Roadway side-roof intelligent three-dimensional combined supporting device and supporting method

Abstract

The invention discloses a roadway side-roof intelligent three-dimensional combined supporting device and a supporting method. The device comprises an intelligent three-dimensional combined supporting structure and an X-shaped bearing structure which are arranged in the direction of a roadway at equal intervals. Each supporting structure is formed by combining a top plate supporting unit and two side supporting units through side top connecting pieces, and each unit comprises a two-force rod, an intelligent tensioning device, a three-dimensional supporting tray and an anchor cable. The adjacent supporting structures are connected through X-shaped force bearing structures, and each X-shaped force bearing structure is composed of a hinge rod, an intelligent tensioning device and an inhaul cable. The intelligent tensioning device can dynamically regulate and control pre-tightening force, the side top connecting piece can adapt to roadway deformation in a self-adaptive mode, and collaborative supporting is achieved. The supporting method comprises the steps that anchor rod parameters and anchoring points are calculated; mounting a roof anchor rod group and blasting to form an anchoring area; connecting the device and applying a pre-tightening force; an intelligent three-dimensional support combined and X-shaped crossed support structure is constructed; the pre-tightening force is monitored and regulated in real time; and a remote monitoring network is established.

Description

Technical Field

[0001] This application relates to the field of tunnel support technology, specifically to a tunnel side-roof intelligent three-dimensional combined support device and support method. Background Technology

[0002] As a crucial passageway in the coal mine production system, roadways bear important functions such as transportation, ventilation, and personnel passage. Their stability and safety during their service life directly affect the mine's efficient operation and safe production. However, under complex mining conditions such as deep high-stress, rock bursts, and extremely close coal seams, the surrounding rock of roadways deforms drastically. Traditional passive support devices and methods that adapt to preload and roadway deformation have certain limitations. These traditional support systems struggle to cope with severe roadway surrounding rock deformation through coordinated, adaptive, and dynamic control of the roof and sidewalls. This manifests primarily in passive bearing, insufficient precision in preload control which is easily lost due to lithological variations, and a lack of dynamic adaptability to surrounding rock deformation. The consequences often include insufficient or failed support system performance, leading to problems such as roof subsidence, sidewall convergence, and floor bulging, and may even result in overall roadway instability or collapse, severely impacting coal mine safety. Therefore, developing a new type of support device and method that can significantly control the deformation of the surrounding rock, achieve synergistic, adaptive, dynamic, and three-dimensional support structure has become a key technical problem that urgently needs to be solved in the field of roadway support. Summary of the Invention

[0003] To overcome the above-mentioned technical deficiencies, the purpose of this application is to provide an intelligent three-dimensional combined support device and method for roadway sidewalls and roof. By providing overall coordinated support for the roadway roof and sidewalls, roof subsidence and sidewall convergence can be effectively prevented, forming a three-dimensional support network; and a dynamic monitoring network for roadway support is formed by intelligent tensioning devices.

[0004] This application provides a roadway sidewall-roof intelligent three-dimensional combined support device, including multiple intelligent three-dimensional combined support structures and an X-shaped load-bearing structure;

[0005] Multiple intelligent three-dimensional combined support structures are arranged at equal intervals along the direction of the roadway; each intelligent three-dimensional combined support structure includes a roof support unit and two side support units. The two side support units are respectively connected to the two ends of the roof support unit through the side-roof connector to form an intelligent three-dimensional combined support structure covering the roof and two sides of the roadway.

[0006] Both the top plate support unit and the side support unit include a two-force bar, an intelligent tensioning device, a three-dimensional support tray, and anchor cables; the two ends of the anchor cables are respectively fixed to two intelligent tensioning devices, forming a support pair that can intelligently tension the anchor cables in both directions;

[0007] The adjacent two intelligent three-dimensional combined support structures are connected by the X-shaped load-bearing structure; the X-shaped load-bearing structure includes two cross-arranged intelligent cable tensioners; the intelligent cable tensioner includes two hinged rods, two intelligent tensioning devices, and a cable connecting the two; the two ends of the cable are respectively fixed to the two intelligent tensioning devices, and the intelligent tensioning devices are respectively connected to the three-dimensional support trays at corresponding positions in the two intelligent three-dimensional combined support structures through the hinged rods; short high-strength anchor rods at corresponding positions are inserted into the circular holes of the hinged rods and fixed to the three-dimensional support trays at corresponding positions by nuts at the exposed ends of the anchor rods, forming an X-shaped load-bearing structure that can compress and lift the top plate.

[0008] As a preferred embodiment of this application, the intelligent tensioning device includes a support base plate, a U-shaped rod, a tensioning plate, a hydraulic cylinder, a tension sensor, an end connector, a controller, and a vertical plate;

[0009] The U-shaped rod and hydraulic cylinder are both fixed to the support base plate via upright plates. The end of the U-shaped rod passes through a fixing hole at one end of the tension plate and is fixedly connected to the tension plate with a nut. The other end of the tension plate is fixed to the support base plate and has an anchor cable hole in the middle for threading the anchor cable. The rod head of the hydraulic cylinder is detachably connected to one end of the tension sensor, and the other end of the tension sensor is detachably connected to the end connector. The end connector is used to fix the end of the anchor cable. The controller is fixed to the support base plate and electrically connected to the hydraulic cylinder and tension sensor to form an intelligent control system. This system receives the anchor cable tension signal and controls the extension and retraction of the hydraulic cylinder, thereby achieving intelligent tensioning of the anchor cable.

