TBM mixed spraying device and mixed spraying method

Abstract

The invention discloses a TBM (Tunnel Boring Machine) mixed spraying device and a mixed spraying method, and solves the problems that a slewing mechanism in the prior art is easy to be invaded by deflection rebounding materials, and the guniting effect cannot be detected and treated in time. The TBM mixed spraying device comprises a guniting bridge frame and a guniting cart, a visual spraying assembly is arranged on the inner ring face of the guniting cart, and a guniting detecting and strickling assembly is arranged on the outer ring face of the guniting cart. The visual spraying assembly comprises a rotary trolley, the rotary trolley can move in the circumferential direction along the inner ring face of the guniting cart, and a mixing spraying head and a visual assembly are arranged on the rotary trolley. The guniting detecting and strickling assembly comprises a detecting assembly and a strickling assembly. The visual spraying assembly is arranged on the inner ring face of the guniting cart, the whole mixed spraying structure is of a sinking type suspension structure, the upper portion and the side edge of a movement mechanism are completely sealed, rebound materials can be effectively prevented from invading, in addition, the length of a cantilever beam can be reduced through the structure, the stress condition of the rotary cart is improved, stability is improved, and the service life is prolonged.

Description

Technical Field

[0001] This invention relates to the field of tunnel construction technology, and in particular to a mixed spraying system. Background Technology

[0002] During tunnel construction, TBMs typically require initial shotcrete support to stabilize the surrounding rock and ensure the TBM can successfully traverse areas with fractured rock. To support shotcrete, TBMs are generally equipped with a mixed-spray system, whose main function is to spray concrete onto the tunnel walls, forming a concrete support layer of a certain thickness after the concrete has hardened.

[0003] A mixed-spray system typically includes a shotcrete bridge and a mixed-spray device, i.e., a concrete spraying device, capable of moving back and forth along the shotcrete bridge of the TBM. In the prior art, such as Chinese invention patent application publication number CN108772230A, a concrete spraying device is provided. This device includes a base frame, on which a circumferential rotating mechanism that moves circumferentially relative to the base frame is mounted, and an arc-shaped track is provided on the base frame for the movement of the circumferential rotating mechanism. An arc-shaped rack structure is also provided between the circumferential rotating mechanism and the base frame. A drive device and a pinion are configured to drive the rotating mechanism; the pinion and rack structure mesh to drive the circumferential rotating mechanism to rotate relative to the base frame, thereby driving the nozzle assembly mounted on the circumferential rotating mechanism to achieve circumferential coverage spraying of the tunnel. However, in actual construction, due to problems such as improper concrete mix proportions, unsuitable distance between the nozzle and the tunnel wall, excessive angle between the nozzle and the tunnel wall, and non-standard operation by workers, a certain amount of rebound concrete material is inevitably generated. The concrete contains a lot of aggregate. If the rebounding material falls onto the curved track, it may cause the circumferential rotating mechanism to jam. If the rebounding material falls onto the rack, it may damage or jam the pinion.

[0004] To address the aforementioned issues, Chinese invention patent application CN117287231A provides a mixing spraying device and system. This mixing spraying device includes a basic frame and a circumferential rotating mechanism. The circumferential rotating mechanism includes a wheel frame for mounting wheels. An arc-shaped track is provided on the basic frame for the circumferential rotating mechanism to move. A baffle plate is provided on the outer side of the wheel frame, with the curvature of the baffle plate not less than that of the arc-shaped track. The baffle plate can cover part or all of the wheel frame, and its vertical projection satisfies the requirement of covering the vertical projection of the arc-shaped track. While this invention patent provides partial protection for the circumferential rotating mechanism by using baffle plates, gaps exist between the baffle plates, making complete isolation of the rotating mechanism impossible. Furthermore, the overall cantilever beam fixing structure of the mixing spray nozzle results in poor stress distribution on the rotating mechanism, leading to problems such as movement jamming during rotation, abnormal wear, and damage to the rotating mechanism.

[0005] To address the issues of motion jamming during rotation caused by rebound material intrusion and the long cantilever beam installation of the mixing nozzle, as well as abnormal wear and damage to the rotation mechanism, it is necessary to design a submerged TBM mixing device.

[0006] In addition, during the actual shotcreting process, uneven shotcrete thickness and uneven surface often occur due to factors such as the quality of shotcrete and the skill level of manual operation. During the later positioning and measurement of the secondary lining construction, it is often found that the thickness of shotcrete in different layers of the tunnel is too thick or too thin. In order to meet the requirements of the concrete thickness of the secondary lining construction, it is necessary to manually remove the excessively thick shotcrete (i.e., the under-excavated area) with pneumatic picks in advance. However, the insufficient shotcrete area leads to the over-consumption of concrete in the secondary lining construction. In the prior art, Chinese invention patent application CN114991822A provides a scraping device for the surface of shotcrete in TBM construction tunnels. This device includes a frame mounted on a shotcrete bridge between two shotcrete devices. The frame is equipped with a scraping mechanism, a rotating moving mechanism, and a forward / backward moving mechanism. The scraping mechanism includes a moving platform, a scraping arm, a scraping plate, and an adjusting cylinder. The rotating moving mechanism includes a suspension fixedly connected to the bottom of the moving platform, with gears at both ends that mesh with corresponding toothed surfaces. The forward / backward moving mechanism includes support frames symmetrically arranged inside the frame, with sliding wheels rotatably mounted at the front end of each support frame. A telescopic cylinder drives the frame to move forward and backward along the main beam of the shotcrete bridge. However, this device requires a newly installed independent mechanism, encroaching on the working space of the shotcrete bridge. Furthermore, it lacks methods for detecting the thickness and quality of the shotcrete, requiring manual inspection and subsequent processing of any defects. This results in a large workload and a delay in processing.

