A universal battery rail trolley based on tunnel operation design and a use method thereof

Abstract

This invention discloses a universal battery-powered railcar designed for tunnel operations, comprising a lithium-ion battery flatbed as a mobile base, and a top control assembly and a side control assembly mounted on top of the lithium-ion battery flatbed. A control module and a power module for providing power support to the top and side control assemblies are also connected to one side of the upper part of the lithium-ion battery flatbed. The side control assembly includes a telescopic arm that slides laterally along the vehicle body and a telescopic drive component that drives its movement. A fine-tuning structure is also connected between the lithium-ion battery flatbed and the telescopic drive component. The top control assembly includes a lifting mechanism driven by the power module and a working platform mounted on its top. The advantages of this invention compared to existing technologies are: it provides a convenient and easy-to-use universal battery-powered railcar designed for tunnel operations, integrating movement, lifting, telescopic movement, and fine-tuning, along with its method of use.

Description

Technical Field

[0001] This invention relates to the field of tunnel construction machinery technology, specifically to a universal battery-powered railcar designed for tunnel operations and its usage method. Background Technology

[0002] In the construction of railway, highway, and subway tunnels, the installation of prefabricated components (such as roof slabs, side slabs, and cable troughs) is a crucial construction step. Traditionally, tunnel component installation mainly relies on large gantry cranes or manual labor in conjunction with simple trolleys.

[0003] However, existing technical solutions often rely on external cable power supply or diesel generators, making wiring inside the tunnel difficult and unsuitable for working in enclosed spaces. In addition, existing trolleys usually only have single transportation or simple lifting functions, lacking fine-tuning mechanisms, making it difficult to adapt to the side panel installation requirements of tunnels with different cross-sections, and unable to directly provide power to other power tools on site, resulting in various inconveniences in use. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the above-mentioned technical defects and provide a universal battery-powered rail trolley designed for tunnel operation that is easy to operate and integrates movement, lifting, extension, and fine adjustment, as well as its usage method.

[0005] To solve the above-mentioned technical problems, the technical solution provided by the present invention is: a universal battery rail trolley based on tunnel operation design, including a lithium battery flatbed trolley as a mobile base and a top plate control assembly and a side plate control assembly disposed on the top of the lithium battery flatbed trolley; The upper side of the lithium battery flatbed vehicle is also connected to a control module and a power module for providing power support to the top plate control component and the side plate control component. The side panel control assembly includes a telescopic arm that slides laterally along the vehicle body and a telescopic drive component that drives its movement. A fine-tuning structure is also provided between the lithium battery flatbed vehicle and the telescopic drive component. The top plate control assembly includes a lifting mechanism driven by a power module and a working platform located at its top.

[0006] As an improvement, the lithium battery flatbed vehicle also integrates a power battery pack. The control module is connected to the power battery pack and is equipped with a power distribution component. The power distribution component is equipped with a multi-functional AC output interface. The multi-functional AC output interface provides AC drive power to the external operating equipment.

[0007] As an improvement, the lithium battery flatbed vehicle also integrates a power battery pack. The control module is connected to the power battery pack and is equipped with a power distribution component. The power distribution component is equipped with a multi-functional AC output interface. The multi-functional AC output interface provides AC drive power to the external operating equipment.

[0008] As an improvement, the fine-tuning structure is a Z-axis hydraulic drive connected between the telescopic drive and the lithium battery flatbed vehicle; The telescopic arm is driven to extend and retract by a telescopic drive component, and its end is connected to an electric suction cup.

[0009] Another aspect of the present invention discloses a construction method for a universal battery-powered railcar based on tunnel operation design, comprising the following steps: S1: Start the lithium battery flatbed truck, check the power battery pack charge and output power status, and confirm that the hydraulic station power supply circuit is connected; S2: Drive the scissor lift to raise the work platform to the preset reference height; Start the hydraulic station, control the lifting cylinder to extend, drive the electric suction cup at the end to grab the top plate component, and continue to lift until the top plate reaches the installation position at the top of the tunnel for fixing; S3: The telescopic drive unit drives the telescopic arm to extend laterally, and the Z-axis hydraulic drive unit is linked to make up-down fine adjustments, which drives the electric suction cup at the end to grab the side plate component and accurately transport it to the installation position on the tunnel side wall for fixing. S4: Release electric suction cup one or electric suction cup two, retract the lifting cylinder, telescopic arm and scissor lift, and drive the lithium battery flatbed truck to move to the next work station.

