Full-automatic segment demolding and overturning system and method

Abstract

The application relates to the field of segment demolding and turnover control, and particularly discloses a full-automatic segment demolding and turnover system and method. The application constructs a segment space model through three-dimensional scanning, accurately plans the arrangement of adsorption points and the demolding direction in combination with the weight of the segment, monitors the reaction force of the adsorption points and the displacement in the vertical direction in real time during the demolding process, dynamically adjusts the lifting speed and the adsorption force to guarantee the demolding synchronism, realizes controllable turnover of the segment by selectively opening and closing the vacuum chuck path, dynamically adjusts the turnover acceleration based on the fluctuation rate of vacuum degree, the motor torque load rate and the vibration acceleration during the turnover process, and ensures the safety and stability of the turnover. The application solves the problems of poor demolding synchronism, inaccurate path planning, weak correction ability and extensive turnover control, realizes full-process automation, high precision and high reliability of segment demolding and turnover, and significantly improves the product quality and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of segment demolding and flipping control, and specifically to a fully automatic segment demolding and flipping system and method. Background Technology

[0002] In the production of tunnel concrete segments, demolding and flipping are crucial steps determining product quality and production efficiency. Demolding refers to the process of smoothly removing the solidified concrete segments from the mold; its success directly affects the integrity of the segments and their subsequent performance. With the development of automated precast component production, vacuum suction cups have become the mainstream technology for demolding and flipping segments. Vacuum suction cups, by creating negative pressure to adsorb segments, offer advantages such as non-destructive operation, strong adaptability, flexible operation, and high degree of automation integration, and are widely used in segment production.

[0003] Although existing technologies have proposed automated demolding and hoisting systems, such as Chinese Patent Publication No. CN117359775A which discloses a method to improve the efficiency of automated hoisting of precast subway segments, and Chinese Patent Publication No. CN118769377A which discloses a fully automated hoisting system and its process based on an automated segment production line, the following shortcomings still exist:

[0004] (1) Inaccurate demolding path planning: The existing method does not fully consider the geometric characteristics and pore distribution of the backing surface of the tube segment, and the arrangement of adsorption points lacks scientific basis, which can easily lead to poor adsorption, vacuum leakage or local stress concentration, increasing the risk of tube segment damage.

[0005] (2) Insufficient control of demolding synchronization: Large tube segments usually need to be set with multiple adsorption points. The existing system is difficult to ensure that all adsorption points achieve precise synchronous action and consistent displacement during demolding. If the synchronization is poor, it will easily lead to uneven stress on the tube segments, resulting in microcracks inside, affecting their load-bearing capacity and durability.

[0006] (3) The control of the flipping process is rough: When the tube segments are flipped, the acceleration adjustment lacks multi-parameter fusion judgment, which can easily lead to tube segment slippage, equipment overload or structural damage due to vacuum fluctuations, motor load or abnormal vibration. The safety and stability of the flipping process need to be improved. Summary of the Invention

[0007] To address the above problems, this invention proposes a fully automatic demolding and flipping system and method for tunnel segments, which realizes the function of controlling the demolding and flipping of tunnel segments.

[0008] The technical solution adopted by this invention to solve its technical problem is: This invention provides a fully automatic demolding and flipping system for tunnel segments, comprising:

[0009] Demolding path planning module: Performs 3D scanning of the tube segment, constructs a spatial model of the tube segment and extracts its geometric features, and determines the number and arrangement of adsorption points on the backing surface of the tube segment and the demolding direction at the adsorption points in combination with the weight of the tube segment.

[0010] Demolding anomaly correction module: During the demolding process, the reaction force and vertical displacement at the adsorption point are monitored in real time. Based on the preset synchronization rules, it is determined whether the demolding action meets the requirements. If it does, the current demolding process is maintained. If it does not, dynamic correction is performed by adjusting the lifting speed and adsorption force.

[0011] The flipping action control module: determines the rotation axis side and the active lifting side of the tube segment, and selectively opens and closes the vacuum passage of the vacuum suction cups on both sides to control the flipping of the tube segment.

[0012] The flip acceleration / deceleration adjustment module monitors the vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration during the flip process to determine whether the flip acceleration needs to be adjusted. If so, the acceleration of the next control cycle is corrected based on the acceleration adjustment information; otherwise, the original flip acceleration is maintained.

