Intelligent shotcrete mechanical arm of shaft sinking machine and control method thereof

Abstract

This invention discloses an intelligent shotcrete manipulator for a vertical shaft tunneling machine and its control method. It includes a central control center serving as the control hub, and modules for material conveying and anti-clogging, dynamic batching and rock debris recovery, and intelligent shotcrete and quality inspection, all connected to the central control center via a wireless communication device. The central control center comprises a material conveying subsystem, an automatic batching subsystem, and a multi-arm shotcrete subsystem, each controlling its corresponding three modules. It receives real-time monitoring data from each module via the wireless communication device, ensuring efficient and stable shotcrete operations. This invention improves the safety and reliability of shotcrete pipeline transportation in vertical shafts; enables the underground recovery and utilization of rock debris resources, reducing material waste; and allows the intelligent shotcrete manipulator to adapt to the complex environment of vertical shafts, completing high-standard shotcrete operations without human intervention, thus improving construction efficiency and ensuring operational safety.

Description

Technical Field

[0001] This invention relates to a shaft tunneling machine, and more particularly to an intelligent shotcrete manipulator for a shaft tunneling machine and its control method. Background Technology

[0002] With the continuous development of the mining industry, mine depths are increasing, leading to higher demands for the efficiency and safety of support operations. Shotcrete support, a crucial component of vertical shaft construction, presents several shortcomings in traditional shotcrete technology and equipment due to its greater depth: 1. Difficulty in resolving blockages during long-distance transport: Traditional shotcrete processes rely heavily on manual labor to address blockages in transport pipelines and lack methods for tiered treatment of blockage severity. Especially at greater shaft depths, traditional methods struggle to determine the location and extent of blockages, requiring shutdowns even for minor blockages, severely impacting construction efficiency. 2. Insufficient control over batching accuracy: Traditional batching ratios rely on manual experience or fixed proportions, resulting in discrepancies with actual needs. Furthermore, they fail to effectively utilize excavated rock debris as a substitute material, leading to resource waste and increased costs. Additionally, traditional batching methods lack dynamic response, failing to adapt to dynamic changes in the flow rate of the shotcrete arm and the pressure on the transport pipeline, easily causing material waste or insufficient shotcrete intensity. Third, the efficiency and quality of shotcreting operations are low: Traditional shotcreting processes mainly rely on robotic arms to perform shotcreting operations according to a preset path. However, as the depth of the shaft increases, the construction environment will continue to change, requiring frequent manual updates to the construction process. It is difficult for workers to go deep into the shaft to carry out inspection and repair work. At the same time, traditional shotcreting arms are mostly single-arm structures with a small shotcreting range, severely impacting construction efficiency. Summary of the Invention

[0003] Purpose of the invention: To address the shortcomings of existing technologies, this invention provides an intelligent shotcrete manipulator for vertical shaft tunneling machines and its control method, solving problems such as difficult-to-clear pipe blockages, difficulty in controlling the accuracy of material mixing, and substandard shotcrete quality that exist when using traditional shotcrete technologies and equipment for deep well shotcreting.

[0004] Summary of the Invention: An intelligent shotcrete manipulator for a vertical shaft tunneling machine includes a central control center. The central control center comprises a material conveying subsystem, an automatic batching subsystem, and a multi-arm shotcrete subsystem. It also includes a dry material conveying device connected to the material conveying subsystem, an intelligent batching device connected to the automatic batching subsystem, and a shotcrete manipulator connected to the multi-arm shotcrete subsystem. The intelligent batching device is divided into a storage layer, a feeding layer, and a mixing layer from top to bottom. The dry material conveying device is connected to the dry material storage bin in the storage layer to convey dry material to the batching stage. The double-helix feeder in the feeding layer pre-mixes the dry material with rock cuttings. The mixing layer receives the material conveyed from the feeding layer and completes the mixing in its downhole mixer to form a homogeneous slurry. The shotcrete manipulator is connected to the downhole mixer and receives the concrete slurry from the intelligent batching device. The shotcrete manipulator is used to perform well wall shotcrete, leveling, and quality inspection.

[0005] The central control center is connected to the material conveying and anti-blocking module, the dynamic batching and rock slag recovery module, and the intelligent shotcrete and quality inspection module via wireless communication devices. The core of the material conveying and anti-blocking module is the dry material conveying device, the core of the dynamic batching and rock slag recovery module is the intelligent batching device, and the core of the intelligent shotcrete and quality inspection module is the shotcrete robotic arm.

