An integrated control system for intelligent equipment of polymer sealing layer in tunnel-type gas storage

Abstract

This invention relates to the field of anti-corrosion spraying for large tunnels, and discloses an intelligent integrated control system for polymer sealing layers in tunnel-type gas storage facilities. This system addresses the problems of poor adaptability, low film thickness accuracy, lack of automatic correction, and poor data traceability in existing equipment. The system uses a PLC as the core control unit, integrating modules for automatic speed calculation, gyroscope-based correction and steering, data recording and export, and actuators. It achieves precise film thickness control by establishing a material-time-velocity correlation model, and performs graded automatic correction based on gyroscope and multi-sensor fusion closed-loop feedback. It also supports formula management, full-process data recording, and USB flash drive export. This invention achieves automated spraying of the sealing layer across the entire cross-section of large artificial tunnels, with small film thickness deviation and minimal heading offset. It is suitable for large tunnels and solves the technical problems of low film thickness control accuracy and poor heading stability in the construction of polymer sealing layers in large artificial tunnels, improving the uniformity of the sealing layer film formation and the continuity of construction.

Description

Technical Field

[0001] This invention relates to the field of anti-corrosion spraying for large tunnels, and more specifically to an intelligent equipment integrated control system for a polymer sealing layer of a tunnel-type gas storage facility. Background Technology

[0002] Tunnel-type or artificial chamber-type gas storage facilities are widely used in compressed air energy storage, underground energy storage, and related energy engineering fields. Their inner walls typically require a continuous, uniform, and long-term sealing layer of polymer to withstand the combined effects of repeated high-pressure loads, temperature changes, and structural micro-deformations. As the scale of gas storage facilities continues to increase, the diameter of the chambers is gradually developing towards tens of meters or even larger. Traditional spraying equipment designed for small and medium-diameter pipelines or conventional underground structures is gradually showing significant shortcomings in terms of adaptability, construction accuracy, and automation.

[0003] In existing technologies, the application of polymer sealing layers typically relies on manual experience to preset or manually adjust the travel speed of the spraying equipment and the rotation speed of the spraying mechanism. This fails to establish a quantitative correlation between the coating thickness and the amount of spraying material, construction time, and motion parameters. When the application is to a large-diameter, long-distance chamber structure, manually set speed parameters are difficult to adapt to complex conditions such as changes in chamber size, irregular cross-sections, or fluctuations in material properties. This can easily lead to quality problems such as uneven sealing layer thickness, localized missed spraying, or excessive layering, thereby affecting the overall sealing reliability of the gas storage facility.

[0004] On the other hand, during long-distance spraying operations, the spraying trolley typically travels along the chamber axis, and its stability directly affects the uniformity and continuity of the spray coverage. However, due to track laying errors, uneven ground, or bends in the chamber axis, the spraying trolley is prone to heading deviations or positional errors during actual operation. Existing technologies mostly rely on manual observation or single sensors for auxiliary correction, which not only has a delayed response but also fails to achieve continuous and stable automatic correction control in curved chambers or bend areas, easily introducing new spraying deviations during the correction process. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide an intelligent integrated control system for polymer sealing layers in tunnel-type gas storage facilities. By constructing a dynamic coupling model of material supply rate and travel speed, deploying a real-time heading correction mechanism based on multi-source sensor fusion, and establishing a data acquisition and backtracking architecture covering the entire construction process, the invention solves the technical problems of low film thickness control accuracy, poor heading stability, and untraceable construction data in the construction of polymer sealing layers in large artificial chambers, thereby improving the uniformity of sealing layer film formation, construction continuity, and engineering verifiability.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An integrated control system for intelligent equipment of polymer sealing layer in a tunnel-type gas storage facility includes: The core control unit is used for unified scheduling of speed control and deviation correction control during the spraying process; The automatic speed matching module is used to establish a correlation model between material usage, construction time and movement speed based on the chamber geometry parameters, the designed spray film thickness and the spray material parameters, and automatically calculate the walking speed of the spraying trolley and the rotation speed of the spraying mechanism according to the correlation model, so that the spray film thickness meets the preset design requirements. The automatic heading and position correction module is used to sense the heading and relative position of the spraying trolley in real time during the spraying process. Based on the fusion calculation results of heading deviation and position deviation, it automatically generates correction control commands to drive the steering actuator to compensate for the travel direction of the spraying trolley. The actuators include a painting carriage, a rotary painting mechanism, and a steering actuator, which are used to complete the painting and correction actions according to the control commands output by the core control unit; The automatic speed matching module and the automatic heading and position correction module operate in parallel under the coordination of the core control unit, so that the spraying process can maintain its movement along the axis of the chamber while meeting the film thickness accuracy requirements.