[0010] Preferably, in S2, the control module monitors the lifting stroke of the scissor lift in real time and automatically stops after reaching the preset reference height.

[0011] Preferably, step S4 further includes providing AC drive power to external operating equipment via a multi-functional AC output interface for performing other operations.

[0012] The advantages of this invention compared with the prior art are: the invention incorporates an AC inverter system, which, in addition to driving its own hydraulic mechanism, can also supply power to external spraying, bolting and other equipment through a multi-functional interface, thus solving the problem of power supply in tunnels; The side plate mechanism integrates lateral telescopic and Z-axis vertical fine adjustment, automatically compensating for mechanical deflection and flexibly adapting to different tunnel cross sections. This invention pioneers a two-stage lifting mode for roof operations, combining coarse scissor lift and fine cylinder adjustment. It first quickly lifts to the reference height, then finely adjusts the lifting to eliminate accumulated errors, ensuring millimeter-level docking accuracy and making it easy to promote and use. Attached Figure Description

[0013] Figure 1 This is a structural diagram of a universal battery-powered railcar designed for tunnel operations.

[0014] Figure 2This is a top view structural diagram of a universal battery-powered track trolley designed for tunnel operations.

[0015] Figure 3 This is a structural schematic diagram of a universal battery-powered track trolley designed for tunnel operations, shown on the right.

[0016] As shown in the figure: 1. Side panel control assembly; 2. Side panel; 3. Working platform; 4. Lifting mechanism; 5. Power module; 6. Lithium battery flatbed truck; 7. Telescopic drive component; 8. Lifting cylinder; 9. Electric suction cup one; 10. Control module; 11. Fine-tuning structure; 12. Electric suction cup two. Detailed Implementation

[0017] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. Identical components are indicated by the same reference numerals.

[0018] It should be noted that the terms front, back, left, right, up, and down used in the following description refer to the directions in the attached diagram, while the terms inside and outside refer to the directions toward or away from the geometric center of a specific component, respectively.

[0019] To make the content of this invention easier to understand, the technical solutions in the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings.

[0020] Combined with appendix Figure 1-3 As shown, a universal battery-powered railcar designed for tunnel operations includes a lithium-ion battery flatbed trolley 6 serving as a mobile base and a top control assembly and a side control assembly 1 located on top of the lithium-ion battery flatbed trolley. A control module 10 and a power module 5 for providing power support to the top control assembly and the side control assembly 1 are also connected to one side of the upper part of the lithium-ion battery flatbed trolley. The side control assembly 1 includes a telescopic arm that slides laterally along the vehicle body and a telescopic drive component 7 that drives its movement. A fine-tuning structure 11 is also connected between the lithium-ion battery flatbed trolley 6 and the telescopic drive component 7. The top control assembly includes a lifting mechanism 4 driven by the power module 5 and a working platform 3 located at its top.

[0021] During use, the lithium battery flatbed truck 6 also integrates a power battery pack. The control module 10 is connected to the power battery pack and is equipped with a power distribution component. The power distribution component is equipped with a multi-functional AC output interface. The multi-functional AC output interface provides AC drive power to the external working equipment.

[0022] To facilitate control of the lifting and alignment of the top plate, the lifting mechanism 4 is a scissor lift; lifting cylinders 8 are also connected to the top two sides of the working platform 3, and electric suction cups 9 are connected to the telescopic ends of the lifting cylinders 8.

[0023] When registering the side plate, the fine-tuning structure 11 is a Z-axis hydraulic drive component connected between the telescopic drive component 7 and the lithium battery flatbed vehicle; The telescopic arm is driven to extend and retract by the telescopic drive component 7, and its end is connected to an electric suction cup 12, which is used for fine-tuning and registration by the Z-axis hydraulic drive component.

[0024] In specific implementation of the present invention, Using a lithium-ion battery flatbed truck 6 as the mobile base, it adopts a track-type four-wheel chassis with front-wheel steering and rear-wheel drive. With the help of mechanical track guide wheel sets, it can adapt to the curved tracks of tunnels and can be connected to the self-propelled retraction and insertion track to meet the needs of continuous passage and work station switching in tunnels.

