Intelligent concrete spraying construction method and system for large-span arc roof

Abstract

The invention relates to an intelligent concrete spraying construction method and system for a large-span arc-shaped roof. The method comprises the steps of system deployment, path planning, intelligent spraying, axial displacement and multi-layer spraying and quality monitoring. The system comprises a mobile platform, a track system, an execution mechanism, a sensing system, a concrete proportion regulation and control module, a pipeline collaborative management system and a central control system. Through cooperation of special equipment and intelligent control, the problems of flow falling, rebound and thickness control are systematically solved, and finally high-quality and high-efficiency automatic construction on the large-span arc-shaped roof is achieved.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, and in particular to an intelligent sprayed concrete construction method and system for large-span curved roofs. Background Technology

[0002] Large-span curved roofs (such as stadiums and airport terminals) are widely used due to their beautiful shapes and excellent structural performance. Shotcrete technology, as a highly efficient formwork-free construction process, has significant application potential in such roof structures.

[0003] In the field of concrete spraying technology, some automated solutions have emerged in the existing technology. For example, Chinese invention patent CN103713647B discloses a "concrete spraying machine and its control method, device and system," which achieves automated operation by scanning the tunnel contour and planning the spraying path, effectively solving the problem of spraying distance control in tunnel engineering. However, this technical solution is specifically designed for the closed or semi-closed environment of underground engineering such as tunnels and roadways, and its equipment deployment and path planning algorithm are based on the characteristics of tunnels with relatively uniform longitudinal contours.

[0004] When this type of existing spraying technology is applied to large-span curved roofs, it faces many insurmountable technical problems: First, its equipment moving platform cannot achieve stable support and precise movement in open roof space; Second, its simple straight path planning algorithm cannot adapt to the complex hyperbolic characteristics of the roof; Third, it does not involve key technologies unique to roof construction, such as preventing concrete from falling, multi-equipment collaboration, and high-altitude pipeline management. Specifically, it is manifested in the following ways: (1) It is impossible to guarantee the optimal distance and vertical angle between the nozzle and the sprayed surface on complex three-dimensional curved surfaces, resulting in high rebound rate and uneven density; (2) Concrete in the sloping section of the roof is prone to falling and sliding, affecting the structural outline and thickness; (3) There is a lack of effective large-span full-coverage equipment deployment scheme, making it difficult to achieve multi-equipment collaborative operation; (4) There is a lack of real-time quality monitoring during the construction process, making it impossible to form an effective closed-loop control; (5) The management of the delivery pipeline on the high-altitude roof is difficult, which can easily interfere with construction and damage the working surface.

[0005] Therefore, existing technologies lack an intelligent, high-precision shotcrete construction method and system that can systematically solve the construction problems of large-span curved roofs. Summary of the Invention

[0006] The present invention aims to address the shortcomings of the prior art by providing an intelligent shotcrete construction method and system for large-span curved roofs, so as to achieve high-quality, high-efficiency, and intelligent shotcrete construction for large-span complex curved roofs.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] The intelligent shotcrete construction method for large-span curved roofs includes the following steps:

[0009] S1. System Deployment: Construct symmetrical construction platforms on both sides of the arched roof, and install gantry frames on the construction platforms that can reciprocate along the axial direction of the arched roof; at the bottom of the crossbeams of the gantry frames, install an arc-shaped track concentrically set with the arched roof; two concrete spraying mechanisms are moved on the arc-shaped track.

[0010] S2. Path planning: Based on the BIM model of the curved roof, a collaborative spraying path is planned for the two concrete spraying mechanisms; the path is a serpentine reciprocating path from bottom to top, starting from the eaves and moving along the curved track towards the ridge.

[0011] S3, Intelligent Injection:

[0012] S31. Control two concrete spraying mechanisms, starting from the eaves on both sides of the curved roof, and move in a serpentine motion from bottom to top along the curved track according to the coordinated spraying path, and perform spraying operations simultaneously until they meet in the ridge area to form a complete concrete spraying layer.

[0013] S32. During the spraying process, the distance information between the nozzle and the curved roof is obtained in real time by a laser scanner integrated on the concrete spraying mechanism, and the distance is adjusted by the controller to keep it constant.

[0014] S33. Real-time images of the sprayed surface are captured by a high-definition industrial camera, and defects such as sags and dry spots in the concrete are determined based on image recognition algorithms.

[0015] S34. Based on distance information and defect judgment results, dynamically adjust the spraying parameters, moving speed, and collaborative working status of multiple nozzles of the concrete spraying mechanism in real time.

[0016] S4, Axial Displacement and Multi-Layer Injection:

[0017] S41. After the spraying layer of an axial section is completed, control the gantry to move the entire system one station along the axial direction of the curved roof, repeat the intelligent spraying steps, and spray the next section.