[0010] As a preferred embodiment of this application, the rib-top connector includes a flexible cable, a tension / compression adaptive adjustment component, and a cable end connector;

[0011] The two ends of the two flexible cables are respectively fixed to the cable end connector and the tension-compression adaptive adjustment component; the tension-compression adaptive adjustment component includes a spring, an inner sleeve and an outer sleeve; the two ends of the spring are respectively fixed inside the inner sleeve and the outer sleeve; the inner sleeve is slidably disposed inside the outer sleeve; the short high-strength anchor rod is inserted into the circular hole of the cable end connector and fixed to the three-dimensional support tray of the roof support unit and the side support unit by the nut at the exposed end of the short high-strength anchor rod, thus forming a connector that can realize the coordinated support connection between the roadway roof and the two sides;

[0012] As a preferred embodiment of this application, the three-dimensional support tray is a circular flat plate with a sandglass-shaped main hole at its center and four sandglass-shaped secondary holes evenly arranged around the circumference of the sandglass-shaped main hole.

[0013] Both the hourglass-shaped main hole and the hourglass-shaped secondary hole are formed by connecting two symmetrical frustum holes about the upper bottom surface along the thickness direction of the plate. The hourglass-shaped main hole is used to insert long high-strength anchor rods, and the hourglass-shaped secondary hole is used to insert short high-strength anchor rods. The three-dimensional support tray is connected to the rear end of the vertical plate through a two-force bar.

[0014] This application also provides a method for intelligent three-dimensional combined support of roadway sidewall and roof, using the aforementioned intelligent three-dimensional combined support device for roadway sidewall and roof, the method comprising the following steps:

[0015] Step S1: Accurately calculate the length and anchoring point of the anchor bolt: The lengths of the long and short high-strength anchor bolts are accurately determined by calculation. The lengths L1 and L2 of the long and short high-strength anchor bolts are calculated using formulas. The anchoring point of the anchor bolt is determined based on the length and the primary and secondary support angles. Specifically, the anchoring point of the long high-strength anchor bolt is located in the conical base area formed by the length L1 and the included angle ∠1, and the anchoring point of the short high-strength anchor bolt is located in the conical base area formed by the length L2 and the included angle ∠2.

[0016] Step S2: Install roof anchor bolt assemblies: Draw guide lines along the width of the roadway roof, drill holes at both ends of the guide lines, and blast the emulsion explosive into the bottom of the holes to create fissures in the surrounding rock mass; insert long, high-strength anchor bolts through the hourglass-shaped main hole of the three-dimensional support tray, and simultaneously feed retarded anchoring agent into the bottom of the borehole and stir evenly. Utilizing the retarded setting properties of the anchoring agent, pull out the long, high-strength anchor bolts before the anchoring agent solidifies, thereby pre-treating the inner wall of the borehole and forming a regular... Anchoring channel; then pull out the long high-strength anchor rod, and send the fast-setting anchoring agent into the borehole. Use nuts to fix the long high-strength anchor rod and the three-dimensional support tray together to the roadway roof, ensuring that the anchoring point is located in the original rock area; then insert multiple short high-strength anchor rods into the hourglass-shaped secondary holes of the three-dimensional support tray, and drive them radially into the surrounding rock with the exposed end of the long high-strength anchor rod as the center. Each long high-strength anchor rod and the short high-strength anchor rods around it form an anchor rod group, forming a balloon-shaped anchoring area;

[0017] Step S3: Connect the support device: Connect the three-dimensional support tray to the rear end of the upright plate through a two-force bar; take an anchor cable and two support units, pass both ends of the anchor cable through the anchor cable holes on the tension plate of each support unit, and fix them to the end connector to form a bidirectional tension link;

[0018] Step S4: Apply pre-tensioning force: Turn on the controller to control the hydraulic cylinder to retract. The tension of the anchor cable is monitored by the tension sensor. The intelligent tensioning device pulls the anchor cable outward to increase the tension force. Thus, the pre-tensioning force is applied to the anchor bolt groups at both ends through the three-dimensional support tray, forming a squeezing and lifting effect on the roadway roof.

[0019] Step S5: Form an intelligent three-dimensional combined support structure: On both sides of the roadway, install anchor bolt groups, support devices and anchor cables in the same way as the roof. Connect the three-dimensional support trays at both ends of the roof support unit with the three-dimensional support trays in the two side support units through side-top connectors to form an intelligent three-dimensional combined support structure covering the roadway roof and both sides.

[0020] Step S6: Forming an X-shaped cross-support structure: On the roadway roof, the row spacing M1 is calculated using a formula. Along the roadway direction, at a distance M1 from the already installed roof support device, symmetrical guide lines parallel to the previous intelligent three-dimensional combined support structure are drawn on the roadway roof. These guide lines are used to determine the installation position of the next intelligent three-dimensional combined support structure. Subsequently, following the operation process of steps S2 to S4, the installation of the next intelligent three-dimensional combined support structure is completed. Two intelligent cable tensioners are symmetrically arranged with the roadway roof centerline as the axis of symmetry. The controller in the intelligent support device is activated to control the hydraulic cylinders at both ends to tighten the cables. The tension of the cables is monitored by the tension sensor to achieve compression and lifting of the roof between two adjacent intelligent three-dimensional combined support structures, forming an X-shaped load-bearing structure. When multiple sets of roof support devices are continuously arranged along the roadway direction in the above manner, the adjacent X-shaped structures are superimposed in space, ultimately forming a stable X-shaped cross-support structure within the roadway roof area.

[0021] Step S7, Dynamic Monitoring and Control: The preload values ​​of the anchor cables and guy cables, calculated using the formula, are set as the lower threshold of the controller. When the preload monitored by the tension sensor is lower than this value, the controller is activated to automatically tighten the hydraulic cylinder until the preload value is higher than the lower threshold. 60% of the ultimate preload values ​​of the anchor cables and guy cables are set as the upper threshold of the controller. When the preload monitored by the tension sensor is higher than this value, the hydraulic cylinder will automatically depressurize, achieving dynamic control.