[0007] To address the aforementioned issues, it is essential to design a novel mixed spraying structure that enables timely detection and processing of the spraying effect during the spraying process. Summary of the Invention

[0008] To address the shortcomings in the aforementioned background technology, this invention proposes a TBM mixing and spraying device and method, which solves the problems in the prior art where the rotary mechanism is susceptible to intrusion by deflected and rebounding material and the spraying effect cannot be detected and processed in a timely manner.

[0009] The technical solution of this invention is implemented as follows: A TBM mixed spraying device includes a spraying bridge and a spraying trolley. A vision spraying component is provided on the inner ring surface of the spraying trolley, and a spraying detection and leveling component is provided on the outer ring surface. The vision spraying component includes a rotating trolley that can move circumferentially along the inner ring surface of the spraying trolley. The rotating trolley is equipped with a mixing nozzle and a vision component. The spraying detection and leveling component includes a detection component and a leveling component. A slag receiving component is also provided on the outer ring surface of the spraying trolley, located at the slag drop position of the leveling component. The vision spraying component is provided on the inner ring surface of the spraying trolley. This mixed spraying structure adopts a sunken suspension structure, with the upper and sides of the moving mechanism completely sealed, effectively preventing rebound material intrusion. Furthermore, this structure reduces the cantilever beam length, improves the stress on the rotating trolley, and enhances stability and service life. The spraying detection and leveling component is provided on the outer ring surface of the spraying trolley to detect and process the spraying effect during the spraying process, ensuring spraying quality and improving work efficiency.

[0010] Further optimized, the leveling assembly includes several leveling units arranged along the outer circumference of the shotcrete trolley; each leveling unit includes a scraper blade and a leveling base connected to the outer circumference of the shotcrete trolley. The scraper blade is connected to the leveling base via a scraper telescopic rod, and the front end face of the scraper blade is provided with a cutting edge. The several leveling units form a large, ring-shaped, segmented scraper to level the shotcrete layer in a timely manner, thereby improving the shotcrete quality.

[0011] Further optimized, four slag-scraping telescopic rods are provided between the leveling base and the slag-scraping plate. The two ends of the four slag-scraping telescopic rods are respectively hinged to the leveling base and the slag-scraping plate through pins to form a parallelogram mechanism. The slag-scraping mechanism of this parallelogram mechanism ensures the flatness of the slag-scraped surface, thereby improving the flatness of the coating.

[0012] Further optimization reveals that the slag receiving assembly includes a slag collection trough positioned on the outer ring surface of the shotcrete trolley. The slag outlet at the bottom of the slag collection trough corresponds to the slag collection hopper positioned on the shotcrete trolley. The slag collection trough is located between the detection assembly and the leveling assembly. A high-pressure water jet is installed on the slag collection trough for flushing. The slurry scraped off by the leveling assembly falls into the slag collection trough, achieving slurry recycling and reducing construction costs. The high-pressure water jet is used to flush the slurry in the slag collection trough, preventing it from sticking together and causing blockages.

[0013] In a further optimized design, an annular baffle plate is provided between the slag collection tank and the detection component, and the annular baffle plate is equipped with a guide plate corresponding to the slag collection tank. The annular baffle plate is used to block slag and prevent mud splashing from the scraping component during the slag scraping process from contaminating the detection component.

[0014] Further optimization involves the detection component comprising several distance sensors arranged along the outer ring surface of the shotcrete trolley, with the distance sensors located on the same concentric circle, enabling simultaneous detection of the entire shotcrete surface.

[0015] Further optimized, the detection component includes a detection gear ring set on the outer ring surface of the shotcrete trolley, a movable seat on the detection gear ring, a small gear driven by a drive motor at the bottom of the movable seat, the small gear meshing with the detection gear ring, and a distance sensor on the movable seat; by driving the small gear to rotate through the drive motor, the distance sensor is moved to perform motion-type ring surface detection; thus increasing mobility.

[0016] Further preferably, the shotcrete trolley includes a trolley frame, with a large gear ring and a circumferential motion track on the inner ring surface of the trolley frame; the rotary trolley includes a trolley main frame adapted to the inner ring surface of the trolley frame, with circumferential traveling wheels and a drive gear on the trolley main frame, the circumferential traveling wheels cooperating with the circumferential motion track, the drive gear meshing with the large gear ring, and the drive gear connected to a rotary drive assembly set on the trolley main frame.

[0017] Further optimization involves an anti-slag plate on the front face of the main trolley frame; the mixing nozzle is connected to the trolley main frame via a telescopic base, and vision components are installed on both sides of the trolley main frame. The vision components are used to observe the spraying status in real time.

[0018] Further preferably, the vision component includes a telescopic mechanism and an image acquisition unit. The image acquisition unit is connected to the telescopic mechanism via a rotating mechanism, and an encoder is installed on the rotating mechanism. A protective cover corresponding to the image acquisition unit is installed on the rotary trolley. In the working state, the image acquisition unit moves forward via the telescopic mechanism to monitor the spraying status in real time; in the non-working state, the image acquisition unit moves backward into the protective cover via the telescopic mechanism.

[0019] In a further preferred embodiment, the trolley frame is connected to the shotcrete bridge via a front and rear traveling mechanism. The front and rear traveling mechanism includes front and rear motion tracks on both sides of the shotcrete bridge and traveling support frames on both sides inside the trolley frame. The traveling support frames are equipped with front and rear traveling wheels, which move along the front and rear motion tracks under the action of the drive component, thereby enabling the trolley frame to move stably back and forth relative to the shotcrete bridge.

[0020] In a further preferred embodiment, the drive assembly includes a drive motor mounted on the trolley frame, a travel gear mounted on the output shaft of the drive motor, the travel gear meshing with a travel rack mounted on the shotcrete bridge, and a travel stroke sensor mounted on the travel support frame to detect and control the forward and backward movement distance of the shotcrete trolley.