[0008] In this invention, preferably, the automatic speed matching module includes: The material consumption calculation unit is used to calculate the total amount of spraying material required for the target spraying operation based on the chamber diameter, chamber length, designed spray film thickness, solid content of spraying material, and material loss coefficient. The construction time calculation unit is used to calculate the construction time required to complete the spraying based on the total amount of spraying material and the spraying flow rate of the spraying mechanism. The speed calculation unit is used to determine the traveling speed of the spraying trolley and the rotational speed of the spraying mechanism under the construction time constraint.

[0009] In this invention, preferably, the speed calculation unit calculates the speed by establishing a cooperative constraint relationship between the walking speed and the rotation speed, so that when the spraying mechanism completes one rotation, the forward distance of the spraying trolley in the axial direction of the chamber and the spraying width meet the preset spraying overlap rate requirement.

[0010] In this invention, preferably, the automatic speed matching module further includes a dynamic adjustment unit, which obtains the actual distance between the spraying mechanism and the inner wall of the chamber based on the spraying distance detection device; When the actual distance or the change in the cross-sectional dimensions of the chamber is detected to exceed a preset threshold, the walking speed and rotation speed are automatically corrected, and the spatial position of the spraying mechanism is adjusted synchronously.

[0011] In this invention, preferably, the automatic heading and position correction module includes: The heading perception unit is used to acquire the heading and attitude information of the painting vehicle; The position sensing unit is used to acquire spatial position offset information of the spraying trolley relative to the inner wall of the chamber; The deviation fusion calculation unit is used to generate a comprehensive deviation based on the heading and attitude information and the spatial position offset information; The deviation correction control unit is used to output deviation correction control commands based on the comprehensive deviation.

[0012] In this invention, preferably, the deviation fusion calculation unit generates the comprehensive deviation by weighted fusion of the heading deviation and the position deviation, so as to reduce the impact of single sensing information error or drift on the accuracy of correction control.

[0013] In this invention, preferably, the automatic heading and position correction module is configured to be suitable for a chamber structure with a curved or bendable orientation. It estimates the curvature of the travel trajectory by pre-setting the curvature parameter of the chamber axis or by dynamically estimating the curvature of the travel trajectory based on the continuous heading change characteristics, and generates correction control commands based on the deviation between the actual travel trajectory and the target curve axis to guide the painting trolley to travel stably along the curve chamber axis.

[0014] In this invention, preferably, the deviation correction control unit operates in a closed-loop control mode and executes a graded deviation correction control strategy according to the magnitude of the comprehensive deviation. When the deviation is within a first range, micro-correction is performed, and when the deviation exceeds a second preset threshold, enhanced correction is performed and the traveling speed of the painting trolley is reduced simultaneously.

[0015] In this invention, preferably, a data recording module is also included, which is used to record speed parameters, correction status, spraying time and material usage during the spraying process, and supports the storage and export of the recorded data.

[0016] In this invention, preferably, a result analysis and system completion module is also included, which is used to summarize and analyze the spraying process parameters after the spraying construction is completed, and to perform spraying mechanism reset and control system status reset operations after the analysis is completed.

[0017] The beneficial effects of this invention are: Compared to existing technologies, this invention avoids uneven coating thickness caused by improperly set speeds through an automatic speed matching mechanism. This ensures a reasonable match between the travel speed of the spraying trolley and the rotation speed of the spraying mechanism in both time and space, significantly improving the overall uniformity and continuity of the sealing layer. Under the automatic heading and position correction mechanism, the spraying trolley can maintain stable movement along the chamber axis during long-distance construction. Even in chamber structures with curves or bends, continuous correction can be achieved through curvature constraints, reducing spraying defects caused by heading deviations.

