High-altitude bridge crack intelligent positioning and rapid repairing integrated device and method

Abstract

The invention discloses a high-altitude bridge crack intelligent positioning and rapid repairing integrated device and method, and belongs to the field of bridge maintaining.The high-altitude bridge crack intelligent positioning and rapid repairing integrated device comprises an intelligent positioning module, a surface treatment module, a grouting compaction module and a high-altitude operation module.The intelligent positioning module rapidly scans and positions a damaged part of a bridge and forms a three-dimensional crack shape to plan a repairing path; the surface treatment module is used for carrying out surface treatment on the damaged part of the bridge, the grouting compaction module is used for pouring slurry into the damaged part of the bridge and compacting the slurry, and the high-altitude operation module comprises a rotatable inertially-stabilized platform, a telescopic arm and a quick-change interface which are connected with one another; and the quick-change interface is detachably connected with the surface treatment module or the grouting compaction module. According to the embodiment of the invention, the effects of efficient cleaning and environmental protection can be achieved, the high-altitude area is efficiently covered, the preparation work time can be saved, the rotatable inertially stabilized platform is high in high-altitude adaptability and can adapt to a special-shaped structure, the manual adjustment frequency is reduced, and then the work efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge maintenance, and in particular to an integrated device and method for intelligently locating and quickly repairing cracks in high-altitude bridges. Background Art

[0002] High-altitude bridges are becoming increasingly important in road networks. Due to the long-term dynamic loads from vehicles and wind, as well as environmental erosion and temperature stress, these bridges are prone to cracks in high-altitude areas such as beams and pylons. The current mainstream approach to high-altitude crack repair relies on a "manual inspection combined with hanging basket work" model. Depending on the actual crack conditions, manual repair methods such as surface mortar sealing, drilling and grouting, and fiber cloth reinforcement are employed to effectively repair cracks in high-altitude bridges.

[0003] At present, the repair of cracks in high-altitude bridges faces challenges such as complex working environment, special structural form and prominent safety risks. The repair location of high-altitude bridges is usually located at an altitude of 30-100 meters above the ground, which is significantly affected by environmental factors such as strong winds and temperature differences. There is also a risk of workers falling from heights. The traditional manual repair mode has many blind spots in detection (missed detection rate > 30%), difficulty in material transportation, and low efficiency in process connection. At the same time, the construction of the aerial work platform deployed by traditional methods takes a long time, accounting for more than 60% of the entire repair cycle. In addition, the special structures of high-altitude bridges (such as cable-stayed bridges, suspension bridges, viaducts, etc.) make it difficult for traditional equipment to accurately locate and operate. These factors have led to low efficiency and difficulty in ensuring the quality of high-altitude bridge crack repair operations. There is an urgent need to develop new intelligent repair technologies to meet these challenges.

[0004] To solve the above problems, it is necessary to develop a high-altitude bridge crack repair device that integrates intelligent positioning, rapid repair, unmanned operation, and a high-altitude stable gimbal to achieve efficient, accurate, and safe repair operations. Summary of the Invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention provides an integrated device and method for intelligently locating and quickly repairing cracks in high-altitude bridges.

[0006] An integrated device for intelligently locating and rapidly repairing cracks in a high-altitude bridge according to an embodiment of the present invention includes:

[0007] Intelligent positioning module, including 3D laser scanning equipment and structured light scanning equipment, is used to quickly scan and locate bridge damage parts and generate 3D crack topography to plan repair paths;

[0008] The surface treatment module includes a high-pressure water jet assembly, a vacuum cleaner assembly, and an epoxy interface agent spraying assembly. The high-pressure water jet assembly is used to remove loose concrete from damaged parts of the bridge. The vacuum cleaner assembly is used to recover debris removed by the high-pressure water jet assembly. The epoxy interface agent spraying assembly is used to spray the epoxy interface agent.

[0009] The grouting and compaction module includes a dual-channel grouting pump assembly, a vibrating roller assembly, a proportioning and mixing assembly, a high-pressure grouting pipeline, and a grouting nozzle, and is used to inject grout and compact the damaged parts of the bridge;

[0010] The aerial work module includes a rotatable inertial stabilization platform, a telescopic arm and a quick-change interface connected in sequence. The rotatable inertial stabilization platform is used to drive the telescopic arm to rotate. The telescopic arm can be retracted and the quick-change interface can be detachably connected to the surface treatment module or the grouting and compaction module.

[0011] An integrated device for intelligently locating and quickly repairing cracks in high-altitude bridges according to an embodiment of the present invention has at least the following beneficial effects:

[0012] The intelligent positioning module can perform damage assessment on damaged parts of bridges, scan damaged parts of bridges and generate three-dimensional crack morphology to plan repair paths and improve repair efficiency.

[0013] The high-pressure water jet component in the surface treatment module can remove loose concrete, and the vacuum suction component can simultaneously recover debris, which can reduce dust emissions and achieve efficient cleaning and environmental protection effects. The epoxy interface agent enhances the adhesion between the new and old materials, prevents material peeling, and improves the durability of the subsequent grouting layer.

[0014] The grouting and compaction module can grout and compact the damaged parts of the bridge, with high repair efficiency.