[0018] S42. When it is necessary to increase the spraying thickness, after the previous layer of concrete reaches the predetermined strength, control the construction system to return to the starting position, repeat the path planning and intelligent spraying steps, and carry out multi-layer spraying from top to bottom or from bottom to top.

[0019] S5. Quality Monitoring: During and after the spraying process, an infrared thermal imager integrated into the concrete spraying mechanism monitors the temperature field distribution on the concrete surface to help assess the uniformity of spraying and feeds the data back to the control system, forming a closed-loop monitoring system for construction quality.

[0020] Specifically, in S3, the strategy for adjusting the collaborative working state of multiple nozzles is as follows: based on the roof curvature data acquired in real time by the laser scanner, the extension length of the middle nozzle is independently controlled, and the pitch and deflection angles of the two side nozzles are independently adjusted. At the same time, the concrete flow rate to each nozzle is independently controlled, so that the jet stream is always perpendicular to the sprayed roof area.

[0021] Specifically, in S3, when the two concrete spraying units come together in the ridge area, the final joint is sprayed using an alternating stepped method.

[0022] Specifically, in S3, data monitored by dust sensors integrated into the concrete spraying mechanism is correlated with spraying parameters, and the spraying pressure or airflow is automatically adjusted when the dust concentration exceeds the standard.

[0023] In particular, the method also includes a concrete mix control step, in which a quick-setting agent is added to the concrete mixture, and the dosage of the quick-setting agent is dynamically adjusted according to the real-time slope information of the curved roof. The greater the slope, the higher the dosage.

[0024] In particular, the method also includes a pipeline management step, in which a movable seat is set on the crossbeam of the gantry, a movable guide wheel is set on the movable seat, and a fixed guide wheel is set on the top and outer wall of the end of the crossbeam, respectively, and the concrete conveying pipeline is guided by the movable guide wheel and the fixed guide wheel.

[0025] Control the movement of the movable seat to keep it synchronized with the position of the concrete spraying mechanism on the axial direction of the curved roof during construction;

[0026] The movable support ensures that the suspended section of the concrete delivery pipe maintains a safe distance from the curved roof surface throughout the entire travel of the concrete spraying mechanism, thus avoiding contact with the sprayed concrete layer.

[0027] A smart shotcrete construction system for large-span curved roofs, comprising a method for intelligent shotcrete construction on large-span curved roofs, including:

[0028] The mobile platform includes a construction platform symmetrically erected on both sides of the curved roof, and a gantry frame erected on the construction platform that can reciprocate along the axial direction of the curved roof.

[0029] The track system includes an arc-shaped track fixedly installed at the bottom of the gantry beam, with the arc-shaped track being concentrically set with the arc-shaped roof.

[0030] The actuator includes two concrete spraying mechanisms that are movable and mounted on an arc track;

[0031] The sensing system, integrated into the concrete spraying mechanism, includes at least a laser scanner, a high-definition industrial camera, an infrared thermal imager, and a dust sensor.

[0032] Concrete mix proportion control module;

[0033] The pipeline collaborative management system includes a movable seat set on the gantry beam, a movable guide wheel set on the movable seat, and fixed guide wheels set on the top and outer side walls of the gantry beam ends. The concrete conveying pipeline is guided to the concrete spraying mechanism through the movable guide wheel and the fixed guide wheel.

[0034] The central control system communicates with the mobile platform, track system, actuators, sensing system, concrete mix proportioning module, and pipeline collaborative management system; the central control system is configured as follows:

[0035] Based on the BIM model of the curved roof, a serpentine reciprocating collaborative spraying path is planned for the two concrete spraying mechanisms, starting from the eaves and going up from the bottom.

[0036] Control the concrete spraying mechanism to move along the path and perform the spraying operation;

[0037] Receive distance information from the laser scanner and adjust the distance between the nozzle and the curved roof;

[0038] It receives image data from high-definition industrial cameras and uses image recognition algorithms to determine concrete defects.

[0039] Based on distance information and defect judgment results, the spraying parameters, moving speed, and collaborative working status of multiple nozzles of the concrete spraying mechanism are dynamically adjusted in real time.

[0040] It receives temperature field distribution data of the concrete surface monitored by an infrared thermal imager to help assess the uniformity of spraying and form a closed-loop monitoring of construction quality.

[0041] The data monitored by the dust sensor is correlated and analyzed with the injection parameters, and the injection pressure or air flow is automatically adjusted when the dust concentration exceeds the standard.

[0042] After completing the spraying of one axial section, the gantry crane is moved to one work position, and the construction system is controlled to perform multi-layer spraying.