[0006] Furthermore, the dry material conveying device includes a variable frequency air compressor, a horizontal input pipe, a three-way valve, a check valve, a high-pressure pulse air valve, and a vertical output pipe. The variable frequency air compressor is connected to the first interface of the three-way valve through the horizontal input pipe, the high-pressure pulse air valve is connected to the second interface of the three-way valve through the check valve, one end of the vertical output pipe is connected to the third interface of the three-way valve, and the other end is connected to the dry material storage bin.

[0007] Ideally, the material conveying subsystem includes a multi-level anti-clogging control unit. The pressure sensor is installed on the vertical output pipe at the connection between the three-way valve and the vertical output pipe, and the flow sensor is installed on the horizontal input pipe. The variable frequency air compressor, high-pressure pulse air valve, pressure sensor and flow sensor are respectively connected to the multi-level anti-clogging control unit for signal transmission.

[0008] The material conveying subsystem includes a multi-level anti-clogging control unit to ensure stable conveying of dry materials. This control unit monitors the rate of change of pipeline pressure and flow in real time using pressure and flow sensors. When both the rate of change of pressure and flow reach a first threshold, the material conveying subsystem generates a first-level unblocking command, increasing the output power of the variable frequency air compressor to handle minor blockages with enhanced airflow. If the data does not return to normal and both reach a second threshold, a second-level unblocking command is generated, activating the high-pressure pulse valve to release high-pressure airflow to clear the blocked material. When the pipeline pressure exceeds the safety limit threshold, a shutdown command is immediately issued and simultaneously fed back to the shaft tunneling machine control system, suspending tunneling operations to prevent dangerous situations.

[0009] Furthermore, the intelligent batching device also includes a rock slag storage bin, a water storage tank, a quick-setting agent storage tank, a water pump, and a quick-setting agent pump. The dry material storage bin, rock slag storage bin, water storage tank, and quick-setting agent storage tank are arranged at intervals to form the storage layer of the intelligent batching device. The twin-screw feeder, water pump, and quick-setting agent pump form the feeding layer of the intelligent batching device. The underground mixer is the mixing layer. The dry material storage bin and rock slag storage bin are respectively connected to the twin-screw feeder. The water storage tank is connected to the underground mixer through the water pump. The quick-setting agent storage tank is connected to the underground mixer through the quick-setting agent pump.

[0010] Ideally, the twin-helix feeder includes a drive motor, a transmission box, a right-hand helical shaft, a left-hand helical shaft, and a trough. The right-hand and left-hand helical shafts are arranged parallel to each other and installed in the trough. The right-hand and left-hand helical shafts are connected to the transmission box, which is installed on one side of the trough and connected to the drive motor.

[0011] Ideally, the automatic batching subsystem includes a shotcrete total demand calculation unit, a feedforward compensation unit, a dynamic proportioning calculation unit, a synchronous timing control unit, and a quality feedback unit. The shotcrete total demand calculation unit and the feedforward compensation unit are respectively connected to the dynamic proportioning calculation unit. The dynamic proportioning calculation unit and the quality feedback unit are respectively connected to the synchronous timing control unit. The twin-helix feeder, water pump, and accelerator pump are respectively connected to the synchronous timing control unit.

[0012] The shotcrete total demand calculation unit first calculates the total shotcrete demand based on the three-dimensional model of the well wall and generates the initial batching ratio; the feedforward compensation unit monitors the pressure of the delivery pipeline through the feedforward compensator and generates the speed compensation amount; the dynamic proportion calculation unit combines the two to obtain the final batching ratio, and then the synchronous timing control unit coordinates the twin-helix feeder, water pump, and quick-setting agent pump to ensure that the dry material, rock cuttings, water and quick-setting agent are synchronously delivered to the downhole mixer for mixing; at the same time, the quality feedback unit monitors the slurry density, dynamically adjusts the batching ratio, and feeds back to the dynamic proportion calculation unit to adjust the final batching ratio to ensure that the slurry performance is compatible with the support requirements of the shaft boring machine.

[0013] Furthermore, the shotcrete robotic arm includes a fixed base, a rotating base, an upper robotic arm, a hydraulic cylinder, a connecting rod, a forearm robotic arm, an end effector, a concrete delivery pipe, and a concrete pump. The fixed base is rigidly connected to the top mounting surface of the shotcrete support beam. The rotating base is connected to the fixed base. The upper robotic arm is connected to the rotating base via a drive joint. The connecting rod is connected to the rotating base via a hydraulic cylinder. The forearm robotic arm is hinged to the connecting rod. An end effector is mounted on the forearm robotic arm. One end of the concrete delivery pipe is connected to the end effector, and the other end is connected to the concrete pump.