[0015] The aerial work module efficiently covers high-altitude areas. The telescopic arm can be extended to the height of bridge piers or beams, eliminating the need for scaffolding or hanging baskets, saving preparation time. The rotatable inertial stabilization platform can adapt to special-shaped structures (such as the curved surface of arch bridges), reducing the need for manual adjustments and thus improving work efficiency. The quick-change interface supports rapid tool switching to meet the needs of different repair processes, providing high work adaptability.

[0016] According to some embodiments of the present invention, the high-pressure water jet assembly includes a high-pressure water pump, a high-pressure water nozzle and a swing unit. The high-pressure water pump is connected to the high-pressure water nozzle through a pipeline. The swing unit is connected to the high-pressure water nozzle. The swing unit is used to drive the high-pressure water nozzle to swing. The high-pressure water nozzle is a fan-shaped rotating nozzle.

[0017] According to some embodiments of the present invention, the vacuum cleaning assembly includes a negative pressure unit, a debris recovery unit, a dust collection pipeline and a suction nozzle connected in sequence, the negative pressure unit is used to generate negative pressure and transmit it to the suction nozzle through the dust collection pipeline, the debris recovery unit is used to filter debris and recover it, and the suction nozzle includes a connection to the outside of the high-pressure water nozzle, and the suction nozzle is coaxially arranged with the high-pressure water nozzle.

[0018] According to some embodiments of the present invention, the epoxy interface agent spraying assembly includes a flow controller for controlling the spraying flow, the surface treatment module also includes a surface treatment control assembly, the surface treatment control assembly includes a pressure sensor, a turbidity sensor, a control terminal and a touch screen, the pressure sensor is used to monitor the water flow pressure in the high-pressure water jet assembly, the turbidity sensor is used to monitor the impurity concentration of the recovered water in the debris recovery unit, the control terminal is electrically connected to the flow controller, the pressure sensor, the turbidity sensor and the touch screen, and the touch screen is used to display the high-pressure water flow pressure and the epoxy interface agent spraying flow.

[0019] According to some embodiments of the present invention, the dual-channel grouting pump assembly includes a screw pump channel, a plunger pump channel and a switching valve, the screw pump channel is used to convey epoxy grouting material, the plunger pump channel is used to convey ultra-early strength grouting material, the switching valve is used to switch the screw pump channel or the plunger pump channel to be connected with the grouting pipeline, the proportioning and mixing assembly includes a mixer, a proportioning control unit and a temperature control unit, the mixer is used to mix slurry, the proportioning control unit is used to control the proportion of slurry components, the temperature control unit is used to control the slurry temperature, and the dual-channel grouting pump assembly is used to convey the slurry mixed by the mixer to the grouting nozzle through the grouting pipeline.

[0020] According to some embodiments of the present invention, the vibrating roller assembly includes a roller body, a vibration generator, a vibration drive unit and a density feedback unit, the roller body, the vibration generator and the vibration drive unit are connected in sequence, the vibration drive unit is used to drive the vibration generator to vibrate, the vibration generator is used to drive the roller body to vibrate to compact the grouting layer, the density feedback unit includes a piezoelectric acceleration sensor and an infrared thermal imager, and the density feedback unit is used to feedback the density of the grouting layer.

[0021] According to some embodiments of the present invention, the telescopic arm includes a multi-stage nested hydraulic cylinder group, a telescopic drive unit and a telescopic control unit, the telescopic drive unit includes a servo motor and a hydraulic pump station, the telescopic control unit includes a displacement sensor and an inclination compensation device, the telescopic drive unit is used to achieve a high response speed, and the telescopic control unit is used to ensure the end positioning accuracy of the telescopic arm.

[0022] A method for intelligently locating and quickly repairing cracks in a high-altitude bridge according to an embodiment of the present invention includes the following steps:

[0023] S1: Preparation of grouting material and wire mesh material;

[0024] S2: The intelligent positioning module scans the damaged parts of the bridge and generates a 3D crack model to plan the repair path;

[0025] S3: The aerial work module is equipped with a surface treatment module to perform base surface treatment on damaged parts of the bridge;

[0026] S4: The aerial work module equipped with a robotic arm implants wire mesh into the cracks of the bridge and locks the nodes with anchors;

[0027] S5: The aerial operation module is equipped with a grouting and compacting module to pour grout and vibrate and compact it;

[0028] S6: Ultrasonic testing to detect the integrity of the grouting layer and spraying the curing film.

[0029] A method for intelligently locating and quickly repairing cracks in high-altitude bridges according to an embodiment of the present invention has at least the following beneficial effects:

[0030] The intelligent positioning module can perform damage assessment on damaged parts of bridges, scan damaged parts of bridges and generate three-dimensional crack models to plan repair paths and improve repair efficiency.

[0031] The high-pressure water jet component in the surface treatment module can remove loose concrete, and the vacuum suction component can simultaneously recover debris, which can reduce dust emissions and achieve efficient cleaning and environmental protection effects. The epoxy interface agent enhances the adhesion between the new and old materials, prevents material peeling, and improves the durability of the subsequent grouting layer.