[0043] Based on the real-time slope information of the curved roof, the dosage of accelerator in the concrete mixture is dynamically adjusted; the greater the slope, the higher the dosage.

[0044] The control unit moves synchronously with the concrete spraying mechanism along the axial direction of the curved roof. The concrete delivery pipe is guided by fixed and moving guide wheels to form a following catenary, thus avoiding contact with the curved roof surface during the entire travel of the concrete spraying mechanism.

[0045] Specifically, the concrete spraying equipment includes:

[0046] Installation box;

[0047] The spraying module includes three nozzles arranged side by side, each nozzle being connected to a corresponding concrete delivery pipe via a flexible pipe that passes through the mounting box.

[0048] The drive adjustment module includes a first electric cylinder for driving the radial movement of the middle nozzle, and a second electric cylinder for driving the two side nozzles to adjust the pitch and yaw angles. The first electric cylinder is fixedly connected to the bottom of the mounting box, and its piston rod is fixedly connected to the corresponding nozzle. The second electric cylinder is movably connected to the bottom of the mounting box, and its piston rod is movably connected to the corresponding nozzle.

[0049] The flow control module includes control valves independently installed on each flexible pipe;

[0050] The drive adjustment module and flow control module are controlled by the central control system to independently adjust the position, angle and concrete flow of each nozzle based on the roof curvature data.

[0051] In particular, the curved track is made up of multiple curved track sections spliced ​​together by connectors. The curved track sections are made of high-strength aluminum alloy extrusion molding, with a cross-section in the shape of a mountain. Several reinforcing rods are provided between the top of the curved track and the crossbeam of the gantry.

[0052] Specifically, the concrete spraying mechanism also includes a crawling module, which includes:

[0053] The crawling seat has a U-shaped cross-section and is supported on an arc-shaped track by rollers that rotate on both inner walls.

[0054] The drive mechanism includes a motor mounted on the outer wall of one side of the crawler seat to drive a roller to rotate;

[0055] The locking mechanism includes a third electric cylinder mounted on the outer walls of both sides of the crawler seat. The piston rod of the third electric cylinder is inserted into the crawler seat and fixed to a pressure plate, which is used to clamp the web of the arc track when the crawler seat needs to lock the vehicle.

[0056] The beneficial effects of this invention are as follows: Compared with existing technologies, this invention, through its innovative collaborative operation system of "mobile platform-arc track-dual spraying mechanism," specifically addresses the challenges of constructing large-span arc-shaped roofs, achieving intelligent, high-precision, and high-quality concrete spraying. Its specific advantages are reflected in:

[0057] Innovative system deployment: The design of double-sided gantry and concentric arc track provides a stable and precise moving foundation for high-altitude curved surface operations, perfectly adapting to the structural characteristics of large-span roofs.

[0058] Intelligent path planning and collaborative control: Based on the BIM model, a bottom-up serpentine reciprocating path is planned, and combined with the synchronous operation of two machines and the ridge closure process, construction efficiency and overall quality are ensured, and concrete dripping is effectively suppressed.

[0059] Comprehensive real-time sensing and closed-loop control: Integrating multiple sensors, it realizes real-time monitoring and dynamic adjustment of multiple parameters such as distance, defects, thickness, temperature, and dust, forming a comprehensive quality closed-loop control system.

[0060] Targeted and specialized design: Dedicated modules such as independent adjustment of multiple nozzles, dynamic proportioning of quick-setting agent, and follow-up management of pipelines systematically solve a series of unique technical problems in roof spraying construction, making it highly practical. Attached Figure Description

[0061] Figure 1 This is a flowchart of the construction method of the present invention;

[0062] Figure 2 This is a schematic diagram of the system structure of the present invention;

[0063] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0064] Figure 4 for Figure 2 Enlarged view of point B in the middle;

[0065] In the diagram: 1-Curved roof; 2-Construction platform; 3-Gantry frame; 4-Curved track; 5-Concrete spraying mechanism; 6-Laser scanner; 7-Sprayer head; 8-High-definition industrial camera; 9-Infrared thermal imager; 10-Dust sensor; 11-Concrete conveying pipe; 12-Moving seat; 13-Moving guide wheel; 14-Fixed guide wheel; 15-Mounting box; 16-First electric cylinder; 17-Second electric cylinder; 18-Crawling seat; 19-Roller; 20-Motor; 21-Third electric cylinder; 22-Pressure plate;

[0066] The following will describe in detail, with reference to the accompanying drawings, embodiments of the present invention. Detailed Implementation

[0067] The present invention will be further described below with reference to embodiments:

[0068] like Figures 1-4As shown, an intelligent shotcrete construction method and system for large-span curved roofs is presented. Its core lies in building a dedicated construction system that integrates mechanical structure, intelligent sensing, and closed-loop control.