[0018] Furthermore, by integrating speed control and deviation correction control into a unified control logic, this invention eliminates the need for deviation correction at the expense of spraying quality, thereby reducing the overall probability of missed spraying, over-spraying, and rework during construction. Through the recording and analysis of construction process data, this invention also enhances the traceability of the construction process, providing reliable data support for subsequent construction quality assessment, process parameter optimization, and equipment maintenance. This ultimately improves the reliability and efficiency of the sealing layer construction for tunnel-type gas storage facilities. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall system architecture and collaborative workflow; Figure 2 This is a schematic diagram of the workflow of the automatic speed calculation module; Figure 3 A schematic diagram of the closed-loop feedback workflow of the gyroscope correction and steering module; Figure 4 This is a schematic diagram of the workflow for the data recording and export module. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is considered "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is considered "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0023] Please also see Figures 1 to 4 This embodiment provides an intelligent integrated control system for polymer sealing layers in tunnel-type gas storage facilities. The system's core consists of a core control unit, an automatic speed matching module, an automatic heading and position correction module, and an actuator. It can also be expanded to include a data recording module, a result analysis module, and a system termination module. The core control unit serves as the scheduling core of the entire system, enabling unified scheduling of speed control and correction control during the spraying process. The automatic speed matching module and the automatic heading and position correction module operate in parallel under the coordination of the core control unit, ensuring that the spraying process maintains its alignment along the tunnel axis while meeting the preset film thickness accuracy requirements. The actuator completes the spraying operation and correction actions based on various control commands output by the core control unit. The expanded modules respectively realize the full-process recording and traceability of construction data, parameter analysis after construction, and equipment reset. Overall, it achieves automated and high-precision spraying construction of the sealing layer across the entire cross-section of a large artificial tunnel gas storage facility.

[0024] The core control unit is built using a programmable logic controller (PLC) and is equipped with a human-machine interface (HMI). As the command center of the entire integrated control system, this unit can schedule various functional modules, calculate various construction parameters, and accurately output control commands. Based on real-time data collected during the construction process, it can flexibly coordinate the operating rhythm of the speed automatic matching module and the heading and position automatic correction module to ensure that the control actions of the two modules do not interfere with each other and work together, providing a basic guarantee for the accuracy and stability of the spraying construction.

[0025] The automatic speed matching module establishes a correlation model between material usage, construction time, and movement speed based on the chamber's geometric parameters, designed spray film thickness, and spray material parameters. It then automatically calculates the travel speed of the spraying trolley and the rotation speed of the spraying mechanism based on this model, ensuring the spray film thickness strictly meets the preset design requirements. This module specifically consists of a material usage calculation unit, a construction time calculation unit, a speed calculation unit, and a dynamic adjustment unit. The material usage calculation unit calculates the total amount of spray material required for the target spraying operation based on the chamber diameter, chamber length, designed spray film thickness, solid content of the spray material, and material loss coefficient, combined with the chamber cross-section correction coefficient. The calculation formula is as follows: , Where V is the total amount of sprayed material; d is the diameter of the chamber; L is the length of the chamber; ζ is the designed spray film thickness; η is the material loss coefficient, which has no unit and is taken as 1.2~1.5 depending on the construction environment; The solid content of the coating material; This is a correction factor for the cross-section of the chamber, determined based on its shape; for circular cross-sections... =1, arc-shaped cross-section =1.05~1.1, irregular cross-section =1.1~1.2.