[0032] The grouting and compaction module can grout and compact the damaged parts of the bridge, with high repair efficiency.

[0033] The aerial work module efficiently covers high-altitude areas. The telescopic arm can extend to the heights of bridge piers or beams, eliminating the need for scaffolding or hanging baskets, saving preparation time. The rotatable inertial stabilization platform is highly adaptable to high altitudes and can adapt to special-shaped structures (such as the curved surface of arch bridges), reducing the need for manual adjustments and improving work efficiency. The quick-change interface supports rapid tool switching to adapt to different repair process requirements, ensuring high work adaptability.

[0034] According to some embodiments of the present invention, in step S4, laser distance measurement is performed after the wire mesh is implanted to ensure that the gap between the wire mesh and the base surface is ≤1 mm.

[0035] According to some embodiments of the present invention, in step S5, the grouting and compacting module adopts a dual-channel grouting pump, and the dual-channel grouting pump has dual channels, and the dual channels respectively transport epoxy grouting material and ultra-early strength grouting material. The epoxy grouting material is used to fill deep cracks to the designed thickness, and the ultra-early strength grouting material is used to fill shallow cracks to the designed thickness.

[0036] Additional aspects and advantages of the present invention will be set forth in part in the description which follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will be further described below with reference to the accompanying drawings and embodiments, in which:

[0038] Figure 1 This is a structural block diagram of an integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to an embodiment of the present invention;

[0039] Figure 2 This is a structural diagram of a high-altitude operation module of an integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to an embodiment of the present invention;

[0040] Figure 3 This is a structural block diagram of a surface treatment module of an integrated device and method for intelligent positioning and rapid repair of cracks in high-altitude bridges according to an embodiment of the present invention;

[0041] Figure 4 This is a structural block diagram of a grouting and compaction module of an integrated device and method for intelligent positioning and rapid repair of cracks in high-altitude bridges according to an embodiment of the present invention;

[0042] Figure 5 This is a structural block diagram of the telescopic arm of the integrated device and method for intelligent positioning and rapid repair of cracks in high-altitude bridges according to an embodiment of the present invention;

[0043] Figure 6 This is a structural block diagram of the intelligent positioning module of the integrated device and method for intelligent positioning and rapid repair of high-altitude bridge cracks according to an embodiment of the present invention.

[0044] Figure Number:

[0045] 100. Intelligent positioning module; 110. Core perception component; 111. 3D laser scanning device; 112. Structured light scanning device; 120. Computing and control component; 130. Operation interface and data management component; 140. Execution control component;

[0046] 200, surface treatment module; 210, high-pressure water jet assembly; 211, high-pressure water pump; 212, high-pressure water nozzle; 213, swing unit; 220, vacuum cleaning assembly; 221, negative pressure unit; 222, debris recovery unit; 223, vacuum pipe; 224, suction nozzle; 230, epoxy interface agent spray assembly; 231, two-component mixing unit; 232, spray execution unit; 233, flow controller; 240, surface treatment control assembly; 241, pressure sensor; 242, turbidity sensor; 243, control terminal; 244, touch screen;

[0047] 300, grouting and compaction module; 310, dual-channel grouting pump assembly; 311, screw pump channel; 312, plunger pump channel; 313, switching valve; 320, vibrating roller assembly; 321, roller body; 322, vibration generator; 323, vibration drive unit; 324, density feedback unit; 330, proportioning and mixing assembly; 331, mixer; 332, proportioning control unit; 333, temperature control unit; 340, grouting pipeline; 350, grouting nozzle;

[0048] 400. Aerial work module; 410. Rotatable inertial stabilization platform; 420. Telescopic arm; 421. Multi-stage nested hydraulic cylinder group; 422. Telescopic drive unit; 423. Telescopic control unit; 430. Quick-change interface. DETAILED DESCRIPTION

[0049] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0050] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, features defined as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0051] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0052] See also Figure 1 、 Figure 2 and Figure 3 According to an embodiment of the present invention, an integrated device for intelligently locating and rapidly repairing cracks in high-altitude bridges comprises an intelligent positioning module 100, a surface treatment module 200, a grouting and compacting module 300, and an aerial work module 400. The intelligent positioning module 100 is used to scan the damaged portion of the bridge and generate a three-dimensional crack model to plan the repair path. The surface treatment module 200 comprises a high-pressure water jet assembly 210, a vacuum cleaner assembly 220, and an epoxy interface agent spraying assembly 230. The high-pressure water jet assembly 210 is used to remove loose concrete from the damaged portion of the bridge, the vacuum cleaner assembly 220 is used to recover debris removed by the high-pressure water jet assembly 210, and the epoxy interface agent spraying assembly 230 is used to spray the epoxy interface agent. The grouting and compacting module 300 comprises a dual-channel grouting pump assembly 310, a vibrating roller assembly 320, a proportioning and mixing assembly 330, a grouting pipeline 340, and a grouting nozzle 350. The grouting and compacting module 300 is used to inject grout into the damaged portion of the bridge and compact it. The aerial work module 400 includes a rotatable inertial stabilization platform 410, a telescopic arm 420 and a quick-change interface 430 connected in sequence. The rotatable inertial stabilization platform 410 is used to drive the telescopic arm 420 to rotate. The telescopic arm 420 can be retracted and the quick-change interface 430 can be detachably connected to the surface treatment module 200 or the grouting and compaction module 300.