[0014] Ideally, the end effector includes an actuator body, an ultrasonic sensor, a 3D laser scanner, a gripper, a nozzle, and a leveler. The actuator body is L-shaped. The ultrasonic sensor, the 3D laser scanner, and the gripper are respectively installed at one end of the actuator body, and the leveler is installed at the other end of the actuator body. The concrete delivery pipe is connected to the gripper, and the nozzle is installed on the concrete delivery pipe.

[0015] Ideally, the multi-arm shotcrete subsystem includes a 3D scanning modeling unit, a shotcrete operation planning unit, a correction unit, and a flatness detection unit. The 3D scanning modeling unit is connected to the 3D laser scanner, the shotcrete operation planning unit is connected to the 3D scanning modeling unit, the correction unit is connected to the ultrasonic sensor, and the flatness detection unit is connected to the 3D laser scanner.

[0016] The 3D scanning and modeling unit first acquires point cloud data of the well wall using a 3D laser scanner. After point cloud registration and surface reconstruction, a 3D model of the well wall with normal vectors is generated. The shotcrete operation planning unit performs surface parameterization processing based on the 3D model, plans the operation path of the shotcrete arm and the attitude of the nozzles at each path point, and ensures that the axis of the nozzles is always perpendicular to the surface of the well wall. During the shotcrete process, the correction unit uses ultrasonic sensors to measure distance data in real time and dynamically adjusts the motion parameters of the robotic arm to achieve real-time correction of the distance between the nozzles and the well wall. After a single round of shotcrete coverage is completed, the 3D laser scanner performs a second scan on the sprayed area. The flatness detection unit calculates the deviation between the shotcrete surface and the standard model based on the point cloud data to evaluate the flatness. If it does not meet the standard, a scraping or re-spraying command is generated to control the robotic arm to replace the scraper or adjust the nozzle attitude for re-spraying until the flatness meets the standard.

[0017] A control method for the intelligent shotcrete manipulator of the above-mentioned shaft tunneling machine includes the following steps: Step 1: The material conveying subsystem controls the dry material conveying device to convey the dry material to the dry material storage bin and controls it in real time to prevent the dry material conveying device from getting blocked.

[0018] Step 2: The automatic batching subsystem controls the dry material storage bin to transport the dry material to the twin screw feeder, completing the pre-mixing of the dry material and rock slag.

[0019] Step 3: The automatic batching subsystem controls the intelligent batching device to simultaneously deliver dry materials, rock cuttings, water, and quick-setting agent to the downhole mixer for mixing, forming a homogeneous slurry.

[0020] Step 4: The multi-arm shotcrete subsystem controls the shotcrete robotic arm to pick up the shotcrete material and perform shotcrete operations. After a single round of shotcrete coverage is completed, the multi-arm shotcrete subsystem performs a second scan of the shotcrete area. If it does not meet the standard, it generates a scraping or re-shotcrete command, controls the shotcrete robotic arm to perform scraping operations or adjust its posture to re-shot until the flatness meets the standard.

[0021] Beneficial effects: Compared with the prior art, the beneficial effects of the present invention are: The present invention adopts a multi-level anti-blockage control strategy and uses an anti-backflow dredging structure to achieve early warning, mid-term intervention and emergency protection of blockage, thereby improving the safety and reliability of vertical shaft shotcrete pipeline transportation.

[0022] The dynamic batching and rock slag recovery module of this invention adopts a dynamic ratio compensation algorithm, which dynamically adapts to the requirements of shotcreting while realizing the downhole recovery and utilization of rock slag resources, reducing material waste.

[0023] The intelligent shotcrete and quality inspection module of this invention integrates three-dimensional scanning modeling, real-time correction and closed-loop quality inspection functions, enabling the intelligent shotcrete robot to adapt to the complex environment of the shaft and complete high-standard shotcrete operations without human intervention, thereby improving construction efficiency and ensuring operational safety. Attached Figure Description

[0024] The features and advantages of the invention will be more clearly understood by referring to the accompanying drawings, which are illustrative and should not be construed as limiting the invention in any way.

[0025] Figure 1 This is a schematic diagram of the overall layout of the main device in this invention.

[0026] Figure 2 This is a schematic diagram of the overall process flow in this invention.

[0027] Figure 3 This is a diagram of the control center in this invention.

[0028] Figure 4 This is a schematic diagram of the dry material conveying device in this invention.

[0029] Figure 5 This is a control flowchart of the material conveying and anti-blocking module in this invention.