[0026] The construction time calculation unit calculates the total construction time required for spraying based on the total amount of spraying material and the spraying flow rate of the spraying mechanism. The spraying mechanism adopts a dual-nozzle parallel design with a total spraying flow rate of 2q. Therefore, the formula for calculating the total construction time is T=V / (2q), where T is the total construction time and q is the flow rate of a single nozzle. The speed calculation unit determines the traveling speed of the spraying trolley and the rotational speed of the spraying mechanism under the constraint of the total construction time. This unit calculates the speed by establishing a cooperative constraint relationship between the traveling speed and the rotational speed, ensuring that when the spraying mechanism completes one rotation, the forward distance of the spraying trolley in the axial direction of the chamber and the spraying width meet the preset spraying overlap rate requirement. The formula for calculating the traveling speed of the spraying trolley is... ,in Where is the trolley travel speed, and k is the spray boom telescopic adjustment coefficient. K is dynamically corrected based on the chamber diameter deviation, and its value ranges from 0.9 to 1.1. To meet the preset coating overlap rate requirements, the rotation cycle is calculated using the following formula: ,in Where W is the rotation period and W is the nozzle width. To preset the minimum coating overlap rate, the conventional design requires a value of 20%, and the rotation speed of the spraying mechanism is then... ,in The formula for calculating the coating overlap rate is: (where is the rotational speed) Where H is the distance the trolley travels when the spraying mechanism rotates one revolution. When the calculated coating overlap rate fails to meet the preset requirements, the system dynamically adjusts by increasing the rotation speed or decreasing the trolley's travel speed to ensure the overlap rate meets design standards. The dynamic adjustment unit of the automatic speed matching module obtains the actual distance between the spraying mechanism and the inner wall of the chamber based on the spraying distance detection device. The spraying distance detection device uses a laser rangefinder sensor, which detects the distance between the end of the spray bar and the inner wall of the chamber in real time. When the deviation between the actual distance and the target distance exceeds ±50mm, or the change in the chamber cross-sectional dimensions exceeds ±1m, or the chamber cross-sectional type changes, the dynamic adjustment unit automatically corrects the travel speed of the spraying trolley and the rotation speed of the spraying mechanism, and simultaneously controls the telescopic mechanism to adjust the spatial position of the spraying mechanism. The adjustment cycle of all parameters does not exceed 0.5s, ensuring the continuity of spraying construction and preventing construction interruptions due to changes in chamber parameters.

[0027] The automatic heading and position correction module can sense the heading and relative position of the painting trolley in real time during the spraying process. Based on the fusion calculation results of heading and position deviations, it automatically generates correction control commands to drive the steering actuator to compensate for the travel direction of the painting trolley. This module is specifically composed of a heading sensing unit, a position sensing unit, a deviation fusion calculation unit, and a correction control unit. The heading sensing unit integrates a MEMS gyroscope, accelerometer, and magnetometer, which together form an attitude reference system (AHRS). It can acquire the heading and attitude information of the painting trolley at a sampling frequency of 1000Hz, accurately collecting data such as the angular velocity and angular displacement of the equipment, providing basic data support for the calculation of heading deviation. The position sensing unit is equipped with four sets of laser rangefinders, which are evenly distributed around the painting trolley. They acquire the spatial position offset information of the painting trolley relative to the inner wall of the chamber at a sampling frequency of 500Hz. By calculating the distance difference between sensors on the same side, it can accurately determine the forward / backward and left / right position offset of the trolley. The deviation fusion calculation unit generates a comprehensive deviation based on the heading and attitude information obtained by the heading perception unit and the spatial position offset information obtained by the position perception unit. Specifically, the comprehensive deviation is generated by weighted fusion of the heading deviation and the position deviation. The formula for calculating the comprehensive deviation is as follows: , in The total deviation is the actual offset angle. The heading offset angle is calculated based on the attitude reference system. The heading correction angle is calculated based on relative position. This weighted fusion method can effectively reduce the impact of single sensing information errors or equipment drift on the accuracy of correction control and improve the accuracy of deviation judgment.

