Roadway surface shape detection device for concrete spraying operation

Abstract

The invention relates to a roadway surface shape detection device for concrete spraying operation, and belongs to the technical field of mine tunnel anchoring and shotcreting support. The invention provides an integrated detection device for solving the problems that in the prior art, manual measurement efficiency is low, data cannot be shared with an injection machine in real time, and three-dimensional laser equipment is extremely prone to being polluted and damaged in the injection operation. The device comprises a bottom plate, a mounting column, a protective top plate, a three-dimensional laser radar, an angular travel actuator, an angle sensor and an openable protective cover, the laser radar is fixed to the front face of the mounting column and communicates with the industrial personal computer of the injection machine in real time through the Ethernet, the protective cover is driven by the angular travel actuator and accurately controlled by the angle sensor, and the laser radar can be automatically opened and exposed to obtain high-density point cloud data of the roadway surface during detection. And concrete pollution and impact are effectively isolated by matching with the design of the protective top plate and the inclined plane. Detection automation, instant data sharing and reliable equipment protection are realized.

Description

Technical Field

[0001] This invention belongs to the field of anchor-sprayed support technology for mining tunnels, and relates to a roadway surface shape detection device for shotcrete operations. Background Technology

[0002] Shotcrete support is one of the most common permanent support methods in underground engineering projects such as mines and tunnels. After the shotcrete support construction is completed, it is necessary to test the thickness, surface smoothness, and foundation depth of the shotcrete layer to determine whether it meets the design requirements. Currently, the industry generally uses a station-based total station for high-precision position measurement of the tunnel outline and a station-based 3D laser scanner for mapping the position information of the tunnel surface structure. However, in the actual acceptance of shotcrete thickness and smoothness, manual contact measurement using tools such as calipers, tape measures, measuring rods, straightedges, and feeler gauges is still the main method.

[0003] The existing manual measurement methods have the following drawbacks: First, the measurement efficiency is low and the labor intensity is high, especially in high tunnels or arch positions where operation is extremely inconvenient; second, the measurement points are sparse and the coverage area is small, making it difficult to fully reflect the overall quality of the sprayed layer; third, the measurement data is discrete and manually recorded, making it impossible to achieve real-time data exchange with the industrial control computer of wet or dry spraying machines, resulting in the inability to intelligently adjust the spraying parameters according to the actual over- or under-excavation situation.

[0004] Although some construction companies have introduced stand-alone 3D laser scanners to attempt digital mapping, this equipment operates independently of the concrete spraying machine. After measurement, data still needs to be manually exported, processed, and input, making it impossible to form a closed-loop control system. More importantly, stand-alone 3D laser scanners lack dedicated protective designs for the sprayed concrete working environment. During spraying, the optical lens is easily contaminated by high-speed rebounding cement slurry or damaged by impacts from larger aggregate particles. Once the lens is covered with cement slurry, it will directly lead to equipment failure, and cleaning and maintenance costs are high.

[0005] Given the significant shortcomings of existing technologies in terms of efficiency, automation, data sharing, and equipment protection, there is an urgent need for a specialized detection device that can quickly acquire information on the location of roadway surface structures, achieve real-time data sharing with the shotcrete machine, and provide reliable protection during shotcrete operations, in order to improve the level of intelligence and quality control of shotcrete construction. Summary of the Invention

[0006] In view of this, the purpose of the present invention is to provide a roadway surface shape detection device for shotcrete operations.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A tunnel surface shape detection device for shotcrete operations includes a base plate 1, a mounting column 2, a protective top plate 3, a lidar 4, an angular stroke actuator 5, an angle sensor 6, and a protective cover 7. The mounting post 2 is vertically fixed on the base plate 1, and the mounting post 2 has a cavity inside for the laser radar wiring. The protective top plate 3 is fixed to the upper surface of the mounting column 2; The lidar 4 is fixedly installed on the front outer surface of the mounting column 2, and is used to scan and acquire the location information of the roadway surface structure and share data with the industrial control computer of the concrete spraying machine via Ethernet. Both the angular stroke actuator 5 and the angle sensor 6 are fixed on the base plate 1; The protective cover 7 is fixedly connected to the rotating shaft of the angular stroke actuator 5. The angular stroke actuator 5 drives the protective cover 7 to open and close around the rotating shaft, so that the protective cover 7 exposes the lidar 4 for roadway surface detection when it is open, and shields and protects the lidar 4 from sprayed concrete pollution and damage when it is closed.

