Concrete spraying device for tunnel repair

Abstract

The invention relates to the field of tunnel repair, and particularly discloses a concrete spraying device for tunnel repair, which comprises an operation vehicle, a material storage system, a stirring system, a spraying system and a waste recovery system, and the material storage system, the stirring system, the spraying system and the waste recovery system are fixedly mounted on the operation vehicle; the storage system comprises a concrete storage tank and a water reducing agent storage tank which are respectively used for independently storing a concrete mixture and a water reducing agent; through the integrated design, material storage, stirring, spraying and recycling systems are integrated on the operation vehicle, and high automation of the construction process is achieved; the automatic metering stirring machine ensures that the concrete proportion is accurate, the hydraulic drive type booster pump provides stable injection pressure, the concrete injection uniformity is greatly improved in cooperation with flexible movement of the six-degree-of-freedom injection mechanical arm, and the construction quality and efficiency are greatly improved.

Description

Technical Field

[0001] The invention belongs to the field of tunnel repair, in particular to a concrete spraying device for tunnel repair. Background Art

[0002] Shotcrete technology is a key construction method in tunnel repair and support projects. It uses high-pressure spraying to quickly form a structural layer by spraying a concrete mixture onto the surface to be repaired. Traditional spraying processes primarily include dry and wet spraying. Wet spraying, with its advantages of low dust production and rebound, has become the mainstream technology for tunnel repair. In wet spraying, the concrete mixture is mixed with admixtures (such as water reducers) and then pumped through a delivery pipe to a nozzle. Finally, compressed air is used to spray the mixture onto the work surface.

[0003] However, the existing concrete spraying equipment lacks an efficient waste recycling mechanism, and the rebound material scattered on the site not only causes material waste, but also affects the construction environment. Summary of the Invention

[0004] In order to solve the above technical problems, the present invention provides a concrete spraying device for tunnel repair, so as to solve the problem of insufficient waste material recovery efficiency of the concrete spraying device in the prior art.

[0005] A concrete spraying device for tunnel repair includes a work vehicle, a material storage system, a mixing system, a spraying system, and a waste material recovery system, wherein the material storage system, the mixing system, the spraying system, and the waste material recovery system are all fixedly installed on the work vehicle;

[0006] The material storage system includes a concrete storage tank and a water reducing agent storage tank, which are used to independently store concrete mixture and water reducing agent respectively. The concrete storage tank and the water reducing agent storage tank are connected by a delivery pump, a pipeline and a mixing system;

[0007] The mixing system includes an automatic metering mixer for fully mixing the concrete mixture and the water reducing agent according to a preset ratio;

[0008] The injection system includes a hydraulically driven booster pump and a multi-directionally adjustable injection mechanical arm. The booster pump is connected to the stirring system. The booster pump and the injection mechanical arm are connected through a high-pressure delivery pipeline to provide stable and adjustable injection pressure.

[0009] The waste recycling system includes a recycling rack mechanism with a conveying function and a sealed waste storage tank. The working range of the recycling rack mechanism covers the spraying operation area and is used to automatically collect and convey rebounded waste to the waste storage tank.

[0010] Preferably, the work vehicle adopts a special engineering chassis and is equipped with a hydraulic outrigger stabilization system for precise positioning in the tunnel.

[0011] Preferably, the spraying robot arm adopts a six-degree-of-freedom robot arm structure, and is equipped with a rotating nozzle at the end, and the spraying angle can be adjusted 360°.

[0012] Preferably, the booster pump adopts a hydraulic system controlled by a proportional valve, and the injection pressure can be continuously adjusted within the range of 5-20 MPa.

[0013] Preferably, the recovery rack mechanism adopts a folding structure, and the maximum operating radius after unfolding is not less than 5 meters, and the surface of its conveyor belt is provided with an anti-stick coating.

[0014] Preferably, it also includes an intelligent control system, the system integrating:

[0015] Material level monitoring module, used to monitor the material remaining in the concrete storage tank and water reducing agent storage tank in real time;

[0016] Pressure feedback module, used to dynamically adjust the output pressure of the booster pump;

[0017] The robotic arm collaborative control module is used to coordinate the operating trajectory of the injection robotic arm and the recovery frame mechanism.

[0018] Preferably, the waste storage tank is equipped with a vibrating screening device to separate aggregates from slurry in the recycled waste.