[0021] A mixed spraying method, using the aforementioned TBM mixed spraying device, specifically works as follows: S1: Mixed spraying preparation, the spraying trolley is in the initial position; complete the spraying preparation work.

[0022] S2: The shotcrete truck moves forward to the area to be shotcreted; to ensure that the distance measuring sensor fully scans the tunnel wall of the area to be shot.

[0023] S3: The distance sensor of the shotcrete detection and leveling component performs a pre-spraying scan of the tunnel wall in the area to be sprayed and transmits the pre-spraying scan data to the host computer.

[0024] S4: The shotcrete trolley reverses to its initial position.

[0025] S5: Spraying begins. The mixing nozzle of the vision spraying component sprays the area to be sprayed, while the vision component of the vision spraying component observes the spraying status in real time.

[0026] S6: After the shotcrete work in the area to be sprayed is completed, the initial spraying area is formed, and the shotcrete truck moves forward to the initial spraying area.

[0027] S7: The distance sensor of the spraying detection and leveling component performs post-spraying scanning detection on the surface of the sprayed coating in the initial spraying area and transmits the post-spraying scanning detection data to the host computer.

[0028] S8: The host computer uses post-spray scanning detection data and pre-spray scanning detection data to build a model, and then analyzes and calculates the spray thickness and coating smoothness. Specifically, the host computer's modeling process using post-spray scanning detection data and pre-spray scanning detection data is as follows: Based on the working area distribution range of the TBM mixed spraying system, its working range is divided into four regions: Region I, Region II, Region III, and Region IV, with corresponding angles of θ, π / 4, π / 4, and θ, respectively; where π / 6 ≤ θ ≤ π / 3.

[0029] The radius of the arc where the range sensor is located is R, the measured value of the range sensor is S, the actual rotation angle of the range sensor is γ, and the actual placement angle of the range sensor is α. The actual distance from the measurement point to the center of the circle. , The compensation angle for the measurement point is ŋ, because , so , The actual angle measured by the distance sensor is , The actual angle measured by the distance sensor is , The axial position distance Z is obtained from the travel sensor on the shotcrete trolley. Based on L, Z, and φ1 or φ2, a three-dimensional digital model of the tunnel in the detection area is then established.

[0030] S9: When the coating thickness is less than the set value, the spraying trolley moves back to the initial position to re-spray the area initially coated; when the coating thickness is greater than the set value and / or the flatness is unqualified, the leveling component is raised to level the area initially coated; when the coating thickness is equal to the set value and the flatness is qualified, the spraying trolley moves forward to spray the next area.

[0031] The beneficial effects of this invention are as follows: The visual spraying component of this invention is set on the inner ring surface of the spraying trolley, adopting a sunken suspension structure. The upper part and sides of the moving mechanism are completely sealed, which can effectively prevent the intrusion of rebounding material. In addition, the structural form can reduce the length of the cantilever beam, improve the stress situation of the rotating trolley, and improve stability and service life. A spraying thickness and quality detection and processing device, namely a spraying detection and leveling group, is arranged on the outside of the mixed spraying structure. During the spraying process, it can realize real-time detection and timely feedback processing of the spraying thickness and condition. It can handle the problem in time before the concrete material solidifies, reduce the difficulty of cleaning when overspraying, and promptly respray when underspraying, ensuring the bonding strength of the concrete and improving the spraying quality.

[0032] The shotcrete inspection and leveling component of this invention performs three-dimensional morphological scanning of the freshly sprayed area to quickly identify problems such as uneven surface and insufficient thickness. The leveling component can immediately perform mechanical leveling or pre-spraying treatment on defective areas, realizing closed-loop control of "inspecting and repairing while spraying," avoiding the inefficient process of "waiting for solidification after spraying → manual inspection → secondary repair" in the traditional way. The inspection component and the leveling component work together to shorten the process cycle, improve construction efficiency, and ensure that the flatness and density of the sprayed layer meet the design requirements.

[0033] The mixing nozzle of the vision-guided spraying assembly of this invention is based on vision guidance and can be dynamically adjusted. It can adjust the spraying angle, speed and slurry volume in real time according to visual feedback, realizing intelligent control of "spraying while watching". It significantly improves spraying quality, reduces material waste and lowers the cost of later repairs.

[0034] The mixed spraying method of this invention calculates thickness / flatness in the same coordinate system before and after spraying, eliminating cumulative errors and improving measurement accuracy. Furthermore, the dual-path defect handling method of "backward respraying + forward scraping" does not occupy additional cycle time, improving work efficiency. In addition, during the mixed spraying process, the vision component monitors rebound, slurry adhesion, and jet angle in real time, adjusting nozzle swing speed and pump speed accordingly. The distance sensor provides quantitative results, providing closed-loop compensation for millimeter-level thickness deviations that the vision system cannot discern. This dual closed-loop superposition improves the coating pass rate. Attached Figure Description

[0035] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying 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.

[0036] Figure 1 This is a schematic diagram of the main view of the present invention; Figure 2 This is a side view schematic diagram of the vision jetting component of the present invention; Figure 3 for Figure 2 Partial display Figure I Schematic diagram; Figure 4 This is a schematic diagram of the vision spraying component; Figure 5 This is a top view of the vision spraying assembly; Figure 6 Schematic diagram of two modes of the vision spraying component; Figure 7 This is a schematic diagram of the present invention without an escalator; Figure 8 for Figure 7 Mid-local view Figure II Schematic diagram; Figure 9 This is a schematic diagram of the shotcrete truck as a whole. Figure 10 for Figure 9 Mid-local view Figure III Schematic diagram; Figure 11 Schematic diagram of shotcrete inspection and leveling components; Figure 12 Figure 11 Mid-local view Figure IV Schematic diagram; Figure 13 This is a schematic diagram of the detection component in Example 3; Figure 14 This is a schematic diagram of the leveling component; Figure 15 A schematic diagram of the scanning and modeling state before shotcreting; Figure 16 This is a schematic diagram of the working state during shotcreting; Figure 17 This is a flowchart of the mixed spraying process; Figure 18 This is a schematic diagram of the contour division during the flatness calculation process; Figure 19 This is a schematic diagram of the calculations for region I during the modeling process; Figure 20 This is a schematic diagram illustrating the calculations for Region II during the modeling process; Figure 21 This is a schematic diagram for calculating the flatness index. Detailed Implementation

[0037] 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.