[0053] The intelligent positioning module 100 can perform damage assessment on damaged parts of the bridge. The intelligent positioning module 100 includes a three-dimensional laser scanning device 111 and a structured light scanning device 112. The three-dimensional laser scanning device 111 quickly scans and locates damaged parts of the bridge, and the structured light scanning device 112 accurately scans and generates three-dimensional crack morphology to plan the repair path and improve repair efficiency.

[0054] The high-pressure water jet component 210 in the surface treatment module 200 can remove loose concrete, and the vacuum cleaner component 220 can simultaneously recycle debris, which can reduce dust emissions and achieve efficient cleaning and environmental protection effects. The epoxy interface agent enhances the adhesion between the new and old materials, prevents material peeling, and improves the durability of the subsequent grouting layer.

[0055] The grouting and compacting module 300 can grout and compact the damaged parts of the bridge, with high repair efficiency.

[0056] The aerial work module 400 efficiently covers high-altitude areas. The telescopic arm 420 can extend to the heights of bridge piers or beams, eliminating the need for scaffolding or hanging baskets, saving preparation time. The rotatable inertial stabilization platform 410 can adapt to special-shaped structures (such as the curved surface of an arch bridge), reducing the need for manual adjustments and improving work efficiency. The quick-change interface 430 supports rapid tool switching to adapt to different repair process requirements, providing high work adaptability.

[0057] In some embodiments, see Figure 1 and Figure 6 The intelligent positioning module 100 includes a core perception component 110, a computing and control component 120, an operation interface and data management component 130, and an execution control component 140, which are electrically connected in sequence. The core perception component 110 includes a three-dimensional laser scanning device 111 (three-dimensional laser scanner, three-dimensional white light scanner, etc.) and a structured light scanning device 112. The three-dimensional laser scanning device 111 quickly scans and locates the damaged parts of the bridge, and the structured light scanning device 112 accurately scans and generates three-dimensional crack morphology to plan the repair path and improve the repair efficiency. The computing and control component 120 is equipped with an AI algorithm. Dual laser radars scan symmetrically, and the AI ​​algorithm removes noise point clouds, identifies areas with crack depths greater than 5mm, marks them as repair target areas, and generates a three-dimensional crack model with a positioning error of ≤2mm. The AI ​​algorithm calculates the shortest path, and reinforcement learning is used to avoid obstacles in real time, avoid areas with dense steel bars, and optimize the grouting path.

[0058] The laser radar + AI vision fusion positioning error is ≤2mm, accurately covering the direction of the crack and improving the repair coverage rate. The Raspberry Pi + Coral accelerator achieves an end-to-end response delay of less than 200ms, supports emergency braking with a high safety guarantee rate, and the repair parameters (pressure, frequency) are uploaded to the cloud in real time. Machine learning dynamically optimizes the process, so that the material curing strength fluctuation is less than ±5%, thereby enabling data-driven optimization.

[0059] In some embodiments, see Figure 1 、 Figure 2 and Figure 3The high-pressure water jet assembly 210 includes a high-pressure water pump 211, a high-pressure water nozzle 212 and a swing unit 213. The high-pressure water pump 211 is connected to the high-pressure water nozzle 212 through a pipeline. The swing unit 213 is connected to the high-pressure water nozzle 212. The swing unit 213 is used to drive the high-pressure water nozzle 212 to swing. The high-pressure water nozzle 212 is a fan-shaped rotating nozzle. The high-pressure water pump 211 includes a three-plunger pump (rated pressure 0-50MPa, flow rate 60L / min), a drive motor (explosion-proof three-phase asynchronous motor, power 55kW, IP67 protection level) and a pressure regulating valve (proportional relief valve control accuracy ±0.5MPa). The high-pressure water nozzle 212 is a fan-shaped rotating nozzle made of tungsten carbide alloy. The swing unit 213 is driven by a servo motor. The fan-shaped rotating nozzle cooperates with the swing unit 213 to expand the coverage range. The tungsten carbide material is suitable for long-term high-wear working conditions.

[0060] The 30MPa high pressure water jet in the high pressure water jet assembly 210 removes loose concrete (efficiency 2m 2 / h), compared with traditional mechanical grinding (0.5m 2 / h) increased by 4 times.

[0061] In some embodiments, see Figure 1 、 Figure 2 and Figure 3 The vacuum cleaner assembly 220 includes a negative pressure unit 221, a debris recovery unit 222, a dust collection line 223, and a suction nozzle 224, which are connected in sequence. The negative pressure unit 221 is used to generate negative pressure and transmit it to the suction nozzle 224 through the dust collection line 223. The debris recovery unit 222 is used to filter and recover debris. The suction nozzle 224 is connected to the outside of the high-pressure water nozzle 212 and is coaxially arranged with the high-pressure water nozzle 212.