[0069] The construction method includes the following steps:

[0070] S1. System Deployment: Construction platforms 2 are symmetrically erected on both sides of the curved roof 1, and a gantry 3 that can reciprocate along the axis of the curved roof 1 is set on the construction platform 2; at the bottom of the crossbeam of the gantry 3, an arc-shaped track 4 is installed concentrically with the curved roof 1; two concrete spraying mechanisms 5 are moved on the arc-shaped track 4.

[0071] This deployment structure forms a stable, mobile support system spanning the roof. The symmetrical construction platform 2 and gantry 3 ensure the overall rigidity and stability of the system during large-span construction. The concentric arc-shaped track 4 provides a precise motion reference for the concrete spraying mechanism 5, ensuring its trajectory always aligns with the roof curvature, laying a solid mechanical foundation for subsequent precise spraying. This fundamentally solves the problem of traditional tunnel shotcrete machines being unable to move stably and accurately position on open, large-span roofs.

[0072] S2. Path planning: Based on the BIM model of the curved roof 1, a collaborative spraying path is planned for the two concrete spraying mechanisms 5. The path is a serpentine reciprocating path from bottom to top, starting from the eaves and moving along the curved track 4 towards the ridge.

[0073] The bottom-up spraying sequence utilizes the already partially set concrete below as support, effectively suppressing the dripping of fresh concrete, which is crucial for ensuring the quality of roof spraying. Secondly, the serpentine path ensures continuous and uniform spraying coverage, reducing equipment start-ups and shutdowns and improving construction efficiency. Finally, planning based on a BIM model enables digital simulation before construction and precise navigation during the construction process, resulting in a significant improvement in both quality and efficiency compared to traditional methods relying on manual experience.

[0074] S3, Intelligent Injection: This step is the execution phase of the core process, integrating real-time monitoring and dynamic adjustment. Details are as follows:

[0075] S31. Control the two concrete spraying mechanisms 5, which, according to the coordinated spraying path, start from the eaves on both sides of the arched roof 1 and move in a serpentine reciprocating motion along the arched track 4 from bottom to top, simultaneously performing spraying operations until they converge in the ridge area to form a complete concrete spraying layer. Specifically, when the two concrete spraying mechanisms 5 converge in the ridge area, a staggered, stepped approach is used for the final joint spraying construction. The simultaneous operation of the two machines theoretically doubles the construction efficiency. The staggered, stepped closure process effectively avoids straight cold joints in the ridge area, ensuring the integrity and waterproofing of the structure in this critical area.

[0076] S32. During the spraying process, the distance information between the nozzle 7 and the curved roof 1 is obtained in real time by the laser scanner 6 integrated on the concrete spraying mechanism 5, and the distance is adjusted by the controller to keep it constant. Maintaining the optimal spraying distance is the core to ensure the compactness of concrete and reduce the rebound rate. Automatic distance control overcomes the accuracy problem caused by manual visual observation and realizes continuous and stable high-quality spraying.

[0077] S33. Real-time image acquisition of the sprayed surface using a high-definition industrial camera 8, and determination of concrete dripping and dry spot defects based on image recognition algorithms;

[0078] S34. Based on distance information and defect judgment results, dynamically adjust the spraying parameters, moving speed, and collaborative working status of multiple nozzles 7 of the concrete spraying mechanism 5 in real time.

[0079] The system can respond instantly to abnormal situations during construction, such as local over-thickness, under-thickness, or sagging, and automatically correct them, transforming post-event remediation into in-process control, significantly improving the reliability and uniformity of construction quality.

[0080] The coordinated working state adjustment strategy of multiple nozzles 7 is as follows: based on the roof curvature data acquired in real time by the laser scanner 6, the extension length of the middle nozzle is independently controlled, and the pitch and deflection angles of the two nozzles on both sides are independently adjusted. At the same time, the concrete flow rate to each nozzle 7 is independently controlled, so that the sprayed jet always remains perpendicular to the sprayed roof area. This strategy enables the sprayed jet to always be perpendicular to the complex and ever-changing roof surface, realizing "flexible fitting" spraying. It solves the problem of uneven coverage and poor edge effect when fixed nozzles are sprayed on double curvature surfaces, ensuring uniform spray thickness and excellent surface appearance on the entire roof.

[0081] The intelligent injection process also includes the following steps:

[0082] By correlating and analyzing the data monitored by the dust sensor 10 integrated on the concrete spraying mechanism 5 with the spraying parameters, the spraying pressure or air flow is automatically adjusted when the dust concentration exceeds the standard. This not only improves the working environment in high-altitude open spaces and meets the requirements of green construction, but also indirectly controls the rebound rate through parameter optimization.

