Three-dimensional integrated double-slurry A-liquid pulping system and method

Abstract

The invention discloses a three-dimensional integrated double-liquid slurry A liquid pulping system and method, the system comprises a lower-layer frame and an upper-layer frame which are distributed in the vertical direction, the lower-layer frame and the upper-layer frame jointly form a three-dimensional integrated carrier, and the lower-layer frame is integrated with a storage container and a conveying pump assembly; the storage container is used for temporarily storing raw materials and intermediate slurry in the pulping process of the liquid A, and the conveying pump assembly is communicated with the storage container to realize material conveying; a pulping assembly, a water supply assembly and an operation assisting assembly are integrated on the upper-layer frame, the pulping assembly is used for completing mixed pulping of all components of the liquid A, the water supply assembly is communicated with the pulping assembly and the storage container to provide a water source needed by pulping and cleaning, and the operation assisting assembly is used for assisting personnel in operating and maintaining the upper-layer frame; the problems that traditional split type pulping equipment is large in occupied area, complex in installation, long in debugging period and high in power consumption are solved.

Description

Technical Field

[0001] This invention relates to the field of shield tunneling synchronous dual-liquid grouting construction technology, and in particular to a three-dimensional integrated dual-liquid grout A-liquid preparation system and method. Background Technology

[0002] In the synchronous grouting construction behind the tunnel lining segments, the two-liquid grouting process is a commonly used technical solution. This process requires the independent preparation of a mixture of liquid A and a commercially available finished liquid B. Liquid A, as a highly fluid grout, is composed of cementitious materials, auxiliary materials, stabilizers, foaming agents, and other components. Typical components include cement, bentonite, mineral powder, water-reducing agent, and water. Each component must be prepared in a strictly predetermined mass ratio to ensure the grouting effect.

[0003] The existing general A-liquid slurry preparation process adopts a segmented operation route: firstly, bentonite slurry is pre-prepared and stored through the first set of slurry preparation equipment, then the components such as water, water-reducing agent, pre-expanded bentonite slurry, cement, and mineral powder are mixed through the second set of slurry preparation equipment, and finally the finished A-liquid is output through the pump body.

[0004] However, when performing synchronous grouting for tunnel boring machines (TBMs) with an excavation diameter of 13 meters or more, a grouting capacity of at least 20 cubic meters per hour is required. Traditional solutions typically necessitate multiple separate grouting units, storage tanks, and transfer pumps. This separate layout presents significant technical drawbacks: firstly, it occupies a large area, requiring ample space on the construction site; secondly, it necessitates the construction of complex connecting pipelines, resulting in a cumbersome installation process; thirdly, the effective installation and commissioning cycle is long, typically requiring 7-10 days before it can be put into operation; and fourthly, the coordinated operation of multiple units leads to high overall power consumption and consequently high comprehensive construction costs. These issues have become key factors restricting the efficiency of dual-liquid grouting construction for large-diameter TBMs and increasing project costs. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned shortcomings and provide a three-dimensional integrated dual-liquid slurry A-liquid preparation system and method, which solves the problems of large footprint, complex installation, long commissioning cycle and high power consumption of traditional split slurry preparation equipment. Under the premise of meeting the slurry preparation capacity, it simplifies the installation process, shortens the commissioning time and reduces the overall cost, while ensuring accurate mixing of the components of A-liquid and stable slurry performance.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a three-dimensional integrated dual-liquid slurry A-liquid preparation system, comprising a lower frame and an upper frame distributed along the vertical direction, wherein the lower frame and the upper frame together constitute a three-dimensional integrated carrier, the lower frame integrating a storage container and a delivery pump assembly, the storage container being used to temporarily store raw materials and intermediate slurry during the A-liquid slurry preparation process, and the delivery pump assembly being connected to the storage container to realize material delivery; the upper frame integrating a slurry preparation component, a water supply component, and an operation auxiliary component, the slurry preparation component being used to complete the mixing and slurry preparation of the various components of the A-liquid, the water supply component being connected to the slurry preparation component and the storage container respectively to provide the water source required for slurry preparation and cleaning, and the operation auxiliary component being used to assist personnel in the operation and maintenance of the upper frame.

[0007] Preferably, the storage container includes a bentonite slurry storage tank, an A-liquid slurry storage tank, and a stabilizer container. The pulping assembly includes a first pulping machine and a second pulping machine. The bottom of the bentonite slurry storage tank is connected to the inlet of the first pulping machine via a conveying pipeline. The outlet of the first pulping machine is connected to the A-liquid slurry storage tank. The outlet of the second pulping machine is connected to the inlet of the bentonite slurry storage tank. The outlet of the stabilizer container is connected to the inlet of the first pulping machine via a pipeline.

[0008] Preferably, the delivery pump assembly includes a bentonite pump, an A-liquid pump, a first stabilizer pump, and a second stabilizer pump; the water supply assembly includes a water tank and a water pump group; the operation auxiliary assembly includes a ladder, a platform, and a foldable inclined support; the bottom of the bentonite slurry storage tank is equipped with multiple slurry discharge ports, one of which is connected to the slurry suction port of the bentonite pump, and the slurry discharge port of the bentonite pump is connected to a detachable pipeline, the detachable pipeline 16 being connected to the slurry inlet of the first pulping machine.

[0009] Preferably, the suction port of the first stabilizer pump is connected to the discharge port of the stabilizer container, the discharge port of the first stabilizer pump extends to the upper frame through the lower stabilizer pipeline and is connected to the intermediate stabilizer container through the first control valve, the bottom outlet of the intermediate stabilizer container is connected to the suction port of the second stabilizer pump, and the discharge port of the second stabilizer pump is connected to the inlet of the first pulping machine through the stabilizer flexible pipeline; a first level gauge is installed on the side wall of the stabilizer container, and a second level gauge is configured in the intermediate stabilizer container.