[0062] The negative pressure unit 221 includes a multi-stage centrifugal fan (air volume 1200m 3 / h, negative pressure -80kPa, power 7.5kW) and a silencer (impedance composite structure noise reduction ≥25dB). The debris recovery unit 222 includes a cyclone separator (diameter 300mm, separation efficiency ≥90%), a HEPA filter (glass fiber filter paper filtration accuracy 0.3μm, dust holding capacity 500g) and a dust collection box (quick-detachable stainless steel box capacity 80L with a full bin alarm sensor). The dust suction pipe 223 is a hard suction pipe (aluminum alloy bellows inner diameter Φ80mm, resistant to negative pressure -100kPa). The suction nozzle 224 is a flat suction nozzle 224 with a width of 200mm, coaxially arranged with the high-pressure water nozzle 212. The vacuum cleaning component 220 and the high-pressure water jet component 210 operate synchronously to achieve "cleaning and recycling at the same time". The HEPA filtration avoids PM2.5 pollution, and the coaxial suction nozzle 224 design reduces debris splashing, meeting OSHA dust control standards.

[0063] The vacuum cleaning component 220 simultaneously recovers debris (recovery rate ≥ 95%), and with HEPA filtration, the dust emission concentration is less than 1mg / m 3 , in line with environmental protection standards, achieving efficient cleaning and environmental protection effects.

[0064] In some embodiments, see Figure 1 、 Figure 2 and Figure 3 The epoxy interface agent spraying assembly 230 includes a two-component mixing unit 231, a spraying execution unit 232, and a flow controller 233. The two-component mixing unit 231 is used to mix and prepare the epoxy interface agent, the spraying execution unit 232 is used to spray the epoxy interface agent, and the flow controller 233 is used to control the spraying flow rate. The surface treatment module 200 also includes a surface treatment control assembly 240. The surface treatment control assembly 240 includes a pressure sensor 241, a turbidity sensor 242, a control terminal 243, and a touch screen 244. The pressure sensor 241 is used to monitor the water flow pressure in the high-pressure water jet assembly 210, and the turbidity sensor 242 is used to monitor the impurity concentration of the recycled water in the debris recovery unit 222. The control terminal 243 is electrically connected to the flow controller 233, the pressure sensor 241, the turbidity sensor 242, and the touch screen 244. The touch screen 244 is used to display the high-pressure water flow pressure and the epoxy interface agent spraying flow rate.

[0065] Pressure sensor 241, with a piezoresistive range of 0-50 MPa, monitors the water jet pressure. Turbidity sensor 242 detects impurity concentration in the recovered water, triggering a filter replacement alarm. Control terminal 243 includes an industrial PLC (Siemens S7-1500 series with integrated PROFINET communication). Touch screen 244 features an HMI interface that displays real-time parameters such as pressure, flow rate, and coating thickness.

[0066] The robotic arm precisely controls the coating thickness (0.2-1.0mm), with a uniformity deviation of <±0.1mm, improving the durability of the subsequent grouting layer.

[0067] In some embodiments, see Figure 1 、 Figure 2 and Figure 4The dual-channel grouting pump assembly 310 includes a screw pump channel 311, a plunger pump channel 312, and a switching valve 313. The screw pump channel 311 is used to transport epoxy grouting material, while the plunger pump channel 312 is used to transport ultra-early strength grouting material. The switching valve 313 is used to switch the screw pump channel 311 or the plunger pump channel 312 to connect with the grouting pipeline 340. The proportioning and mixing assembly 330 includes a mixer 331, a proportioning control unit 332 (a mass flow meter monitors the ratio of grouting material to curing agent in real time, and an electric regulating valve dynamically adjusts the ratio according to a preset ratio), and a temperature control unit 333 (a heating belt maintains the grouting material temperature at 30±2°C). The mixer 331 is used to mix the slurry, the proportioning control unit 332 is used to control the ratio of the slurry components, and the temperature control unit 333 is used to control the slurry temperature. The dual-channel grouting pump assembly 310 is used to transport the slurry mixed by the mixer 331 to the grouting nozzle 350 through the grouting pipeline 340.

[0068] Epoxy grouting material has high viscosity, so a screw pump provides stable, low-pressure delivery. Ultra-early-strength grouting material requires high-pressure penetration, so a plunger pump adapts to its fluidity. The switching valve 313 features a fast switching and self-cleaning design to minimize cross-contamination. The ratio control unit 332 precisely mixes the material (e.g., epoxy resin: curing agent = 5:1) to ensure curing strength. Temperature control prevents premature curing or loss of fluidity.

[0069] The grouting and compaction module 300 has good material adaptability and efficient filling effects. The dual-channel pumps deliver epoxy grouting material (deep cracks) and ultra-early strength grouting material (shallow layer) respectively. The switching time is short and the repair efficiency is high. High-pressure grouting (0.8MPa) penetrates into micro cracks (≥0.1mm) with a filling rate of ≥98%, avoiding the hidden danger of voids.

[0070] In some embodiments, see Figure 1 、 Figure 2 and Figure 4 The vibrating roller assembly 320 includes a roller body 321, a vibration generator 322, a vibration drive unit 323, and a density feedback unit 324. The roller body 321, the vibration generator 322, and the vibration drive unit 323 are sequentially connected. The vibration drive unit 323 is used to drive the vibration generator 322 to vibrate, and the vibration generator 322 is used to drive the roller body 321 to vibrate to compact the grouting layer. The density feedback unit 324 includes a piezoelectric acceleration sensor and an infrared thermal imager and is used to provide feedback on the density of the grouting layer.