[0083] The concrete mix design involves adding an accelerator to the concrete mixture, and the dosage of the accelerator is dynamically adjusted based on the real-time slope information of the curved roof 1. The steeper the slope, the higher the dosage. This step directly addresses the core challenge of concrete sagging during roof construction. Increasing the dosage of the accelerator in areas with steep slopes can accelerate concrete setting and fundamentally enhance its resistance to sagging.

[0084] In the pipeline management process, a movable seat 12 is set on the crossbeam of the gantry 3, and a movable guide wheel 13 is set on the movable seat 12. Fixed guide wheels 14 are set on the top and outer side walls of the end of the crossbeam, respectively. The concrete conveying pipeline 11 is guided by the movable guide wheel 13 and the fixed guide wheel 14.

[0085] The movement of the control seat 12 is synchronized with the position of the concrete spraying mechanism 5 on the axial direction of the curved roof 1 during construction.

[0086] The movable support 12 ensures that the suspended section of the concrete conveying pipe 11 maintains a safe distance from the surface of the curved roof 1 throughout the entire travel of the concrete spraying mechanism 5, thus avoiding contact with the sprayed concrete layer.

[0087] This step addresses the pain point of heavy, rigid delivery pipes being prone to falling and interfering with construction during high-altitude operations. Dynamic follow-up supports ensure that the pipes maintain a safe distance from the roof throughout their entire stroke, protecting the completed spraying surface and guaranteeing smooth, unobstructed movement of the spraying mechanism. This is a crucial guarantee for the system's continuous and efficient operation.

[0088] S4, Axial Displacement and Multi-Layer Injection:

[0089] S41. After the spraying layer of an axial section is completed, the gantry 3 is controlled to move the entire system one position along the axial direction of the curved roof 1, and the intelligent spraying steps are repeated to spray the next section. Through the step-by-step axial movement of the gantry 3, a systematic and orderly continuous coverage of a large area of ​​roof is achieved, and the complex surface construction is decomposed into an orderly linear construction, making the organization and management more scientific and efficient.

[0090] S42. When it is necessary to increase the spraying thickness, after the previous layer of concrete reaches the predetermined strength, the construction system is controlled to return to the starting position and repeat the path planning and intelligent spraying steps to perform multi-layer spraying from top to bottom or from bottom to top. Strict layered spraying is a key process requirement for controlling the thickness of each spray, preventing sagging and voids, and ensuring the final structural thickness.

[0091] S5. Quality Monitoring: During and after spraying, the temperature field distribution on the concrete surface is monitored by an infrared thermal imager 9 integrated into the concrete spraying mechanism 5 to assist in assessing the uniformity of spraying. The data is then fed back to the control system, forming a closed-loop monitoring system for construction quality. The heat of hydration of concrete is related to its thickness and density. The infrared thermal imager 9 provides a non-contact, full-coverage quality assessment method. The uniformity of the temperature field indirectly reflects the uniformity of thickness and quality, enabling macroscopic and rapid diagnosis of the construction results. Together with laser thickness measurement and image recognition, it constitutes a multi-dimensional, full-process, final quality closed-loop monitoring system.

[0092] like Figures 2-4 As shown, an intelligent shotcrete construction system for large-span curved roofs is used to implement an intelligent shotcrete construction method for large-span curved roofs, including:

[0093] The mobile platform includes a construction platform 2 symmetrically erected on both sides of the curved roof 1, and a gantry 3 erected on the construction platform 2 and capable of reciprocating along the axis of the curved roof 1.

[0094] The track system includes an arc-shaped track 4 fixedly installed at the bottom of the crossbeam of the gantry 3. The arc-shaped track 4 is concentrically set with the arc-shaped roof 1. Specifically, the arc-shaped track 4 is spliced ​​together by multiple arc-shaped track sections through connectors. The arc-shaped track sections are made of high-strength aluminum alloy extrusion molding, with a cross-section in the shape of a mountain. Several reinforcing rods are provided between the top of the arc-shaped track 4 and the crossbeam of the gantry 3.

[0095] The actuator includes two concrete spraying mechanisms 5 that are movable and mounted on the arc-shaped track 4; specifically, the concrete spraying mechanism 5 includes:

[0096] Installation box 15;

[0097] The spraying module includes three nozzles 7 arranged side by side. Each nozzle 7 is connected to a corresponding concrete delivery pipe 11 via a flexible pipe, which passes through the mounting box 15.