[0013] This invention provides a fully automated demolding and flipping method for tunnel segments, comprising the following steps:

[0014] Step 1: Perform a 3D scan of the tube segment, construct a spatial model of the tube segment and extract its geometric features. Combined with the weight of the tube segment, determine the number and arrangement of adsorption points on the backing surface of the tube segment and the demolding direction at the adsorption points.

[0015] Step 2: During the demolding process, monitor the reaction force and vertical displacement at the adsorption point in real time. Based on the preset synchronization rules, determine whether the demolding action meets the requirements. If it does, maintain the current demolding process. If it does not, dynamically correct the deviation by adjusting the lifting speed and adsorption force.

[0016] Step 3: Determine the rotation axis and active lifting side of the tube segment, and selectively open and close the vacuum passages of the vacuum suction cups on both sides to control the tube segment to flip.

[0017] Step 4: During the flipping process, monitor the vacuum fluctuation rate, drive motor torque load rate and vibration acceleration within the current control cycle to determine whether the flipping acceleration needs to be adjusted. If so, correct the acceleration of the next control cycle based on the acceleration adjustment information. If not, maintain the original flipping acceleration.

[0018] Compared with existing technologies, the fully automatic demolding and flipping system and method for pipe segments described in this invention have the following advantages:

[0019] 1. This invention constructs a spatial model of the tube segment through three-dimensional scanning. Based on the geometric features and weight information of the tube segment, it scientifically determines the number, arrangement, and demolding direction of adsorption points on the backing surface of the tube segment, avoids interference from pores, and ensures adsorption reliability and optimal demolding path.

[0020] 2. This invention monitors the deviation between the reaction force and vertical displacement between adsorption points in real time, determines whether demolding is synchronized based on preset synchronization rules, and dynamically corrects deviation by adjusting the lifting speed and adsorption force, thereby preventing the tube sheet from tilting, jamming, or developing microcracks.

[0021] 3. This invention achieves controllable flipping of the tube segment by selectively opening and closing the vacuum passage of the vacuum chuck, and dynamically adjusts the flipping acceleration based on multiple parameters such as vacuum fluctuation rate, motor torque load rate and vibration acceleration, so as to avoid equipment overload and tube segment damage. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a system module connection diagram of the present invention.

[0024] Figure 2 This is a schematic diagram of the method flow of the present invention.

[0025] Figure 3 This is a diagram of the demolding and flipping machine of the present invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Please see Figure 1 and Figure 3 As shown, the present invention provides a fully automatic demolding and flipping system for pipe segments, including a demolding path planning module, a demolding abnormality correction module, a flipping action control module, and a flipping acceleration and deceleration adjustment module.

[0028] The demolding anomaly correction module is connected to the demolding path planning module and the flipping action control module, respectively, and the flipping acceleration / deceleration adjustment module is connected to the flipping action control module.

[0029] The demolding path planning module is used to perform three-dimensional scanning of the pipe segment, construct a spatial model of the pipe segment and extract its geometric features, and determine the number and arrangement of adsorption points on the backing surface of the pipe segment and the demolding direction at the adsorption points in combination with the weight of the pipe segment.

[0030] Furthermore, the specific working process of the demolding path planning module is as follows:

[0031] After the mold is fully released, the segment is 3D scanned by the visual recognition unit of the demolding and flipping machine, and a spatial model of the segment is constructed based on the acquired 3D point cloud data.

[0032] Based on the spatial model, the location and size of each hole on the backing surface of the tube segment are identified.

[0033] Based on the pre-stored hole safety distances in the database, a circular area is constructed with the center of each hole as the origin and the sum of the hole radius and the corresponding safety distance as the radius, which serves as the area where the hole is located.

[0034] Exclude all areas containing the holes from the curved region of the segment backing surface to obtain the deployable adsorption point region.

[0035] The weight information of the tube segment is obtained, and combined with the rated adsorption force of a single vacuum suction cup, the safety factor and overall efficiency of the lifting system, which are pre-stored in the database, the number of adsorption points required on the backing surface of the tube segment is determined according to the set adsorption point number calculation formula.

[0036] Based on the determined number of adsorption points, multiple adsorption points are symmetrically arranged within the area where adsorption points can be deployed.