[0019] Preferably, it further comprises a support plate mounted on the work vehicle;

[0020] The recovery rack mechanism includes a temporary storage box, a recovery rack and a cylinder. The temporary storage box is installed on the work vehicle. A collection plate is installed on the upper edge of the temporary storage box. The cylinder is fixedly installed on the edge of the support plate. The recovery rack and the output end of the cylinder are fixedly connected;

[0021] The recovery rack is slidably embedded in the upper side of the collecting plate.

[0022] Preferably, the recovery frame includes a support frame, a limiting slide groove is provided inside the support frame, a recovery inclined frame is fixed to one side of the support frame, a safety baffle is fixed to the end of the recovery inclined frame, and a fixing block is also fixed to the outside of the support frame;

[0023] The limiting chute is slidably embedded in the outer edges of both sides of the collecting plate, the recovery inclined frame is used to collect the fallen concrete and transfer it to the collecting plate, and the cylinder is fixedly connected to the fixed block;

[0024] The cylinder drives the fixed block to move the limiting slide, and the recovery inclined frame moves so that the concrete on the collecting plate is pushed and falls into the temporary storage box. The concrete falling into the temporary storage box is transferred to the waste storage tank by pumping.

[0025] A tunnel repair construction method comprises the following steps:

[0026] S1. Fill the concrete storage tank with ready-mixed concrete and the water-reducing agent storage tank with water-reducing agent;

[0027] S2: Drive the work vehicle to the tunnel repair area and deploy the hydraulic outriggers to stabilize the vehicle.

[0028] S3, unfold the spraying robot arm and the recovery frame mechanism, and start the self-test of the intelligent control system;

[0029] S4, automatically mixes the materials according to the proportion, pressurizes them through the booster pump, and then sprays them accurately through the spraying robot arm;

[0030] S5, waste recycling: The rebound material is collected in real time through the recycling rack mechanism and transported to the waste storage tank for processing through the conveying function;

[0031] S6. Retract the robotic arm, shut down the system, and move the work vehicle to the next workstation.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] The integrated design combines the storage, mixing, spraying, and recycling systems on the work vehicle, achieving a highly automated construction process. The automatic metering mixer ensures precise concrete mix proportions, while the hydraulically driven booster pump provides stable spraying pressure. Combined with the flexible movement of the six-degree-of-freedom spraying robot, this significantly improves concrete spraying uniformity, significantly enhancing construction quality and efficiency.

[0034] When the retractable recovery rack is deployed, its anti-stick coating conveying function can efficiently collect rebounded materials and automatically separate aggregate and slurry through a vibrating screening device. This not only improves material utilization, but also maintains a clean working environment, meeting the requirements of modern green construction projects.

[0035] The sliding cooperation between the cylinder-driven recovery rack and the collection plate, as well as the tilted design of the recovery inclined rack, can automatically collect the rebounded concrete waste and push it to the temporary storage box, greatly improving the waste recovery efficiency compared with the traditional manual method;

[0036] The integrated design of the support plate provides a stable installation platform for the injection and recovery systems, enabling coordinated operation of all components. Waste is automatically pumped into waste storage tanks, enabling fully automated processing of the "collection-temporary storage-transfer" process. This not only reduces manual intervention but also avoids environmental pollution caused by waste accumulation in traditional construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0038] Figure 2 It is a schematic diagram of the decomposition structure of the present invention;

[0039] Figure 3 This is a structural schematic diagram of a temporary storage box of the present invention;

[0040] Figure 4 This is a schematic structural diagram of the recovery rack of the present invention;

[0041] Figure 5 This is a schematic diagram of the recovery inclined frame structure of the present invention;

[0042] Figure 6 It is a cross-sectional view of the recovery rack mechanism of the present invention.

[0043] In the figure: 1. Work vehicle; 2. Water reducing agent storage tank; 3. Waste storage tank; 4. Mixing system; 5. Spraying robot arm; 6. Recovery rack mechanism; 61. Temporary storage box; 62. Recovery rack; 621. Support frame; 622. Limiting slide; 623. Recovery inclined frame; 624. Safety baffle; 625. Fixed block; 63. Cylinder; 64. Collection plate; 7. Concrete storage tank; 8. Booster pump; 9. Support plate. DETAILED DESCRIPTION

[0044] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0045] like Figure 1 As shown:

[0046] Embodiment 1: The present invention provides a concrete spraying device for tunnel repair, comprising a work vehicle 1, a material storage system, a mixing system 4, a spraying system, and a waste recovery system, wherein the material storage system, the mixing system 4, the spraying system, and the waste recovery system are all fixedly mounted on the work vehicle 1;

[0047] The material storage system includes a concrete storage tank 7 and a water reducing agent storage tank 2, which are used to independently store concrete mixture and water reducing agent respectively. The concrete storage tank 7 and the water reducing agent storage tank 2 are connected by a delivery pump, a pipeline and a mixing system 4;

[0048] The mixing system 4 includes an automatic metering mixer for fully mixing the concrete mixture and the water reducing agent according to a preset ratio;

[0049] The injection system includes a hydraulically driven booster pump 8 and a multi-directionally adjustable injection robot arm 5. The booster pump 8 is connected to the stirring system 4. The booster pump 8 and the injection robot arm 5 are connected through a high-pressure delivery pipeline to provide stable and adjustable injection pressure.