[0038] Example 1, as Figure 1 As shown, a TBM mixed spraying device includes a spraying bridge 1 and a spraying trolley 2. The spraying bridge 1, similar to existing technologies, includes a bridge body 11 and a protective canopy 12, with the protective canopy located on the upper part of the bridge body 11. A vision spraying component 5 is provided on the inner ring surface of the spraying trolley 2. Based on visual guidance, the vision spraying component 5 can be dynamically adjusted to improve spraying accuracy. Furthermore, the vision spraying component 5, located on the inner ring surface of the spraying trolley 2, adopts a sunken suspension structure, completely sealing the upper and side parts of the moving mechanism, effectively preventing material rebound intrusion. This structure also reduces the length of the cantilever beam, improves the stress on the rotating trolley, and enhances stability and service life. A spraying detection and leveling component 4 is provided on the outer ring surface of the spraying trolley 2. This component, located on the outer ring surface of the spraying trolley 2, is a spraying thickness and quality detection and processing device arranged on the outside of the mixed spraying structure. During the spraying process, the spraying effect is detected and processed to ensure spraying quality and improve work efficiency.

[0039] Specifically, such as Figure 2 As shown, the vision-based spraying assembly 5 includes a rotating trolley 22, which can move circumferentially along the inner ring surface of the shotcrete trolley 2; achieving full-coverage spraying and avoiding missed or repeated spraying. The rotating trolley 22 is equipped with a mixing nozzle 226 and a vision assembly 3; the vision assembly 3 is used for image acquisition, acquiring images of the spraying area in real time and identifying defects such as spraying thickness, uniformity, and voids; the mixing nozzle, based on vision guidance, can achieve dynamic adjustment, that is, adjusting the spraying angle, speed, and slurry volume in real time according to visual feedback, realizing intelligent control of "spraying while watching"; significantly improving spraying quality, reducing material waste, and lowering subsequent repair costs.

[0040] In this embodiment, as Figure 11As shown, the shotcrete inspection and leveling component 4 includes an inspection component 41 and a leveling component 43. The inspection component 41 performs a three-dimensional morphological scan of the freshly shot area to quickly identify problems such as uneven surface and insufficient thickness. The leveling component 43 can immediately perform mechanical leveling or pre-spraying treatment on defective areas, realizing a closed-loop control of "inspecting and repairing while spraying," avoiding the inefficient process of "waiting for solidification after spraying → manual inspection → secondary repair" in the traditional way. The inspection component 41 and the leveling component 43 work together to shorten the process cycle, improve construction efficiency, and ensure that the flatness and density of the shotcrete layer meet the design requirements. A slag receiving component 42 is also provided on the outer ring surface of the shotcrete trolley 2. The slag receiving component 42 is located at the slag drop position of the leveling component 43. The slag receiving component is located below the leveling component and collects the scraped slurry or lumps in real time to prevent them from falling into the bottom of the tunnel or equipment gaps; it reduces the amount of manual cleaning work and avoids the accumulation of waste slag that leads to equipment wear or tunnel pollution; the collected slurry can be partially recycled and reused, improving material utilization. This invention integrates four major functions—spraying, inspection, trimming, and slag collection—onto a single shotcrete truck, eliminating the need for additional equipment or secondary site visits. The inner ring (spraying) and outer ring (inspection / trimming) spaces are utilized in layers without interference, adapting to the confined space of a TBM. The integrated structural design reduces system complexity and enhances the safety of operations within the tunnel.

[0041] Example 2, as Figure 9 As shown, a TBM mixed spraying device is further optimized based on Embodiment 1. In this embodiment, the leveling component 43 includes several leveling units arranged along the outer ring surface of the spraying trolley 2. The several leveling units form a large scraper arranged in a ring and in sections to level the sprayed layer in a timely manner to improve the spraying quality. Modular setting and segmented control can flexibly deal with local defects. The several leveling units are distributed along the outer ring surface to form a "ring-shaped blade array", which can be activated locally or adjusted individually. When the detection component detects that there is a protrusion or excessive thickness in a certain area, only the leveling unit at the corresponding position is activated to avoid over-trimming caused by "full-section scraping". In this embodiment, the leveling component supports switching between two modes: "fixed-point leveling" and "full-area leveling" to adapt to different defect distribution characteristics.

[0042] Specifically, such as Figure 14As shown, the leveling unit in this embodiment includes a scraper plate 435 and a leveling base 431 connected to the outer ring surface of the shotcrete trolley 2. The leveling base is fixed to the outer ring surface of the shotcrete trolley 2 by bolts, and the scraper plate 435 is connected to the leveling base 431 by a scraper telescopic rod 432. The extension length of each leveling unit can be independently adjusted to automatically adapt to uneven tunnel cross-sections, over-excavation, or under-excavation areas. The front end of the scraper plate 435 is provided with a cutting edge to improve leveling efficiency, reduce equipment load, and adapt to high-intensity continuous operation. When the lifting leveling component detects over-spraying or unqualified flatness, the scraper drive extends, causing the scraper plate to automatically rise for scraping. When the shotcrete thickness is insufficient, an alarm is triggered, and the entire trolley retracts for supplementary spraying.