[0037] The normal direction of the surface at each adsorption point is determined as the demolding direction of the corresponding adsorption point.

[0038] It should be noted that the mold for the tube segment specifically includes a top mold, a side mold, and an end mold.

[0039] It should be noted that the present invention uses a vacuum suction cup to achieve demolding and flipping of the tube. Its working principle is to use a vacuum pump to remove the air between the suction cup and the contact surface of the tube to form a negative pressure, and use atmospheric pressure to firmly adsorb the tube.

[0040] It should be noted that the backing surface of the tube segment is the outer arc surface of the tube segment. For the vacuum suction cup to operate, it needs to form a complete seal with the surface of the tube segment. The backing surface must be flat and smooth to ensure a tight fit between the suction cup lip and the backing surface, effectively preventing air leakage. This is the most basic requirement for safe suction; therefore, suction points are arranged on the backing surface of the tube segment. Simultaneously, the backing surface is the side of the tube segment subjected to pressure during manufacturing. Its surface concrete is the densest, free of air bubbles or defects, and can withstand the concentrated stress from the suction cup, preventing damage to the tube segment surface during lifting.

[0041] It should be noted that the holes on the backing surface of the segment include bolt holes, grouting holes, and hoisting holes.

[0042] It should be noted that, in order to avoid the vacuum suction cup not sealing properly and the suction force decreasing due to the suction point being too close to the edge of the hole, a safe distance should be maintained between the suction point and the hole when arranging the suction point on the backing surface of the tube segment. This ensures the reliability and stability of the suction during demolding and flipping, and prevents the tube segment from shifting, slipping or being damaged due to local stress concentration or vacuum leakage.

[0043] It should be noted that the formula for calculating the number of adsorption points is:

[0044] ;

[0045] in This indicates the number of adsorption sites required. The symbol represents rounding up. This represents the weight of the tunnel segment calculated from the weight of the tunnel segment itself. This indicates the safety factor of the spreading system. This indicates the rated suction force of a single vacuum suction cup. This indicates the overall efficiency of the lifting device system.

[0046] It should be noted that the number, arrangement, and demolding direction information of the adsorption points in the demolding unit are transmitted to the control unit of the demolding and flipping machine. The control unit generates control commands based on this information to drive the execution end to perform the corresponding demolding action.

[0047] In this example, the present invention constructs a spatial model of the tube segment through three-dimensional scanning. Based on the geometric features and weight information of the tube segment, it scientifically determines the number, arrangement and demolding direction of adsorption points on the backing surface of the tube segment, avoids interference from pores, and ensures adsorption reliability and optimal demolding path.

[0048] The demolding anomaly correction module is used to monitor the reaction force and vertical displacement at the adsorption point in real time during the demolding process. Based on the preset synchronization rules, it judges whether the demolding action meets the requirements. If it does, the current demolding process is maintained. If it does not, the lifting speed and adsorption force are adjusted for dynamic correction.

[0049] Furthermore, the specific working process of the demolding anomaly correction module in determining whether the demolding action meets the requirements is as follows:

[0050] The sensor unit of the demolding and flipping machine monitors the reaction force and vertical displacement at each adsorption point on the backing surface of the tube sheet in real time.

[0051] Calculate the maximum deviation of the reaction force between all adsorption points and the maximum deviation of the vertical displacement.

[0052] Determine if the following conditions are met simultaneously:

[0053] (1) The maximum deviation of the reaction force is less than or equal to the preset reaction force deviation threshold.

[0054] (2) The maximum deviation of the vertical displacement is less than or equal to the preset vertical displacement deviation threshold.

[0055] If both conditions are met simultaneously, the demolding action is deemed to meet the synchronization requirements.

[0056] Otherwise, the demolding action is deemed not to meet the synchronization requirements.

[0057] It should be noted that the sensor unit includes a pressure sensor and a laser rangefinder.

[0058] In another specific embodiment, the vertical displacement of each adsorption point on the backing surface of the tube segment is obtained by the visual recognition unit of the demolding and flipping machine.

[0059] It should be noted that the reaction force refers to the force exerted by the tube sheet on the vacuum suction cup during the demolding process.