[0022] Step S8: Establish a monitoring network: Connect each controller in the roadway to the control center wirelessly. The control center assigns numbers to the controllers to form a dynamic monitoring network. This network transmits the preload data of the anchor cables and tension cables in real time and supports remote adjustment, enabling comprehensive management of the entire roadway support system.

[0023] As a preferred embodiment of this application, in step S1, the length L1 of the long, high-strength anchor rod is calculated using the following formula:

[0024]

[0025] Where a is half the width of the roadway; b is half the height of the roadway; C is the cohesion; e is half the length of the support unit; P0 is the self-weight stress of the anchor body; P Sθ represents the support resistance; θ represents the internal friction angle; ∠1 represents the principal support angle.

[0026] As a preferred embodiment of this application, in step S1, the length L2 of the short high-strength anchor rod is calculated using the following formula:

[0027]

[0028] Where, σ Z This refers to the vertical stress of the surrounding rock in the tunnel.

[0029] As a preferred embodiment of this application, in step S2, the formula for the preload of the long, high-strength anchor bolt is:

[0030]

[0031] Where c is 1 / 2 of the effective support span of the rock stratum; μ1 is the friction coefficient between the long and short high-strength anchors and the surrounding rock mass; γ is the average unit weight of the rock; λ is the lateral pressure coefficient of the rock; F is the Protodyakonov coefficient; and L1 is the length of the long high-strength anchor.

[0032] In step S2, the formula for calculating the preload of the short high-strength anchor bolt is:

[0033]

[0034] Among them, ∠2 is the secondary support angle.

[0035] As a preferred embodiment of this application, in step S4, the formula for calculating the anchor cable preload is:

[0036]

[0037] Where μ2 is the friction coefficient between the anchor cable and the surrounding rock.

[0038] As a preferred embodiment of this application, in step S6, the formula for calculating the spacing of the tunnel roof is:

[0039]

[0040] Where l is the length of the long, high-strength anchor bolt exceeding the radius of the stable zone.

[0041] As a preferred embodiment of this application, in step S6, the formula for calculating the cable preload is:

[0042]

[0043] Where g is 1 / 2 of the intelligent cable tensioner, and M1 is the row spacing of the device.

[0044] Compared with the prior art, this application has the following significant advantages:

[0045] 1. Advantages of Intelligent Three-Dimensional Combined Support and X-Type Bearing Structure: This application uses roof and sidewall support units to connect the roof and sidewall support units, forming an intelligent three-dimensional combined support structure, achieving coordinated support for the roadway roof and sidewalls. The intelligent three-dimensional combined support structure forms an X-type bearing structure through two cross-set intelligent cable tensioners. This design not only enhances the overall integrity and stability of the support but also achieves multi-directional compression and lifting of the surrounding rock. The X-type cross support structure allows adjacent structures to be spatially superimposed, effectively dispersing stress and preventing local failure, making it particularly suitable for high-stress surrounding rock conditions.

[0046] 2. Adaptive Adjustment Capability: The roof and sidewall connector integrates cable end connectors, flexible cables, springs, inner sleeves, and outer sleeves. When there is no significant deformation in the roadway roof and sidewalls, the springs remain taut, supporting the surrounding rock within the anchorage range of the roof and sidewalls. When significant deformation occurs in the roof or sidewalls, the flexible cables begin to compress the sleeve structure, causing the springs to change from tension to compression, creating a reaction force on the roof and sidewalls, thus compressing the surrounding rock.

[0047] 3. Intelligent Dynamic Control Capability: The intelligent tensioning device integrates the support base plate, U-shaped rod, tension plate, hydraulic cylinder, tension sensor, end connector, controller, and vertical plate. It can monitor the preload of anchor cables and tension cables in real time and dynamically adjust it through closed-loop control. The preload value of anchor cables and tension cables, calculated using formulas, is set as the lower threshold of the controller. When the preload monitored by the tension sensor is lower than this value, the controller is activated to control the hydraulic cylinder to automatically tighten until the preload value is higher than the lower threshold. 60% of the ultimate preload value of anchor cables and tension cables is set as the upper threshold of the controller. When the preload monitored by the tension sensor is higher than this value, the intelligent tensioning device will automatically depressurize. This dynamic control mechanism ensures that the support force remains within the optimal range for a long time, overcoming the defect of easy preload decay in traditional support systems and achieving a leap from static to dynamic adaptive control.

[0048] 4. Innovative Precision Anchoring and Post-Blast Balloon-like Anchoring Zone: Based on the suspension theory of anchor bolt support, the length of the anchor bolt is precisely determined through calculation formulas, thereby optimizing the anchoring points. An innovative approach combines pre-treatment with blasting (such as emulsion explosive blasting to create fissures) with radial anchor bolt arrangement to form a balloon-like anchoring zone. This design significantly improves the uniformity of anchoring force distribution and the density of the surrounding rock, enhancing deformation resistance.

[0049] 5. Systematic Monitoring and Management: By connecting the controllers of all support units within the roadway to a network using wireless communication technology, a centralized dynamic monitoring network is constructed. The control center can remotely monitor the working condition of all anchor cables in real time and adjust parameters, achieving comprehensive, information-based, and intelligent management of the entire roadway support system, greatly improving the mine's safety level and operational efficiency.

[0050] In summary, this invention has achieved significant breakthroughs in support concepts, technical methods, and system intelligence, providing an efficient and reliable solution for the long-term stability of tunnels under complex geological conditions. Attached Figure Description

[0051] Figure 1 This is a schematic diagram of the support unit of the present invention;

[0052] Figure 2 This is a structural schematic diagram of the intelligent tensioning device;

[0053] Figure 3 This is a structural schematic diagram of a three-dimensional support tray;

[0054] Figure 4 This is a structural diagram of an intelligent cable tensioner.

[0055] Figure 5 This is a spatial layout diagram of the intelligent support device;

[0056] Figure 6 yes Figure 5 Partial top-view diagram of the support structure;

[0057] Figure 7 This is a structural diagram of the top connector.