[0025] The lithium-ion battery flatbed truck 6 has a top control assembly and a side control assembly 1 on its top. A control module 10 and a power module 5 are installed on one side of the vehicle body. The power module 5 provides hydraulic and driving power to the top and side control assemblies 1. The control module 10 adopts a three-mode control, supporting local manual control, 20-meter wired remote control, and 4G remote monitoring. The operation panel meets the IP65 protection level and is suitable for the humid and dusty environment of tunnels. The lithium-ion flatbed truck 6 integrates a power battery pack, employing a dual-battery configuration of a 96V 100Ah main lithium battery pack and a 48V 50Ah auxiliary battery pack, providing enough power for continuous operation for 46 hours under normal working conditions. The control module 10 connects to the power battery pack via a power distribution component and is equipped with a dual inverter system. The 10kW power frequency inverter supplies power to high-power external equipment such as concrete spraying, while the 5kW high-frequency inverter supplies power to the hydraulic and control systems. The power distribution unit is equipped with a multi-functional AC output interface, which can directly provide AC drive power to external operating equipment such as anchor drilling rigs, concrete spraying machines, and fastening tools in the tunnel without the need for external temporary lines.

[0026] The power chassis uses a 15kW AC variable frequency motor, with a maximum operating speed of 3km / h and a maximum unloaded speed of 5km / h. The vehicle body is equipped with an energy recovery system, which can realize the recovery of braking energy during downhill driving and the potential energy recovery of the hydraulic system, thereby improving range and energy utilization. When working on the roof: The roof control assembly consists of a scissor lift 4 and a working platform 3, driven by a power module 5. Lifting cylinders 8 are installed on both sides of the top of the working platform 3, with electric suction cups 9 connected to the telescopic ends of the cylinders for gripping and lifting the tunnel roof components. During operation, the scissor lift 4 first raises the working platform 3 to a preset reference height. The control module 10 monitors the lifting stroke in real time and automatically stops upon reaching the desired position. Then, the lifting cylinders 8 perform a second lift, precisely delivering the roof component to its installation position at the top of the tunnel for fixation. Both the scissor lift 4 and the lifting cylinders 8 are hydraulically powered by the power module 5, and the system has a real-time hydraulic pressure monitoring function to ensure stable and safe lifting.

[0027] When working on the side panels: The side panel control assembly 1 includes a telescopic arm, a telescopic drive component 7, and a Z-axis hydraulic drive component. The Z-axis hydraulic drive component, acting as a fine-tuning structure 11, connects the telescopic drive component 7 and the lithium-ion flatbed trolley 6, enabling fine-tuning of the telescopic arm's vertical height. The telescopic arm, driven by the telescopic drive component 7, slides laterally along the vehicle body, and an electric suction cup 12 is installed at its end for gripping and transporting the tunnel side panel components. During operation, the telescopic drive component 7 drives the telescopic arm to extend laterally, simultaneously coordinating with the fine-tuning structure 11 for vertical fine-tuning, precisely transporting the side panel components to the installation position on the tunnel sidewall. The fine-tuning action and the lateral telescopic action work together to ensure installation alignment accuracy.

[0028] The specific operating procedure is as follows: The self-test starts the lithium battery flatbed truck 6. The control module 10 automatically detects the power battery pack charge, output power, and BMS battery status, confirms that the hydraulic station power supply circuit is connected and the hydraulic pressure is normal, and completes the preparations before operation.

[0029] The scissor lift 4, which drives the installation of the top plate components, raises the work platform 3 to the preset reference height. The control module 10 monitors the stroke and automatically stops the machine. The hydraulic station is started, the lifting cylinder 8 extends, and the electric suction cup 9 adsorbs the top plate components, continuing to lift them to the installation position at the top of the tunnel and completing the fixing.

[0030] The side panel component is installed with the telescopic drive component 7, which drives the telescopic arm to extend laterally. The micro-adjustment structure 11 adjusts the height up and down. The electric suction cup 12 adsorbs the side panel component and accurately delivers it to the installation position on the tunnel sidewall and fixes it.

[0031] The mechanism resets and the electric suction cups 9 and 12 are released for workstation transfer. The lifting cylinder 8, telescopic arm, and scissor lift 4 are then retracted in sequence. After all mechanisms have fully reset, the lithium-ion flatbed trolley 6 travels at low speed along the track to the next workstation. During the journey, the multi-functional AC output interface can be used to power external tools and carry out auxiliary operations simultaneously.