[0060] It should be noted that the method for determining the reaction force deviation threshold and the vertical displacement deviation threshold is as follows: First, based on the characteristics of the tube segment material, structural dimensions, and the performance of the vacuum adsorption system, theoretical initial values ​​are calculated through mechanical modeling and dynamic simulation; then, during the system debugging phase, sensor data are collected during multiple smooth demolding processes, and the normal fluctuation range of the reaction force and vertical displacement is statistically determined, with the upper limit of the statistical range taken as the empirical threshold; finally, the theoretical and empirical values ​​are comprehensively corrected by combining process safety specifications and preset safety factors, thereby determining the final threshold that combines reliability, safety, and engineering applicability.

[0061] It should be noted that if the reaction force deviation at each adsorption point is too large during the demolding process, it indicates uneven stress on the tube segment, which may lead to localized stress concentration or adsorption failure, thus violating the mechanical equilibrium conditions required for smooth demolding. Furthermore, the vertical displacement deviation at each adsorption point directly reflects the synchronicity of the tube segment's posture; excessive displacement differences can cause the tube segment to tilt or become stuck, affecting the stability of the demolding path.

[0062] Furthermore, the specific working process of dynamic correction in the demolding anomaly correction module is as follows:

[0063] D1: Identify the adsorption points where there is stagnation based on the reaction force and vertical displacement at each adsorption point.

[0064] D2: Based on the pre-stored demolding speed adjustment unit in the database, reduce the lifting speed of the stuck adsorption point as an initial trial adjustment.

[0065] D3: After the initial adjustment, re-test the maximum deviation of the reaction force between all adsorption points and the maximum deviation of the vertical displacement.

[0066] If at least one of the maximum deviations decreases, the initial adjustment is deemed effective, and adjustment continues in the current direction until the synchronization requirement is met.

[0067] If the maximum deviation is not reduced, the initial adjustment is deemed invalid, and D4 is executed.

[0068] D4: Based on the pre-stored vacuum suction cup adsorption force unit adjustment amount in the database, increase the adsorption force of the stuck adsorption point as a secondary trial adjustment.

[0069] D5: After the second trial adjustment, re-detect the maximum deviation of the reaction force between all adsorption points and the maximum deviation of the vertical displacement.

[0070] If at least one of the maximum deviations decreases, the second trial adjustment is deemed effective, and adjustment continues in the current direction until the synchronization requirement is met.

[0071] If the maximum deviation is not reduced, the second trial adjustment is deemed invalid, and a system warning is triggered.

[0072] It should be noted that segment jamming is essentially a manifestation of an imbalance between local resistance and adsorption force. Prioritizing the adjustment of the lifting speed can directly alleviate mechanical resistance, while enhancing the adsorption force can overcome adhesion stress. By tentatively adjusting the lifting speed and adsorption force, and using the reduction of system deviation as the criterion for effectiveness, an effective correction strategy can be quickly identified through continuous trial and error. Its effect is to gradually eliminate asynchronous states with minimal intervention costs, avoiding system oscillation or demolding failure due to the failure of a single adjustment method or over-adjustment, thereby improving the reliability and adaptability of the correction process while ensuring demolding stability.

[0073] Furthermore, the specific process for identifying the presence of stuck adsorption points is as follows:

[0074] A coordinate system was established with the adsorption point number as the abscissa and the reaction force and vertical displacement as the ordinates. The corresponding data of each adsorption point were marked in the coordinate system, and point distribution maps of reaction force and vertical displacement were formed respectively.

[0075] Linear fitting is performed on the data points in the point distribution map to obtain the reaction force fitting line and the vertical displacement fitting line, respectively.

[0076] An adsorption point is considered a stuck adsorption point if it meets any of the following conditions:

[0077] (1) The reaction force value of the adsorption point is above the reaction force fitting line, and its deviation is greater than the set first deviation threshold.

[0078] (2) The vertical displacement value of the adsorption point is below the vertical displacement fitting line, and its deviation is greater than the set second deviation threshold.

[0079] In this example, the present invention monitors the deviation between the reaction force and vertical displacement between adsorption points in real time, determines whether demolding is synchronized based on preset synchronization rules, and dynamically corrects deviation by adjusting the lifting speed and adsorption force, thereby preventing the tube segment from tilting, jamming, or developing microcracks.