[0028] The steering correction control unit outputs steering correction control commands based on the aforementioned comprehensive deviation. This unit operates in a closed-loop control mode and executes a graded steering correction control strategy according to the magnitude of the comprehensive deviation. When the deviation is within the first range, i.e., within the preset allowable threshold range, it performs micro-correction. Specifically, it calculates the compensation steering angle using a PID algorithm and sends it to the steering actuator. The formula for calculating the compensation steering angle using the PID algorithm is as follows: , in To compensate for the steering angle, Here, Ki is the preset proportional coefficient, Kd is the preset integral coefficient, and Kd is the preset derivative coefficient. When the deviation exceeds the second preset threshold, the correction control unit will perform enhanced correction and simultaneously reduce the travel speed of the painting cart. The compensation steering angle for enhanced correction is... Furthermore, the maximum compensation steering angle does not exceed ±10°, and the trolley's travel speed will be reduced to 70% of its original speed to quickly correct deviations and prevent them from widening and causing construction defects. Simultaneously, this automatic heading and position correction module is configured for use in chamber structures with curved or bend-oriented paths. It can dynamically estimate the curvature of the travel trajectory by pre-setting the curvature parameters of the chamber axis or based on continuous heading change characteristics. When the actual travel trajectory curvature deviates from the curvature of the target curve axis by more than 1m, the module generates a corresponding correction control command based on this deviation, adjusting the steering angle of the steering actuator to guide the painting trolley to travel stably along the curved chamber axis.

[0029] In addition, to address the error caused by gyroscope drift, the automatic heading and position correction module employs Kalman filtering, zero-bias calibration, and multi-sensor fusion for error correction. Kalman filtering involves establishing an attitude prediction model. With observation model Dynamic drift correction ensures that the drift error is controlled to less than 0.1° / h. Before starting the equipment, the spraying carriage is placed in a horizontal and stationary state for 30 seconds for gyroscope zero-bias calibration. During the construction process, dynamic zero-bias calibration is performed every 30 minutes. At the same time, the pitch and roll angle errors are corrected by combining the gravity direction signal from the accelerometer and the heading angle error by combining the geomagnetic signal from the magnetometer. Through multiple error correction methods, the accuracy of the correction control is further improved.

[0030] The actuators include a spraying trolley, a rotary spraying mechanism, and a steering actuator. Lifting and telescopic mechanisms can also be added to meet specific construction needs. The spraying trolley serves as the mobile carrier of the entire construction equipment, flexibly adjusting its travel speed according to speed commands from the core control unit. The rotary spraying mechanism, equipped with a rotary nozzle, can precisely adjust its rotation speed based on speed commands to achieve uniform spraying of polymer sealing materials. The steering actuator is a steering wheel with a servo motor, with a response time ≤0.1s. It accurately receives correction control commands from the correction control unit and quickly executes steering actions to compensate for the spraying trolley's travel direction. The lifting and telescopic mechanisms adjust the spatial height and spray boom length of the spraying mechanism according to commands from the dynamic adjustment unit, ensuring the spraying distance remains within a preset safe distance range. All components of the actuators work together to precisely execute all control commands from the core control unit, completing various spraying and correction actions, and serving as the action execution carrier for the entire control system.

[0031] This system also includes a data recording module, which comprehensively and in real-time records speed parameters, correction status, spraying time, and material usage during the spraying process. It also simultaneously records product parameters, equipment status parameters, process alarm information, and handling measures. The data recording frequency is 1 second per record, enabling full lifecycle recording of the construction process data. This module supports local storage and external export of recorded data. Local storage relies on PLC memory and can support the storage of no less than 1000 construction records, each containing complete construction cycle data. External export is achieved via USB flash drive. Data is backed up in real-time upon insertion of the USB flash drive and supports resume capability. Exported data is presented in Excel format, including data tables and trend curves for key parameters. Exported data also includes a verification code to ensure data immutability, facilitating subsequent quality traceability and process optimization. In addition, this module also has a formula management function, which can save various formula parameters for spraying construction. Each formula includes all construction-related parameters such as product name, chamber parameters, material parameters, and nozzle parameters. It supports the modification, deletion, import and export of formulas and can store no less than 1,000 formulas. Before production, the corresponding formula can be loaded directly through the human-machine interface. The system will automatically identify and load all construction parameters, which greatly improves the efficiency of the construction preparation stage.