[0030] Figure 6 This is a schematic diagram of the three-layer structure of the intelligent batching device in this invention.

[0031] Figure 7 This is a schematic diagram of the intelligent batching device in this invention.

[0032] Figure 8 This is a schematic diagram of the twin-helix feeder in this invention.

[0033] Figure 9 This is a control flowchart for the dynamic batching and rock slag recovery module in this invention.

[0034] Figure 10 This is a schematic diagram of the shotcrete robotic arm structure in this invention.

[0035] Figure 11This is a schematic diagram of the end effector of the robotic arm in this invention.

[0036] Figure 12 This is a control flowchart of the intelligent shotcrete and quality inspection module in this invention.

[0037] Among them: 1-Dry material conveying device; 101-Variable frequency air compressor; 102-Horizontal input pipeline; 103-Three-way valve; 104-One-way valve; 105-High pressure pulse air valve; 106-Vertical output pipeline; 2-Intelligent batching device; 201-Dry material storage bin; 202-Slag storage bin; 203-Water storage tank; 204-Accelerating agent storage tank; 205-Twin spiral feeder; 205-1-Drive motor; 205-2-Transmission box; 205-3-Right-hand spiral shaft; 205-4-Left-hand spiral shaft; 205-5-Material... 206-Water pump; 207-Accelerating agent pump; 208-Downhole mixer; 3-Shotcrete robotic arm; 301-Fixed base; 302-Rotating base; 303-Upper arm of robotic arm; 304-Hydraulic cylinder; 305-Connecting rod; 306-Forearm of robotic arm; 307-End effector; 307-1-Ultrasonic sensor; 307-2-3D ​​laser scanner; 307-3-Claw; 307-4-Nozzle; 307-5-Scraper; 308-Concrete delivery pipe; 309-Concrete pump; 4-Shotcrete support beam. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0039] The present invention will be further illustrated below with reference to specific embodiments. Those skilled in the art should understand that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Modifications to the present invention in various equivalent forms all fall within the scope defined by the appended claims.

[0040] This invention provides an intelligent shotcrete manipulator for a shaft boring machine, such as... Figure 1 As shown, the intelligent shotcrete manipulator of the present invention is arranged in the upper part of the shaft tunneling machine, including three core devices: a dry material conveying device 1, an intelligent batching device 2, and a shotcrete manipulator 3, realizing full-process automation from material conveying and precise batching to shotcrete operation.

[0041] The dry material conveying device 1 stably transports dry materials from the ground to the dry material storage bin 201 of the intelligent batching device 2. The intelligent batching device 2, relying on its three-layer distribution structure, pre-mixes dry materials and rock cuttings via a middle-layer feeding device, and then simultaneously sends them, along with liquid materials transported by water pump 206 and quick-setting agent pump 207, to the lower-layer downhole mixer 208 for mixing, forming concrete slurry. Subsequently, the slurry is transported to the shotcrete robotic arm 3, which is stably installed on the top working area of ​​the shotcrete support beam 4. Finally, two identical shotcrete robotic arms 3 perform the final well wall shotcreting, leveling, and quality inspection tasks.

[0042] like Figure 3 As shown, the centralized control center, which serves as the control center in this invention, includes a material conveying subsystem, an automatic batching subsystem, and a multi-arm shotcrete subsystem. The material conveying subsystem includes a multi-level anti-clogging control unit. The automatic batching subsystem includes a shotcrete total demand calculation unit, a feedforward compensation unit, a dynamic proportion calculation unit, a synchronous timing control unit, and a quality feedback unit. The multi-arm shotcrete subsystem includes a three-dimensional scanning modeling unit, a shotcrete operation planning unit, a correction unit, and a flatness detection unit.

[0043] like Figure 4 As shown, the dry material conveying device 1 of the present invention comprises a variable frequency air compressor 101, a horizontal input pipe 102, a three-way valve 103, a check valve 104, a high-pressure pulse valve 105, and a vertical output pipe 106. The variable frequency air compressor 101 is the power source of the system, and its outlet is connected to the horizontal input pipe 102. The end of the horizontal input pipe 102 is connected to the vertical output pipe 106 through the three-way valve 103, forming the main conveying channel for materials. In specific implementation, the dry material will flow sequentially through the horizontal input pipe 102, the three-way valve 103, and the vertical output pipe 106 under the drive of the variable frequency air compressor 101, and is finally stably conveyed to the dry material storage bin 201 of the intelligent batching device 2. The second interface of the three-way valve 103 is connected in series with the check valve 104 and the high-pressure pulse valve 105, which together form an anti-clogging structure. The one-way valve 104 prevents materials from flowing back into the high-pressure pulse air circuit under normal conveying conditions. The high-pressure pulse air valve 105, as a dredging actuator, can generate high-pressure airflow when started. This airflow can pass through the one-way valve 104 and enter the vertical output pipe 106 for dredging operations.

