Steel arch frame wall back guniting blind area filling device and method

Abstract

The invention relates to the technical field of tunnel and underground engineering support construction, and discloses a filling device and method for a guniting blind area behind a steel arch wall. The technical problems that in the prior art, a filling blind area which cannot be touched is formed behind a steel arch web and behind the wall tightly attached to a flange, cavities are left, and the supporting strength and durability are seriously affected are solved. The device comprises a support, a walking mechanism is arranged below the support and connected with a walking control module, and the walking control module is in communication connection with a wireless remote control module; a plurality of steel arch frame fixing mechanisms are arranged on the two sides of the support, each steel arch frame fixing mechanism comprises a rotating part, and end plates on the steel arch frames are avoided through the rotating action of the rotating parts; the bracket is provided with at least two steel arch wall back grouting mechanisms; the support is provided with at least two steel arch web blind area grouting mechanisms. The automatic filling device can automatically advance, position and fix on the steel arch frame, and mechanical, automatic and accurate filling of the gap behind the wall and the blind area of the web is achieved.

Description

Technical Field

[0001] This invention relates to the field of tunnel and underground engineering support construction technology, and in particular to a device and method for filling the blind zone of shotcrete behind a steel arch frame wall. Background Technology

[0002] In tunnels constructed using the TBM method, steel arch frames are crucial initial support structures. During assembly, the uneven surface of the surrounding rock creates gaps of varying sizes between the installed steel arch frames and the rock. Furthermore, the weight of multiple connected arch sections causes sagging at the arch crown, resulting in significant cavities between the crown and the surrounding rock. These gaps and cavities severely weaken the overall load-bearing capacity of the support system, negatively impacting its effectiveness.

[0003] To fill these gaps, existing techniques typically involve shotcreting after the steel arch frame is installed (i.e., shotcreting in zones L1 and L2). However, this process has inherent technical drawbacks: because the shotcrete operator cannot change the spraying angle, the shotcrete is essentially sprayed vertically onto the surface of the steel arch frame. This spraying method results in a significant amount of shotcrete being blocked by the I-beam flanges in front of the steel arch frame, creating hard-to-reach shotcrete filling blind spots in the area behind the I-beam webs of the steel arch frame and in the area between the steel arch frame and the surrounding rock, close to the flange roots. The cavities within these blind spots cannot be effectively filled by conventional shotcreting.

[0004] Currently, construction sites lack effective and dedicated equipment and methods for addressing the aforementioned blind spots. Sometimes, attempts are made to simply increase the shotcrete pressure, hoping the grout will be forced into the blind spots. However, practice has shown that this method is ineffective; numerous cavities remain in the blind spots, and the increased pressure easily leads to grout rebound, resulting in material waste and a deterioration of the construction environment. These unfilled blind spots not only reduce the integrity and density of the shotcrete layer but also leave potential safety hazards for later operation, such as uneven stress on the support structure, deformation of the surrounding rock, and even water leakage.

[0005] Therefore, there is an urgent need to propose a device and method for filling the blind spot of shotcrete behind the steel arch frame wall. Summary of the Invention

[0006] In view of the above technical problems, this disclosure provides a device and method for filling the blind spot of shotcrete behind a steel arch frame wall. It solves the technical problem that in the existing technology, due to the vertical angle, the slurry is blocked by the flange of the steel arch frame, resulting in an inaccessible filling blind spot behind the web of the steel arch frame and the root of the wall close to the flange, leaving voids and seriously affecting the support strength and durability.

[0007] According to one aspect of this disclosure, a device and method for filling the blind spot of shotcrete behind a steel arch frame wall are provided for traveling along the steel arch frame and performing shotcrete operations. The steel arch frame is composed of multiple I-beams connected sequentially via end plates. The system includes a support frame, the width of which is not less than the width of the steel arch frame. A walking mechanism is provided below the support frame to support the support frame and drive it to move along the steel arch frame. The walking mechanism is connected to a walking control module, and the walking control module is communicatively connected to a wireless remote control module. Multiple steel arch frame fixing mechanisms are provided on both sides of the support frame for fixing it to the steel arch frame during shotcreting operations; The steel arch frame fixing mechanism includes a rotating component, which rotates to avoid the end plate on the steel arch frame. The support is equipped with at least two steel arch frame wall grouting mechanisms for grouting into the gap between the outer side of the steel arch frame and the surrounding rock; The bracket is equipped with at least two grouting mechanisms for the blind spots of the steel arch web, which are used to grout the blind spots behind the steel arch web formed by the limitation of the grouting angle.