[0080] The flipping action control module is used to determine the rotation axis side and the active lifting side of the tube segment, and selectively open and close the vacuum passage of the vacuum suction cups on both sides to control the flipping of the tube segment.

[0081] Furthermore, the specific working process of the flipping action control module is as follows:

[0082] Based on the predetermined rotation direction of the segment, determine one side as the rotation axis and the other side as the active lifting side.

[0083] Close the vacuum passages of all vacuum suction cups on the rotating shaft side, while keeping the vacuum passages of all vacuum suction cups on the active lifting side open.

[0084] After the tube segment is flipped to the target angle, the vacuum passage of the rotating shaft-side vacuum chuck is reopened.

[0085] It should be noted that the segment flipping is achieved by selectively releasing and establishing a vacuum to gradually shift the center of gravity of the segment, thus realizing controllable flipping. The flipping action is achieved by closing or opening the vacuum passage of a specific suction cup.

[0086] It should be noted that if the segment rotates around one side, that side is the rotation axis side, and the other side is the active lifting side.

[0087] It should be noted that when the tube is flipped, the vacuum passage of the vacuum chuck on the rotating shaft side is closed, while the vacuum passage of the vacuum chuck on the active lifting side remains open. Although the vacuum chuck on the rotating shaft side is still attached to the tube, it has lost its suction force and becomes free or only provides slight support, while the vacuum chuck on the active lifting side remains in a strong suction state, which causes the center of gravity of the tube to begin to move naturally towards the active lifting side.

[0088] The reversing acceleration / deceleration adjustment module is used to monitor the vacuum fluctuation rate, drive motor torque load rate and vibration acceleration during the reversing process in the current control cycle, and determine whether the reversing acceleration needs to be adjusted. If so, the acceleration of the next control cycle is corrected based on the acceleration adjustment information; if not, the original reversing acceleration is maintained.

[0089] Furthermore, the specific process of determining whether the roll acceleration needs to be adjusted in the roll acceleration / deceleration adjustment module is as follows:

[0090] The flipping process is divided into segments according to a set time window to obtain a continuous control cycle.

[0091] Monitor the vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration during the current control cycle.

[0092] The vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration are compared with their respective preset warning thresholds.

[0093] If any of the parameters exceeds the corresponding warning threshold, it is determined that the rollover acceleration needs to be adjusted.

[0094] If all parameters do not exceed the corresponding warning threshold, it is determined that there is no need to adjust the rollover acceleration.

[0095] It should be noted that the formula for calculating the vacuum degree fluctuation rate is:

[0096] ;

[0097] in Indicates vacuum degree volatility. This indicates the set vacuum level. This indicates the vacuum level as monitored in real time.

[0098] It should be noted that the formula for calculating the torque load rate of the drive motor is as follows:

[0099] ;

[0100] in Indicates the torque load rate of the drive motor. This indicates the real-time output torque of the drive motor. This indicates the rated torque of the drive motor.

[0101] It should be noted that vacuum fluctuations directly reflect adsorption reliability, torque load rate characterizes the real-time load status of the drive system, and vibration acceleration reflects mechanical stability and motion smoothness. These three factors together constitute a safety and efficiency monitoring system for the flipping process. Therefore, the decision to adjust the flipping acceleration is based on vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration. This method, through multi-parameter fusion monitoring, can promptly trigger acceleration adjustments in the early stages of adsorption failure, sudden load changes, or abnormal vibration, preventing equipment overload, segment slippage, or structural damage, thereby achieving adaptive optimization and safe control of the flipping process.

[0102] Furthermore, the specific process for obtaining acceleration adjustment information in the flip acceleration / deceleration adjustment module is as follows:

[0103] The overshoot of vacuum fluctuation rate, drive motor torque load rate and vibration acceleration exceeding their respective warning thresholds is obtained, and the parameter corresponding to the largest overshoot is selected as the adjustment reference parameter.

[0104] The system calls the pre-stored correction model corresponding to each parameter in the database. The correction model includes the quantized mapping relationship between the overshoot and the decrease in flip acceleration.

[0105] Based on the overshoot of the aforementioned adjustment reference parameter, the adjustment amount of the rollover acceleration is determined through the corresponding correction model.