[0010] Preferably, the A-liquid storage tank is an elliptical barrel with a filter screen component at the top, a second non-contact level gauge installed on the top side, second stirring shaft moving components symmetrically installed on both sides of the top, a second cleaning port at the top, and multiple discharge ports at the bottom. The discharge ports of the A-liquid storage tank are connected to the suction port of the A-liquid pump. The bentonite storage tank has a first stirring shaft moving component installed at the middle of the top, a first non-contact level gauge installed on the top side, a slurry inlet on the side, a first cleaning port at the top, and a discharge port at the bottom. Preferably, the lower frame is further provided with an electrical control room for controlling the power components of the entire system. The electrical control room is an independent space enclosed by partitions. The electrical control room contains a control cabinet, which is electrically connected to all motor components in the system to achieve control. The operation auxiliary components include a ladder, a platform, and foldable diagonal braces. The platform is connected to both sides of the upper frame and is supported by foldable diagonal braces to achieve stability. The ladder is connected to the width of the platform and its bottom contacts the ground to form a passage for personnel to go up and down.

[0011] Preferably, the first pulper and the second pulper have the same structure; a weighing module is provided on the side of the barrel of the first pulper, the weighing module is distributed at equal angles along the circumference of the barrel wall and the bottom is supported on the top plane of the support; a rotating shaft is installed on the top of the barrel, and a feed inlet is provided, and multiple pulp inlets are provided along the gaps; a quick-release maintenance door is provided on the lower part of the side of the barrel, and a second control valve is connected to the center of the bottom, the other end of the second control valve is connected to the pulp discharge port of the first pulper; a third control valve is provided at the bottom off-center, and the third control valve is connected to the pulp discharge rigid pipe through a flexible pipeline.

[0012] Preferably, the top of the water tank is equipped with a third non-contact level gauge and a water tank inlet pipe, and the slurry outlet at the bottom is connected to the suction port of the water pump unit; the water pump unit provides slurry water source to the first slurry mixer and the second slurry mixer through pipelines, and provides cleaning water source to the first cleaning port of the bentonite slurry storage tank and the second cleaning port of the A liquid slurry storage tank.

[0013] In addition, the present invention also discloses a method for preparing the A-liquid of the above-mentioned three-dimensional integrated dual-liquid slurry A-liquid preparation system, comprising the following steps: Step 1, Water Supply and Cleaning Preparation: Start the water pump group of the water supply component to deliver the clean water in the water tank to the first pulper and the second pulper to provide pulping water source, and supply clean water to the first cleaning port of the bentonite storage tank and the second cleaning port of the A liquid storage tank to complete the pre-cleaning of the system pipelines and containers. Step 2, Bentonite Slurry Preparation and Storage: Bentonite raw material is fed into the second pulping machine. After being stirred and mixed by the rotating shaft of the second pulping machine, bentonite slurry is prepared. The bentonite slurry is transported to the bentonite storage tank through the discharge port of the second pulping machine for temporary storage. During this period, the moving parts of the first stirring shaft continuously stir to maintain the uniformity of the bentonite slurry. Step 3, staged delivery of stabilizer: Start the first stabilizer pump to deliver the stabilizer in the stabilizer container to the stabilizer intermediate container through the lower stabilizer pipeline and the first control valve. Then start the second stabilizer pump to deliver the stabilizer to the first pulper through the stabilizer flexible pipeline. During the process, the stabilizer level is monitored in real time by the first level gauge and the second level gauge. Step 4: Multi-component mixing and pulping: Start the bentonite pump to transport the bentonite slurry in the bentonite storage tank to the first pulping machine through a detachable pipeline. At the same time, cement, mineral powder and other powder raw materials are added to the feed inlet of the first pulping machine, and water-reducing agent and other liquid raw materials are added to the slurry inlet. After being stirred and mixed by the rotating shaft of the first pulping machine, liquid A mixture is obtained. Step 5, Filtration and storage of liquid A: The A-liquid mixture in the first pulping machine is transported to the A-liquid storage tank via the second control valve, and temporarily stored after being filtered by the filter screen component. During this period, the second stirring shaft moving component continuously stirs to maintain the uniformity of the A-liquid. When the second control valve is damaged or blocked and cannot flow, the pulp is independently discarded through the third control valve, without needing to be transported to the A-liquid storage tank. Step 6: Liquid A is delivered on demand: According to the grouting requirements of the tunnel boring machine, start the A liquid pump and transport the finished A liquid in the A liquid storage tank to the grouting system through pipeline; In this process, the bentonite pump, liquid A pump, various stabilizer pumps and control valves in steps 1-6 are all centrally and automatically controlled by the control cabinet in the electrical control room, so as to realize the continuous and precise operation of the liquid A preparation process.