[0008] In some embodiments of this disclosure, the steel arch frame fixing mechanism includes a tripod structure, which is mounted on the side of the support via a pivot and crosses the end plate of the steel arch frame by rotating.

[0009] In some embodiments of this disclosure, a grouting pipe is installed above the support, connecting the grouting mechanism behind the steel arch frame wall and the grouting mechanism for the blind zone of the steel arch frame web. The grouting pipe is connected to the grouting control module via a control line.

[0010] In some embodiments of this disclosure, the walking mechanism includes a plurality of walking wheels capable of traveling along the steel arch frame, the arrangement of which matches the contour of the upper surface of the steel arch frame.

[0011] In some embodiments of this disclosure, the grouting mechanism behind the steel arch frame is rotatably mounted on both sides of the support via hinged connectors.

[0012] In some embodiments of this disclosure, the grouting mechanism for the blind zone of the steel arch web includes a ball joint connector, with a grout delivery pipeline connected above the ball joint connector, and at least two grouting ports opened on the ball joint connector toward the blind zone of the steel arch web.

[0013] A method for filling the blind zone of shotcrete behind a steel arch frame wall, applicable to a shotcrete blind zone filling device for steel arch frame walls, includes the following steps: S1 Travel and Positioning: Controls the movement of the traveling mechanism and drives the support to travel along the steel arch to the target working position; S2 Obstacle Crossing: When encountering an end plate connecting adjacent I-beams during the journey, the tripod structure of the steel arch frame fixing mechanism rotates around the pivot to cross the end plate and continue the journey. S3 Fixing: Upon reaching the target working position, the tripod structure clamps and confines the object to the steel arch frame; S4 grouting: a. Grouting behind the steel arch frame: Control the operation of the grouting mechanism behind the steel arch frame so that its grouting port faces the gap between the outside of the steel arch frame and the surrounding rock, and perform grouting; b. Grouting of blind spots in the web of steel arch frame: Control the operation of the grouting mechanism for the blind spots in the web of steel arch frame, adjust the angle of its grouting port so that it faces the blind spot behind the web of steel arch frame, and perform grouting; S5 cycle: Repeat steps S1 to S4 until the blind spot filling operation of the entire steel arch frame is completed.

[0014] In some embodiments of this disclosure, during the grouting step of the blind zone of the steel arch web, the angle of the grouting port of the grouting mechanism for the blind zone of the steel arch web is adjusted by a ball joint connector.

[0015] In some embodiments of this disclosure, during the grouting step behind the steel arch frame wall, the angle of the grouting mechanism behind the steel arch frame wall is adjusted by the hinged connector.

[0016] The beneficial effects of this invention are as follows: It achieves automated and continuous precision filling of blind spots. Through the integrated walking mechanism, wireless remote control module and fixing mechanism, this device can move autonomously on the steel arch frame, accurately position and fix itself, completely changing the traditional operation mode that relies on manual labor, is inefficient and cannot guarantee quality, and realizes mechanized and automated precision filling of the gap behind the wall and the blind spot of the web.

[0017] This innovative design solves the obstacle-crossing challenge when traveling along a continuous steel arch frame. The steel arch frame fixing mechanism, through the rotational movement of its rotating components, cleverly avoids and crosses the end plates connecting the steel arch frames. This design enables the device to travel and operate continuously and without obstruction along the entire length of the steel arch frame, solving the accessibility problem of automated equipment in complex support structures and is key to achieving continuous automated construction.

[0018] It effectively eliminates two different types of shotcrete blind spots, achieving excellent filling results. Through the multi-angle adjustable grouting mechanism behind the steel arch frame, it can penetrate deep into the large gap between the outer side of the steel arch frame and the surrounding rock, ensuring that the cavity is fully filled and guaranteeing the close fit between the support system and the surrounding rock.

[0019] With its omnidirectional adjustable grouting mechanism for the blind spot of the steel arch web and its multi-grouting port design, the grout can be precisely sprayed into the narrow space behind the I-beam web that traditional shotcreting cannot reach, thus fundamentally eliminating the dead corner for filling in this area.

[0020] This significantly improves construction safety and economy. Operators can operate the equipment wirelessly from a safe distance, avoiding high-altitude and high-intensity work in the high-risk environment of the tunnel face. At the same time, automated and precise grouting reduces grout rebound and waste, lowers material costs, and shortens support cycle time due to increased work efficiency.