[0106] It should be noted that the quantitative mapping relationship between overshoot and the decrease in rollover acceleration is obtained in the following way: During the system debugging phase, by applying a stepped simulated load or setting a step acceleration signal, vacuum fluctuation rate, drive motor torque load rate and vibration acceleration data under different operating conditions are collected, and the overshoot and the corresponding decrease in acceleration required to maintain stability are recorded; based on a large amount of test data, regression analysis or system identification methods are used to establish the correspondence between the overshoot of each parameter and the acceleration adjustment, and after engineering verification and optimization, the quantitative mapping relationship is formed and pre-stored in the database for real-time control calls.

[0107] It should be noted that the acceleration adjustment information in the flipping unit is transmitted to the control unit of the demolding flipping machine. The control unit generates control commands based on this information to drive the execution end to perform the corresponding flipping action.

[0108] Furthermore, the specific process of correcting the acceleration in the next control cycle in the flip acceleration / deceleration adjustment module is as follows:

[0109] Based on historical segment flipping data, the acceleration change trend curves of each historical flipping operation and their corresponding segment feature information are obtained. The feature information includes weight, center of gravity position and geometric dimensions.

[0110] Obtain the feature information of the current segment, calculate its similarity with the features of historical segments, and select the overturning acceleration trend curve corresponding to the historical segment with the highest similarity as the reference overturning acceleration trend curve of the current segment.

[0111] Based on the reference trend curve of the reversal acceleration, the reference reversal acceleration for the next control cycle is determined.

[0112] The reference roll acceleration is corrected by combining the obtained roll acceleration adjustment amount to obtain the corrected roll acceleration for the next control cycle.

[0113] It should be noted that the similarity between the current segment and historical segments is calculated by extracting and quantifying key features that affect the flipping dynamics, such as weight, center of gravity position and geometric dimensions. Algorithms such as weighted Euclidean distance or cosine similarity are used to measure the overall feature matching degree between the current segment and historical segment samples in a multi-dimensional feature space, thereby identifying the historical reference sample with the closest dynamic behavior.

[0114] In this example, the present invention achieves controllable flipping of the tube segment by selectively opening and closing the vacuum passage of the vacuum chuck, and dynamically adjusts the flipping acceleration based on multiple parameters such as vacuum fluctuation rate, motor torque load rate and vibration acceleration to avoid equipment overload and tube segment damage.

[0115] Please see Figure 2 As shown, the present invention provides a fully automatic demolding and flipping method for tunnel segments, comprising the following steps:

[0116] Step 1: Perform a 3D scan of the tube segment, construct a spatial model of the tube segment and extract its geometric features. Combined with the weight of the tube segment, determine the number and arrangement of adsorption points on the backing surface of the tube segment and the demolding direction at the adsorption points.

[0117] Step 2: During the demolding process, monitor the reaction force and vertical displacement at the adsorption point in real time. Based on the preset synchronization rules, determine whether the demolding action meets the requirements. If it does, maintain the current demolding process. If it does not, dynamically correct the deviation by adjusting the lifting speed and adsorption force.

[0118] Step 3: Determine the rotation axis and active lifting side of the tube segment, and selectively open and close the vacuum passages of the vacuum suction cups on both sides to control the tube segment to flip.

[0119] Step 4: During the flipping process, monitor the vacuum fluctuation rate, drive motor torque load rate and vibration acceleration within the current control cycle to determine whether the flipping acceleration needs to be adjusted. If so, correct the acceleration of the next control cycle based on the acceleration adjustment information. If not, maintain the original flipping acceleration.

[0120] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0121] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0122] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0123] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0124] Finally, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A fully automatic demolding and flipping system for tunnel segments, characterized in that, include: Demolding path planning module: Performs 3D scanning of the tube segment, constructs a spatial model of the tube segment and extracts its geometric features, and determines the number and arrangement of adsorption points on the backing surface of the tube segment and the demolding direction at the adsorption points by combining the weight of the tube segment. Demolding anomaly correction module: During the demolding process, the reaction force and vertical displacement at the adsorption point are monitored in real time. Based on the preset synchronization rules, it is determined whether the demolding action meets the requirements. If it does, the current demolding process is maintained. If it does not, dynamic correction is performed by adjusting the lifting speed and adsorption force. The flipping action control module: determines the rotation axis side and the active lifting side of the tube segment, and selectively opens and closes the vacuum passage of the vacuum suction cups on both sides to control the flipping of the tube segment; The flip acceleration / deceleration adjustment module monitors the vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration during the flip process to determine whether the flip acceleration needs to be adjusted. If so, the acceleration of the next control cycle is corrected based on the acceleration adjustment information; otherwise, the original flip acceleration is maintained.