[0050] The waste recycling system includes a recycling rack mechanism 6 with a conveying function and a sealed waste storage tank 3. The working range of the recycling rack mechanism 6 covers the spraying operation area and is used to automatically collect and convey rebounded waste to the waste storage tank 3.

[0051] As can be seen from the above, when in use, first put the ready-mixed concrete into the concrete storage tank 7, and the water reducer into the water reducer storage tank 2;

[0052] After the work vehicle 1 arrives at the tunnel repair location, the automatic metering mixer starts working and fully mixes the two materials according to the preset ratio;

[0053] The mixed slurry is pressurized by a hydraulically driven booster pump 8 and transported to the multi-directionally adjustable spraying robot 5 through a high-pressure delivery pipeline. The stable pressure provided by the booster pump 8 ensures uniform concrete spraying and effectively reduces material rebound.

[0054] During the spraying operation, the spraying robot arm 5 can flexibly adjust the angle to achieve full coverage spraying of the tunnel wall;

[0055] At the same time, the recovery rack mechanism 6 with conveying function is synchronously deployed in the working area, and its working range completely covers the spraying area, and can capture and collect the rebounded waste in real time;

[0056] The collected waste is quickly transported to the sealed waste storage tank 3 for centralized processing through the conveying function. This process not only improves the material utilization rate, but also keeps the working environment clean.

[0057] Embodiment 2: This embodiment is basically the same as the previous embodiment, except that the work vehicle 1 adopts a special engineering chassis and is equipped with a hydraulic outrigger stabilization system for precise positioning in the tunnel.

[0058] Specifically, the spraying robot arm 5 adopts a six-degree-of-freedom robot arm structure, and is equipped with a rotating nozzle at the end, and the spraying angle can be adjusted 360 degrees.

[0059] Specifically, the boost pump 8 adopts a hydraulic system controlled by a proportional valve, and the injection pressure can be continuously adjusted within the range of 5-20 MPa.

[0060] Specifically, the recovery rack mechanism 6 adopts a folding structure, and the maximum operating radius after unfolding is not less than 5 meters. The surface of its conveyor belt is provided with an anti-stick coating.

[0061] Specifically, it also includes intelligent control systems and system integration:

[0062] Material level monitoring module, used to monitor the material remaining in the concrete storage tank 7 and the water reducing agent storage tank 2 in real time;

[0063] A pressure feedback module, used to dynamically adjust the output pressure of the booster pump 8;

[0064] The robotic arm collaborative control module is used to coordinate the operating trajectories of the spraying robotic arm 5 and the recovery frame mechanism 6.

[0065] Specifically, the waste storage tank 3 is equipped with a vibrating screening device to separate the aggregate and slurry in the recycled waste.

[0066] As can be seen from the above, when in use, the work vehicle 1 achieves precise positioning through the engineering-specific chassis and hydraulic outrigger stabilization system, ensuring stable operation in a narrow tunnel environment;

[0067] After the intelligent control system is started, the material level monitoring module monitors the material remaining in the concrete storage tank 7 and the water-reducing agent storage tank 2 in real time. At the same time, the pressure feedback module dynamically adjusts the booster pump 8 controlled by the proportional valve to make the injection pressure accurately controllable within the range of 5-20MPa, effectively ensuring the injection quality of concrete;

[0068] The spraying robot arm 5 with a six-degree-of-freedom structure and the 360-degree rotating nozzle at the end can flexibly adjust the spraying angle to achieve full coverage and repair without dead angles;

[0069] The retractable recovery rack mechanism 6 has an operating radius of 5 meters when unfolded, and its anti-stick coating can efficiently collect rebound materials to prevent them from sticking.

[0070] The vibrating screening device of the waste storage tank 3 automatically separates aggregate and slurry, thereby improving the waste recycling rate.