[0032] Throughout the safe and cyclical operation, the vehicle's attitude is monitored by tilt sensors, with over-limit warnings; the hydraulic and battery systems are monitored in real time, with automatic protection in case of abnormalities. Repeating the above steps enables continuous assembly of the tunnel's roof and side panels.

[0033] The trolley has dimensions of 3.2 x 1.6 x 2.1 m when folded and weighs approximately 1.8 tons (including battery), making it suitable for the narrow spaces of tunnels. It adopts a modular interface design, allowing for quick replacement of operating modules such as the spraying system, support system, and anchor drilling rig, expanding its multi-functional applications. The overall design complies with the GB / T3450~2019 tunnel equipment standard, and explosion-proof certification can be added for gas tunnels to meet the construction requirements of different tunnels.

[0034] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

[0035] All standard parts used in this invention can be purchased from the market, and irregular parts can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art, and the circuit connection adopts conventional connection methods in the prior art, which will not be described in detail here. The contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0036] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A universal battery-powered rail trolley designed for tunnel operations, characterized in that: Includes a lithium battery flatbed vehicle (6) serving as a mobile base and a top plate control assembly and a side plate control assembly (1) located on the top of the lithium battery flatbed vehicle. The upper side of the lithium battery flatbed vehicle is also connected to a control module (10) and a power module (5) for providing power support to the top plate control component and the side plate control component (1). The side panel control assembly (1) includes a telescopic arm that slides laterally along the vehicle body and a telescopic drive component (7) that drives its movement. A fine-tuning structure (11) is also provided between the lithium battery flatbed vehicle (6) and the telescopic drive component (7). The top plate control assembly includes a lifting mechanism (4) driven by a power module (5) and a working platform (3) located at its top.

2. The universal battery-powered railcar based on tunnel operation design according to claim 1, characterized in that: The lithium battery flatbed vehicle (6) also integrates a power battery pack. The control module (10) is connected to the power battery pack and is equipped with a power distribution component. The power distribution component is equipped with a multi-functional AC output interface. The multi-functional AC output interface provides AC drive power to the external operating equipment.

3. The universal battery-powered railcar based on tunnel operation design according to claim 1, characterized in that: The lifting mechanism (4) is a scissor lift; The top two sides of the work platform (3) are also connected to lifting cylinders (8), and the telescopic end of the lifting cylinder (8) is connected to an electric suction cup (9).

4. The universal battery-powered railcar designed for tunnel operations according to claim 1, characterized in that: The fine-tuning structure (11) is a Z-axis hydraulic drive component connected between the telescopic drive component (7) and the lithium battery flatbed vehicle; The telescopic arm is driven to extend and retract by a telescopic drive component (7), and its end is connected to an electric suction cup (12).

5. A construction method for a universal battery-powered railcar based on tunnel operation design according to any one of claims 1 to 4, characterized in that: Includes the following steps: S1: Start the lithium battery flatbed truck (6), check the power battery pack charge and output power status, and confirm that the hydraulic station power supply circuit is connected; S2: Drive the scissor lift to raise the work platform (3) to the preset reference height; Start the hydraulic station, control the lifting cylinder (8) to extend, drive the electric suction cup (9) at the end to grab the top plate component, and continue to lift until the top plate reaches the installation position at the top of the tunnel for fixing; S3: The telescopic drive component (7) drives the telescopic arm to extend laterally, and the Z-axis hydraulic drive component is linked to make up-down fine adjustments, which drives the electric suction cup (12) at the end to grab the side plate component and accurately transport it to the installation position on the tunnel side wall for fixing. S4: Release electric suction cup one (9) or electric suction cup two (12), retract lifting cylinder (8), telescopic arm and scissor lift, and drive lithium battery flatbed truck (6) to move to the next work station.

6. The construction method of the universal battery track trolley according to claim 5, characterized in that: The control module (10) in S2 monitors the lifting stroke of the scissor lift in real time and automatically stops after reaching the preset reference height.

7. The construction method of the universal battery track trolley according to claim 5, characterized in that: The S4 also includes providing AC drive power to external operating equipment via a multi-functional AC output interface for other operations.

Images