2. The fully automatic demolding and flipping system for tunnel segments according to claim 1, characterized in that: The specific working process of the demolding path planning module is as follows: After the mold is fully released, the segment is 3D scanned by the visual recognition unit of the demolding and flipping machine, and a spatial model of the segment is constructed based on the acquired 3D point cloud data. Based on the spatial model, identify the position and size of each hole on the backing surface of the tube segment; Based on the pre-stored hole safety distances in the database, a circular area is constructed with the center of each hole as the origin and the sum of the hole radius and the corresponding safety distance as the radius, which serves as the area where the hole is located; Exclude all areas containing the holes from the curved area of ​​the segment backing surface to obtain the area of ​​deployable adsorption points; The weight information of the tube segment is obtained, and combined with the rated adsorption force of a single vacuum suction cup, the safety factor and overall efficiency of the lifting system, which are pre-stored in the database, the number of adsorption points required on the backing surface of the tube segment is determined according to the set adsorption point number calculation formula. Based on the determined number of adsorption points, multiple adsorption points are symmetrically arranged within the area where adsorption points can be deployed. The normal direction of the surface at each adsorption point is determined as the demolding direction of the corresponding adsorption point.

3. The fully automatic demolding and flipping system for tunnel segments according to claim 1, characterized in that: The specific working process of the demolding anomaly correction module in determining whether the demolding action meets the requirements is as follows: The sensor unit of the demolding and flipping machine monitors the reaction force and vertical displacement at each adsorption point on the backing surface of the tube sheet in real time. Calculate the maximum deviation of the reaction force between all adsorption points and the maximum deviation of the vertical displacement. Determine if the following conditions are met simultaneously: (1) The maximum deviation of the reaction force is less than or equal to a preset reaction force deviation threshold; (2) The maximum deviation of the vertical displacement is less than or equal to the preset vertical displacement deviation threshold; If both conditions are met simultaneously, the demolding action is deemed to meet the synchronization requirement. Otherwise, the demolding action is deemed not to meet the synchronization requirements.

4. The fully automatic demolding and flipping system for tunnel segments according to claim 1, characterized in that: The specific working process of dynamic correction in the demolding anomaly correction module is as follows: D1: Identify the adsorption points where there is stagnation based on the reaction force and vertical displacement at each adsorption point; D2: Based on the pre-stored demolding speed unit adjustment amount in the database, reduce the lifting speed of the stuck adsorption point as an initial trial adjustment; D3: After the initial adjustment, re-test the maximum deviation of the reaction force between all adsorption points and the maximum deviation of the vertical displacement. If at least one of the maximum deviations decreases, the initial trial adjustment is deemed effective, and adjustment continues in the current direction until the synchronization requirement is met. If the maximum deviations mentioned above do not decrease, the initial adjustment is deemed invalid, and D4 is executed. D4: Based on the pre-stored vacuum suction cup adsorption force unit adjustment amount in the database, increase the adsorption force of the stuck adsorption point as a secondary trial adjustment; D5: After the second trial adjustment, re-detect the maximum deviation of the reaction force between all adsorption points and the maximum deviation of the vertical displacement. If at least one of the maximum deviations decreases, the second trial adjustment is deemed effective, and adjustment continues in the current direction until the synchronization requirement is met. If the maximum deviation is not reduced, the second trial adjustment is deemed invalid, and a system warning is triggered.

5. The fully automatic demolding and flipping system for tunnel segments according to claim 4, characterized in that: The specific process for identifying the presence of stuck adsorption points is as follows: A coordinate system was established with the adsorption point number as the abscissa and the reaction force and vertical displacement as the ordinates. The corresponding data of each adsorption point were marked in the coordinate system, and point distribution maps of reaction force and vertical displacement were formed respectively. Linear fitting is performed on the data points in the point distribution map to obtain the reaction force fitting line and the vertical displacement fitting line, respectively. An adsorption point is considered a stuck adsorption point if it meets any of the following conditions: (1) The reaction force value at the adsorption point is above the reaction force fitting line, and its deviation is greater than the set first deviation threshold. (2) The vertical displacement value of the adsorption point is below the vertical displacement fitting line, and its deviation is greater than the set second deviation threshold.