[0008] Furthermore, the protective cover 7 has an outward-facing slope 8 when closed, which is used to reduce the accumulation of rebound debris on the surface of the protective cover 7 during shotcrete operations.

[0009] Furthermore, the protective top plate 3 extends above the top area of ​​the protective cover 7 when it is closed, in order to reduce the accumulation of concrete on the surface of the protective cover 7 during shotcrete operations.

[0010] Furthermore, the lidar 4 is a three-dimensional lidar.

[0011] Furthermore, the angle sensor 6 detects the rotation angle of the angular stroke actuator 5 in real time and feeds the angle information back to the control system to achieve precise opening and closing control of the protective cover 7.

[0012] Furthermore, the signal lines and power lines of the lidar 4 are routed through the internal cavity of the mounting post 2 and then connected to the outside.

[0013] Furthermore, the base plate 1 is used to stably fix the entire device in the working position within the roadway.

[0014] Furthermore, the device performs the following process during operation: When it is necessary to perform tunnel surface shape detection, the angular stroke actuator 5 drives the protective cover 7 to open, the lidar 4 is exposed and scans the tunnel surface, and the acquired point cloud data is transmitted to the industrial control computer of the concrete spraying machine in real time via Ethernet. During shotcrete operation, the angular stroke actuator 5 drives the protective cover 7 to close, so that the lidar 4 is completely shielded and protected. At the same time, the protective top plate 3 and the inclined surface 8 together reduce the accumulation of concrete and its rebound debris on the surface of the device.

[0015] Furthermore, the control system performs closed-loop control of the angular stroke actuator 5 based on the real-time angle signal fed back by the angle sensor 6, thereby precisely controlling the opening and closing angle and speed of the protective cover 7.

[0016] Furthermore, the device is specifically designed for automated digital detection and data sharing of the thickness of the sprayed grout on the inner wall of the tunnel, the surface flatness, and the foundation depth before and after the sprayed concrete operation in mine or tunnel anchor-spray support projects.

[0017] The beneficial effects of this invention are as follows: (1) Through the coordinated design of the protective cover and the protective top plate, the lidar can be completely shielded during the shotcrete operation, effectively avoiding the contamination of the optical lens by the high-speed sprayed cement slurry and the impact damage of the large aggregate particles. This allows the lidar to remain clean and intact in the harsh environment of high dust and high rebound, greatly extending the service life of the equipment and reducing maintenance costs.

[0018] (2) Three-dimensional lidar is used to quickly acquire high-density point cloud data of the roadway surface, and real-time data communication is achieved directly with the industrial control computer of the concrete spraying machine via Ethernet. This enables the spraying machine to automatically adjust the spraying angle, speed and thickness according to the actual over-excavation and under-excavation situation, so as to achieve precise leveling and uniform coverage, thereby fundamentally improving the thickness consistency and surface flatness of the sprayed concrete layer.

[0019] (3) The opening and closing of the protective cover is fully automatic and precise controlled by the angular stroke actuator combined with the angle sensor. It can quickly switch between the two working conditions of detection and spraying without manual intervention, completely getting rid of the traditional manual contact measurement method of ruler and measuring rod, significantly reducing the labor intensity of workers, and shortening the single cycle detection and re-spraying time, thus improving the overall construction efficiency.

[0020] (4) The device is integrated on a single base plate, which is small in size and light in weight, making it easy to deploy and move quickly in narrow tunnels. When the protective cover is closed, the outer surface is designed with a slope, which further reduces the accumulation of concrete rebound material and keeps the device clean for a long time, making it particularly suitable for anchor spraying support operations in wet, dusty, and space-constrained environments such as mines and tunnels.

[0021] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0022] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the main structure of the tunnel surface shape detection device of the present invention in the open state; Figure 2 This is a schematic diagram of the main structure of the roadway surface shape detection device of the present invention in the closed state.

[0023] Attached reference numerals: 1-base plate, 2-mounting column, 3-protective top plate, 4-laser radar, 5-angular stroke actuator, 6-angle sensor, 7-protective cover, 8-sloping surface. Detailed Implementation

[0024] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0025] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0026] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0027] Example 1 like Figure 1 and Figure 2As shown, the device mainly consists of a base plate 1, a mounting column 2, a protective top plate 3, a lidar 4, an angular stroke actuator 5, an angle sensor 6, and a protective cover 7.