[0044] like Figure 5As shown, during the material conveying process, the material conveying and anti-blocking module will implement the following anti-blocking protection measures: The material conveying subsystem of the central control center collects the pipeline pressure and flow rate change rate in real time through pressure sensors and flow sensors. When both change rates reach the first threshold, the system determines it as a minor blockage, generates a first-level unblocking command, and performs initial unblocking by increasing the output power of the variable frequency air compressor 101, continuously monitoring the situation after adjustment; if the data does not return to normal, the output power is further increased. When both change rates reach the second threshold, it is determined as a moderate blockage, generates a second-level unblocking command, and activates the high-pressure pulse air valve 105 to launch high-pressure airflow for powerful unblocking. If the data still does not return to normal and the pressure does not exceed the safety limit, the system will restart the unblocking device; if the pressure exceeds the safety limit threshold, the central control center will issue a shutdown command and an alarm, notifying personnel to come for maintenance.

[0045] like Figures 6-8 As shown, the intelligent batching device 2 of the present invention adopts a three-layer distribution structure consisting of an upper storage layer, a middle feeding layer, and a lower mixing layer. It includes a dry material storage bin 201, a rock slag storage bin 202, a water storage tank 203, a quick-setting agent storage tank 204, a double-helix feeder 205, a water pump 206, a quick-setting agent pump 207, and an underground mixer 208. The double-helix feeder 205 is the core component of the middle feeding layer, including a drive motor 205-1, a transmission box 205-2, a right-hand spiral shaft 205-3, a left-hand spiral shaft 205-4, and a material trough 205-5. In practice, the dry material storage bin 201 and rock slag storage bin 202 in the upper storage layer are fed by a bottom feeding device to the material trough 205-5 of the double helix feeder 205 in the middle feeding layer according to a preset ratio. The double helix feeder 205 is driven by a drive motor 205-1, which drives the gear transmission mechanism in the transmission box 205-2, thereby driving the right-hand helical shaft 205-3 and the left-hand helical shaft 205-4 to rotate synchronously in opposite directions, realizing the continuous advancement and uniform premixing of dry material and rock slag. After the premixed rock slag and dry material enter the underground mixer 208 in the lower mixing layer, the water pump 206 and the quick-setting agent pump 207 in the middle feeding layer draw water and quick-setting agent from the water storage tank 203 and the quick-setting agent storage tank 204 in the upper storage layer, respectively, and send them into the underground mixer 208 according to the ratio. After thorough mixing, a homogeneous slurry is formed, providing material support for the operation of the shotcrete robotic arm.

[0046] like Figure 9As shown, the specific control method of the automatic batching subsystem of the present invention is as follows: The total shotcrete demand calculation unit first calculates the total shotcrete demand based on the three-dimensional model and generates the initial batching ratio; then, the feedforward compensation unit generates the speed compensation amount based on the pressure data of the conveying pipeline; the dynamic ratio calculation unit integrates the two information to calculate the final dynamic ratio, in which rock slag replaces 30%-40% of the dry material; then, the synchronous timing control unit coordinates the flow rate of water pump 206 and quick-setting agent pump 207 and the speed of twin-helix feeder 205, in which the twin-helix feeder 205 premixes the materials from dry material storage bin 201 and rock slag storage bin 202 in proportion; finally, the batching is sent to the downhole mixer 208 for mixing to form concrete slurry. At the same time, the quality feedback unit monitors the slurry density in real time, dynamically fine-tunes the batching ratio, and feeds the data back to the dynamic ratio calculation unit to correct the final batching ratio in real time, forming a closed-loop control to ensure that the performance of the final slurry is accurately matched with the support requirements of the shaft boring machine.