[0058] Figure 8 It is a layout diagram of the three sides of the alleyway;

[0059] Figure label:

[0060] 1-Support base plate, 2-U-shaped rod, 3-Tensioning plate, 4-Hydraulic cylinder, 5-Tension sensor, 6-End connector, 7-Controller, 8-Upright plate, 9-Three-dimensional support tray, 91-Hourglass-shaped main hole, 92-Hourglass-shaped secondary hole, 10-Long high-strength anchor bolt, 11-Short high-strength anchor bolt, 12-Anchor cable, 13-Side and top connector, 14-Two-force bar, 15-Intelligent tensioning device, 16-Intelligent cable tensioner; 17-Hinged rod; 18-Cable; 19-Flexible cable; 20-Tension and compression adaptive adjustment component; 21-Cable end connector; 22-Spring; 23-Inner sleeve; 24-Outer sleeve. Detailed Implementation

[0061] The present invention will now be described in further detail with reference to the accompanying drawings.

[0062] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals.

[0063] It should be noted that the terms “front,” “back,” “left,” “right,” “up,” and “down” used in the following description refer to the directions shown in the attached diagram, while the terms “inside” and “outside” refer to the directions toward or away from the geometric center of a specific component, respectively.

[0064] To make the content of this invention easier to understand, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0065] As attached Figure 1 To be continued Figure 8As shown, this application provides a roadway side-roof intelligent three-dimensional combined support device. Its core lies in the arrangement of multiple intelligent three-dimensional combined support structures at equal intervals along the roadway direction, interconnected by X-shaped load-bearing structures to form a three-dimensional support structure. Each intelligent three-dimensional combined support structure includes one roof support unit and two side support units. The two side support units are connected to both ends of the roof support unit via side-roof connectors 13, forming an intelligent three-dimensional combined support structure covering the roadway roof and both sides. Both the roof support unit and the side support unit include a two-force bar 14, an intelligent tensioning device 15, a three-dimensional support tray 9, and anchor cables 12, constituting a support pair capable of bidirectional intelligent tensioning of the anchor cables 12. The roof and side support connector 13 includes flexible cables 19, tension-compression adaptive adjustment components 20, and cable end connectors 21. The two ends of the two flexible cables 19 are respectively fixed to the cable end connectors 21 and the tension-compression adaptive adjustment components 20. The tension-compression adaptive adjustment components 20 include springs 22, inner sleeves 23, and outer sleeves 24. The two ends of the springs 22 are respectively fixed inside the inner sleeves 23 and the outer sleeves 24. The inner sleeves 23 are slidably disposed inside the outer sleeves 24. The short high-strength anchor rods 11 are inserted into the circular holes of the cable end connectors 21 and fixed to the three-dimensional support trays 9 of the roof support unit and the side support unit by the nuts at the exposed ends of the short high-strength anchor rods 11, thus forming a connector that can realize the coordinated support of the roadway roof and the two sides. The adjacent two intelligent three-dimensional combined support structures are connected by the X-shaped load-bearing structure. The X-shaped load-bearing structure includes two cross-arranged intelligent cable tensioners 16. Each intelligent cable tensioner 16 includes two hinged rods 17, two intelligent tensioning devices 15, and a cable 18 connecting the two. The two ends of the cable 18 are respectively fixed to the two intelligent tensioning devices 15. The intelligent tensioning devices 15 are respectively connected to the three-dimensional support trays 9 at corresponding positions in the two intelligent three-dimensional combined support structures through the hinged rods 17. The short high-strength anchor bolts 11 at the corresponding positions are inserted into the circular holes of the hinged rods 17 and fixed to the three-dimensional support trays 9 at the corresponding positions by the nuts at the exposed ends of the anchor bolts. This design achieves three-dimensional support for the surrounding rock of the roadway by applying dynamically adjustable preload to the anchor cables 12 and the cable 18, and by using the three-dimensional support trays 9 to transfer the force to the anchor bolt group composed of long and short high-strength anchor bolts.

[0066] Specifically, the intelligent tensioning device 15 is key to achieving dynamic support, comprising a support base plate 1, a U-shaped rod 2, a tension plate 3, a hydraulic cylinder 4, a tension sensor 5, an end connector 6, a controller 7, and a vertical plate 8. The U-shaped rod 2 and the hydraulic cylinder 4 are both fixed to the support base plate 1 via the vertical plate 8. The end of the U-shaped rod 2 passes through a fixing hole at one end of the tension plate 3 and is fixedly connected to the tension plate 3 with a nut. The tension plate 3 is a perforated flat plate, 20mm thick, 100mm long, and 250mm high, with a 28mm diameter anchor cable hole in the center for threading the anchor cable 12. Two 20mm diameter fixing holes are provided at one end of the tension plate 3. The piston rod of the hydraulic cylinder 4 is connected to the end connector 6 via the tension sensor 5, and the end of the anchor cable 12 is fixed to the end connector 6. The controller 7 receives signals from the tension sensor 5 and precisely controls the extension and retraction of the hydraulic cylinder 4, thereby achieving intelligent tensioning of the anchor cable 12. This intelligent device provides the support structure with adaptive capability, enabling it to adjust the preload in real time according to the deformation of the surrounding rock, effectively overcoming the defect of easy attenuation of preload in traditional support systems.