[0043] As a preferred embodiment, four slag-scraping telescopic rods 432 are provided between the leveling base 431 and the slag-scraping plate 435. The two ends of the four slag-scraping telescopic rods 432 are respectively hinged to the leveling base 431 and the slag-scraping plate 435 through pins 433 to form a parallelogram mechanism. The opposite sides of the parallelogram mechanism remain parallel, and the slag-scraping plate moves as a whole; the surface of the sprayed layer is planed parallel to the surface, and the flatness meets the standard in one go, without the need for repeated repairs.

[0044] In this embodiment, as a preferred solution, such as Figure 11 , 12 As shown, the slag receiving assembly 42 includes a slag collection trough 421 disposed on the outer ring surface of the shotcrete trolley 2. The slag collection trough is a large arc-shaped trough adapted to the outer ring surface of the shotcrete trolley 2; it is used to receive the slag scraped off by the leveling unit. The slag can be reused, meeting the requirements of green construction. The slag outlet at the bottom of the slag collection trough 421 corresponds to the slag collection hopper 422 disposed on the shotcrete trolley 2; the slag in the slag collection trough 421 enters the slag collection hopper 422 for collection. The slag collection trough 421 is located between the detection assembly 41 and the leveling assembly 43; detection is performed before leveling, and no slag is wasted. The slag collection trough 421 is equipped with a high-pressure water spray nozzle 423; the number of high-pressure water spray nozzles 423 can be set as needed. The high-pressure water spray nozzles are angled downwards to facilitate the washing of the slag; the high-pressure water spray nozzles wash the slag and collect it into the slag collection hopper.

[0045] As a preferred embodiment, an annular baffle plate 424 is provided between the slag collection trough 421 and the detection component 41 to prevent scraped-off slag from contaminating the detection component. The annular baffle plate 424 is equipped with a guide plate corresponding to the slag collection trough 421, which guides the slurry on the annular baffle plate into the slag collection trough, further improving slag collection efficiency. It should be noted that, to prevent scraped-off slag from contaminating the detection component, an openable box structure can also be used to enclose the detection component. The box is opened during operation and closed during non-operation; this is existing technology and will not be elaborated upon here.

[0046] In one implementation, the detection component 41 in this embodiment includes several distance sensors 401 arranged along the outer ring surface of the shotcrete trolley 2. The distance sensors 401 are located on the same concentric circle, meaning they are statically arranged in a ring, simplifying the three-dimensional contour measurement to a two-dimensional polar coordinate scan for pure radial measurement; this improves measurement accuracy and allows for simultaneous measurement of the entire ring surface, increasing measurement efficiency. The distance sensors are pan-tilt distance sensors, such as ultrasonic, laser, or radar distance sensors. It should be noted that the shotcrete working area is set up as several detection and processing units according to the circumference of the distance sensors; the arc length of the scraper blade is a multiple of the scanning range of a single distance sensor, facilitating scraping and leveling.

[0047] Example 3, a TBM mixed spraying device, such as Figure 13 As shown, this embodiment is a further optimization based on Embodiment 1. The difference between this embodiment and Embodiment 2 is that the detection component 41 includes a detection gear ring 411 disposed on the outer ring surface of the shotcrete trolley 2. A movable seat 412 is mounted on the detection gear ring 411, and a small gear driven by a drive motor is located at the bottom of the movable seat 412. The small gear meshes with the detection gear ring 411, and a distance sensor 401 is mounted on the movable seat 412. The drive motor drives the small gear to rotate, causing the movable seat to move along the outer ring surface of the shotcrete trolley 2, thereby realizing the circumferential movement of the distance sensor for motion-based ring surface detection, increasing mobility. Compared to Embodiment 2, this embodiment upgrades the "distance sensor" from a "fixed ring" to a "single-point high-speed ring-running" form, reducing the investment cost of the distance sensor. Furthermore, other auxiliary components such as supplementary lighting and image acquisition can be integrated on the movable seat to further improve detection integration and accuracy.

[0048] like Figure 4 , 5As shown, the shotcrete trolley 2 in this embodiment includes a trolley frame 21, which has a large arc-shaped structure to adapt to circular tunnel support. A large gear ring 211 and a circumferential motion track 212 are provided on the inner ring surface of the trolley frame 21. The rotary trolley 22 includes a trolley main frame 221 adapted to the inner ring surface of the trolley frame 21. Circumferential traveling wheels 222 and a drive gear 224 are provided on the trolley main frame 221. The circumferential traveling wheels 222 cooperate with the circumferential motion track 212, allowing the rotary trolley to be suspended on the inner ring surface of the trolley frame 21. The drive gear 224 meshes with the large gear ring 211, and the drive gear 224 is connected to a rotary drive assembly 225 provided on the trolley main frame 221. The rotary drive assembly can be a motor, which drives the drive gear to rotate while moving along the large gear ring, realizing the circumferential movement of the rotary trolley. The main frame of the trolley has a U-shaped symmetrical structure with several internal support ribs. A rotary drag chain 223 is arranged at the internal notch, and circumferential traveling wheels 222 are arranged on both sides. The rotary drag chain 2223 is arranged on the upper part of the rotary trolley, with the moving end connected to the main frame of the rotary trolley and the fixed end connected to the main frame of the trolley. Preferably, the nozzle is mounted on the lower part of the main frame of the trolley via an adapter, with the center of rotation of the nozzle located at the center line to ensure consistent spraying range on both sides. In addition, one or more sets of drive gears are arranged at the bottom of the main frame of the trolley to drive stable circumferential movement.

