A smart anchor bolt and stress monitoring system and application method suitable for automatic installation of tunneling and anchoring machines.

Abstract

This invention discloses an intelligent anchor bolt and stress monitoring system and application method suitable for automatic installation by a tunneling and anchoring machine, belonging to the field of mine roadway support and intelligent monitoring technology. The intelligent anchor bolt stress monitoring system includes an anchor bolt stress sensor, an automated installation adapter module, a data acquisition and transmission unit, and a ground monitoring and early warning platform. The intelligent anchor bolt stress monitoring system and method designed in this invention have strong adaptability, a high degree of automation, and high installation and monitoring accuracy.

Description

Technical Field

[0001] This invention belongs to the field of mine roadway support and intelligent monitoring technology, specifically relating to an intelligent anchor bolt and stress monitoring system and application method suitable for automatic installation by an integrated tunneling and anchoring machine. Background Technology

[0002] Rock bolt support is a primary means of controlling surrounding rock in coal mine roadways. In recent years, integrated roadheader-rock bolting machines, as core equipment for rapid roadway excavation, have been widely used in major coal enterprises such as Shaanxi Coal Group, China Energy Investment Corporation, and China Coal Group, enabling parallel operations of excavation and support. Existing integrated roadheader-rock bolting machines already possess functions such as one-click drilling and one-click rock bolt installation, and are equipped with intelligent modules to achieve remote operation and automatic guided excavation. Industry benchmarks, such as China Coal Technology & Engineering Group's "Coal Sea Dragon" integrated roadheader-support-transport system, have achieved parallel operations of excavation, support, and transportation for the first time globally, with a monthly advance of 3088 meters in stable surrounding rock.

[0003] However, existing anchor stress monitoring systems still have the following technical problems: 1. Installation incompatibility: Existing anchor stress gauges are all designed for manual installation, and their dimensions are incompatible with the gripping interface of the tunneling and anchoring machine's robotic arm, making automated installation impossible. Although existing technologies include anchor stress sensors, their installation still requires manual intervention and does not consider collaborative operation with the tunneling and anchoring machine's drilling rig.

[0004] 2. Lack of System Integration: Currently, several automated anchoring technologies exist—such as Sany Heavy Equipment's intelligent anchoring control method for automated anchor hole drilling, China University of Mining and Technology's automated collaborative drilling and anchoring robot for coordinated mesh laying and drilling / anchoring operations, and Anhui University of Science and Technology's integrated drilling and anchoring system for fully automating the entire process of drill rod connection / disconnection, anchoring agent filling, and anchor bolt installation. However, none of these technologies incorporate the crucial step of anchor bolt stress monitoring into the automation process.

[0005] 3. Installation damage risk: Traditional manual installation makes it difficult to control the accuracy of the preload, which can easily damage the internal components of the sensor.

[0006] 4. Lack of unified technical specifications: Currently, there are no product standards for anchor stress gauges specifically designed for the automatic installation of tunneling and anchoring machines. Products from different manufacturers are incompatible with each other, making it difficult to form a large-scale supporting system.

[0007] Therefore, developing an intelligent anchor stress monitoring system that can be seamlessly integrated with an integrated tunneling and anchoring machine to achieve automated grasping, installation, pre-tightening, and data acquisition of anchor stress sensors is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0008] The purpose of this invention is to provide an intelligent anchor bolt and stress monitoring system and application method suitable for automatic installation of integrated tunneling and anchoring machines, so as to solve the problems existing in the current automated anchor bolt support installation mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution: an intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine, the intelligent anchor bolt including a rod body, a tray, a locking device, and an anchor bolt stress sensor. The anchor bolt stress sensor is disposed between the fixing disc of the anchor bolt and the locking device, and includes a sensor body. The sensor body has a ring structure with a through hole in its center that matches the outer diameter of the anchor bolt. A stress sensing unit is embedded on the upper surface of the sensor body, and a communication interface and a built-in storage module are provided on the side of the sensor body.

[0010] Preferably, the upper surface of the sensor body housing has 2-4 symmetrically symmetrically opened gripping positioning notches, and the upper surface of the sensor body housing is fitted with an annular magnetic attraction strip.