[0032] This system also includes a results analysis and system completion module. This module is used to comprehensively summarize and analyze the spraying process parameters after the spraying construction is completed. Specifically, it compares the theoretical spraying parameters with the actual construction parameters, accurately calculates the actual deviation of the sprayed film thickness, analyzes the causes of the deviation, and generates a complete construction report. The construction report includes core contents such as parameter summary, deviation analysis, and alarm records, providing data support for subsequent construction process optimization. After completing the summary and analysis of all process parameters, this module will automatically perform spraying mechanism reset and control system status reset operations. Spraying mechanism reset includes actions such as spray boom retraction, steering wheel return to center, and lifting and telescopic mechanisms returning to their original positions. Control system status reset will restore various control parameters to their initial state, preparing for the next spraying construction and realizing closed-loop management of the construction process.

[0033] Under the unified scheduling of the core control unit, the entire integrated control system completes the full-process control of the spraying construction in three stages: startup, spraying, and termination. During startup, the system first loads the preset formula through the human-machine interface. The core control unit automatically identifies the chamber cross-sectional type and dimensional parameters. The automatic speed matching module calculates various speed parameters based on the identified parameters. Simultaneously, the automatic heading and position correction module performs gyroscope zero-bias calibration and laser rangefinder sensor calibration. The core control unit comprehensively checks the equipment status of the actuators and confirms that the remaining spraying material is not less than 90% of the theoretical usage. Once all conditions are met, the system starts the spraying operation. During the spraying stage, the automatic speed matching module outputs speed commands in real time to control the movement speed of the spraying carriage and the rotating spraying mechanism. The dynamic adjustment unit corrects parameters and adjusts the spatial position of the spraying mechanism in real time based on spraying distance detection data. The automatic heading and position correction module synchronizes... The system monitors the heading and position deviations of the spraying trolley in real time and corrects these deviations through closed-loop control. The data recording module records and stores all construction parameters and status information at a preset frequency. If alarms such as insufficient materials, excessive deviations, or equipment malfunctions occur during construction, the core control unit will immediately pause the spraying operation and indicate the fault location. After the fault is cleared, the system can resume construction from the paused position without restarting. At the end of the process, after the spraying operation is completed, the results analysis and system closing module immediately summarizes and analyzes all construction process parameters, generates a construction report, and the data recording module automatically exports all construction data to a USB flash drive for data backup. Subsequently, the results analysis and system closing module performs a reset operation on the spraying mechanism and control system, completing the entire control process for the spraying construction.

[0034] The intelligent spraying equipment integrated control system for polymer sealing layers in tunnel-type gas storage facilities, as described in this invention, is deployed at the spraying construction site. The core control unit first calculates the relationship between the amount of spraying material and the construction time based on the input chamber geometric parameters, designed spray film thickness, and spraying material parameters. Based on this, it determines the traveling speed of the spraying trolley and the rotational speed of the spraying mechanism. After the spraying operation starts, the spraying trolley moves along the chamber axis at the stated traveling speed, while the spraying mechanism simultaneously rotates and sprays to cover the target area on the chamber wall.

[0035] During the painting process, the automatic heading and position correction module continuously acquires the heading and attitude information of the painting trolley and its spatial position offset relative to the inner wall of the chamber. This information is then fused to obtain a comprehensive deviation reflecting the actual deviation of the painting trolley. When the painting trolley deviates from the target travel state, the correction control unit outputs a corresponding correction control command based on the comprehensive deviation, driving the steering actuator to adjust the travel direction of the painting trolley. When the chamber axis exhibits a curved or curved trajectory, the correction control also incorporates preset curvature parameters or estimates the travel trajectory through continuous heading change characteristics, thereby ensuring the painting trolley operates stably along the target curved axis.

[0036] While the correction control is executed, the core control unit coordinates and manages the output of the automatic speed matching module, ensuring that the painting carriage maintains a movement speed that matches the current painting state during the correction process, avoiding adverse effects on the painting coverage due to changes in the travel state. Throughout the painting process, the system records key parameters such as painting speed, correction status, painting time, and material usage. After completion, these parameters are summarized and analyzed, followed by the execution of spray mechanism reset and control system status reset operations, thus completing a full painting process.

[0037] The following section takes the construction of a polymer sealing layer in a circular cross-section artificial tunnel gas storage facility with a diameter of 15m and a length of 20m as an example to explain in detail the specific implementation process of the intelligent equipment integrated control system for the polymer sealing layer of this tunnel-type gas storage facility.