[0049] like Figure 3 As shown, in this embodiment, the trolley frame is also equipped with a ladder 24, arranged symmetrically on both sides, with a passageway in the center for easy passage of personnel and materials. A slag-prevention plate 213 is provided on the front face of the trolley frame 21; the slag-prevention plate 213 extends above the front face of the frame, forming a rigid curtain to prevent mud splashing and contamination. The mixing nozzle 226 is connected to the trolley main frame 221 via a telescopic base 227, which can be used to adjust the extension distance of the mixing nozzle. In this embodiment, the vision component 3 is located on both sides of the trolley main frame 221; the nozzles are symmetrically arranged on both sides to ensure the accuracy of image acquisition and to achieve blind-spot-free monitoring.

[0050] like Figure 6As shown in the illustration, in this embodiment, the vision component 3 specifically includes a telescopic mechanism 31 and an image acquisition unit 34. The telescopic mechanism can be a telescopic cylinder or a rack and pinion mechanism; in this embodiment, a telescopic cylinder is used as an example. The image acquisition unit can be an industrial camera. The image acquisition unit 34 is connected to the telescopic mechanism 31 via a rotating mechanism 33. The rotating mechanism can be a motor or a rotating shaft driven by a motor, used to adjust the working angle of the image acquisition unit. An encoder is provided on the rotating mechanism 33; the rotating mechanism and the nozzle are interlocked at the angle to ensure that the monitoring range is within the spraying working range. A protective cover 32 corresponding to the image acquisition unit 34 is provided on the rotary trolley 22. The vision component 3 has two working states. When the telescopic mechanism extends, it enters the working position, and the rotating mechanism adjusts the angle of the image acquisition unit in real time to observe the spraying status. In the non-working state, when the telescopic mechanism retracts, the image acquisition unit enters the protective cover.

[0051] In this embodiment, as shown... Figure 7 , 8 As shown, the trolley frame 21 is connected to the shotcrete bridge 1 via a front-rear traveling mechanism 23, which is used for the forward and backward movement of the shotcrete trolley on the shotcrete bridge. In this embodiment, the front-rear traveling mechanism 23 includes front-rear movement tracks 235 arranged on both sides of the shotcrete bridge 1 and traveling support frames 236 arranged on both sides inside the trolley frame 21, as shown. Figure 9 , 10 As shown, the walking support frame 236 is equipped with front and rear walking wheels 234. Under the action of the drive component, the front and rear walking wheels 234 move along the front and rear movement tracks 235. The drive component can be a motor, which directly drives the front and rear walking wheels 234 to move along the rear movement track 235. To ensure the stability of the front and rear movement, the walking support frame 236 preferably adopts an asymmetrical structure as shown in the figure, with the drive component arranged in the middle of the front and rear guide wheels to optimize the force on the front and rear walking drive components.

[0052] In this preferred embodiment, the drive assembly includes a drive motor 231 mounted on the main frame 21. A traveling gear 232 is mounted on the output shaft of the drive motor 231, and the traveling gear 232 meshes with a traveling rack 233 mounted on the shotcrete bridge 1. The drive motor drives the traveling gear to rotate along the traveling rack, while the front and rear traveling wheels move on the front and rear tracks, thereby achieving stable front-to-back movement of the main frame. In this embodiment, a travel distance sensor 237 is mounted on the traveling support frame 236 to detect the front-to-back movement distance of the shotcrete trolley, thereby controlling its axial movement relative to the tunnel and achieving precise regional shotcrete mixing.

[0053] Example 4, a mixed spraying method, using the TBM mixed spraying device described in Example 3, such as... Figure 17 As shown, the specific working process is as follows: S1: Mixing preparation, the shotcrete trolley 2 is in the initial position; complete the shotcrete preparation work.

[0054] S2: As Figure 15 As shown, the shotcrete trolley 2 moves forward to the area to be shot; to ensure that the ranging sensor fully scans the tunnel wall of the area to be shot.

[0055] S3: The distance sensor 401 of the shotcrete detection and leveling component 4 performs pre-spraying scanning detection on the tunnel wall of the area to be sprayed, and transmits the pre-spraying scanning detection data to the host computer.

[0056] S4: As Figure 16 As shown, the spraying trolley 2 retracts to its initial position. The host computer calculates the amount and thickness to be sprayed based on the pre-spray scanning and detection data to control the operation of the vision spraying component.

[0057] S5: Spraying begins. The mixing nozzle 226 of the vision spraying assembly 5 sprays the area to be sprayed, while the vision component 3 of the vision spraying assembly 5 observes the spraying status in real time. The vision component acquires images of the spraying process and then transmits the image information to the host computer. The host computer monitors the spraying status and spraying effect based on the image information.

[0058] S6: After the spraying operation in the area to be sprayed is completed, the initial spraying area is formed. The spraying trolley 2 moves forward to the initial spraying area so that the distance sensor can perform post-spray scanning detection on the surface of the sprayed layer in the initial spraying area.

[0059] S7: The distance sensor 401 of the spraying detection and leveling component 4 performs post-spraying scanning detection on the surface of the sprayed coating in the initial spraying area and transmits the post-spraying scanning detection data to the host computer.

[0060] S8: The host computer uses post-spray scanning and detection data and pre-spray scanning and detection data to build a model, and then analyzes and calculates the spray thickness and coating smoothness. Specifically, the host computer's modeling process using post-spray scanning and detection data and pre-spray scanning and detection data is as follows: Based on the working area distribution range of the TBM mixed spraying system, its working range is divided into four regions: Region I, Region II, Region III, and Region IV, with corresponding angles of θ, π / 4, π / 4, and θ, respectively; where π / 6 ≤ θ ≤ π / 3; calculations are performed for Region I as follows... Figure 19 As shown, the calculation for region II is as follows: Figure 20 As shown, regions III and IV are analogous to the two regions mentioned above.

[0061] The radius of the arc where the range sensor 401 is located is R, the measured value of the range sensor is S, the actual rotation angle of the range sensor is γ, the actual placement angle of the range sensor is α, and the rotatable measurement angle of the range sensor is 2β. The above data can be obtained through actual measurement or through the sensor. The actual distance from the measuring point to the center of the circle. .