[0014] Furthermore, steps 2, 3, and 4 specifically include the following processes: Step 2.1: Dynamic concentration control of bentonite slurry linked with liquid level: Real-time concentration calculation: The weighing module of the second pulping machine collects the total weight of the mixed materials in real time, and calculates the real-time concentration of the bentonite slurry by combining the volume of clean water added by the flow sensor of the water pump group, as well as the preset density of bentonite raw materials and density of clean water. Concentration deviation correction: Compare the real-time concentration with the preset target concentration. If the deviation exceeds a certain value, adjust the water supply of the water pump group to the second pulper through the control cabinet in the electrical control room. If the concentration is too high, increase the amount of clean water added; if the concentration is too low, decrease the amount of clean water added. After adjustment, keep stirring for a period of time and check the concentration again until the deviation is reduced to within the threshold. Liquid level linkage start / stop: The real-time liquid level height to the total height of the tank is calculated using the first non-contact liquid level gauge in the bentonite slurry storage tank; when the ratio is below 30%, the control cabinet automatically triggers the second pulping machine to start replenishing slurry, and simultaneously starts the feeding of bentonite raw materials and the supply of clean water; when the ratio is above 80%, the second pulping machine automatically stops and closes the feeding port, while controlling the bentonite pump to continuously deliver at a low flow rate to balance the liquid level in the storage tank; Step 3.1, Precise linkage adjustment of multi-component feeding: Weight deviation judgment: The weighing module of the first pulper compares the actual total weight of the material in the barrel with the preset total weight in real time. If the deviation between the two exceeds a certain value, the corresponding deviation correction amount is allocated according to the weight ratio of each component in the formula. Synchronous adjustment of components: Based on the deviation correction amount, the delivery parameters of each component are adjusted separately, and all adjustment actions are synchronously triggered by the PLC in the control cabinet. Bentonite slurry: Adjust the frequency of the variable frequency motor of the bentonite pump to increase or decrease the delivery flow rate according to the correction amount; For powder raw materials such as cement and mineral powder: adjust the speed of the variable frequency screw conveyor at the feed inlet and increase or decrease the feeding rate according to the correction amount. Stabilizer: Adjust the outlet pressure of the second stabilizer pump and increase or decrease the delivery rate according to the correction amount. Deviation closed-loop elimination: After adjustment, keep stirring for a period of time and check the total weight of materials again until the deviation ratio between the actual total weight and the total weight of the formula is within the threshold, ensuring that each component is always mixed according to the design ratio. Step 4.1: Real-time quality control and performance correction during the pulping process: Indirect viscosity judgment: Based on the correlation between "rotating shaft operating current and slurry viscosity" established in previous experiments, the operating current is collected in real time by the motor current sensor of the rotating shaft of the first pulper, and the current slurry viscosity is inferred; when the viscosity is lower than the preset lower limit or higher than the preset upper limit, performance correction is triggered. Dynamic correction of slurry properties: If the viscosity is higher than the upper limit: the control cabinet will automatically increase the amount of water supplied to the first pulping machine by the water pump group until the viscosity drops back to within the upper limit; If the viscosity is below the lower limit: the control cabinet will automatically increase the amount of stabilizer delivered through the stabilizer flexible pipeline until the viscosity rises back above the lower limit; Precipitation prevention control during storage: The second non-contact level gauge in the A liquid storage tank collects the liquid level in real time, and the rotation speed of the second stirring shaft increases by 10%-20% as the liquid level rises; when the rotation speed is lower than 25 r / min, the control cabinet triggers an alarm, indicating that the slurry may precipitate, and automatically shortens the stirring interval from 5 minutes / time to 2 minutes / time to avoid slurry stratification.

[0015] Beneficial effects of this invention: 1. This invention involves the overall hoisting and assembly of the upper and lower frame layers at the construction site, followed by rapid assembly of detachable pipelines. After the water, electricity, and gas pipelines are debugged, production of liquid A can begin immediately, with effective construction time controlled within 1-2 days. This reduces the difficulty of on-site pipeline installation. Compared to the same liquid A production volume, the site area is reduced by 1 / 2 compared to the previous split-type equipment, and the total power is reduced by 1 / 3. Due to the reduced construction time and installation difficulty, the overall cost is lowered.

[0016] 2. This invention dynamically and precisely controls and improves the quality stability of liquid A, avoiding raw material waste. During the bentonite slurry preparation stage, the weighing module monitors the material weight in real time, and the level gauge provides feedback on the slurry volume. Combined with closed-loop adjustment logic, the concentration deviation of the bentonite slurry is controlled within ±2%, avoiding concentration fluctuations caused by traditional "experience-based water addition." During the multi-component mixing stage, the parameters of the bentonite pump, stabilizer pump, and powder conveyor are synchronously controlled by PLC, keeping the feeding error of each component within 1%. This ensures that cement, mineral powder, water-reducing agent, etc., are precisely mixed according to the design ratio, solving the problem of "imbalanced proportions leading to substandard slurry performance" in traditional slurry preparation. Real-time slurry performance correction: Based on the "rotating shaft current-viscosity" correlation logic, the slurry viscosity is calculated in real time and dynamically corrected by adding water or stabilizer (avoiding excessively high viscosity causing pipe blockage or excessively low viscosity causing bleeding). This ensures that the fluidity and stability of the finished liquid A meet the requirements of shield tunneling grouting, reducing rework and raw material waste caused by substandard slurry performance.

[0017] 3. This invention reduces energy consumption and overall costs, improving economic efficiency: Integrated design reduces energy consumption: Compared to traditional multi-unit independent operation of multiple separate equipment (requiring multiple motors and pump sets for separate drive), this invention optimizes pipeline paths through framework integration, reduces material transfer losses, and achieves on-demand start-up and shutdown of equipment through centralized electrical control, reducing total power consumption by 1 / 3, and significantly reducing electricity costs in the long term. Reduced overall costs: On the one hand, shorter installation time and reduced labor requirements directly reduce on-site construction costs; on the other hand, precise grout ratio and stable performance reduce the hidden costs of raw material waste and grouting failures (such as pipe blockage and rework), while the modular structure facilitates later maintenance, reducing equipment operation and maintenance costs.