[0071] Example 3: This example is basically the same as the previous example, except that Figures 2 to 6 As shown:

[0072] It also includes a support plate 9 mounted on the work vehicle 1;

[0073] Among them, the support plate 9 can support the spraying robot arm 5, the concrete storage tank 7 and the booster pump 8;

[0074] The recovery rack mechanism 6 includes a temporary storage box 61, a recovery rack 62 and a cylinder 63. The temporary storage box 61 is installed on the work vehicle 1. A collecting plate 64 is installed on the upper edge of the temporary storage box 61. The cylinder 63 is fixedly installed on the edge of the support plate 9. The recovery rack 62 and the output end of the cylinder 63 are fixedly connected;

[0075] The recovery rack 62 is slidably engaged with the upper side of the collecting plate 64 .

[0076] Specifically, such as Figure 5 and Figure 6 As shown, the recovery frame 62 includes a support frame 621, a limited sliding groove 622 is provided inside the support frame 621, a recovery inclined frame 623 is fixed to one side of the support frame 621, a safety baffle 624 is fixed to the end of the recovery inclined frame 623, and a fixing block 625 is also fixed to the outside of the support frame 621;

[0077] The limiting chute 622 is slidably engaged with the outer edges of both sides of the collecting plate 64. The recovery inclined frame 623 is used to collect the fallen concrete and transfer it to the collecting plate 64. The cylinder 63 is fixedly connected to the fixing block 625.

[0078] The cylinder 63 drives the fixed block 625 to move the limiting slide 622, and the recovery inclined frame 623 moves so that the concrete on the collecting plate 64 is pushed and falls into the temporary storage box 61. The concrete falling into the temporary storage box 61 is transferred to the waste storage tank 3 by pumping.

[0079] As can be seen from the above, when the spraying robot arm 5 performs the concrete spraying operation, the rebounded concrete waste will naturally fall onto the recovery inclined frame 623. Its inclined design ensures that the waste can automatically slide to the collection plate 64; the safety baffle 624 can prevent rear-end collisions, and at the same time, the safety baffle 624 can be attached to the tunnel wall when it is against the tunnel wall to limit the position;

[0080] The cylinder 63 drives the entire recovery frame 62 to slide by driving the fixed block 625. During sliding, the limiting slide groove 622 slides and is embedded in the outer side of the collection plate 64, so that the recovery inclined frame 623 pushes the concrete waste on the collection plate 64 into the temporary storage box 61; this reciprocating motion process realizes the automatic collection and transfer of waste, which significantly improves the efficiency compared with traditional manual cleaning; the collected waste is then transported to the waste storage tank 3 by pumping for centralized processing. The entire process does not require human intervention, which not only improves construction safety but also ensures the timely recycling of waste.

[0081] Example 4: This example is basically the same as the previous example, except that it provides a tunnel repair construction method, comprising the following steps:

[0082] S1. Fill ready-mixed concrete into the concrete storage tank 7 and fill the water reducing agent into the water reducing agent storage tank 2;

[0083] S2: Drive work vehicle 1 to the tunnel repair area and deploy the hydraulic outriggers to stabilize the vehicle.

[0084] S3, unfold the spraying robot arm 5 and the recovery frame mechanism 6, and start the intelligent control system self-test;

[0085] S4, automatically mix the materials according to the proportion, pressurize them through the booster pump 8, and then accurately spray them through the spraying robot arm 5;

[0086] S5, waste recovery: The rebounded materials are collected in real time by the recovery rack mechanism 6 and transported to the waste storage tank 3 for processing through the conveying function;

[0087] S6. Retract the robotic arm, shut down the system, and transfer the work vehicle 1 to the next workstation.

[0088] The embodiments of the present invention are provided for the purpose of illustration and description. Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present invention. Any changes, modifications, replacements and variations of the above embodiments by ordinary technicians in this field within the scope of the present invention should be included in the scope of protection of the present invention.

Claims

1. A concrete spraying device for tunnel repair, characterized in that: It comprises an operating vehicle (1), a material storage system, a stirring system (4), an injection system, and a waste material recovery system, wherein the material storage system, the stirring system (4), the injection system, and the waste material recovery system are all fixedly installed on the operating vehicle (1); The material storage system comprises a concrete storage tank (7) and a water reducing agent storage tank (2), which are used to independently store concrete mixture and water reducing agent, respectively. The concrete storage tank (7) and the water reducing agent storage tank (2) are both connected via a delivery pump, a pipeline and a stirring system (4); The mixing system (4) includes an automatic metering mixer for fully mixing the concrete mixture and the water reducing agent according to a preset ratio; The injection system comprises a hydraulically driven booster pump (8) and a multi-directionally adjustable injection mechanical arm (5), wherein the booster pump (8) is connected to the stirring system (4), and the booster pump (8) is connected to the injection mechanical arm (5) via a high-pressure delivery pipeline, for providing a stable and adjustable injection pressure; The waste recycling system comprises a recycling rack mechanism (6) with a conveying function and a sealed waste storage tank (3). The working range of the recycling rack mechanism (6) covers the spraying operation area and is used for automatically collecting and conveying rebounded waste to the waste storage tank (3).