[0038] In the preparation phase before construction, a new formula is first created and parameters are entered in the product parameter interface of the human-machine interface. The entered parameters include: product name 15m circular gas storage sealing layer, chamber diameter d=15m, chamber length L=20m, cross-section type circular, and designed spray film thickness. =5mm, material solid content =100%, Material Loss Coefficient =1.4, single nozzle flow rate q=5L / min, nozzle width W=200mm, spraying safety distance 500mm. After completing the formula settings, directly load the formula, and the system will automatically recognize all construction parameters. Then, perform equipment calibration: place the spraying carriage on a horizontal track, start the gyroscope zero-bias calibration and keep it stationary for 30 seconds, set the target heading angle to 0°, and simultaneously complete the laser rangefinder sensor calibration. Calculate and set the target distance based on the chamber diameter and the spraying safety distance. Next, the material usage calculation unit calculates the usage according to the formula. Calculate the total amount of sprayed material and substitute the parameters to obtain the result. Prepare 6597L of polymer material and reserve 5% margin to ensure sufficient material.

[0039] After the construction preparation is completed, the system starts the spraying operation, and the construction time calculation unit calculates the time according to the formula. Calculate the total construction time and substitute the parameters to obtain the result. The velocity solution unit is based on the formula Calculate the initial trolley travel speed, and the initial extension / retraction adjustment coefficient of the spray boom is k=1. Substitute the parameters to obtain... Combined with a preset minimum overlap rate of 20%, according to the formula The calculated rotation period is approximately 317 seconds, and then based on... The calculated rotational speed was approximately 1.136° / s, at which point the coating overlap was 20%, meeting the preset design requirements. During the spraying process, the laser rangefinder detected an actual distance D=7.1m between the spray boom and the inner wall, and the dynamic adjustment unit immediately adjusted accordingly. The spray boom extension / retraction adjustment coefficient is corrected to 0.986, and the trolley travel speed is simultaneously corrected to 0.498 mm / s. At the same time, the extension / retraction mechanism is controlled to retract the spray boom until the actual distance is restored to the target distance of 7m. If the attitude reference system detects the actual heading angle during the spraying process... The laser rangefinder detected the difference in distance between the left and right sides. The heading correction angle is calculated by combining the wheelbase of the vehicle. The deviation fusion calculation unit is based on the formula The calculated overall deviation was approximately 2.26°. The correction control unit, using a PID algorithm, calculated a compensation steering angle of approximately 1.81° and sent this command to the steering wheel. After the steering wheel performed the adjustment, the attitude reference system detected that the heading angle had recovered to 0.3°, and the laser rangefinder detected that the position offset difference had decreased to 30mm. Both the heading and position deviations were within the preset threshold range, and the correction action was completed. Throughout the entire spraying process, the data recording module recorded all data in real time at a frequency of 1 second, including the change in the trolley's position from 0 to 20000mm, rotation speed, actual material usage, spraying time, changes in the spray boom extension adjustment coefficient, number of corrections, and angles. No major alarms were recorded during this construction.

[0040] After the spraying operation is completed, the system enters the final stage. The results analysis and system closing module summarizes and analyzes the construction process parameters, concluding that the actual sprayed film thickness is between 5.0 and 5.25 mm, with the film thickness deviation controlled within ±5%, meeting the design accuracy requirements. This module then generates a construction report containing parameter summaries and deviation analysis. After inserting the USB drive into the human-machine interface, the data recording module automatically exports all construction data to the USB drive in Excel format. The exported file includes trend charts for time-position-speed and film thickness-distance, a material consumption comparison table, and an alarm record summary table. Finally, the results analysis and system closing module performs a reset operation, retracting the spray boom and returning the steering wheel to center, restoring all parameters of the control system to their initial state, thus completing the entire spraying construction and control process.