[0071] The dual channels in the grouting and compaction module 300 respectively transport epoxy grouting material (deep cracks) and ultra-early strength grouting material (shallow layer) to fill to the designed thickness. The solenoid valve switches the channels with one button, and the pressure is controlled in a closed loop (error ±0.1MPa). After filling is completed, the vibrating roller reciprocates and compacts at a frequency of 50Hz, and the density is tested simultaneously to ensure that there are no voids, achieving a compaction degree ≥95% and a porosity <2% (ASTMC642 standard).

[0072] In some embodiments, see Figure 1 、 Figure 2 and Figure 5 The telescopic arm 420 includes a multi-stage nested hydraulic cylinder assembly 421, a telescopic drive unit 422, and a telescopic control unit 423. The telescopic drive unit 422 includes a servo motor and a hydraulic pump station, and is designed to achieve high response speed. The telescopic control unit 423 includes a displacement sensor and an inclination compensation device, and is used to ensure the positioning accuracy of the end of the telescopic arm 420 to meet the requirements of precision operations such as grouting and drilling.

[0073] The multi-stage nested hydraulic cylinder group 421 features a four-stage telescopic structure, with each stage being 5m long, for a total extension length of 20m. The outer diameter of each stage decreases from Φ220mm for the first stage to Φ120mm for the fourth stage, with a nesting gap of ≤1mm. This multi-stage nested structure enables a wide range of extension within a limited space. The cylinder barrel is constructed of high-strength alloy steel with a hard chrome plated surface, while the piston rod is constructed of high-strength alloy steel with a laser-clad nickel-based wear-resistant coating. These high-strength materials and wear-resistant coating ensure long-term load-bearing reliability. The main seal utilizes a double-lip polyurethane seal, and the dust seal utilizes a multi-layer labyrinth structure with a scraper ring to prevent sand and gravel intrusion. The sealing system is adapted to the dusty and high-humidity environment found at bridge repair sites.

[0074] The telescopic arm 420 is equipped with mechanical and hydraulic / electrical interfaces. Standardized interfaces (ISO standards) support rapid switching between modules such as surface treatment and grouting and compaction. The rotatable inertial stabilization platform 410 is constructed and driven by crossed roller bearings and a cycloidal hydraulic motor, respectively. The rotatable inertial stabilization platform 410 can rotate continuously 360° to adapt to the repair of curved bridge pier surfaces. The crossed roller bearings ensure smooth movement under high loads.

[0075] See Figure 1 、 Figure 2 and Figure 3 According to an embodiment of the present invention, a method for intelligently locating and quickly repairing cracks in a high-altitude bridge comprises the following steps:

[0076] S1: Prepare grouting material and wire mesh. The grouting material uses an epoxy resin-based cementitious material + nano-silica fume + an early strength agent (24-hour compressive strength ≥ 40 MPa). It is self-compacting and shrink-free, with initial setting within 1 hour and reaching 70% of the design strength within 3 hours to meet emergency repair needs. The wire mesh is galvanized, with a bidirectional weave (mesh size 10 mm × 10 mm), a diameter of 1.2 mm, and a tensile strength ≥ 400 MPa. The wire mesh restrains cracking in the grouting material and improves the ductility of the repair area.

[0077] S2: Intelligent Positioning Module 100 scans the damaged bridge area and generates a 3D crack model to plan the repair path. Before construction, Intelligent Positioning Module 100 first performs a damage assessment of the damaged bridge area. Dual LiDARs perform symmetrical scanning. An AI algorithm removes noisy point clouds, identifies areas with crack depths greater than 5mm, marks them as repair targets, and generates a 3D crack model with a positioning error of ≤2mm. The AI ​​algorithm calculates the shortest path, using reinforcement learning to avoid obstacles in real time, avoiding areas with dense rebar and optimizing the grouting path.

[0078] S3: Aerial Work Module 400, equipped with Surface Treatment Module 200, performs surface treatment on the damaged bridge surface. The hydraulic arm of Aerial Work Module 400 extends to a maximum height of 20 meters. A servo motor controls the progressive extension of multiple hydraulic cylinders. A 360° rotatable inertial stabilization platform 410 is mounted at the end, carrying repair tools (grouting pump, pressure rollers, etc.). The hydraulic arm is positioned at the target area.

[0079] The quick-change interface 430 of the telescopic arm 420 is connected to the high-pressure water jet component 210. The 30MPa pressure water flow impacts the damaged surface. The synchronous swing unit 213 drives the high-pressure water nozzle 212 to swing to expand the cleaning range and remove the peeling concrete. The vacuum cleaning component 220 vacuums at a negative pressure of -80kPa. After three levels of filtration, the debris is stored in the dust collection box to recover and avoid secondary pollution.

[0080] The robotic arm in the epoxy interface agent spraying assembly 230 sprays the epoxy interface agent according to a preset path, and the flow controller 233 dynamically adjusts the thickness (0.2-1.0mm). The epoxy interface agent enhances the interface adhesion between the new and old materials, and the bonding strength is ≥3MPa (ASTMD4541 standard) to prevent material peeling.