6. The fully automatic demolding and flipping system for tunnel segments according to claim 1, characterized in that: The specific working process of the flipping motion control module is as follows: Based on the predetermined rotation direction of the tunnel segment, determine one side as the rotation axis side and the other side as the active lifting side. Close the vacuum passages of all vacuum suction cups on the rotating shaft side, while keeping the vacuum passages of all vacuum suction cups on the active lifting side open. After the tube segment is flipped to the target angle, the vacuum passage of the rotating shaft-side vacuum chuck is reopened.

7. The fully automatic demolding and flipping system for tunnel segments according to claim 1, characterized in that: The specific process for determining whether the roll acceleration needs adjustment in the roll acceleration / deceleration adjustment module is as follows: The flipping process is divided into segments according to a set time window to obtain a continuous control cycle; Monitor the vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration during the current control cycle; The vacuum fluctuation rate, drive motor torque load rate, and vibration acceleration are compared with their respective preset warning thresholds. If any of these parameters exceeds the corresponding warning threshold, it is determined that the rollover acceleration needs to be adjusted. If all parameters do not exceed the corresponding warning threshold, it is determined that there is no need to adjust the rollover acceleration.

8. The fully automatic demolding and flipping system for tunnel segments according to claim 1, characterized in that: The specific process for obtaining acceleration adjustment information in the flip acceleration / deceleration adjustment module is as follows: The overshoot of vacuum fluctuation rate, drive motor torque load rate and vibration acceleration exceeding their respective warning thresholds is obtained, and the parameter corresponding to the largest overshoot is selected as the adjustment reference parameter. The correction model corresponding to each parameter is pre-stored in the database. The correction model includes a quantized mapping relationship between overshoot and the decrease in flip acceleration. Based on the overshoot of the aforementioned adjustment reference parameter, the adjustment amount of the rollover acceleration is determined through the corresponding correction model.

9. The fully automatic demolding and flipping system for tunnel segments according to claim 8, characterized in that: The specific process of correcting the acceleration in the next control cycle in the flip acceleration / deceleration adjustment module is as follows: Based on historical segment flipping data, the acceleration change trend curves of each historical flipping operation and their corresponding segment feature information are obtained. The feature information includes weight, center of gravity position and geometric dimensions. Obtain the feature information of the current segment, calculate its similarity with the features of historical segments, and select the overturning acceleration change trend curve corresponding to the historical segment with the highest similarity as the reference change trend curve of the overturning acceleration of the current segment. Based on the aforementioned trend curve of the overturning acceleration reference change, determine the reference overturning acceleration for the next control cycle; The reference roll acceleration is corrected by combining the obtained roll acceleration adjustment amount to obtain the corrected roll acceleration for the next control cycle.

10. A fully automated method for demolding and flipping tunnel segments, characterized in that, Includes the following steps: Step 1: Perform a 3D scan of the tube segment, construct a spatial model of the tube segment and extract its geometric features. Combined with the weight of the tube segment, determine the number and arrangement of adsorption points on the backing surface of the tube segment and the demolding direction at the adsorption points. Step 2: During the demolding process, monitor the reaction force and vertical displacement at the adsorption point in real time. Based on the preset synchronization rules, determine whether the demolding action meets the requirements. If it does, maintain the current demolding process. If it does not, dynamically correct the deviation by adjusting the lifting speed and adsorption force. Step 3: Determine the rotation axis side and the active lifting side of the tube segment, and selectively open and close the vacuum passage of the vacuum suction cups on both sides to control the tube segment to flip. Step 4: During the flipping process, monitor the vacuum fluctuation rate, drive motor torque load rate and vibration acceleration within the current control cycle to determine whether the flipping acceleration needs to be adjusted. If so, correct the acceleration of the next control cycle based on the acceleration adjustment information. If not, maintain the original flipping acceleration.

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