[0021] The traveling wheels are matched with the outline of the steel arch frame, ensuring the stability of the movement; the hinge of the wall grouting mechanism is connected to the ball joint of the web grouting mechanism, which allows the device to flexibly adapt to the complex curved shape of the steel arch frame and the gap changes caused by the unevenness of the surrounding rock, making it highly versatile. Attached Figure Description

[0022] Figure 1 A schematic diagram of a shotcrete blind zone filling device installed on a steel arch frame. Figure 2 Front view of the shotcrete blind zone filling device installed on the steel arch frame; Figure 3 Side view of the shotcrete blind zone filling device installed on the steel arch frame; Figure 4 A schematic diagram of the structure of the shotcrete blind zone filling device behind the steel arch frame wall; Figure 5 Another structural schematic diagram of the shotcrete blind zone filling device behind the steel arch frame wall; The components in the diagram are named as follows: 1. Steel arch frame; 2. End plate; 3. Support; 4. Walking mechanism; 5. Walking control module; 6. Wireless remote control module; 7. Steel arch frame fixing mechanism; 8. Steel arch frame wall grouting mechanism; 9. Steel arch frame web blind zone grouting mechanism; 10. Tripod structure; 11. Grouting pipe; 12. Control circuit; 13. Grouting control module; 14. Hinged support connector; 15. Ball-and-socket connector; 16. Grouting port. Detailed Implementation

[0023] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example 1

[0024] This example discloses a device for filling the blind spot of shotcrete behind a steel arch frame wall. See [link / reference] Figures 1 to 5 , Used for moving along the steel arch frame 1 and performing shotcrete operations. The steel arch frame 1 is composed of multiple I-beams connected sequentially via end plates 2. The shotcrete blind spot filling device behind the steel arch frame wall includes a support 3. The width of the support 3 is not less than the width of the steel arch frame. A walking mechanism 4 is set below the support 3 to support the support 3 and drive the support 3 to move along the steel arch frame 1. The walking mechanism 4 is connected to the walking control module 5, and the walking control module 5 is communicatively connected to the wireless remote control module 6. Multiple steel arch frame fixing mechanisms 7 are provided on both sides of the bracket 3 for fixing to the steel arch frame 1 during shotcreting operations; The steel arch frame fixing mechanism 7 includes a rotating component, which rotates to avoid the end plate 2 on the steel arch frame. The support 3 is equipped with at least two steel arch frame wall grouting mechanisms 8, which are used to grout the gap between the outer side of the steel arch frame and the surrounding rock; The bracket 3 is equipped with at least two steel arch web blind zone grouting mechanisms 9, which are used to grout the blind zone behind the steel arch web formed by the limitation of the grouting angle.

[0025] The steel arch frame fixing mechanism 7 includes a tripod structure 10, which is mounted on the side of the support via a pivot. The tripod structure 10 rotates to cross the end plate 2 of the steel arch frame.

[0026] A grouting pipe 11 is installed above the support 3. The grouting pipe 11 connects the grouting mechanism behind the steel arch frame wall and the grouting mechanism in the blind area of ​​the steel arch frame web. The grouting pipe 11 is connected to the grouting control module 13 via the control line 12.

[0027] The traveling mechanism includes multiple traveling wheels that can travel along the steel arch frame, and the arrangement of the traveling wheels matches the contour of the upper surface of the steel arch frame.

[0028] The grouting mechanism behind the steel arch frame wall is rotatably installed on both sides of the support through the hinged connector 14.

[0029] The grouting mechanism for the blind zone of the web of the steel arch frame includes a ball joint connector 15, with a grout delivery pipeline 16 connected above the ball joint connector 15, and at least two grouting ports 16 opened on the ball joint connector 15 toward the blind zone of the web of the steel arch frame.

[0030] A method for filling the blind zone of shotcrete behind a steel arch frame wall, applicable to a shotcrete blind zone filling device for steel arch frame walls, includes the following steps: S1 Travel and Positioning: Controls the movement of the traveling mechanism and drives the support to travel along the steel arch to the target working position; S2 Obstacle Crossing: When encountering an end plate connecting adjacent I-beams during the journey, the tripod structure of the steel arch frame fixing mechanism rotates around the pivot to cross the end plate and continue the journey. S3 Fixing: Upon reaching the target working position, the tripod structure clamps and confines the object to the steel arch frame; S4 grouting: a. Grouting behind the steel arch frame: Control the operation of the grouting mechanism behind the steel arch frame so that its grouting port faces the gap between the outside of the steel arch frame and the surrounding rock, and perform grouting; b. Grouting of blind spots in the web of steel arch frame: Control the operation of the grouting mechanism for the blind spots in the web of steel arch frame, adjust the angle of its grouting port so that it faces the blind spot behind the web of steel arch frame, and perform grouting; S5 cycle: Repeat steps S1 to S4 until the blind spot filling operation of the entire steel arch frame is completed.