[0028] The base plate 1 is made of 15mm thick steel plate with a corrosion-resistant paint coating to ensure long-term stable support of the entire device in humid and dusty tunnel environments. The mounting column 2 is a hollow square steel column, vertically welded and fixed to the center of the base plate 1. Its internal cavity allows for neat routing of the network and power cables of the lidar 4, preventing exposed cables from being scratched by concrete rebound. The protective top plate 3 is made of stainless steel plate, inclinedly welded to the top of the mounting column 2, extending forward 350mm to form an umbrella-shaped shielding structure. The lidar 4 is a 16-line 3D lidar, firmly installed in the upper center of the front of the mounting column 2, secured by a dedicated shock-absorbing bracket. Its network cable passes through the inside of the mounting column 2 and is directly connected to the industrial control computer of the concrete spraying machine. The angular stroke actuator 5 is a 180... An electric push-rod type angular actuator is fixed to the right side of the base plate 1, with its output shaft connected to the bottom of the protective cover 7. Angle sensor 6 is a high-precision absolute encoder, coaxially mounted with the angular actuator 5, used to provide real-time feedback on the opening and closing angle of the protective cover 7. The protective cover 7 is formed by bending 5mm thick steel plate, and in the closed state, it forms a 45° angle. The inclined outer surface forms a slope 8 to reduce the accumulation of concrete rebound material.

[0029] Workflow: After the device enters the working face along with the wet spraying trolley or the anchor bolt trolley, the base plate 1 is placed stably on the roadway floor and fixed with expansion bolts.

[0030] Testing phase: The industrial control computer issues a "test" command, and the angular stroke actuator 5 rotates 180 degrees in the forward direction. This causes the protective cover 7 to fully rotate to a horizontally open position (e.g. Figure 1 As shown), LiDAR 4 is fully exposed. LiDAR 4 activates 360. The horizontal rotation scan completes the high-density point cloud acquisition of a single section within 10 seconds, and transmits it in real time to the spraying machine's industrial control computer via Ethernet to generate an over- and under-excavation color deviation map.

[0031] Spraying Phase: After scanning is complete, the industrial control computer automatically issues a "spraying" command, the angular stroke actuator 5 rotates in the reverse direction, and the protective cover 7 quickly closes to the vertically closed state (e.g., Figure 2 As shown), the lidar 4 is completely enclosed and protected. The spraying machine automatically adjusts the posture of the robotic arm according to the deviation diagram for precise supplementary spraying. During the spraying process, the protective top plate 3 blocks falling concrete from above, and the inclined surface 8 causes the rebounding material to follow a 45-degree angle. Slide at an angle to avoid accumulation.

[0032] Angle sensor 6 monitors the shaft angle in real time throughout the entire process and feeds it back to the industrial control computer, forming a closed-loop control to ensure that the positioning accuracy of the protective cover 7 is within ±1. Within.

[0033] After a single cycle of operation is completed, the device moves forward with the trolley to the next section and repeats the above process.

[0034] This embodiment achieves full automation of the detection, data sharing, precision spraying, and equipment protection processes, and is particularly suitable for large cross-section tunnels with a cross-section of 5 meters × 5 meters or more.

[0035] Example 2 This embodiment is a further optimization based on embodiment 1, adding a wireless communication module and a backup battery, making it suitable for extreme working conditions where there is no wired network or temporary power outage.

[0036] The hardware structure of the device is basically the same as that of Example 1, except that: in addition to the wired Ethernet, the lidar 4 integrates a 4G / 5G industrial-grade wireless communication module, and has a built-in 12Ah lithium battery pack that can work continuously for more than 2 hours when the external power is off. A transparent acrylic observation window is added to the inner surface of the protective cover 7, which allows on-site personnel to visually confirm the cleaning status of the lidar.

[0037] Workflow: When operating in a single-ended tunnel with poor network signal, the device prioritizes uploading point cloud data to the cloud server in real time via the 5G module, and then the server forwards it to the jet machine industrial control computer in the remote control center to achieve ultra-long-distance data sharing.

[0038] When the external power supply is interrupted, the built-in battery automatically and seamlessly switches over, and the angular stroke actuator 5 and the lidar 4 continue to work normally, ensuring that the detection and protection functions are not interrupted in case of emergencies.

[0039] The remaining detection-opening the protective shield-scanning-closing the protective shield-spraying process is exactly the same as in Example 1.

[0040] This embodiment significantly improves the device's adaptability in environments with unstable networks or unreliable power supply, making it particularly suitable for long-distance single-heading tunneling and shotcreting operations in deep mines.