[0047] like Figure 10 and Figure 11 As shown, the shotcrete operation actuator of the present invention consists of two identical shotcrete robotic arms 3 symmetrically arranged in the top region of the shotcrete support beam 4. The fixed base 301 of the shotcrete robotic arm 3 is rigidly connected to the top mounting surface of the shotcrete support beam 4; the rotating base 302, mounted on the fixed base 301, achieves horizontal rotation through a built-in drive motor, enabling the robotic arm to perform circular operations. The upper arm 303 of the robotic arm is connected to the rotating base 302 via a drive joint, responsible for a wide range of vertical position adjustments; the cylinder body of the hydraulic cylinder 304 is hinged to the rotating base 302, its piston rod is connected to one end of a connecting rod 305, and the other end of the connecting rod 305 is hinged to one end of the robotic arm's forearm 306. When the hydraulic cylinder 304 extends or retracts, it drives the connecting rod 305 to move, which in turn causes the robotic arm forearm 306 to pitch around its hinge point with the upper robotic arm 303, thereby precisely controlling the distance between the end effector 307 and the well wall. At the end of the forearm, the end effector 307 rotates via a rotary drive joint, used to replace the scraper 307-5 after operation to perform scraping operations, or to adjust the spraying posture of the nozzle 307-4. The slurry is powered by the concrete pump 309 and transported by the concrete delivery pipe 308 to the nozzle 307-4, which is fixed to the end effector 307 via the jaws 307-3. The concrete delivery pipe 308 passes through a channel provided on the inner side of the robotic arm forearm 306. The entire robotic arm's spraying adjustment relies on ultrasonic sensor 307-1 and 3D laser scanner 307-2. Ultrasonic sensor 307-1 is responsible for real-time distance measurement and dynamic correction of the robotic arm's posture, while 3D laser scanner 307-2 is used to scan the well wall appearance, providing data support for path planning and quality assessment.

[0048] like Figure 12As shown, before the shotcreting operation, the control center controls the robotic arm to move the end effector 307 to the preset scanning position. The 3D laser scanner 307-2 on the end effector emits a laser beam towards the well wall. The well wall reflects the laser beam back to the scanner. By using the time difference and phase difference between transmission and reception, combined with the current position information, the original point cloud data of each spatial point on the well wall is collected. At the same time, the 3D laser scanner 307-2 achieves a panoramic scan of the well wall of the current section through an internal high-speed rotating reflector mechanism, without moving the robotic arm. The 3D scanning modeling unit preprocesses the collected point cloud data to remove noise and other interference information. Then, a point cloud registration algorithm is used to align and fuse the point clouds from multiple perspectives under different coordinate systems, forming a point cloud set that can completely reflect the shape of the well wall under a unified coordinate system. Then, a surface reconstruction algorithm is used to connect the registered discrete point clouds into a continuous surface to generate a 3D model of the well wall, and calculate the normal vector information for each point on the model surface. The shotcrete operation planning unit parametrically processes the three-dimensional well wall surface and divides the operation area for each shotcrete robotic arm. At the same time, the shotcrete operation planning unit plans the movement speed of the nozzle based on the surface curvature of each point on the path, such as decreasing speed on concave surfaces and increasing speed on convex surfaces, and plans the nozzle posture so that its axis is always perpendicular to the well wall surface, ultimately forming a work plan that includes the shotcrete path, speed, and posture.

[0049] During the shotcreting execution phase, the ultrasonic sensor 307-1, installed on the end effector 307, emits sound waves towards the well wall. The well wall then reflects the sound waves back to the sensor. The distance between the nozzle and the well wall is obtained in real time by calculating the round-trip time of the sound waves. The calibration unit synchronously receives the target distance preset by the path planning unit, compares the measured distance with the target distance, and calculates the precise distance deviation value and its direction. Based on this deviation, the system uses a PID control algorithm to dynamically generate adjustment commands, drive the robotic arm joints to adjust, and thus adjust the shotcreting posture to ensure that the nozzle 307-4 always follows the planned operation scheme during the shotcreting process.

[0050] After a single round of shotcrete coverage is completed, the system enters a closed-loop quality inspection process. The 3D laser scanner 307-2 rescans the sprayed area, and the flatness detection unit compares the point cloud data of the 3D model before and after shotcreting, and uses normal vector variance analysis to quantitatively evaluate the flatness of the shotcrete surface. If the evaluation result does not meet the standard, the control center will generate corresponding instructions. The rotation drive joint at the end of the forearm controls the end effector 307 to rotate, replace the scraper 307-5 to scrape the surface, or adjust the attitude of the nozzle 307-4 for re-spraying, and then scan and evaluate again until the flatness index fully meets the preset standard.

[0051] like Figure 2As shown, the overall control method of the intelligent shotcrete manipulator of the aforementioned shaft boring machine is as follows: Point cloud data of the shaft wall is acquired using a 3D laser scanner 307-2 to generate a 3D model, which is then used to plan the shotcrete path and various operational parameters. Simultaneously with the shotcrete operation planning, the automatic batching subsystem of the control center initiates the batching process of the dynamic batching and rock debris recovery module. Based on the generated 3D model and the actual conditions, the final dynamic proportion is calculated. Then, the flow rates of the water pump 206 and the accelerator pump 207, as well as the rotation speed of the twin-helix feeder 205, are coordinated through the synchronous timing control unit. The twin-helix feeder 205 premixes the materials from the dry material storage bin 201 and the rock debris storage bin 202 in a proportional manner, with the rock debris replacing 30%-40% of the dry material.