[0098] The drive adjustment module includes a first electric cylinder 16 for driving the central nozzle 7 to move radially, and a second electric cylinder 17 for driving the two side nozzles 7 to adjust the pitch and yaw angles. The first electric cylinder 16 is fixedly connected to the bottom of the mounting box 15, and its piston rod is fixedly connected to the corresponding nozzle 7. The second electric cylinder 17 is movably connected to the bottom of the mounting box 15, and its piston rod is movably connected to the corresponding nozzle 7.

[0099] The flow control module includes control valves independently installed on each flexible pipe;

[0100] Among them, the drive adjustment module and the flow control module are controlled by the central control system to independently adjust the position, angle and concrete flow of each nozzle 7 based on the roof curvature data.

[0101] The concrete spraying mechanism 5 also includes a crawling module, which includes:

[0102] The crawling seat 18 has a U-shaped cross-section and is supported on the arc-shaped track 4 by rollers 19 that are rotatably installed on the inner walls of both sides.

[0103] The drive mechanism includes a motor 20 disposed on the outer wall of one side of the crawler seat 18 to drive a roller 19 to rotate;

[0104] The locking mechanism includes a third electric cylinder 21 installed on the outer walls of both sides of the crawler seat 18. The piston rod of the third electric cylinder 21 is inserted into the crawler seat 18 and fixed with a pressure plate 22, which is used to clamp the web of the arc track 4 when the crawler seat 18 needs to lock the vehicle.

[0105] The sensing system, integrated into the concrete spraying mechanism 5, includes at least a laser scanner 6, a high-definition industrial camera 8, an infrared thermal imager 9, and a dust sensor 10.

[0106] Concrete mix proportion control module.

[0107] The pipeline collaborative management system includes a movable seat 12 set on the crossbeam of the gantry 3, a movable guide wheel 13 set on the movable seat 12, and a fixed guide wheel 14 set on the top and outer side of the end of the crossbeam of the gantry 3. The concrete conveying pipeline 11 is guided to the concrete spraying mechanism 5 through the movable guide wheel 13 and the fixed guide wheel 14.

[0108] The central control system communicates with the mobile platform, track system, actuators, sensing system, concrete mix proportioning module, and pipeline collaborative management system; the central control system is configured as follows:

[0109] Based on the BIM model of the curved roof 1, a serpentine reciprocating collaborative spraying path is planned for the two concrete spraying mechanisms 5, starting from the eaves and going up from bottom to top;

[0110] Control the concrete spraying mechanism 5 to move along the path and perform the spraying operation;

[0111] Receive distance information from laser scanner 6 and adjust the distance between nozzle 7 and curved roof 1;

[0112] It receives image data from a high-definition industrial camera 8 and uses an image recognition algorithm to determine concrete defects.

[0113] Based on distance information and defect judgment results, the spraying parameters, moving speed, and collaborative working status of multiple nozzles 7 of the concrete spraying mechanism 5 are dynamically adjusted in real time.

[0114] The infrared thermal imager 9 receives temperature field distribution data of the concrete surface to assist in assessing the uniformity of spraying and form a closed-loop monitoring of construction quality.

[0115] The data monitored by the dust sensor 10 is correlated and analyzed with the injection parameters, and the injection pressure or air flow is automatically adjusted when the dust concentration exceeds the standard.

[0116] After completing the spraying of one axial section, the gantry 3 is moved to one work position, and the construction system is controlled to perform multi-layer spraying.

[0117] Based on the real-time slope information of the curved roof 1, the dosage of accelerator in the concrete mixture is dynamically adjusted. The greater the slope, the higher the dosage.

[0118] The control moving seat 12 is synchronized with the concrete spraying mechanism 5 in the axial direction of the curved roof 1. The concrete conveying pipe 11 is guided by the fixed guide wheel 14 and the moving guide wheel 13 to form a following catenary, so as to avoid contact with the surface of the curved roof 1 during the entire moving stroke of the concrete spraying mechanism 5.

[0119] The various components of this invention's system, including the mobile platform, track system, actuator, sensing system, concrete mix proportioning module, pipeline collaborative management system, and central control system, are all specialized devices designed to efficiently and reliably implement the aforementioned methods. Their collaborative operation integrates the traditionally fragmented, manual-dependent construction process into a highly integrated, automated, and intelligent organic whole, ultimately achieving the goal of high-quality concrete spraying on large-span curved roofs.

[0120] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this 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, they should not be construed as limitations on this invention.