[0081] S4: Aerial Work Module 400, equipped with a robotic arm, implanted wire mesh into the bridge cracks, securing the joints with anchors. The robotic arm laid a double layer of galvanized wire mesh, securing the joints with L-shaped anchors and using laser distance measurement to ensure a gap of ≤1mm between the mesh and the base surface.

[0082] S5: The aerial work module 400, equipped with the grouting and compaction module 300, injects grout and performs vibration compaction. The dual channels in the grouting and compaction module 300 respectively deliver epoxy grouting material (deep cracks) and ultra-early strength grouting material (shallow layers) to the designed thickness. The solenoid valve switches channels with one click, and the pressure is controlled in a closed loop (error ±0.1MPa). After filling, the vibrating roller reciprocates at a frequency of 50Hz for compaction. The density is simultaneously tested to ensure the absence of voids, achieving a compaction degree of ≥95% and a porosity of <2% (ASTMC642 standard). The joints are sealed with underwater rapid-setting epoxy slurry (curing time ≤2h), and the flatness of the repair surface is controlled by a hydraulic synchronous leveling system, with a deviation of ≤1 / 500 of the repair height.

[0083] S6: Ultrasonic testing to detect the integrity of the grouting layer and spraying the curing film.

[0084] Through modular design, intelligent control and material coordination, efficient operation of the entire process of bridge earthquake damage repair is achieved, shortening the construction period by 80% compared with traditional methods, improving the equivalent viscous damping coefficient of the repair area, enhancing the energy consumption capacity, and the ultrasonic detection void rate of 0.8%, which is far lower than the industry standard (≤5%), providing strong support for the rapid repair of bridge earthquake damage.

[0085] Acceptance criteria require that the ultrasonic flaw detection void rate in the repaired area be ≤1%, the 28-day equivalent viscous damping coefficient be ≥0.18, and energy dissipation capacity be increased by 80%. In the integrated health monitoring system, pre-buried fiber optic sensors must operate continuously for 30 days without failure, providing real-time feedback on strain (accuracy ±5με), temperature (±0.5°C), and water seepage alarms, with a data sampling rate of ≥10Hz, to ensure the reliability of the repaired structure throughout its lifecycle. For emergency protection, S460 steel reinforcement plates (20mm thick) are added as a redundant design, increasing resistance to aftershock impacts by 50%.

[0086] The intelligent positioning module 100 can perform damage assessment on the damaged parts of the bridge, scan the damaged parts of the bridge and generate a three-dimensional crack model to plan the repair path and improve the repair efficiency.

[0087] The high-pressure water jet component 210 in the surface treatment module 200 can remove loose concrete, and the vacuum cleaner component 220 can simultaneously recycle debris, which can reduce dust emissions and achieve efficient cleaning and environmental protection effects. The epoxy interface agent enhances the adhesion between the new and old materials, prevents material peeling, and improves the durability of the subsequent grouting layer.

[0088] The grouting and compacting module 300 can grout and compact the damaged parts of the bridge, with high repair efficiency.

[0089] The aerial work module 400 efficiently covers high-altitude areas. The telescopic arm 420 can extend to the heights of bridge piers or beams, eliminating the need for scaffolding or hanging baskets, saving preparation time. The rotatable inertial stabilization platform 410 can adapt to special-shaped structures (such as the curved surface of an arch bridge), reducing the need for manual adjustments and improving work efficiency. The quick-change interface 430 supports rapid tool switching to adapt to different repair process requirements, providing high work adaptability.

[0090] In some embodiments, see Figure 1 、 Figure 2 and Figure 3 In step S4, laser distance measurement is performed after the wire mesh is implanted to ensure that the gap between the wire mesh and the base surface is ≤1mm.

[0091] In some embodiments, see Figure 1 、 Figure 2 and Figure 3In step S5, the grouting and compacting module 300 adopts a dual-channel grouting pump. The dual-channel grouting pump has dual channels, which respectively transport epoxy grouting material and ultra-early strength grouting material. The epoxy grouting material is used to fill deep cracks to the designed thickness, and the ultra-early strength grouting material is used to fill shallow cracks to the designed thickness.

[0092] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, illustrative uses of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0093] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to the embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the claims and their equivalents.

Claims

1. An integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges, characterized in that: include: Intelligent positioning module, including 3D laser scanning equipment and structured light scanning equipment, is used to quickly scan and locate bridge damage parts and generate 3D crack topography to plan repair paths; The surface treatment module includes a high-pressure water jet assembly, a vacuum cleaner assembly, and an epoxy interface agent spraying assembly. The high-pressure water jet assembly is used to remove loose concrete from damaged parts of the bridge. The vacuum cleaner assembly is used to recover debris removed by the high-pressure water jet assembly. The epoxy interface agent spraying assembly is used to spray the epoxy interface agent. The grouting and compaction module includes a dual-channel grouting pump assembly, a vibrating roller assembly, a proportioning and mixing assembly, a high-pressure grouting pipeline, and a grouting nozzle, and is used to inject grout and compact the damaged parts of the bridge; The aerial work module includes a rotatable inertial stabilization platform, a telescopic arm and a quick-change interface connected in sequence. The rotatable inertial stabilization platform is used to drive the telescopic arm to rotate. The telescopic arm can be retracted and the quick-change interface can be detachably connected to the surface treatment module or the grouting and compaction module.