[0067] The three-dimensional support tray 9 is ingeniously designed as a circular plate with a central hourglass-shaped main hole 91 and four evenly distributed hourglass-shaped secondary holes 92. The hourglass-shaped hole structure is formed by the mating of two symmetrical frustum holes about the top and bottom surfaces along the thickness direction of the plate, facilitating anchor installation and allowing for some angle adjustment. Long, high-strength anchors 10 pass through the hourglass-shaped main hole 91, while short, high-strength anchors 11 pass through the hourglass-shaped secondary holes 92. The three-dimensional support tray 9 is connected to the rear end of the vertical plate 8 via a two-force bar 14, effectively transmitting and distributing the tension force generated by the anchor cable 12 to each anchor, thus acting on the surrounding rock. The anchor group, composed of long and short high-strength anchors, has a lifting effect as the long anchors tilt outwards to form an inverted trapezoidal force-applying surface with the anchor cable, while the short anchors tilt inwards to form a regular trapezoidal force-applying surface with the anchor cable, generating a squeezing effect. The coupling effect of these two effects significantly enhances the integrity of the roadway roof, forming a highly efficient three-dimensional support mechanism. In one embodiment of this application, the thickness of the three-dimensional support tray 9 is 20mm, the outer diameter of the hourglass-shaped main hole 91 is 35mm, the inner diameter is 29mm, the main support angle is ∠1=0~72°, the outer diameter of the hourglass-shaped secondary hole 92 is 29mm, the inner diameter is 23mm, and the secondary support angle is ∠2=0~74°.

[0068] The intelligent tensioning device 15 also includes a tension gauge (not shown in the figure), which is installed on the support base plate 1 and is electrically connected to the controller 7.

[0069] This intelligent three-dimensional combined support device for roadways can support the deformation and damage of surrounding rock such as roof subsidence, sidewall convergence, and floor bulge in rectangular, trapezoidal, horseshoe-shaped, and semi-circular arch roadways.

[0070] Please refer to Figures 5-8This application also provides a method for intelligent three-dimensional combined support of tunnel sides and roof. Using the aforementioned intelligent three-dimensional combined support device, the tunnel excavation in this embodiment forms a rectangular tunnel with a width of 5.0m, a height of 4.5m, and a distance of 1017m from the cut-in point. The formulas involved in this method, and the meanings of their parameters, are summarized below:

[0071] a is half the width of the roadway; b is half the height of the roadway; c is half the effective span of the rock strata supported by the device; d is the reserved construction distance for the three-dimensional support tray, generally taken as 0.1~0.15m; e is half the length of the support unit; F is the Protodyakonov coefficient; g is half the intelligent cable tensioner; C is the cohesion; σ Z P0 is the vertical stress of the surrounding rock in the tunnel; P0 is the stress due to the self-weight of the anchor body; P2 S γ is the support resistance; θ is the internal friction angle; μ1 is the friction coefficient between the long and short high-strength anchor bolts and the surrounding rock mass; μ2 is the friction coefficient between the anchor cable and the surface of the anchored surrounding rock mass; γ is the average unit weight of the rock; ∠1 is the main support angle, which is generally taken as 0~72° according to the parameters of the hourglass-shaped main hole described above; ∠2 is the secondary support angle, which is generally taken as 0~74° according to the parameters of the hourglass-shaped secondary hole described above; l is the length of the long high-strength anchor bolt beyond the stable zone of the surrounding rock, which is generally taken as 0.15~0.20m.

[0072] The method specifically includes the following steps:

[0073] Step S1: Precisely calculate the anchor length and anchoring point: The lengths of the long high-strength anchor 10 and the short high-strength anchor 11 are precisely determined through calculation. The lengths L1 of the long high-strength anchor 10 and L2 of the short high-strength anchor 11 are calculated using formulas. The anchoring points are determined based on the length and the primary and secondary support angles. Specifically, the anchoring point of the long high-strength anchor 10 is located in the conical base area formed by length L1 and included angle ∠1, and the anchoring point of the short high-strength anchor 11 is located in the conical base area formed by length L2 and included angle ∠2. The purpose is to find precise and scientific anchoring points for the anchors. Specifically, the length of the long high-strength anchor 10 is first calculated, and the primary support angle is determined. The length of the long high-strength anchor 10 is:

[0074]

[0075] When determining the anchorage area of ​​the short high-strength anchor 11, it is necessary to first calculate the length of the short high-strength anchor 11 and determine the secondary support angle. The length of the short high-strength anchor 11 is:

[0076]

[0077] This step provides a theoretical basis for the precise anchoring of subsequent anchor bolts, ensuring that the long high-strength anchor bolt 10 and the short high-strength anchor bolt 11 are anchored in the stable area of ​​the surrounding rock, thus optimizing the support effect from the design source.

[0078] Step S2: Install roof anchor bolt assembly: Draw guide lines along the width direction on the roof of the roadway, drill holes at both ends of the guide lines, and blast the emulsion explosive into the bottom of the hole to create fissures in the surrounding rock mass; pass the long, high-strength anchor bolt 10 through the hourglass-shaped main hole 91 of the three-dimensional support tray 9, and simultaneously send the retarded anchoring agent into the bottom of the borehole and stir it evenly. Utilizing the retarded setting properties of the anchoring agent, pull out the long, high-strength anchor bolt 10 before the anchoring agent solidifies, thereby pre-treating the inner wall of the borehole and forming a regular anchoring channel. Then, the long high-strength anchor rod 10 is pulled out, and the fast-setting anchoring agent is sent into the borehole. The long high-strength anchor rod 10 and the three-dimensional support tray 9 are fixed together to the roof of the roadway with nuts to ensure that the anchoring point is located in the original rock area. Then, multiple short high-strength anchor rods 11 are inserted into the hourglass-shaped secondary holes 92 of the three-dimensional support tray 9. With the exposed end of the long high-strength anchor rod 10 as the center, they are driven radially into the surrounding rock. Each long high-strength anchor rod 10 and the short high-strength anchor rods 11 around it form an anchor rod group, forming a balloon-shaped anchoring area.

[0079] Specifically, according to the length formulas of the long high-strength anchor rod 10 and the short high-strength anchor rod 11 derived above, the main support angle ranges from ∠1=0~72°, and the secondary support angle ∠2=0~74°.