[0121] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0122] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0123] The present invention has been described above by way of example. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made by adopting the inventive concept and technical solution of the present invention, or direct application to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A smart shotcrete construction method for large-span arched roofs, characterized in that, Includes the following steps: S1. System deployment: Construction platforms (2) are erected symmetrically on both sides of the curved roof (1), and a gantry frame (3) that can move back and forth along the axis of the curved roof (1) is set on the construction platform (2); at the bottom of the crossbeam of the gantry frame (3), an arc track (4) is installed concentrically with the curved roof (1); two concrete spraying mechanisms (5) are moved on the arc track (4). S2, Path planning: Based on the BIM model of the curved roof (1), a collaborative spraying path is planned for the two concrete spraying mechanisms (5); the path is a serpentine reciprocating path from bottom to top along the curved track (4) towards the ridge, starting from the eaves; S3, Intelligent Injection: S31. Control the two concrete spraying mechanisms (5) according to the coordinated spraying path, starting from the eaves on both sides of the curved roof (1), and move back and forth along the curved track (4) from bottom to top, and perform spraying operations simultaneously until they are joined in the ridge area to form a complete concrete spraying layer. S32. During the spraying process, the distance information between the nozzle (7) and the curved roof (1) is obtained in real time by the laser scanner (6) integrated on the concrete spraying mechanism (5), and the distance is adjusted by the controller to keep it constant. S33. Real-time image acquisition of the sprayed surface using a high-definition industrial camera (8), and determination of concrete dripping and dry spot defects based on image recognition algorithm; S34. Based on the distance information and the defect judgment results, adjust the spraying parameters, moving speed and the collaborative working status of multiple nozzles (7) of the concrete spraying mechanism (5) in real time. S4, Axial Displacement and Multi-Layer Injection: S41. After the spraying layer of an axial section is completed, control the gantry (3) to move the entire system along the arc roof (1) axially by one station, repeat the intelligent spraying steps, and spray the next section. S42. When it is necessary to increase the spraying thickness, after the previous layer of concrete reaches the predetermined strength, control the construction system to return to the starting position, repeat the path planning and intelligent spraying steps, and carry out multi-layer spraying from top to bottom or from bottom to top. S5. Quality monitoring: During and after spraying, the temperature field distribution on the concrete surface is monitored by an infrared thermal imager (9) integrated on the concrete spraying mechanism (5) to assist in evaluating the uniformity of spraying and to feed the data back to the control system to form a closed-loop monitoring of construction quality.

2. The intelligent shotcrete construction method for large-span arched roofs according to claim 1, characterized in that, In S3, the coordinated working state adjustment strategy of multiple nozzles (7) is as follows: based on the roof curvature data obtained in real time by the laser scanner (6), the extension length of the middle nozzle is independently controlled, and the pitch and deflection angles of the two nozzles on both sides are independently adjusted. At the same time, the concrete flow rate to each nozzle (7) is independently controlled so that the jet stream is always perpendicular to the sprayed roof area.

3. The intelligent shotcrete construction method for large-span arched roofs according to claim 1, characterized in that, In S3, when the two concrete spraying mechanisms (5) come together in the ridge area, the final joint is sprayed using an alternating stepped method.

4. The intelligent shotcrete construction method for large-span arched roofs according to claim 1, characterized in that, In S5, the data monitored by the dust sensor (10) integrated on the concrete spraying mechanism (5) is correlated with the spraying parameters, and the spraying pressure or air flow is automatically adjusted when the dust concentration exceeds the standard.

5. The intelligent shotcrete construction method for large-span arched roofs according to claim 1, characterized in that, The method also includes a concrete mix control step, in which a quick-setting agent is added to the concrete mixture, and the amount of quick-setting agent is dynamically adjusted according to the real-time slope information of the curved roof (1). The greater the slope, the higher the amount of quick-setting agent.

6. The intelligent shotcrete construction method for large-span arched roofs according to claim 1, characterized in that, The method also includes a pipeline management step, in which a movable seat (12) is set on the crossbeam of the gantry (3), a movable guide wheel (13) is set on the movable seat (12), and a fixed guide wheel (14) is set on the top and outer side of the end of the crossbeam, respectively. The concrete conveying pipeline (11) is guided by the movable guide wheel (13) and the fixed guide wheel (14). Control the movement of the movable seat (12) so that it remains synchronized with the position of the concrete spraying mechanism (5) on the axial direction of the curved roof (1) during construction. By using the follow-up support of the movable seat (12), the suspended section of the concrete conveying pipe (11) maintains a safe distance from the surface of the curved roof (1) throughout the entire travel of the concrete spraying mechanism (5), thus avoiding contact with the sprayed concrete layer.