[0018] 4. Enhanced Operation and Maintenance, Improving System Applicability: Automation and Safety Enhancement: An independent electrical control room enables centralized automated control of all motors and valves, reducing manual intervention and operational errors; the upper frame features a foldable, diagonally supported platform and ladder, providing safe operating space for personnel maintenance and material feeding, avoiding the safety hazards of traditional equipment lacking a fixed operating platform; Flexible Structure Adaptable to Various Scenarios: The water tank can be replaced by an external container, and detachable pipelines allow for easy adjustment of connection methods according to site conditions, adapting to different shield tunneling sites' water source locations and grouting pipeline layout requirements; a quick-release maintenance door is located on the side of the slurry mixer, allowing for inspection of internal components without complete disassembly, improving maintenance efficiency.

[0019] 5. Ensuring Continuous Grouting and Adapting to the Needs of Large-Diameter Shield Tunneling: Through the process design of "pre-storage of bentonite slurry + real-time preparation of liquid A + liquid level linkage material replenishment", the volume of the bentonite slurry storage tank is more than twice that of the second slurry mixer, and the volume of the liquid A slurry storage tank is more than four times that of the first slurry mixer. This enables continuous connection of "slurry preparation-storage-transportation", avoiding grouting shutdowns caused by material transfer interruptions in traditional split equipment. It meets the construction needs of continuous grouting for large-diameter shield tunnels (slurry preparation volume of more than 20 cubic meters / hour), ensures the grouting quality behind the shield tunnel segments, and reduces the risk of tunnel settlement. Attached Figure Description

[0020] Figure 1 This is a three-dimensional schematic diagram of the three-dimensional structure of the present invention; Figure 2 This is the front view of the present invention; Figure 3 This is a top view of the upper frame of the present invention; Figure 4 This is a top view of the lower frame of the present invention; Figure 5 This is a right view of the present invention; Figure 6 This is a diagram of the stabilizer pipeline in this invention; Figure 7 This is a structural diagram of the first pulping machine in this invention; Figure 8 This is a three-dimensional schematic diagram of the first pulping machine in this invention. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0022] Example 1: As Figures 1 to 8As shown, a three-dimensional integrated dual-liquid slurry A-liquid preparation system includes a lower frame 7 and an upper frame 8 distributed vertically. The lower frame 7 and the upper frame 8 together form a three-dimensional integrated carrier. The lower frame 7 integrates a storage container and a delivery pump assembly. The storage container is used to temporarily store raw materials and intermediate slurry during the A-liquid slurry preparation process. The delivery pump assembly is connected to the storage container to realize material transportation. The upper frame 8 integrates a slurry preparation assembly, a water supply assembly, and an operation auxiliary assembly. The slurry preparation assembly is used to complete the mixing and slurry preparation of the various components of A-liquid. The water supply assembly is connected to the slurry preparation assembly and the storage container to provide the water source required for slurry preparation and cleaning. The operation auxiliary assembly is used to assist personnel in the operation and maintenance of the upper frame 8.

[0023] Preferably, the storage container includes a bentonite slurry storage tank 1, an A-liquid slurry storage tank 3, and a stabilizer container 5. The pulping assembly includes a first pulper 9 and a second pulper 10. The bottom of the bentonite slurry storage tank 1 is connected to the inlet of the first pulper 9 via a conveying pipeline. The outlet of the first pulper 9 is connected to the A-liquid slurry storage tank 3 (specifically, the outlet of the first pulper 9 is connected to the filter screen component 301 at the top of the A-liquid slurry storage tank 3). The outlet of the second pulper 10 is connected to the inlet of the bentonite slurry storage tank 1. The outlet of the stabilizer container 5 is connected to the inlet of the first pulper 9 via a pipeline.

[0024] Preferably, the delivery pump assembly includes a bentonite pump 2, an A-liquid pump 4, a first stabilizer pump 501, and a second stabilizer pump 506; the water supply assembly includes a water tank 11 and a water pump group 12; the operation auxiliary assembly includes a ladder 13, a platform 14, and a foldable diagonal brace 15; the bottom of the bentonite slurry storage tank 1 is equipped with multiple slurry discharge ports, one of which is connected to the slurry suction port of the bentonite pump 2, and the slurry discharge port of the bentonite pump 2 is connected to a detachable pipeline 16, which is connected to the slurry inlet of the first pulping machine 9.

[0025] Preferably, the suction port of the first stabilizer pump 501 is connected to the discharge port of the stabilizer container 5, the discharge port of the first stabilizer pump 501 extends into the upper frame 8 through the lower stabilizer pipeline 502, and is connected to the intermediate stabilizer container 504 through the first control valve 503. The bottom outlet of the intermediate stabilizer container 504 is connected to the suction port of the second stabilizer pump 506, and the discharge port of the second stabilizer pump 506 is connected to the inlet of the first pulper 9 through the flexible stabilizer pipeline 507. A first level gauge 505 is installed on the side wall of the stabilizer container 5, and a second level gauge 508 is configured in the intermediate stabilizer container 504.