[0062] The compensation angle for the measurement point is ŋ, because , so .

[0063] The actual angle measured by the distance sensor is The actual angle measured by the ranging sensor is The axial position distance Z is obtained from the travel distance sensor 237 on the shotcrete trolley; then, based on L, Z, and φ1 or φ2, a three-dimensional digital model of the tunnel in the detection area is established. Then, the method for detecting the smoothness index in the "High-Speed ​​Railway Tunnel Engineering Construction Quality Acceptance Standard" (TB10753-2018) is adopted, with stricter requirements for the smoothness index, such as... Figure 21 As shown, the flatness index P = D / L ≤ 1 / 20; and L is not greater than 1m, D is the height difference between the highest and lowest points of the sprayed surface within a 1m detection range, which does not exceed 50mm. For flatness detection, according to the flatness index calculation method, it is represented by the ratio of the height difference between the highest and lowest points in the measured area to the distance. Therefore, after obtaining the coordinate information of the measured area in three-dimensional space (the various points that make up the area), that is, the area is digitized into a series of scattered points, and the coordinate value of each point is known, the flatness index can be calculated.

[0064] S9: When the coating thickness is less than the set value, the spraying trolley 2 retracts to the initial position and performs additional spraying on the area initially coated; when the coating thickness is greater than the set value and / or the flatness is unqualified, the leveling component 43 rises and performs leveling operation on the area initially coated; when the coating thickness is equal to the set value and the flatness is qualified, the spraying trolley 2 moves forward to perform spraying operation on the next area.

[0065] For example, let L0 be the distance from the inspection point to the center before shotcreting; L1 be the distance from the inspection point to the center after shotcreting; Tmin be the minimum required shotcreting thickness; and Tmax be the minimum required shotcreting thickness. For excessively thin shotcrete layers (L0–L1 < Tmin), record the angle, position, and other information, and promptly re-spray. For excessively thick shotcrete layers (L0–L1 > Tmax), raise the scraper and clean the over-sprayed area.

[0066] Smoothness Assessment: Since typical mountain tunnels are generally circular, when measuring smoothness on-site, the measuring tape is kept as parallel as possible to the tunnel axis. Therefore, this plan divides the tunnel into several inspection units along its circumference. Data analysis is performed on the tunnel profile obtained after shotcreting is completed: (e.g.) Figure 18As shown, the arc length C of the shotcrete range is divided into m measurement units; the axial length D of the tunnel in each measurement unit is 1 meter or an integer multiple of 1 meter. Mature algorithms exist for flatness analysis based on the tunnel wall digital model, and will not be elaborated here. When the flatness is acceptable, the next shotcrete unit is proceeded; when the flatness is unacceptable, the scraper is upgraded, and the unacceptable areas are promptly scraped and leveled.

[0067] In summary, this invention employs a pre-spraying distance sensor to scan and measure a designated area, establishing a digital model. The system then retracts to perform the spraying operation, while the spraying bridge simultaneously monitors the sprayed surface during its forward movement. If overspraying is encountered or the flatness does not meet requirements, a scraper is raised to remove slag. If the spray thickness is insufficient, an alarm is triggered, and the location of the defective area is recorded. The spraying system then retracts for respraying. Thickness / flatness is calculated in the same coordinate system before and after spraying, eliminating cumulative errors and improving measurement accuracy. The dual-path defect handling method of "reverse respraying + forward scraping" does not occupy additional cycle time, improving work efficiency. During this process, the vision component monitors rebound, slurry adhesion, and jet angle in real time, adjusting nozzle swing speed and pump speed accordingly. The distance sensor provides quantitative results, providing closed-loop compensation for millimeter-level thickness deviations that the vision system cannot discern. This dual-loop superposition improves the spraying pass rate.

[0068] 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 TBM mixed shotcrete device, comprising a shotcrete bridge (1) and a shotcrete trolley (2), characterized in that: The inner ring surface of the shotcrete trolley (2) is provided with a vision spraying component (5), and the outer ring surface of the shotcrete trolley (2) is provided with a shotcrete detection and leveling component (4). The vision spraying component (5) includes a rotary trolley (22), which can move circumferentially along the inner ring surface of the shotcrete trolley (2). The rotary trolley (22) is provided with a mixing nozzle (226) and a vision component (3). The shotcrete detection and leveling component (4) includes a detection component (41) and a leveling component (43). The outer ring surface of the shotcrete trolley (2) is also provided with a slag receiving component (42), which is located at the slag drop position of the leveling component (43).

2. The TBM mixing and spraying device according to claim 1, characterized in that: The leveling assembly (43) includes several leveling units arranged along the outer ring surface of the shotcrete trolley (2); the leveling unit includes a scraper plate (435) and a leveling base (431) connected to the outer ring surface of the shotcrete trolley (2). The scraper plate (435) is connected to the leveling base (431) through a scraper telescopic rod (432), and the front end face of the scraper plate (435) is provided with a cutting edge.

3. The TBM mixing and spraying device according to claim 2, characterized in that: Four slag-scraping telescopic rods (432) are provided between the leveling base (431) and the slag-scraping plate (435). The two ends of the four slag-scraping telescopic rods (432) are respectively hinged to the leveling base (431) and the slag-scraping plate (435) through pins (433) to form a parallelogram mechanism.

4. The TBM mixing and spraying device according to claim 2 or 3, characterized in that: The slag receiving assembly (42) includes a slag collection trough (421) set on the outer ring surface of the shotcrete trolley (2). The slag outlet at the bottom of the slag collection trough (421) corresponds to the slag collection hopper (422) set on the shotcrete trolley (2). The slag collection trough (421) is located between the detection assembly (41) and the leveling assembly (43). The slag collection trough (421) is provided with a high-pressure water spray nozzle (423).