[0011] Preferably, multiple miniature pressure sensors are symmetrically embedded in the lower surface of the housing of the sensor body along the circumferential direction.

[0012] Preferably, the sensor body has an elastic centering ring along the inner edge of its central perforation. The elastic centering ring is made of polyurethane elastomer material and its inner diameter is 2-3 mm smaller than the diameter of the rod.

[0013] Preferably, the thickness of the sensor body housing is controlled at 8-12mm, and it is made of high-strength material with a hardness of not less than HRC38-42 after heat treatment.

[0014] The present invention also provides an intelligent anchor stress monitoring system suitable for automatic installation of tunneling and anchoring machines. The intelligent anchor stress monitoring system includes the intelligent anchor as described above, an automated installation adapter module, a data acquisition and transmission module, and a ground monitoring and early warning platform. The automated installation adapter module includes a sensor gripping self-adaptation unit and a locking process torque transmission unit. The sensor gripping self-adaptation unit includes a positioning notch between the end-positioning claw of the manipulator of the integrated excavator and anchor and the positioning notch of the sensor body, and an electromagnetic chuck of the manipulator and a magnetic attraction band between the electromagnetic chuck of the manipulator and the sensor body. The locking process torque transmission unit includes anti-slip textures on the upper and lower surfaces of the housing of the sensor body. The data acquisition and transmission module includes a data acquisition instrument, which is connected to the anchor bolt stress sensor via a 485 / CAN wired communication line. After amplifying, filtering and converting the stress signal transmitted by the sensor to analog-to-digital, the data is uploaded to the data aggregation base station in real time via a wireless transmission module. The data aggregation base station uploads the acquired data to the ground monitoring and early warning platform through the underground industrial ring network. The ground monitoring and early warning platform receives and stores data, analyzes the received data, and automatically issues an audible and visual alarm when the stress value exceeds a preset threshold or the rate of change is abnormal. It also visualizes the data in the form of graphics and charts and monitors the communication status of each anchor stress sensor and data acquisition instrument in real time.

[0015] Preferably, the intelligent anchor bolt stress monitoring system further includes an anchor bolt installation in place triggering mechanism. The anchor bolt installation in place triggering mechanism consists of multiple miniature pressure sensors set on the lower surface of the sensor body. The miniature pressure sensors monitor the pressure of the anchor bolt stress sensor being clamped by the tray and lock during the installation process, and the pressure data is collected in real time by the data acquisition instrument. When the pressure reaches a preset threshold, the installation in place signal is triggered, and the data acquisition instrument records the current stress value of the anchor bolt stress sensor as the initial value for automatic calibration.

[0016] Preferably, the anchor stress sensor of the smart anchor bolt stores a unique identification code, which is transmitted to the data acquisition device via 485 / CAN wired communication after installation.