[0026] Preferably, the A-liquid storage tank 3 is an elliptical barrel with a filter screen component 301 on the top, a second non-contact level gauge 302 installed on the top side, second stirring shaft moving components 303 symmetrically installed on both sides of the top, a second cleaning port 305 on the top, and multiple discharge ports on the bottom. The discharge ports of the A-liquid storage tank 3 are connected to the suction port of the A-liquid pump 4. The bentonite storage tank 1 has a first stirring shaft moving component 102 installed at the middle of the top, a first non-contact level gauge 101 installed on the top side, a slurry inlet on the side, a first cleaning port 103 on the top, and a discharge port on the bottom. Preferably, the lower frame 7 is further provided with an electrical control room 6 for controlling the power components of the entire system. The electrical control room 6 is an independent space enclosed by partitions. The electrical control room 6 is equipped with a control cabinet, which is electrically connected to all motor components in the system to achieve control. The operation auxiliary components include a ladder 13, a platform 14, and a foldable diagonal brace 15. The platform 14 is connected to both sides of the upper frame 8 and is supported by the foldable diagonal brace 15 to achieve stability. The ladder 13 is connected to the width direction of the platform 14 and its bottom contacts the ground to form a passage for personnel to go up and down.

[0027] Preferably, the first pulper 9 and the second pulper 10 have the same structure; a weighing module 902 is arranged on the side of the barrel of the first pulper 9, the weighing module 902 is distributed at equal angles along the circumference of the barrel wall and the bottom is supported on the top plane of the bracket 907; a rotating shaft moving part 901 is installed on the top of the barrel, and a feed inlet 909 is arranged, and multiple pulp inlets are arranged along the gaps; a quick-release maintenance door 908 is arranged on the lower part of the side of the barrel, and a second control valve 903 is connected to the center of the bottom, the other end of the second control valve 903 is connected to the pulp discharge port of the first pulper 9; a third control valve 904 is arranged at the bottom off-center, and the third control valve 904 is connected to the pulp discharge rigid pipe 912 through a flexible pipe 905.

[0028] Preferably, the top of the water tank 11 is equipped with a third non-contact level gauge 1102 and a water tank inlet pipe 1101, and the slurry outlet at the bottom is connected to the suction port of the water pump group 12; the water pump group 12 provides slurry-making water to the first slurry 9 and the second slurry 10 through the pipeline 1103, and provides cleaning water to the first cleaning port 103 of the bentonite slurry storage tank 1 and the second cleaning port 305 of the A liquid slurry storage tank 3.

[0029] In preferred embodiments, non-contact level gauges may be ultrasonic level gauges, radar level gauges, etc.

[0030] In the preferred embodiment, the control valve can be a pneumatic, hydraulic, or electrically controllable valve.

[0031] In the preferred embodiment, the volume of the bentonite slurry storage tank 1 is more than twice the volume of the second pulping machine 10, and the volume of the A liquid slurry storage tank 3 is more than four times the volume of the first pulping machine 9.

[0032] In the preferred embodiment, the bentonite pump 2 can be a centrifugal pump, screw pump, etc. The A-liquid pump 4 can be a flexible hose pump, screw pump, reciprocating plunger pump, etc.

[0033] In a preferred embodiment, the water tank 11 may not be placed inside the upper frame 8 and can be replaced by any container.

[0034] Example 2: The present invention also discloses a method for preparing liquid A in the above-mentioned three-dimensional integrated dual-liquid slurry A-liquid preparation system, comprising the following steps: Step 1, Water Supply and Cleaning Preparation: Start the water pump group 12 of the water supply component to deliver the clean water in the water tank 11 to the first pulper 9 and the second pulper 10 to provide pulping water source, and supply clean water to the first cleaning port 103 of the bentonite storage tank 1 and the second cleaning port 305 of the A liquid storage tank 3 to complete the pre-cleaning of the system pipelines and containers. Step 2, Bentonite Slurry Preparation and Storage: Bentonite raw material is fed into the second pulping machine 10. After being stirred and mixed by the rotating shaft moving part 901 of the second pulping machine 10, bentonite slurry is prepared. The bentonite slurry is transported to the bentonite storage tank 1 through the discharge port of the second pulping machine 10 for temporary storage. During this period, the first stirring shaft moving part 102 continuously stirs to maintain the uniformity of the bentonite slurry. Step 3, staged delivery of stabilizer: Start the first stabilizer pump 501 to transport the stabilizer in stabilizer container 5 to stabilizer intermediate container 504 through stabilizer lower pipeline 502 and first control valve 503. Then start the second stabilizer pump 506 to transport the stabilizer to first pulper 9 through stabilizer flexible pipeline 507. During the process, the stabilizer level is monitored in real time by first level gauge 505 and second level gauge 508. Step 4: Multi-component mixing and pulping: Start the bentonite pump 2 to transport the bentonite slurry in the bentonite storage tank 1 to the first pulping machine 9 through the detachable pipeline 16. At the same time, cement, mineral powder and other powder raw materials are added to the feed port of the first pulping machine 9, and water-reducing agent and other liquid raw materials are added to the slurry inlet. After being stirred and mixed by the rotating shaft moving part 901 of the first pulping machine 9, liquid A mixture is obtained. Step 5, Filtration and storage of liquid A: The A-liquid mixture in the first pulper 9 is transported to the A-liquid storage tank 3 via the second control valve 903, and temporarily stored after being filtered by the filter screen component 301. During this period, the second stirring shaft moving component 303 continuously stirs to maintain the uniformity of the A-liquid. When the second control valve 903 is damaged or blocked and cannot flow, the pulp is independently discarded through the third control valve 904, without needing to be transported to the A-liquid storage tank 3. Step 6: Liquid A is delivered on demand: According to the grouting requirements of the tunnel boring machine, start the A liquid pump 4 and transport the finished A liquid in the A liquid storage tank 3 to the grouting system through the pipeline; In particular, the bentonite pump 2, liquid A pump 4, various stabilizer pumps and control valves in steps 1-6 are all centrally and automatically controlled by the control cabinet in the electrical control room 6, so as to realize the continuous and precise operation of the liquid A preparation process.