[0041] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An integrated control system for intelligent equipment of polymer sealing layer in a tunnel-type gas storage facility, characterized in that, include: The core control unit is used for unified scheduling of speed control and deviation correction control during the spraying process; The automatic speed matching module is used to establish a correlation model between material usage, construction time and movement speed based on the chamber geometry parameters, the designed spray film thickness and the spray material parameters, and automatically calculate the walking speed of the spraying trolley and the rotation speed of the spraying mechanism according to the correlation model, so that the spray film thickness meets the preset design requirements. The automatic heading and position correction module is used to sense the heading and relative position of the spraying trolley in real time during the spraying process. Based on the fusion calculation results of heading deviation and position deviation, it automatically generates correction control commands to drive the steering actuator to compensate for the travel direction of the spraying trolley. The actuators include a painting carriage, a rotary painting mechanism, and a steering actuator, which are used to complete the painting and correction actions according to the control commands output by the core control unit; The automatic speed matching module and the automatic heading and position correction module operate in parallel under the coordination of the core control unit, so that the spraying process can maintain its movement along the axis of the chamber while meeting the film thickness accuracy requirements.

2. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 1, characterized in that, The automatic speed matching module includes: The material consumption calculation unit is used to calculate the total amount of spraying material required for the target spraying operation based on the chamber diameter, chamber length, designed spray film thickness, solid content of spraying material, and material loss coefficient. The construction time calculation unit is used to calculate the construction time required to complete the spraying based on the total amount of spraying material and the spraying flow rate of the spraying mechanism. The speed calculation unit is used to determine the traveling speed of the spraying trolley and the rotational speed of the spraying mechanism under the construction time constraint.

3. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 2, characterized in that, The speed calculation unit calculates the speed by establishing a cooperative constraint relationship between the walking speed and the rotation speed, so that when the spraying mechanism completes one rotation, the forward distance of the spraying trolley in the axial direction of the chamber and the spraying width meet the preset spraying overlap rate requirements.

4. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 1, characterized in that, The automatic speed matching module also includes a dynamic adjustment unit, which obtains the actual distance between the spraying mechanism and the inner wall of the chamber based on the spraying distance detection device. When the actual distance or the change in the cross-sectional dimensions of the chamber is detected to exceed a preset threshold, the walking speed and rotation speed are automatically corrected, and the spatial position of the spraying mechanism is adjusted synchronously.

5. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 1, characterized in that, The automatic heading and position correction module includes: The heading perception unit is used to acquire the heading and attitude information of the painting vehicle; The position sensing unit is used to acquire spatial position offset information of the spraying trolley relative to the inner wall of the chamber; The deviation fusion calculation unit is used to generate a comprehensive deviation based on the heading and attitude information and the spatial position offset information; The deviation correction control unit is used to output deviation correction control commands based on the comprehensive deviation.

6. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 5, characterized in that, The deviation fusion calculation unit generates the comprehensive deviation by weighting and fusing the heading deviation and the position deviation, thereby reducing the impact of single sensing information errors or drift on the accuracy of the correction control.

7. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 1, characterized in that, The automatic heading and position correction module is configured to be suitable for chamber structures with curved or bendable orientations. It estimates the curvature of the travel trajectory by pre-setting the curvature parameters of the chamber axis or by dynamically estimating the curvature of the travel trajectory based on the continuous heading change characteristics, and generates correction control commands based on the deviation between the actual travel trajectory and the target curve axis to guide the painting trolley to travel stably along the axis of the curved chamber.

8. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 5, characterized in that, The correction control unit operates in a closed-loop control mode and executes a graded correction control strategy according to the magnitude of the comprehensive deviation. When the deviation is within the first range, it performs micro-correction; when the deviation exceeds the second preset threshold, it performs enhanced correction and simultaneously reduces the travel speed of the painting trolley.

9. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 1, characterized in that, It also includes a data recording module, which is used to record speed parameters, correction status, spraying time and material usage during the spraying process, and supports the storage and export of the recorded data.

10. The intelligent equipment integrated control system for the polymer sealing layer of the tunnel-type gas storage facility according to claim 1, characterized in that, It also includes a results analysis and system completion module, which is used to summarize and analyze the spraying process parameters after the spraying construction is completed, and to perform spraying mechanism reset and control system status reset operations after the analysis is completed.

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