meanwhile, when the power battery 91 is low on power and there is no spare power battery 91 to replace it, the concrete wet spraying machine can be directly powered by an external power source connected via cable. Figure 10 As shown, the overhead crane chassis 1 is equipped with a reel 94 for winding up cables. When the cables are not in use, they can be wound up onto the reel 94 to prevent damage to the cables or to prevent them from affecting the movement of the concrete wet spraying machine.

[0109] This example provides the concrete wet spraying machine with the power required for operation through two power supply methods: cable and power battery 91. Different power supply methods can be selected according to different working environments. At the same time, when using power battery 91 to power the concrete wet spraying machine, there are multiple energy replenishment methods, which can also be selected according to different environments, making the application range wider.

[0110] The above are merely preferred embodiments of the present invention and are not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automatic shotcrete method for tunnel and shaft concrete support, wherein the automatic shotcrete support is applied using a wet shotcrete machine, characterized in that: The concrete wet spraying machine includes a traveling chassis (1), a pumping mechanism (2), a boom mechanism (3), an environmental scanning mechanism (4), and a traveling computer (5). The pumping mechanism (2), boom mechanism (3), environmental scanning mechanism (4) and vehicle computer (5) are all mounted on the vehicle chassis (1); The automatic shotcrete method for tunnel shaft concrete support includes the following steps: S1, obtain the coordinates of the tunnel construction location and input them into the vehicle computer (5), and the vehicle computer (5) controls the vehicle chassis (1) to move to the tunnel construction location; S2, use the environmental scanning mechanism (4) to scan and model the tunnel outline, and calculate the thickness of the concrete base layer based on the concrete support forming outline and the tunnel outline model; S3, start the pumping mechanism (2) and boom mechanism (3) to spray the bottom layer of each scanning cloud point area. When spraying, first spray the arch foot of the tunnel excavation face to the waist, and after the concrete at the arch foot to the waist has solidified, spray the waist to the top. S4. After the base layer has solidified, the nozzle (6) is moved to the over-excavation point by the boom mechanism (3) to spray and fill the over-excavation point and fill the pits on the surface of the base layer. S5, the surface of the base layer is scanned and modeled by the environmental scanning mechanism (4), and the modeled data is transmitted to the vehicle computer (5) for analysis to obtain the contour data of the base layer surface; S6, by planning the swing speed of the boom mechanism (3) and the spraying speed of the pumping mechanism (2) when the leveling layer is sprayed using the surface contour data of the base layer, the leveling layer is then sprayed on the base layer surface to obtain concrete support. In step S2, the modeled data is transmitted to the vehicle computer (5) to analyze the size of the excavation face and the locations of over-excavation and under-excavation. After removing over-excavation points and under-excavation points that exceed the preset size, the excavation face is divided into multiple scanning point areas. The concrete support forming contour is compared with the excavation face to calculate the required concrete volume and average thickness of each scanning point area. The average concrete thickness is subtracted from the leveling layer thickness to obtain the bottom layer thickness.

2. The automatic shotcrete method for tunnel shaft support according to claim 1, characterized in that: In step S1, the coordinates of the tunnel construction location are obtained through the survey report of the tunnel construction location. The coordinates of the starting position of the concrete wet spraying machine and the coordinates of the tunnel construction location are input into the vehicle computer (5). The cruise software in the vehicle computer (5) controls the movement of the vehicle chassis (1) so that the concrete wet spraying machine moves to the tunnel construction location.

3. The automatic shotcrete method for tunnel shaft support according to claim 2, characterized in that: During the movement of the vehicle chassis (1) in step S1, the environmental scanning mechanism (4) scans the road surface inside the tunnel in real time and feeds back the scan data to the vehicle computer (5) in real time. After processing by the cruise software, the vehicle plans the route in real time.

4. The automatic shotcrete method for tunnel shaft support according to claim 2, characterized in that: In step S2, the preset dimensions are the over-excavation depth and under-excavation thickness specified in the tunnel construction requirements. When there are no over-excavation points or / and under-excavation points exceeding the preset dimensions, the over-excavation points with the maximum depth or / and under-excavation points with the maximum thickness are removed.

5. The automatic shotcrete method for tunnel shaft support according to claim 3, characterized in that: In step S2, the tunnel profile is divided into multiple scanning point regions according to the spray range of the nozzle (6).

6. The automatic shotcrete method for tunnel shaft support according to claim 1, characterized in that: The environmental scanning mechanism (4) includes a laser scanner (41), a mounting platform (42) and a rotating platform (43). The rotating platform (43) is mounted on one end of the length direction of the vehicle chassis (1) via the mounting platform (42). The laser scanner (41) is mounted on the rotating platform (43) so that the laser scanner (41) has rotational degrees of freedom in the X, Y and N axis directions.

7. The automatic shotcrete method for tunnel shaft support according to claim 6, characterized in that: The mounting platform (42) includes a base (421), a push rod motor (422), and a protective cover (423). The base (421) is fixed on the vehicle chassis (1) for mounting the laser scanner (41). The protective cover (423) is hinged to one end of the base (421) and has a first state that covers the laser scanner (41) on the base (421) and a second state that exposes the laser scanner (41) on the base (421). The push rod motor (422) is hinged to the base (421) and the protective cover (423) at both ends, so that the protective cover (423) can be switched between the first state and the second state by the action of the push rod motor (422).

8. The automatic shotcrete method for tunnel shaft support according to claim 1, characterized in that: The vehicle chassis (1) includes a chassis assembly (11), wheels (12) and wheel-side motors (13). The chassis assembly (11) has at least two connecting bridges at its bottom. Both ends of the connecting bridge are provided with wheels (12) and wheel-side motors (13). The wheel-side motors (13) at both ends of the connecting bridge are used to drive the wheels (12) at both ends of the connecting bridge.

9. The automatic shotcrete method for tunnel shaft support according to claim 1, characterized in that: The boom mechanism (3) includes a boom traveling mechanism (31), a boom turntable (32), a first boom (33), a second boom (34), a third boom (35), and a fourth boom (36). The boom traveling mechanism (31) is fixed on the chassis assembly (11), so that the boom turntable (32), the first boom (33), the second boom (34), the third boom (35) and the fourth boom (36) can travel as a whole along the length of the chassis assembly (11); The boom turntable (32) is mounted on the boom traveling mechanism (31), so that the first boom (33), second boom (34), third boom (35) and fourth boom (36) have rotational degrees of freedom in the X and Y directions; The arm (33) is connected to the boom turntable (32) by a pin and a hydraulic cylinder to achieve pitch adjustment; The two arms (34) are nested inside one arm (33) by a pin and a hydraulic cylinder, and can extend and retract along the length of one arm (33); The three arms (35) are connected to the end of the two arms (34) away from the first arm (33) by pins and cylinders, and are used for folding the boom assembly; One end of the four arms (36) is nested in the end of the three arms (35) away from the two arms (34) by a hydraulic cylinder and a pin, and can extend and retract along the length of the three arms (35). The other end is connected to the nozzle (6) by a bolt.

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