[0080] A simplified mechanical model of the support device was constructed, and the preload of the long, high-strength anchor rod 10 was calculated under static equilibrium conditions. The preload of the long, high-strength anchor rod 10 was then obtained as follows:

[0081]

[0082] The formula for calculating the preload of short high-strength anchor bolt 11 is as follows:

[0083]

[0084] The preload is measured using a force gauge to ensure it meets the preload requirements.

[0085] Step S3: Connect the support device: Connect the three-dimensional support tray 9 to the rear end of the upright plate 8 through the two-force bar 14; take an anchor cable 12 and two support units, pass the two ends of the anchor cable 12 through the anchor cable holes on the tension plate 3 of each support unit, and fix them to the end connector 6 to form a bidirectional tension link.

[0086] Step S4, Applying Pre-tension: Controller 7 is activated, controlling the hydraulic cylinder 4 to retract. The tension of the anchor cable 12 is monitored by the tension sensor 5. The intelligent tensioning device 15 pulls the anchor cable 12 outwards, increasing the tension. This applies pre-tension to the anchor bolt groups at both ends through the three-dimensional support tray 9, creating a squeezing and lifting effect on the roadway roof. By analyzing the mechanical model of the anchor cable 12 and combining it with static equilibrium conditions, the pre-tension design value of the anchor cable 12 is calculated.

[0087]

[0088] like Figure 5 As shown, two long high-strength anchor bolts 10 and a short high-strength anchor bolt 11, together with an anchor cable 12, form an inverted trapezoidal lifting surface, lifting the roof rock upwards and slowing its subsidence. Meanwhile, the two short high-strength anchor bolts 11 and the anchor cable 12, after pre-tightening, form a trapezoidal compression surface, squeezing the fractured roof rock inwards to increase its density. Both structures effectively support the roof rock. When the roadway rock is not deformed, the compressive force generated by the device strengthens the interaction between the roadway rock masses. According to the friction formula, as the normal pressure increases, the friction between rock layers also increases, increasing the overall integrity of the rock mass. When the roadway anchored rock mass deforms, the flexibility of the anchor cable and the intelligent device's adjustment of the pre-tightening force effectively adapt to the deformation of the anchored rock mass and improve the pre-tightening force, achieving active reinforcement of the roadway rock mass.

[0089] Step S5: Forming an intelligent three-dimensional combined support structure: On both sides of the roadway, anchor bolt groups, support devices, and anchor cables are installed in the same manner as the roof. The three-dimensional support trays 9 at both ends of the roof support unit are connected to the three-dimensional support trays 9 in the two side support units through the side-to-top connectors 13 to form an intelligent three-dimensional combined support structure covering the roadway roof and both sides. If necessary, it can be further extended to the floor to achieve all-round reinforcement of the roadway surrounding rock.

[0090] Step S6: Forming an X-shaped cross-support structure: On the roadway roof, the row spacing M1 is calculated using a formula. Along the roadway direction, at a distance M1 from the already installed roof support device, symmetrical guide lines parallel to the previous intelligent three-dimensional combined support structure are drawn on the roadway roof. These guide lines are used to determine the installation position of the next intelligent three-dimensional combined support structure. Subsequently, following the operation flow from steps S2 to S5, the installation of the next intelligent three-dimensional combined support structure is completed. Two intelligent three-dimensional combined support structures are symmetrically arranged with the roadway roof centerline as the axis of symmetry. The cable tensioner 16 activates the controller 7 in the intelligent support device 15, controlling the hydraulic cylinders 4 at both ends to tighten the cable 18. The tension sensor 5 monitors the tension of the cable 18, thereby compressing and lifting the roof between two adjacent intelligent three-dimensional combined support structures to form an X-shaped load-bearing structure. When multiple sets of roof support devices are continuously arranged along the roadway direction in the above manner, adjacent X-shaped structures overlap spatially, ultimately forming a stable X-shaped cross support structure within the roadway roof area. Specifically, the spacing of the device in this invention is:

[0091]

[0092] This invention provides a method for calculating the spacing of the tunnel excavation apparatus.

[0093] By analyzing the mechanical model of cable 18 and calculating its preload under static equilibrium conditions, the design value of the preload is obtained as follows:

[0094]

[0095] Step S7, Dynamic Monitoring and Control: The preload values ​​of anchor cables 12 and tension cables 18, calculated using the formula, are set as the lower threshold of controller 7. When the preload monitored by tension sensor 5 is lower than this value, controller 7 is activated to control hydraulic cylinder 4 to automatically tighten until the preload value is higher than the lower threshold. 60% of the ultimate preload values ​​of anchor cables 12 and tension cables 18 are set as the upper threshold of controller 7. When the preload monitored by tension sensor 5 is higher than this value, hydraulic cylinder 4 will automatically depressurize, achieving dynamic control. This dynamic control mechanism ensures that the support system can adapt to surrounding rock deformation, maintain optimal working condition over a long period, and effectively avoid the failure risk caused by uncontrolled preload in traditional support systems, demonstrating the intelligent advantages of this invention.

[0096] Step S8: Establish a monitoring network: Connect each controller 7 in the roadway to the control center wirelessly. The control center assigns numbers to the controllers 7, forming a dynamic monitoring network that transmits real-time preload data of anchor cables 12 and tension cables 18, and supports remote adjustment, thus achieving comprehensive management of the entire roadway support system. This network can collect, transmit, and analyze all preload data of anchor cables 12 and tension cables 18 in real time, and supports remote parameter setting and control command issuance, realizing comprehensive information-based and intelligent management of the roadway support system, greatly improving the mine's safety level.

[0097] The above embodiments are only used to illustrate the technical solutions of the embodiments of this application, and are not intended to limit them. Although the embodiments of this application have been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope defined by the claims of this application.