2. A concrete spraying device for tunnel repair according to claim 1, characterized in that: The work vehicle (1) adopts a special engineering chassis and is equipped with a hydraulic outrigger stabilization system for precise positioning in the tunnel.

3. A concrete spraying device for tunnel repair according to claim 1, characterized in that: The spraying mechanical arm (5) adopts a six-degree-of-freedom mechanical arm structure, and is equipped with a rotating nozzle at the end, and the spraying angle can be adjusted 360 degrees.

4. A concrete spraying device for tunnel repair according to claim 1, characterized in that: The booster pump (8) adopts a hydraulic system controlled by a proportional valve, and the injection pressure can be continuously adjusted within the range of 5-20 MPa.

5. The concrete spraying device for tunnel repair according to claim 1, characterized in that: The recovery rack mechanism (6) adopts a folding structure, and the maximum operating radius after unfolding is not less than 5 meters, and the surface of its conveyor belt is provided with an anti-stick coating.

6. A concrete spraying device for tunnel repair according to claim 1, characterized in that: It also includes an intelligent control system that integrates: A material level monitoring module for real-time monitoring of the material remaining in the concrete storage tank (7) and the water reducing agent storage tank (2); A pressure feedback module for dynamically adjusting the output pressure of the booster pump (8); The robot arm cooperative control module is used to coordinate the operation trajectory of the spray robot arm (5) and the recovery frame mechanism (6).

7. The concrete spraying device for tunnel repair according to claim 1, characterized in that: The waste storage tank (3) is equipped with a vibrating screening device, which can separate the aggregate and slurry in the recycled waste.

8. The concrete spraying device for tunnel repair according to claim 1, characterized in that: It also includes a support plate (9) mounted on the work vehicle (1); The recovery rack mechanism (6) comprises a temporary storage box (61), a recovery rack (62) and a cylinder (63); the temporary storage box (61) is mounted on the working vehicle (1); a collecting plate (64) is mounted on the upper edge of the temporary storage box (61); the cylinder (63) is fixedly mounted on the edge of the support plate (9); and the output ends of the recovery rack (62) and the cylinder (63) are fixedly connected; The recovery rack (62) is slidably engaged with the upper side of the collecting plate (64).

9. A concrete spraying device for tunnel repair according to claim 8, characterized in that: The recovery frame (62) includes a support frame (621), a limiting sliding groove (622) is provided inside the support frame (621), a recovery inclined frame (623) is fixed on one side of the support frame (621), a safety baffle (624) is fixed at the end of the recovery inclined frame (623), and a fixing block (625) is also fixed on the outside of the support frame (621); The limiting chute (622) is slidably engaged with the outer edges of both sides of the collecting plate (64); the recovery inclined frame (623) is used to collect the fallen concrete and transfer it to the collecting plate (64); the cylinder (63) and the fixed block (625) are fixedly connected; The cylinder (63) drives the fixed block (625) to move the limiting chute (622), and the recovery inclined frame (623) moves so that the concrete on the collecting plate (64) is pushed and falls into the temporary storage box (61). The concrete falling into the temporary storage box (61) is transferred to the waste storage tank (3) by pumping.

10. A tunnel repair construction method using the device according to any one of claims 1 to 7, characterized in that: The following steps are involved: S1, filling ready-mixed concrete into the concrete storage tank (7), and filling water reducing agent into the water reducing agent storage tank (2); S2, driving the work vehicle (1) to the tunnel repair area and deploying the hydraulic outriggers to stabilize the vehicle body; S3, unfolding the spraying mechanical arm (5) and the recovery frame mechanism (6), and starting the self-check of the intelligent control system; S4, automatically mix the materials according to the proportion, pressurize them through the booster pump (8), and then spray them accurately through the spraying robot arm (5); S5, waste recycling: The rebounded materials are collected in real time by the recycling rack mechanism (6) and transported to the waste storage tank (3) for processing through the conveying function; S6. The robotic arm is retracted, the system is shut down, and the work vehicle (1) is transferred to the next work station.

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