[0035] Furthermore, steps 2-4 include a dynamic ratio adjustment and coordinated control process. Through a closed-loop logic of "real-time parameter acquisition - quantitative judgment of deviation - synchronous execution of adjustment," precise control of the preparation of liquid A is achieved. Specifically, this includes the following: Step 2.1: Dynamic concentration control of bentonite slurry linked with liquid level: (1) Real-time concentration calculation: The weighing module 902 of the second pulping machine 10 collects the total weight of the mixed materials in real time, and calculates the real-time concentration of the bentonite slurry by combining the volume of clean water added by the flow sensor of the water pump group 12, as well as the preset density of bentonite raw materials (usually 2600-2800 kg / m³) and density of clean water (1000 kg / m³). (2) Concentration deviation correction: Compare the real-time concentration with the preset target concentration (set to 5%-8% according to construction needs). If the deviation exceeds ±2%, adjust the water supply of the water pump group 12 to the second pulping machine 10 through the control cabinet of the electrical control room 6. When the concentration is too high, increase the amount of clean water added and when the concentration is too low, reduce the amount of clean water added. After adjustment, keep stirring for 30 seconds and check the concentration again until the deviation is reduced to within ±2%. (3) Liquid level linkage start and stop: The ratio of the real-time liquid level height to the total height of the tank is calculated by the first non-contact liquid level gauge 101 of the bentonite slurry storage tank 1; when the ratio is less than 30%, the control cabinet automatically triggers the second pulping machine 10 to start replenishing slurry (simultaneously start the feeding of bentonite raw materials and the supply of clean water); when the ratio is higher than 80%, the second pulping machine 10 automatically stops and closes the feeding port, while controlling the bentonite pump 2 to continuously deliver at a low flow rate to balance the liquid level of the storage tank.

[0036] Step 3.1, Precise linkage adjustment of multi-component feeding: (1) Weight deviation judgment: The weighing module 902 of the first pulping machine 9 compares the actual total weight of the material in the barrel with the preset total weight of the formula (according to the A liquid design ratio, such as cement 30%, mineral powder 20%, bentonite slurry 45%, stabilizer 5%) in real time. If the deviation of the two accounts for more than 1% of the total weight of the formula, the corresponding deviation correction amount is allocated according to the weight ratio of each component in the formula. (2) Synchronous adjustment of components: The delivery parameters of each component are adjusted separately according to the deviation correction amount, and all adjustment actions are synchronously triggered by the PLC in the control cabinet. Bentonite slurry: Adjust the frequency of the variable frequency motor of bentonite pump 2 to increase or decrease the delivery flow rate according to the correction amount; For powder raw materials such as cement and mineral powder: Adjust the speed of the variable frequency screw conveyor at the feed inlet 909 and increase or decrease the feeding rate according to the correction amount. Stabilizer: Adjust the outlet pressure of the second stabilizer pump 506 to increase or decrease the delivery rate according to the correction amount. (3) Deviation closed-loop elimination: After adjustment, keep stirring for 60 seconds and check the total weight of materials again until the deviation between the actual total weight and the total weight of the formula is ≤1%, to ensure that each component is always mixed according to the design ratio.

[0037] Step 4.1: Real-time quality control and performance correction during the pulping process: (1) Indirect determination of viscosity: Based on the correlation between "rotating shaft operating current and slurry viscosity" established in the previous test, the operating current is collected in real time through the motor current sensor of the rotating shaft moving part 901 of the first pulping machine 9, and the current slurry viscosity is inferred; when the viscosity is lower than the preset lower limit (e.g., 50 Pa·s, to prevent slurry bleeding) or higher than the preset upper limit (e.g., 150 Pa·s, to prevent pipeline blockage), performance correction is triggered; (2) Dynamic correction of slurry properties: If the viscosity is higher than the upper limit: the control cabinet will automatically increase the amount of water supplied by the water pump group 12 to the first pulper 9 until the viscosity drops back to within the upper limit; If the viscosity is below the lower limit: the control cabinet will automatically increase the amount of stabilizer delivered through the stabilizer flexible pipeline 507 until the viscosity rises back above the lower limit; Precipitation prevention control during storage: The second non-contact level gauge 302 of the A liquid storage tank 3 collects the liquid level height in real time, and the rotation speed of the second stirring shaft moving part 303 increases by 10%-20% as the liquid level rises; when the rotation speed is lower than 25 r / min, the control cabinet triggers an early warning (indicating that the slurry may precipitate) and automatically shortens the stirring interval from 5 minutes / time to 2 minutes / time to avoid slurry stratification.

[0038] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A three-dimensional integrated double-solution pulp A-solution pulping system comprising a lower frame (7) and an upper frame (8) distributed in a vertical direction, the lower frame (7) and the upper frame (8) together constituting a three-dimensionally integrated carrier, characterized in that, The lower frame (7) integrates a storage container and a delivery pump assembly. The storage container is used to temporarily store the raw materials and intermediate slurry in the A liquid pulping process. The delivery pump assembly is connected to the storage container to realize material transportation. The upper frame (8) integrates a pulping assembly, a water supply assembly and an operation auxiliary assembly. The pulping assembly is used to complete the mixing and pulping of the components of A liquid. The water supply assembly is connected to the pulping assembly and the storage container to provide the water source required for pulping and cleaning. The operation auxiliary assembly is used to assist personnel in the operation and maintenance of the upper frame (8).

2. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 1, characterized in that, The storage container includes a bentonite slurry tank (1), an A-liquid slurry tank (3), and a stabilizer container (5). The pulping assembly includes a first pulper (9) and a second pulper (10). The bottom of the bentonite slurry tank (1) is connected to the inlet of the first pulper (9) through a conveying pipeline. The discharge port of the first pulper (9) is connected to the A-liquid slurry tank (3). The discharge port of the second pulper (10) is connected to the inlet of the bentonite slurry tank (1). The discharge port of the stabilizer container (5) is connected to the inlet of the first pulper (9) through a pipeline.

3. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 1, characterized in that, The delivery pump assembly includes a bentonite pump (2), an A liquid pump (4), a first stabilizer pump (501), and a second stabilizer pump (506); the water supply assembly includes a water tank (11) and a water pump group (12); the operation auxiliary assembly includes a ladder (13), a platform (14), and a foldable brace (15); the bottom of the bentonite slurry storage tank (1) is equipped with multiple slurry discharge ports, one of which is connected to the slurry suction port of the bentonite pump (2), and the slurry discharge port of the bentonite pump (2) is connected to a detachable pipeline (16), which is connected to the slurry inlet of the first pulping machine (9).

4. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 2, characterized in that, The suction port of the first stabilizer pump (501) is connected to the discharge port of the stabilizer container (5). The discharge port of the first stabilizer pump (501) extends to the upper frame (8) through the lower stabilizer pipeline (502) and is connected to the intermediate stabilizer container (504) through the first control valve (503). The bottom outlet of the intermediate stabilizer container (504) is connected to the suction port of the second stabilizer pump (506). The discharge port of the second stabilizer pump (506) is connected to the inlet of the first pulper (9) through the stabilizer flexible pipeline (507). A first level gauge (505) is installed on the side wall of the stabilizer container (5), and a second level gauge (508) is installed on the intermediate stabilizer container (504).

5. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 2, characterized in that, The A liquid storage tank (3) adopts an elliptical barrel body, with a filter screen component (301) on the top, a second non-contact level gauge (302) installed on the top side, a second stirring shaft motion component (303) symmetrically installed on both sides of the top, a second cleaning port (305) configured on the top, and multiple discharge ports configured at the bottom. The discharge port of the A liquid storage tank (3) is connected to the suction port of the A liquid pump (4). The bentonite storage tank (1) has a first stirring shaft motion component (102) installed at the middle position of the top, a first non-contact level gauge (101) installed on the top side, a slurry inlet configured on the side, a first cleaning port (103) configured on the top, and a discharge port configured at the bottom.

6. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 1, characterized in that, The lower frame (7) is also equipped with an electrical control room (6) for controlling the power components of the entire system. The electrical control room (6) is an independent space enclosed by partitions. The electrical control room (6) is equipped with a control cabinet, which is electrically connected to all motor components in the system to achieve control. The operation auxiliary components include a ladder (13), a platform (14) and a foldable diagonal brace (15). The platform (14) is connected to both sides of the upper frame (8) and is supported by the foldable diagonal brace (15) to achieve stability. The ladder (13) is connected to the width direction of the platform (14) and its bottom contacts the ground to form a passage for personnel to go up and down.

7. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 1, characterized in that, The first pulper (9) and the second pulper (10) have the same structure; a weighing module (902) is provided on the side of the barrel of the first pulper (9), the weighing module (902) is distributed at the same angle along the circumference of the barrel wall and the bottom is supported on the top plane of the bracket (907); a rotating shaft moving part (901) is installed on the top of the barrel, and a feed inlet (909) is provided, and multiple pulp inlets are provided along the gaps; a quick-release maintenance door (908) is provided on the lower part of the side of the barrel, and a second control valve (903) is connected to the center of the bottom, the other end of the second control valve (903) is connected to the discharge port of the first pulper (9); a third control valve (904) is provided at the bottom off-center, and the third control valve (904) is connected to the discharge pipe (912) through a flexible pipe (905).

8. The three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 1, characterized in that, The top of the water tank (11) is equipped with a third non-contact level gauge (1102) and a water tank inlet pipe (1101), and the bottom of the slurry outlet is connected to the suction port of the water pump group (12). The water pump group (12) provides slurry water source for the first slurry machine (9) and the second slurry machine (10) through the pipeline (1103), and provides cleaning water source for the first cleaning port (103) of the bentonite slurry storage tank (1) and the second cleaning port (305) of the A liquid slurry storage tank (3).