[0041] Example 3 This embodiment is a miniaturized structure, mainly used for small and medium-sized tunnels or chambers with a cross-section of less than 4 meters × 4 meters.

[0042] Compared to Example 1, the protective top plate 3 is omitted, and the protective cover 7 is made of semi-cylindrical transparent polycarbonate material, which can both protect the device and allow direct observation of the lidar's working status. The angular stroke actuator 5 is changed to 90°. The rotary cylinder draws its air directly from the air tank of the jet engine.

[0043] Workflow: During testing, the cylinder drives the protective cover 7 to rotate 90 degrees. Open to the side, and expose the LiDAR 4 for scanning.

[0044] Before spraying, the cylinder quickly resets, and the semi-cylindrical protective cover 7 completely encloses the lidar 4. The polycarbonate material is sufficient to withstand the impact of concrete rebound and does not easily accumulate material.

[0045] Data is still transmitted in real time via Ethernet.

[0046] This embodiment shows a significant weight reduction effect, making it particularly suitable for use with lightweight wet spraying trolleys that require frequent movement in confined spaces.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A roadway profile detection device for a shotcrete operation, characterized by: It comprises a base plate (1), a mounting column (2), a protective top plate (3), a laser radar (4), an angular stroke actuator (5), an angle sensor (6) and a protective cover (7); The mounting column (2) is vertically fixed on the base plate (1), and has a cavity inside for laser radar wiring; The protective top plate (3) is fixed on the upper surface of the mounting column (2); The laser radar (4) is fixedly installed on the front outer surface of the mounting column (2), used for scanning and acquiring the position information of the roadway surface structure and sharing data with the industrial computer of the concrete spraying machine through Ethernet; The angular stroke actuator (5) and the angle sensor (6) are both fixed on the base plate (1); The protective cover (7) is fixedly connected to the rotating shaft of the angular stroke actuator (5), and the angular stroke actuator (5) drives the protective cover (7) to rotate around the rotating shaft to open and close, so that the protective cover (7) exposes the laser radar (4) in the open state to detect the roadway surface shape, and shields and protects the laser radar (4) from being contaminated and damaged by sprayed concrete in the closed state.

2. The roadway surface shape detection device for sprayed concrete operation according to claim 1, wherein the protective cover (7) has an outward inclined surface (8) in the closed state, which is used to reduce the accumulation of rebounded material slag on the surface of the protective cover (7) during the sprayed concrete operation.

3. The roadway surface shape detection device for sprayed concrete operation according to claim 1 or 2, wherein the protective top plate (3) extends above the top area of the protective cover (7) in the closed state, which is used to reduce the accumulation of concrete on the surface of the protective cover (7) during the sprayed concrete operation.

4. The roadway surface shape detection device for sprayed concrete operation according to claim 1, wherein the laser radar (4) is a three-dimensional laser radar.

5. The roadway surface shape detection device for sprayed concrete operation according to claim 1, wherein the angle sensor (6) detects the rotating angle of the angular stroke actuator (5) in real time and feeds back the angle information to the control system to realize accurate opening and closing control of the protective cover (7).

6. The roadway surface shape detection device for sprayed concrete operation according to claim 1, wherein the signal line and power line of the laser radar (4) are connected to the outside after being wired through the cavity inside the mounting column (2).

7. The roadway surface shape detection device for sprayed concrete operation according to claim 1, wherein the base plate (1) is used to stably fix the entire device at the working position in the roadway.

8. The roadway surface shape detection device for sprayed concrete operation according to any one of claims 1-7, wherein the device performs the following process when working: When the roadway surface shape detection is needed, the angular stroke actuator (5) drives the protective cover (7) to open, and the laser radar (4) is exposed and scans the roadway surface, and the acquired point cloud data is transmitted to the industrial computer of the concrete spraying machine in real time through Ethernet. When the spraying concrete operation is carried out, the angular stroke actuator (5) drives the protective cover (7) to close, so that the laser radar (4) is completely shielded and protected, and the protective top plate (3) and the slope (8) jointly reduce the accumulation of concrete and rebounded slag on the surface of the device.

9. The roadway surface shape detection device for spraying concrete operation according to claim 8, wherein the control system carries out closed-loop control on the angular stroke actuator (5) according to the real-time angle signal fed back by the angle sensor (6), so as to accurately control the opening and closing angle and the opening and closing speed of the protective cover (7).

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