2. The integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to claim 1 is characterized in that: The high-pressure water jet assembly includes a high-pressure water pump, a high-pressure water nozzle and a swing unit. The high-pressure water pump is connected to the high-pressure water nozzle through a pipeline. The swing unit is connected to the high-pressure water nozzle. The swing unit is used to drive the high-pressure water nozzle to swing. The high-pressure water nozzle is a fan-shaped rotating nozzle.

3. The integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to claim 2 is characterized in that: The vacuum cleaning assembly includes a negative pressure unit, a debris recovery unit, a dust collection pipeline and a suction nozzle connected in sequence. The negative pressure unit is used to generate negative pressure and transmit it to the suction nozzle through the dust collection pipeline. The debris recovery unit is used to filter and recover debris. The suction nozzle includes a connection to the outside of the high-pressure water nozzle, and the suction nozzle is coaxially arranged with the high-pressure water nozzle.

4. The integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to claim 3 is characterized in that: The epoxy interface agent spraying assembly includes a flow controller for controlling the spraying flow, the surface treatment module also includes a surface treatment control assembly, the surface treatment control assembly includes a pressure sensor, a turbidity sensor, a control terminal and a touch screen, the pressure sensor is used to monitor the water flow pressure in the high-pressure water jet assembly, the turbidity sensor is used to monitor the impurity concentration of the recovered water in the debris recovery unit, the control terminal is electrically connected to the flow controller, the pressure sensor, the turbidity sensor and the touch screen, and the touch screen is used to display the high-pressure water flow pressure and the epoxy interface agent spraying flow.

5. The integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to claim 1 is characterized in that: The dual-channel grouting pump assembly includes a screw pump channel, a plunger pump channel and a switching valve. The screw pump channel is used to convey epoxy grouting material, and the plunger pump channel is used to convey ultra-early strength grouting material. The switching valve is used to switch the screw pump channel or the plunger pump channel to be connected with the grouting pipeline. The proportioning and mixing assembly includes a mixer, a proportioning control unit and a temperature control unit. The mixer is used to mix slurry, the proportioning control unit is used to control the proportion of slurry components, and the temperature control unit is used to control the slurry temperature. The dual-channel grouting pump assembly is used to convey the slurry mixed by the mixer to the grouting nozzle through the grouting pipeline.

6. The integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to claim 5 is characterized in that: The vibrating roller assembly includes a roller body, a vibration generator, a vibration drive unit and a density feedback unit. The roller body, the vibration generator and the vibration drive unit are connected in sequence. The vibration drive unit is used to drive the vibration generator to vibrate. The vibration generator is used to drive the roller body to vibrate to compact the grouting layer. The density feedback unit includes a piezoelectric acceleration sensor and an infrared thermal imager. The density feedback unit is used to feedback the density of the grouting layer.

7. The integrated device for intelligent positioning and rapid repair of cracks in high-altitude bridges according to claim 1 is characterized in that: The telescopic arm includes a multi-stage nested hydraulic cylinder group, a telescopic drive unit and a telescopic control unit. The telescopic drive unit includes a servo motor and a hydraulic pump station. The telescopic control unit includes a displacement sensor and an inclination compensation device. The telescopic drive unit is used to achieve high response speed. The telescopic control unit is used to ensure the end positioning accuracy of the telescopic arm.

8. A method for intelligently locating and quickly repairing cracks in high-altitude bridges, using an integrated device for intelligently locating and quickly repairing cracks in high-altitude bridges as described in any one of claims 1 to 7, characterized in that: The following steps are involved: S1: Preparation of grouting material and wire mesh material; S2: The intelligent positioning module quickly scans and locates the damaged parts of the bridge and generates a three-dimensional crack morphology to plan the repair path; S3: The aerial work module is equipped with a surface treatment module to perform base surface treatment on damaged parts of the bridge; S4: The aerial work module equipped with a robotic arm implants wire mesh into the cracks of the bridge and locks the nodes with anchors; S5: The aerial operation module is equipped with a grouting and compacting module to pour grout and vibrate and compact it; S6: Ultrasonic testing to detect the integrity of the grouting layer and spraying the curing film.

9. The method for intelligently locating and quickly repairing cracks in high-altitude bridges according to claim 8, characterized in that: In step S4, laser distance measurement is performed after the wire mesh is implanted to ensure that the gap between the wire mesh and the base surface is ≤1mm.

10. The method for intelligently locating and quickly repairing cracks in high-altitude bridges according to claim 8, characterized in that: In step S5, the grouting and compacting module adopts a dual-channel grouting pump, which has dual channels. The dual channels respectively convey epoxy grouting material and ultra-early strength grouting material. The epoxy grouting material is used to fill deep cracks to the designed thickness, and the ultra-early strength grouting material is used to fill shallow cracks to the designed thickness.

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