Claims

1. A roadway side and roof intelligent three-dimensional combined supporting device, characterized in that, The utility model relates to a kind of intelligent three-dimensional combined support structure and X type bearing structure; Multiple intelligent three-dimensional combined support structures are arranged along the direction of roadway development;Each of the intelligent three-dimensional combined support structures includes a roof support unit and two side support units, and the two side support units are connected to the two ends of the roof support unit through the roof-to-side connecting members (13), forming an intelligent three-dimensional combined support structure covering the roof and two sides of the roadway. The roof support unit and the side support unit each include a two-force rod (14), an intelligent tensioning device (15), a three-dimensional support tray (9) and an anchor cable (12). The two ends of the anchor cable (12) are fixed on two intelligent tensioning devices (15), respectively, forming a support pair capable of bidirectional intelligent tensioning of the anchor cable (12). The X type bearing structure includes two cross-connected intelligent cable tensioners (16). The intelligent cable tensioner (16) includes two hinged rods (17), two intelligent tensioning devices (15) and a cable (18). The two ends of the cable (18) are fixed on two intelligent tensioning devices (15), respectively. The intelligent tensioning devices (15) are connected to the three-dimensional support trays (9) at corresponding positions of the front and rear intelligent three-dimensional combined support structures through the hinged rods (17). A short high-strength anchor rod (11) at the corresponding position is arranged in the round hole of the hinged rod (17) and is fixed on the three-dimensional support tray (9) at the corresponding position through the nut on the exposed end of the anchor rod, forming an X type bearing structure capable of pressing and lifting the roof.

2. The smart three-dimensional modular support device according to claim 1, characterized in that, The intelligent tensioning device (15) includes a support base plate (1), a U-shaped rod (2), a tensioning plate (3), a hydraulic cylinder (4), a tension sensor (5), an end connector (6), a controller (7) and a vertical plate (8). The U-shaped rod (2) and the hydraulic cylinder (4) are fixed on the support base plate (1) through the vertical plate (8). The end of the U-shaped rod (2) is arranged in the fixed hole of the tensioning plate (3), and is fixedly connected to the tensioning plate (3) through a nut. The other end of the tensioning plate (3) is fixed on the support base plate (1) and has an anchor cable hole in the middle for arranging the anchor cable (12). The rod head of the hydraulic cylinder (4) is detachably connected to one end of the tension sensor (5), and the other end of the tension sensor (5) is detachably connected to the end connector (6). The end connector (6) is used to fix the end of the anchor cable (12). The controller (7) is fixed on the support base plate (1) and is electrically connected to the hydraulic cylinder (4) and the tension sensor (5) to form an intelligent control system for receiving the anchor cable tension signal and controlling the extension and retraction of the hydraulic cylinder (4), thereby realizing intelligent tensioning of the anchor cable (12).

3. The smart three-dimensional modular support device according to claim 1, wherein, The roof-to-rib connection (13) comprises flexible cables (19), tension and compression self-adaptive adjusting members (20) and cable end connectors (21); two ends of the two flexible cables (19) are fixed on the cable end connector (21) and the tension and compression self-adaptive adjusting member (20) respectively; the tension and compression self-adaptive adjusting member (20) comprises a spring (22), an inner sleeve (23) and an outer sleeve (24); two ends of the spring (22) are fixed in the inner sleeve (23) and the outer sleeve (24) respectively; the inner sleeve (23) is slidingly arranged in the outer sleeve (24); the short high-strength anchor rod (11) is arranged in the round hole of the cable end connector (21) and is fixed on the three-dimensional support tray (9) of the roof support unit and the rib support unit through the nut of the exposed end of the short high-strength anchor rod (11), thereby forming a connection that can realize the collaborative support of the roof and the two ribs of the roadway; The three-dimensional support tray (9) is a circular flat plate, a sandglass-shaped main hole (91) is arranged at the center thereof, and four sandglass-shaped secondary holes (92) are uniformly arranged along the circumference of the sandglass-shaped main hole (91); the sandglass-shaped main hole (91) and the sandglass-shaped secondary hole (92) are both formed by butt joint of two circular truncated cone holes symmetrical about the upper bottom surface along the plate thickness direction, the sandglass-shaped main hole (91) is used for penetrating the long high-strength anchor rod (10), and the sandglass-shaped secondary hole (92) is used for penetrating the short high-strength anchor rod (11); the three-dimensional support tray (9) is connected with the rear end of the vertical plate (8) through the two-force rod (14).