[0031] In the grouting step of the blind zone of the steel arch web, the angle of the grouting port of the grouting mechanism for the blind zone of the steel arch web is adjusted by the ball joint connector.

[0032] In the grouting step behind the steel arch frame wall, the angle of the grouting mechanism behind the steel arch frame wall is adjusted by the hinged connector.

[0033] Although some preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0034] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this application and their equivalents, this invention also intends to include these modifications and variations.

Claims

1.A steel arch wall back shotcrete blind area filling device and method, used for traveling along a steel arch and performing shotcrete work, the steel arch being composed of a plurality of I-shaped steels connected in sequence by end plates, characterized in that: a support is provided, the width of the support being not less than the width of the steel arch, a walking mechanism being provided below the support for carrying and driving the support to travel along the steel arch; the walking mechanism is connected to a walking control module, and the walking control module is communicatively connected to a wireless remote control module; a plurality of steel arch fixing mechanisms are provided on both sides of the support for being fixed to the steel arch during the shotcrete work; the steel arch fixing mechanism comprises a rotating part, and the rotating part is rotated to avoid the end plate on the steel arch; at least two steel arch wall back grouting mechanisms are mounted on the support for grouting to the gap between the outside of the steel arch and the surrounding rock; at least two steel arch web blind area grouting mechanisms are mounted on the support for grouting to the blind area behind the web of the steel arch formed due to the limitation of the shotcrete angle; the steel arch fixing mechanism comprises a tripod structure, the tripod structure is mounted on the side edge of the support through a rotating shaft, and the rotating part is rotated to span the end plate of the steel arch; a grouting pipe is mounted above the support, the grouting pipe is connected to the steel arch wall back grouting mechanism and the steel arch web blind area grouting mechanism through a control line, and the grouting pipe is connected to a grouting control module; the walking mechanism comprises a plurality of walking wheels capable of walking along the steel arch, and the arrangement of the walking wheels matches the profile of the upper surface of the steel arch; the steel arch wall back grouting mechanism is rotatably mounted on both sides of the support through a torsion support connector; the steel arch web blind area grouting mechanism comprises a ball torsion connector, a grout delivery pipeline is connected above the ball torsion connector, and at least two grouting openings are formed in the ball torsion connector towards the steel arch web blind area; the method comprises the following steps: S1.traveling and positioning: controlling the walking mechanism to drive the support to travel along the steel arch to a target work position; S2.obstacle crossing: during the traveling, when an end plate connecting adjacent I-shaped steels is encountered, the tripod structure of the steel arch fixing mechanism is rotated around the rotating shaft to span the end plate and continue traveling; S3.fixing: when the target work position is reached, the tripod structure is clamped and limited on the steel arch; S4.grouting: a. steel arch wall back grouting: controlling the steel arch wall back grouting mechanism to make its grouting opening face the gap between the outside of the steel arch and the surrounding rock, and performing grouting; b. steel arch web blind area grouting: controlling the steel arch web blind area grouting mechanism to adjust the angle of its grouting opening, face the blind area behind the web of the steel arch, and perform grouting; S5.circulation: repeating steps S1-S4 until the blind area filling work of the entire steel arch is completed; in the steel arch web blind area grouting step, the angle of the grouting opening of the steel arch web blind area grouting mechanism is adjusted through the ball torsion connector; in the steel arch wall back grouting step, the angle of the steel arch wall back grouting mechanism is adjusted through the torsion support connector. ​ ​ ​ ​ ​ 2. The steel arch wall post-jetting blind area filling device according to claim 1, characterized in that: ​ 3. The steel arch wall post-jetting blind area filling device according to claim 1, characterized in that: ​ 4. The steel arch wall post-jetting blind area filling device according to claim 1, characterized in that: ​ 5. The steel arch wall post-jetting blind area filling device according to claim 1, characterized in that: ​ 6. The steel arch wall post-jetting blind area filling device of claim 1, wherein: ​ 7. A method of filling a blind area of a steel arch wall back shotcrete, suitable for the steel arch wall back shotcrete blind area filling device according to any one of claims 1 to 6, characterized in that, ​ ​ ​ ​ ​ ​ ​ ​ 8. The steel arch wall post-jetting blind area filling method of claim 1, wherein: ​ 9. The steel arch wall post-jetting blind area filling method of claim 1, wherein: ​

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