5. The TBM mixing and spraying device according to claim 4, characterized in that: An annular baffle plate (424) is provided between the slag collection tank (421) and the detection component (41), and a guide plate corresponding to the slag collection tank (421) is provided on the annular baffle plate (424).

6. The TBM mixing and spraying device according to claim 5, characterized in that: The detection component (41) includes several distance sensors (401) arranged along the outer ring surface of the shotcrete trolley (2), and the distance sensors (401) are located on the same concentric circle.

7. The TBM mixing and spraying device according to claim 5, characterized in that: The detection component (41) includes a detection gear ring (411) set on the outer ring surface of the shotcrete trolley (2), a movable seat (412) is provided on the detection gear ring (411), a small gear driven by a drive motor is provided at the bottom of the movable seat (412), the small gear meshes with the detection gear ring (411), and a distance sensor (401) is provided on the movable seat (412).

8. The TBM mixing and spraying device according to any one of claims 1-3 and 5-6, characterized in that: The shotcrete trolley (2) includes a trolley frame (21), and a large gear ring (211) and a circumferential motion track (212) are provided on the inner ring surface of the trolley frame (21). The rotary trolley (22) includes a trolley main frame (221) that is adapted to the inner ring surface of the trolley frame (21). The trolley main frame (221) is provided with circumferential traveling wheels (222) and a drive gear (224). The circumferential traveling wheels (222) cooperate with the circumferential motion track (212), the drive gear (224) meshes with the large gear ring (211), and the drive gear (224) is connected to the rotary drive assembly (225) provided on the trolley main frame (221).

9. The TBM mixing and spraying device according to claim 8, characterized in that: The front end of the large frame (21) is provided with a slag-proof plate (213); the mixing nozzle (226) is connected to the main frame (221) of the small car through the telescopic seat (227), and the vision component (3) is set on both sides of the main frame (221).

10. The TBM mixing and spraying device according to claim 8, characterized in that: The vision component (3) includes a telescopic mechanism (31) and an image acquisition unit (34). The image acquisition unit (34) is connected to the telescopic mechanism (31) via a rotating mechanism (33). An encoder is provided on the rotating mechanism (33). A protective cover (32) corresponding to the image acquisition unit (34) is provided on the rotary trolley (22).

11. The TBM mixing and spraying device according to claim 1, 9, or 10, characterized in that: The main frame (21) is connected to the shotcrete bridge (1) via the front and rear traveling mechanism (23); The front and rear traveling mechanism (23) includes front and rear motion tracks (235) set on both sides of the shotcrete bridge (1) and traveling support frames (236) set on both sides inside the trolley frame (21). The traveling support frames (236) are equipped with front and rear traveling wheels (234). Under the action of the drive component, the front and rear traveling wheels (234) move along the front and rear motion tracks (235).

12. The TBM mixing and spraying device according to claim 11, characterized in that: The drive assembly includes a drive motor (231) mounted on the trolley frame (21), a travel gear (232) mounted on the output shaft of the drive motor (231), the travel gear (232) meshing with a travel rack (233) mounted on the shotcrete bridge frame (1), and a travel stroke sensor (237) mounted on the travel support frame (236).

13. A mixed spraying method, characterized in that: The TBM mixed spraying device according to claim 12 has the following specific working process: S1: Mixed spraying preparation, the shotcrete trolley (2) is in the initial position; S2: The shotcrete truck (2) moves forward to the area to be shotcreted; S3: The distance sensor (401) of the shotcrete detection and leveling component (4) performs pre-spraying scanning detection on the tunnel wall of the area to be sprayed and transmits the pre-spraying scanning detection data to the host computer. S4: The shotcrete trolley (2) moves back to its initial position; S5: Shotcreting begins. The mixing nozzle (226) of the vision spraying component (5) performs shotcreting operation on the area to be sprayed, while the vision component (3) of the vision spraying component (5) observes the shotcreting status in real time. S6: After the spraying operation of the area to be sprayed is completed, the initial spraying area is formed, and the spraying truck (2) moves forward to the initial spraying area; S7: The distance sensor (401) of the spraying detection and leveling component (4) performs post-spraying scanning detection on the surface of the sprayed coating in the initial spraying area and transmits the post-spraying scanning detection data to the host computer. S8: The host computer uses the post-spray scanning detection data and the pre-spray scanning detection data to create a model, and then analyzes and calculates the spray coating thickness and the smoothness of the spray coating layer. S9: When the coating thickness is less than the set value, the spraying trolley (2) moves back to the initial position and performs additional spraying on the first-sprayed area; when the coating thickness is greater than the set value and / or the flatness is not up to standard, the leveling component (43) rises and performs leveling operation on the first-sprayed area; when the coating thickness is equal to the set value and the flatness is up to standard, the spraying trolley (2) moves forward to perform spraying operation on the next area.

14. The mixing spraying method according to claim 13, characterized in that: The modeling process of the host computer using post-spray scanning detection data and pre-spray scanning detection data is as follows: Based on the distribution range of the working area of ​​the TBM mixed spraying system, its working range is divided into four regions: Region I, Region II, Region III, and Region IV. The corresponding angles of each region are θ, π / 4, π / 4, and θ, respectively; where π / 6≤θ≤π / 3. The radius of the arc where the range sensor (401) is located is R, the measured value of the range sensor (401) is S, the actual rotation angle of the range sensor (401) is γ, and the actual placement angle of the range sensor is α. The actual distance from the measurement point to the center of the circle. , The compensation angle for the measurement point is ŋ, because , so , The actual angle measured by the distance sensor (401) is... , The actual angle measured by the distance sensor (401) is: , The axial position distance Z is obtained from the travel distance sensor (237) on the shotcrete trolley (2); Based on L, Z, and φ1 or φ2, a three-dimensional digital model of the tunnel in the detection area is then established.

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