4. A roadway roof and sidewall intelligent three-dimensional combined support method, using the intelligent three-dimensional combined support structure and the X-shaped bearing structure of claim 1, characterized in that, The method comprises the following steps: Step S1, accurately calculating the length of the anchor rod and the anchoring point: the lengths of the long high-strength anchor rod (10) and the short high-strength anchor rod (11) are accurately determined by calculation, the length L1 of the long high-strength anchor rod (10) and the length L2 of the short high-strength anchor rod (11) are calculated by formula, and the anchoring points of the anchor rods are determined according to the lengths and the primary and secondary support angles, specifically, the anchoring point of the long high-strength anchor rod (10) is located in the conical bottom surface region formed by the length L1 and the angle ∠1, and the anchoring point of the short high-strength anchor rod (11) is located in the conical bottom surface region formed by the length L2 and the angle ∠2; Step S2, install the roof anchor rod group: draw a guide line on the roadway roof along the width direction, drill holes at the endpoints of the guide line, and place emulsion explosive at the bottom of the hole to blast and cause cracks in the surrounding rock mass; pass a long high-strength anchor rod (10) through the sandglass-shaped main hole (91) of the three-dimensional support tray (9), and send the retarding anchor agent into the bottom of the hole and stir it evenly, use the retarding property of the retarding anchor agent to pull out the long high-strength anchor rod (10) before the anchor agent solidifies, thereby pretreating the inner wall of the hole and forming a regular anchor channel; immediately pull out the long high-strength anchor rod (10), then send the fast-setting anchor agent into the hole, and use a nut to fix the long high-strength anchor rod (10) and the three-dimensional support tray (9) together on the roadway roof, ensuring that the anchor point is located in the original rock area; then pass a plurality of short high-strength anchor rods (11) into the sandglass-shaped secondary holes (92) of the three-dimensional support tray (9), and set up radially towards the surrounding rock mass with the long high-strength anchor rod (10) as the center, each long high-strength anchor rod (10) and its surrounding short high-strength anchor rods (11) form an anchor rod group, forming a balloon beam type anchor area; Step S3, connect the support device: connect the three-dimensional support tray (9) and the rear end of the vertical plate (8) through the two-force rod (14); take one anchor cable (12) and two support units, pass the anchor cable (12) through the anchor cable hole on the tensioning plate (3) of each support unit at both ends, and fix it to the end connector (6) to form a bidirectional tension link; Step S4, apply pre-tightening force: turn on the controller (7) to control the hydraulic oil cylinder (4) to retract, monitor the tension of the anchor cable (12) through the tension sensor (5), and the intelligent tensioning device (15) pulls the anchor cable (12) outward to increase the tension, thereby applying pre-tightening force to the anchor rod groups at both ends through the three-dimensional support tray (9), forming a squeezing and lifting effect on the roadway roof; Step S5, form an intelligent three-dimensional combined support structure: on both sides of the roadway, set anchor rod groups, install support devices and anchor cables in the same way as the roof, and connect the three-dimensional support trays (9) at both ends of the roof support unit with the three-dimensional support trays (9) in the two side support units through the side-roof connectors (13), forming an intelligent three-dimensional combined support structure covering the roadway roof and both sides. Step S6, forming an X-shaped cross support structure: on the roadway roof, the row distance M1 is obtained by formula calculation, a guide line parallel to the previous intelligent three-dimensional combined support structure is symmetrically drawn on the roadway roof at a distance M1 along the direction of the roadway, the guide line is used to determine the installation position of the next intelligent three-dimensional combined support structure; then, the next intelligent three-dimensional combined support structure is installed according to the operation procedures of steps S2 to S5; two intelligent cable tensioners (16) are symmetrically arranged across the roadway roof central axis as the symmetry axis, the controller (7) in the intelligent support device (15) is turned on, the hydraulic oil cylinder (4) at both ends is controlled to tension the cable (18), the tension of the cable (18) is monitored by the tension sensor (5), the roof between the adjacent two intelligent three-dimensional combined support structures is extruded and lifted to form an X-shaped bearing structure; when a plurality of roof support devices are continuously arranged along the direction of the roadway in the above manner, the adjacent X-shaped structures are superimposed in space, and finally a stable X-shaped cross support structure is formed in the range of the roadway roof; Step S7, dynamic monitoring and control: the pre-tightening force value of the anchor cable (12) and the cable (18) obtained by the calculation formula is set as the lower threshold value of the controller (7), when the pre-tightening force monitored by the tension sensor (5) is lower than the value, the controller (7) is started to control the hydraulic oil cylinder (4) to automatically tension until the pre-tightening force value is higher than the lower threshold value. 60% of the limit pre-tightening force value of the anchor cable (12) and the cable (18) is set as the upper threshold value of the controller (7), when the pre-tightening force monitored by the tension sensor (5) is higher than the value, the hydraulic oil cylinder (4) will automatically release pressure to realize dynamic control; Step S8, forming a monitoring network: each controller (7) in the roadway is connected to the control center by wireless means, the control center numbers the controllers (7) to form a dynamic monitoring network, which transmits the pre-tightening force data of the anchor cable (12) and the cable (18) in real time and supports remote adjustment to complete the overall management of the entire roadway support system.

5. The roadway side and top intelligent three-dimensional combined support method according to claim 4, characterized in that, In step S1, the length L1 of the long high-strength anchor rod is calculated by the following formula: wherein a is 1 / 2 of the roadway width; b is 1 / 2 of the roadway height; C is the cohesion; e is 1 / 2 of the length of the supporting unit; P0 is the self-weight stress of the anchoring body; P S is the supporting resistance; θ is the internal friction angle; ∠1 is the main supporting angle.

6. The roadway side and top intelligent three-dimensional combined support method according to claim 4, characterized in that, In step S1, the length L2 of the short high-strength anchor rod is calculated by the following formula: where σ Z is the vertical stress of the roadway surrounding rock.

7. The roadway side and top intelligent three-dimensional combined support method according to claim 6, characterized in that, In step S2, the long high-strength anchor rod pre-tightening force formula is: Wherein, c is 1 / 2 of the effective support span of the device; μ1 is the friction coefficient of the long high-strength anchor rod and the short high-strength anchor rod and the surrounding rock mass; γ is the average unit weight of the rock; λ is the lateral pressure coefficient of the rock; F is the Protodyakonov coefficient; L1 is the length of the long high-strength anchor rod. In step S2, the short high-strength anchor rod pre-tightening force calculation formula is: Wherein, ∠2 is the secondary support angle.

8. The roadway side and top intelligent three-dimensional combined support method according to claim 7, characterized in that, In step S4, the anchor cable pre-tightening force calculation formula is: Wherein, μ2 is the friction coefficient of the anchor cable and the cable and the surrounding rock.

9. The roadway side and top intelligent three-dimensional combined support method according to claim 9, characterized in that, In step S6, the row distance calculation formula of the roadway roof is: Wherein, l is the length of the long high-strength anchor rod beyond the stable zone of the surrounding rock.

10. The roadway side and top intelligent three-dimensional combined support method according to claim 8, characterized in that, In step S6, the cable pre-tightening force calculation formula is: Wherein, g is 1 / 2 of the intelligent cable tensioner, and M1 is the row distance of the device.

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