[0052] The mixed dry materials and liquids are combined and stirred in the downhole mixer 208 to form a mixed slurry, which is then supplied to the shotcreting robotic arm 3. The robotic arm performs shotcreting operations according to the planned path. During the process, the ultrasonic sensor 307-1 performs real-time distance measurement and corrects the shotcreting posture. After a single round of shotcreting is completed, the 3D laser scanner 307-2 rescans the shotcreted area to detect the concrete quality and evaluate the flatness. If it does not meet the standard, corresponding remedial measures are generated and implemented. Then, the quality is detected and evaluated again until it meets the standard, and the entire process ends. The dry materials in the process are sent to the dry material storage bin 201 by the variable frequency air compressor 101 along the conveying pipeline. During the conveying process, it will flow through an anti-clogging structure including a three-way valve 103, a one-way valve 104, and a high-pressure pulse air valve 105. This module implements a graded anti-clogging strategy by monitoring the pipeline status in real time to ensure that the material is stably delivered to the downhole working area.

[0053] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes that can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention are all within the protection scope of the claims of the present invention.

Claims

1. An intelligent shotcrete robot of a shaft heading machine, characterized in that, The application relates to a centralized control center which comprises a material conveying subsystem, an automatic batching subsystem and a multi-arm shotcreting subsystem, and further comprises a dry material conveying device (1) which is signal-connected with the material conveying subsystem, an intelligent batching device (2) which is signal-connected with the automatic batching subsystem and a shotcreting mechanical arm (3) which is signal-connected with the multi-arm shotcreting subsystem, the intelligent batching device (2) is sequentially divided into a storage layer, a feeding layer and a stirring layer from top to bottom, the dry material conveying device (1) is connected with a dry material storage bin (201) of the storage layer and is used for conveying dry materials to a batching link; a double-helix feeder (205) of the feeding layer completes premixing of dry materials and rock slag; the stirring layer receives materials conveyed by the feeding layer and completes stirring in an underground stirring machine (208) to form homogeneous slurry; the shotcreting mechanical arm (3) is connected with the underground stirring machine (208) and receives concrete slurry of the intelligent batching device (2), the shotcreting mechanical arm (3) is used for performing well wall shotcreting, scraping and quality detection; the intelligent batching device (2) further comprises a rock slag storage bin (202), a water storage tank (203), a quick-setting agent storage tank (204), a water pump (206) and a quick-setting agent pump (207), the dry material storage bin (201), the rock slag storage bin (202), the water storage tank (203) and the quick-setting agent storage tank (204) are arranged at intervals to form the storage layer of the intelligent batching device (2), the double-helix feeder (205), the water pump (206) and the quick-setting agent pump (207) form the feeding layer of the intelligent batching device (2), the underground stirring machine (208) is the stirring layer, the dry material storage bin (201) and the rock slag storage bin (202) are connected with the double-helix feeder (205) respectively, the water storage tank (203) is connected with the underground stirring machine (208) through the water pump (206), the quick-setting agent storage tank (204) is connected with the underground stirring machine (208) through the quick-setting agent pump (207); the automatic batching subsystem comprises a total shotcreting demand calculation unit, a feedforward compensation unit, a dynamic proportioning calculation unit, a synchronous timing control unit and a quality feedback unit, the total shotcreting demand calculation unit and the feedforward compensation unit are signal-connected with the dynamic proportioning calculation unit respectively, the dynamic proportioning calculation unit and the quality feedback unit are signal-connected with the synchronous timing control unit respectively, and the double-helix feeder (205), the water pump (206) and the quick-setting agent pump (207) are signal-connected with the synchronous timing control unit respectively.

2. An intelligent shotcrete robot of a shaft heading machine according to claim 1, characterized in that, The dry material conveying device (1) comprises a variable frequency air compressor (101), a horizontal input pipeline (102), a three-way valve (103), a one-way valve (104), a high-pressure pulse air valve (105) and a vertical output pipeline (106), the variable frequency air compressor (101) is connected with a first interface of the three-way valve (103) through the horizontal input pipeline (102), the high-pressure pulse air valve (105) is connected with a second interface of the three-way valve (103) through the one-way valve (104), one end of the vertical output pipeline (106) is connected with a third interface of the three-way valve (103), and the other end is connected with the dry material storage bin (201).