9. A method for preparing A-liquid based on the three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claims 1-8, characterized in that, Includes the following steps: Step 1, Water Supply and Cleaning Preparation: Start the water pump group (12) of the water supply component to deliver the clean water in the water tank (11) to the first pulper (9) and the second pulper (10) respectively to provide pulping water source, and supply clean water to the first cleaning port (103) of the bentonite storage tank (1) and the second cleaning port (305) of the A liquid storage tank (3) to complete the pre-cleaning of the system pipelines and containers; Step 2, Bentonite Slurry Preparation and Storage: Bentonite raw materials are put into the second pulping machine (10), and after being stirred and mixed by the rotating shaft moving part (901) of the second pulping machine (10), bentonite slurry is prepared. The bentonite slurry is transported to the bentonite storage tank (1) through the slurry outlet of the second pulping machine (10) for temporary storage. During this period, the first stirring shaft moving part (102) continuously stirs to maintain the uniformity of the bentonite slurry. Step 3, staged delivery of stabilizer: Start the first stabilizer pump (501) to transport the stabilizer in the stabilizer container (5) to the stabilizer intermediate container (504) through the stabilizer lower pipeline (502) and the first control valve (503). Then start the second stabilizer pump (506) to transport the stabilizer to the first pulper (9) through the stabilizer flexible pipeline (507). During the process, the stabilizer level is monitored in real time by the first level gauge (505) and the second level gauge (508). Step 4: Multi-component mixing and pulping: Start the bentonite pump (2) and transport the bentonite slurry in the bentonite storage tank (1) to the first pulping machine (9) through the detachable pipeline (16). At the same time, cement, mineral powder and other powder raw materials are put into the feed port of the first pulping machine (9), and water-reducing agent and other liquid raw materials are put into the slurry inlet. After being stirred and mixed by the rotating shaft moving part (901) of the first pulping machine (9), liquid A mixture is obtained. Step 5, Filtration and storage of liquid A: The A-liquid mixture in the first pulper (9) is transported to the A-liquid storage tank (3) via the second control valve (903), and temporarily stored after being filtered by the filter screen component (301). During this period, the second stirring shaft moving component (303) continuously stirs to maintain the uniformity of the A-liquid. When the second control valve (903) is damaged or blocked and cannot flow, the pulp is independently discharged through the third control valve (904) without needing to be transported to the A-liquid storage tank (3). Step 6: Liquid A is delivered on demand: According to the grouting requirements of the shield tunnel, start the A liquid pump (4) and transport the finished A liquid in the A liquid storage tank (3) to the grouting system through the pipeline; Among them, the bentonite pump (2), liquid A pump (4), each stabilizer pump and control valve in steps 1-6 are all centrally and automatically controlled by the control cabinet in the electrical control room (6) to realize the continuous and precise operation of the liquid A preparation process.

10. The method for preparing A-liquid in the three-dimensional integrated dual-liquid slurry A-liquid preparation system according to claim 9, characterized in that, Steps 2, 3, and 4 specifically include the following processes: Step 2.1: Dynamic concentration control of bentonite slurry linked with liquid level: Real-time concentration calculation: The weighing module (902) of the second pulping machine (10) collects the total weight of the mixed materials in real time, and calculates the real-time concentration of the bentonite slurry by combining the volume of clean water added by the flow sensor of the water pump group (12) with the preset density of bentonite raw materials and density of clean water. Concentration deviation correction: Compare the real-time concentration with the preset target concentration. If the deviation exceeds a certain value, adjust the water supply of the water pump group (12) to the second pulper (10) through the control cabinet of the electrical control room (6). When the concentration is too high, increase the amount of clean water added; when the concentration is too low, reduce the amount of clean water added. After adjustment, keep stirring for a period of time and then check the concentration again until the deviation is reduced to within the threshold. Liquid level linkage start and stop: The ratio of real-time liquid level height to total tank height is calculated by the first non-contact liquid level gauge (101) of the bentonite slurry storage tank (1); when the ratio is less than 30%, the control cabinet automatically triggers the second pulping machine (10) to start slurry replenishment, and simultaneously starts the bentonite raw material feeding and clean water supply; when the ratio is higher than 80%, the second pulping machine (10) automatically stops and closes the feeding port, while controlling the bentonite pump (2) to continuously deliver at a low flow rate to balance the liquid level of the slurry storage tank; Step 3.1, Precise linkage adjustment of multi-component feeding: Weight deviation judgment: The weighing module (902) of the first pulper (9) compares the actual total weight of the material in the barrel with the preset total weight in real time. If the deviation of the two accounts for more than a certain value of the total weight of the formula, the corresponding deviation correction amount is allocated according to the weight ratio of each component in the formula. Synchronous adjustment of components: Based on the deviation correction amount, the delivery parameters of each component are adjusted separately, and all adjustment actions are synchronously triggered by the PLC in the control cabinet. Bentonite slurry: Adjust the frequency of the variable frequency motor of the bentonite pump (2) and increase or decrease the delivery flow rate according to the correction amount; Powder raw materials such as cement and mineral powder: Adjust the speed of the variable frequency screw conveyor at the feed inlet (909) and increase or decrease the feeding rate according to the correction amount ratio; Stabilizer: Adjust the outlet pressure of the second stabilizer pump (506) to increase or decrease the delivery amount according to the correction amount ratio; Deviation closed-loop elimination: After adjustment, keep stirring for a period of time and check the total weight of materials again until the deviation ratio between the actual total weight and the total weight of the formula is within the threshold, ensuring that each component is always mixed according to the design ratio. Step 4.1: Real-time quality control and performance correction during the pulping process: Indirect determination of viscosity: Based on the correlation between "rotating shaft operating current and slurry viscosity" established in the previous test, the operating current is collected in real time through the motor current sensor of the rotating shaft moving part (901) of the first pulper (9), and the current slurry viscosity is inferred. When the viscosity is below the preset lower limit or above the preset upper limit, performance correction is triggered. Dynamic correction of slurry properties: If the viscosity is higher than the upper limit: the control cabinet automatically increases the amount of water supplied by the water pump group (12) to the first pulper (9) until the viscosity drops back to within the upper limit; If the viscosity is below the lower limit: the control cabinet automatically increases the amount of stabilizer delivered through the stabilizer flexible pipeline (507) until the viscosity rises back above the lower limit; Precipitation control during storage: The second non-contact level gauge (302) of the A liquid storage tank (3) collects the liquid level height in real time, and the rotation speed of the second stirring shaft moving part (303) increases by 10%-20% as the liquid level rises; when the rotation speed is lower than 25r / min, the control cabinet triggers an early warning, indicating that the slurry may precipitate, and automatically shortens the stirring interval from 5 minutes / time to 2 minutes / time to avoid slurry stratification.

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