7. An intelligent shotcrete construction system for large-span curved roofs, used to implement the intelligent shotcrete construction method for large-span curved roofs as described in any one of claims 1-6, characterized in that, include: The mobile platform includes a construction platform (2) symmetrically erected on both sides of the curved roof (1), and a gantry (3) erected on the construction platform (2) and capable of reciprocating along the axial direction of the curved roof (1). The track system includes an arc track (4) fixedly installed at the bottom of the crossbeam of the gantry (3), and the arc track (4) is concentrically set with the arc roof (1); The actuator includes two concrete spraying mechanisms (5) that are movable on an arc track (4). The sensing system, integrated on the concrete spraying mechanism (5), includes at least a laser scanner (6), a high-definition industrial camera (8), an infrared thermal imager (9), and a dust sensor (10). Concrete mix proportion control module; The pipeline collaborative management system includes a movable seat (12) set on the crossbeam of the gantry (3), a movable guide wheel (13) set on the movable seat (12), and a fixed guide wheel (14) set on the top end and outer side wall of the crossbeam of the gantry (3). The concrete conveying pipeline (11) is guided to the concrete spraying mechanism (5) through the movable guide wheel (13) and the fixed guide wheel (14). The central control system communicates with the mobile platform, track system, actuators, sensing system, concrete mix proportioning module, and pipeline collaborative management system; the central control system is configured as follows: Based on the BIM model of the curved roof (1), a serpentine reciprocating collaborative spraying path is planned for the two concrete spraying mechanisms (5) starting from the eaves and going up from bottom to top; Control the concrete spraying mechanism (5) to move along the path and perform the spraying operation; Receive distance information from the laser scanner (6) and adjust the distance between the nozzle (7) and the curved roof (1); Receive image data from a high-definition industrial camera (8) and determine concrete defects using an image recognition algorithm; Based on distance information and defect judgment results, the spraying parameters, moving speed and collaborative working status of multiple nozzles (7) of the concrete spraying mechanism (5) are dynamically adjusted in real time. Receive the temperature field distribution data of the concrete surface monitored by the infrared thermal imager (9) to assist in evaluating the uniformity of spraying and form a closed-loop monitoring of construction quality; The data monitored by the dust sensor (10) is correlated with the injection parameters, and the injection pressure or air flow is automatically adjusted when the dust concentration exceeds the standard. After completing the spraying of an axial section, the gantry (3) is moved to one station and the construction system is controlled to perform multi-layer spraying. Based on the real-time slope information of the curved roof (1), the dosage of accelerator in the concrete mixture is dynamically adjusted. The greater the slope, the higher the dosage. The control moving seat (12) is synchronized with the concrete spraying mechanism (5) in the axial direction of the curved roof (1). The concrete conveying pipe (11) is guided by the fixed guide wheel (14) and the moving guide wheel (13) to form a following catenary to avoid contact with the surface of the curved roof (1) during the entire moving stroke of the concrete spraying mechanism (5).

8. The intelligent shotcrete construction system for large-span arched roofs according to claim 7, characterized in that, The concrete spraying mechanism (5) includes: Installation box (15); The spraying module includes three nozzles (7) arranged side by side, each nozzle (7) being connected to a corresponding concrete delivery pipe (11) via a flexible pipe, the flexible pipe passing through the mounting box (15). The drive adjustment module includes a first electric cylinder (16) for driving the central nozzle (7) to move radially, and a second electric cylinder (17) for driving the two side nozzles (7) to adjust the pitch and yaw angles. The first electric cylinder (16) is fixedly connected to the bottom of the mounting box (15), and its piston rod is fixedly connected to the corresponding nozzle (7). The second electric cylinder (17) is movably connected to the bottom of the mounting box (15), and its piston rod is movably connected to the corresponding nozzle (7). The flow control module includes control valves independently installed on each flexible pipe; Among them, the drive adjustment module and the flow control module are controlled by the central control system to independently adjust the position, angle and concrete flow of each nozzle (7) based on the roof curvature data.

9. The intelligent shotcrete construction system for large-span arched roofs according to claim 7, characterized in that, The arc track (4) is spliced ​​together by multiple arc track sections through connectors. The arc track sections are made of high-strength aluminum alloy extrusion molding, and the cross section is mountain-shaped. Several reinforcing rods are provided between the top of the arc track (4) and the crossbeam of the gantry frame (3).

10. The intelligent shotcrete construction system for large-span arched roofs according to claim 9, characterized in that, The concrete spraying mechanism (5) also includes a crawling module, which includes: The crawling seat (18) has a U-shaped cross section and is supported on the arc-shaped track (4) by rollers (19) that are rotatably set on the inner walls of both sides; The drive mechanism includes a motor (20) that drives a roller (19) to rotate, which is disposed on the outer wall of one side of the crawler seat (18). The locking mechanism includes a third electric cylinder (21) installed on the outer walls of both sides of the crawler seat (18). The piston rod of the third electric cylinder (21) is inserted into the crawler seat (18) and fixed with a pressure plate (22) for clamping the web of the arc track (4) when the crawler seat (18) needs to lock the vehicle.

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