3. An intelligent shotcrete robot of a shaft heading machine according to claim 2, characterized in that, The material conveying subsystem comprises a multi-level anti-blocking control unit, a pressure sensor is installed on the vertical output pipeline (106) at the connection between the three-way valve (103) and the vertical output pipeline (106), and a flow sensor is installed on the horizontal input pipeline (102); the variable frequency air compressor (101), the high-pressure pulse air valve (105), the pressure sensor and the flow sensor are respectively signal-connected with the multi-level anti-blocking control unit.

4. An intelligent shotcrete robot of a shaft heading machine according to claim 1, wherein, The double-helix feeder (205) comprises a driving motor (205-1), a transmission box (205-2), a right-helix shaft (205-3), a left-helix shaft (205-4) and a trough (205-5), the right-helix shaft (205-3) and the left-helix shaft (205-4) are arranged in parallel and at intervals and are respectively installed in the trough (205-5), the right-helix shaft (205-3) and the left-helix shaft (205-4) are respectively connected with the transmission box (205-2), and the transmission box (205-2) is installed on one side surface of the trough (205-5) and is connected with the driving motor (205-1).

5. An intelligent shotcrete robot of a mine shaft boring machine as claimed in claim 1, characterized in that, The shotcreting mechanical arm (3) comprises a fixed base (301), a rotating base (302), a mechanical arm upper arm (303), a hydraulic cylinder (304), a connecting rod (305), a mechanical arm forearm (306), an end effector (307), a concrete conveying pipe (308) and a concrete pump (309), the fixed base (301) is rigidly connected to a top mounting surface of a shotcreting support beam (4), the rotating base (302) is connected with the fixed base (301), the mechanical arm upper arm (303) is connected with the rotating base (302) through a driving joint, the connecting rod (305) is connected with the rotating base (302) through the hydraulic cylinder (304), the mechanical arm forearm (306) is hinged with the connecting rod (305), the end effector (307) is installed on the mechanical arm forearm (306), one end of the concrete conveying pipe (308) is connected with the end effector (307), and the other end of the concrete conveying pipe (308) is connected with the concrete pump (309).

6. An intelligent shotcrete robot of a shaft heading machine according to claim 5, characterized in that, The end effector (307) comprises an effector body, an ultrasonic sensor (307-1), a three-dimensional laser scanner (307-2), a claw (307-3), a spray head (307-4) and a screed (307-5), the effector body is in an L shape, the ultrasonic sensor (307-1), the three-dimensional laser scanner (307-2) and the claw (307-3) are respectively installed at one end of the effector body, the screed (307-5) is installed at the other end of the effector body, the concrete conveying pipe (308) is connected with the claw (307-3), and the spray head (307-4) is installed on the concrete conveying pipe (308).

7. An intelligent shotcrete robot of a shaft heading machine as claimed in claim 6, characterized in that, The multi-arm shotcreting subsystem comprises a three-dimensional scanning modeling unit, a shotcreting operation planning unit, a correction unit and a flatness detection unit, the three-dimensional scanning modeling unit is signal-connected with the three-dimensional laser scanner (307-2), the shotcreting operation planning unit is signal-connected with the three-dimensional scanning modeling unit, the correction unit is signal-connected with the ultrasonic sensor (307-1), and the flatness detection unit is signal-connected with the three-dimensional laser scanner (307-2).

8. A control method of an intelligent guniting robot of a shaft heading machine according to any one of claims 1 to 7, characterized in that The method comprises the following steps: Step one: the material conveying subsystem controls the dry material conveying device (1) to convey dry materials into the dry material storage bin (201) and controls in real time to prevent the dry material conveying device (1) from being blocked; Step two: the automatic batching subsystem controls the dry material storage bin (201) to convey dry materials into the double-screw feeder (205) to complete the premixing of dry materials and rock slag; Step three: the automatic batching subsystem controls the intelligent batching device (2) to synchronously convey dry materials, rock slag, water, and accelerating agent into the underground mixer (208) to mix and form homogeneous slurry; Step four: the multi-arm spraying subsystem controls the spraying mechanical arm (3) to suck slurry to perform spraying work; after single-wheel spraying coverage is completed, the multi-arm spraying subsystem performs secondary scanning on the sprayed area; if it is not up to standard, a scraping or supplementary spraying instruction is generated to control the spraying mechanical arm (3) to perform scraping work or adjust the posture for supplementary spraying until the flatness is up to standard.

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