[0017] This invention also provides an application method for the intelligent anchor bolt stress monitoring system applicable to the automatic installation of an integrated tunneling and anchoring machine, as described above. The specific steps of the application method are as follows: Step 1: Drilling preparation. After the tunnel cutting machine completes the roadway cutting, the anchor drilling machine moves to the preset anchor hole position and completes the drilling operation according to the preset hole diameter and hole depth parameters. Step 2: Anchor bolt and pallet installation. The robotic arm of the tunneling and anchoring machine grabs the anchor bolt and inserts it into the anchor hole. Then, it grabs a standard mining pallet, puts the pallet on the exposed end of the anchor bolt, and presses it tightly against the surface of the roadway rock wall to ensure that the pallet fits tightly against the rock wall. Step 3: Automatic sensor grabbing. The automatic anchor drilling machine of the integrated tunneling and anchoring machine moves to the anchor stress sensor storage location. The robotic arm aligns the end positioning claw with the V-shaped positioning notch on the upper surface of the anchor stress sensor housing. At the same time, the electromagnetic chuck is activated to attract the magnetic attraction strip on the upper surface of the anchor stress sensor, realizing the stable grabbing of the anchor stress sensor. The grabbing force of the robotic arm is controlled at 50-80N. Step 4: Automatic insertion and positioning. The robotic arm picks up the anchor stress sensor, moves it to the anchor position on the installed tray, aligns the center hole of the anchor stress sensor with the exposed end of the anchor, and slowly inserts it. The elastic centering ring in the center of the anchor stress sensor automatically guides the anchor stress sensor to align with the center of the anchor and the tray, while ensuring that the communication interface of the anchor stress sensor faces the direction that facilitates subsequent cable connection. Step 5: Automatic locking. The robotic arm releases the anchor stress sensor, moves it to the locking storage, grabs the locking nut, and fits it onto the exposed end of the anchor. The drilling rig rotates the locking nut according to the preset torque value, pressing the locking nut, sensor, and tray in sequence to ensure that the anchor stress sensor is firmly clamped between the tray and the locking, and that the locking torque meets the design requirements without damaging the internal components and communication interface of the anchor stress sensor. The preset torque value of the drilling rig is 300-500 N·m. Step 6: Wired Connection and Automatic Calibration. Connect the anchor stress sensor and the data acquisition unit using a 485 / CAN communication cable. When the locking torque reaches the preset value, the miniature pressure sensor on the lower surface of the anchor stress sensor is clamped by the tray and the locking unit. When the pressure reaches the preset threshold, a "installation in place" signal is triggered. This signal is transmitted to the data acquisition unit via 485 / CAN wired communication. The preset pressure threshold is 100-150kN. The data acquisition unit reads the unique identification code of the anchor stress sensor, records the installation position, installation time, and current stress value, and records the stress value detected by the anchor stress sensor as the initial value, i.e., the "zero reference," completing automatic calibration, eliminating stress deviations during installation, and ensuring the accuracy of monitoring data.

[0018] Preferably, the application method further includes, Step 7: Real-time monitoring and data transmission. The anchor bolt stress sensor enters the working state, continuously sensing changes in the axial stress of the anchor bolt. The stress sensing unit is only responsible for collecting stress signals and transmitting them to the data acquisition unit in real time via 485 / CAN wired communication. The data acquisition unit conditions and converts the received signals and stores them in the built-in storage module, while simultaneously uploading the data to the data aggregation base station in real time. The data acquisition unit synchronously monitors the communication status of the anchor bolt stress sensor and promptly issues a fault alert if a communication interruption occurs. Step 8: Data aggregation and uploading. The data aggregation base station receives stress data and status signals sent by each data acquisition unit, performs temporary caching and data verification, removes abnormal data, and uploads it to the ground monitoring center in real time through the underground industrial ring network. If the underground industrial ring network is interrupted, the data acquisition unit automatically caches the data and automatically re-uploads the cached data to the ground after the network is restored to ensure that no data is lost. Step 9: Data Analysis and Early Warning. The ground monitoring center stores, analyzes, and visualizes the received time-series stress data, performs trend analysis and anomaly detection on the stress data, and calculates the stress change rate. When the stress value exceeds the preset threshold or the change rate is abnormal, the system automatically issues an audible and visual alarm and notifies the relevant responsible persons via SMS, APP push, and other means. Step 10: Post-maintenance and data traceability. The ground monitoring center monitors the communication status of the anchor stress sensor and the data acquisition instrument in real time, as well as the working status of the data acquisition instrument. When communication interruptions or data anomalies occur, maintenance reminders are issued. Staff can accurately locate faulty sensors based on the unique identification code and installation location of the anchor stress sensor, troubleshoot cable and interface problems, and repair or replace them. At the same time, historical data stored in the data acquisition instrument and the ground platform can be queried and exported at any time, facilitating the analysis and summary of the stability of the surrounding rock in the tunnel and the optimization of support schemes.

[0019] Compared with existing technologies, the advancements of this invention, which provides an intelligent anchor bolt and stress monitoring system and application method suitable for automatic installation by an integrated tunneling and anchoring machine, lie in the following aspects: 1. No change to the existing installation location, highly adaptable: The core retains the conventional installation method of "installing the anchor stress sensor between the tray and the lock", without modifying the original anchor, tray, and lock structure, and without changing the existing support process in the coal mine. It is suitable for both new tunneling and anchoring machines and the retrofitting of existing equipment, and can be quickly promoted and applied, reducing the cost of retrofitting.

[0020] 2. Achieve full-process automation and eliminate safety risks: The entire process of grabbing, inserting, and positioning the anchor stress sensor is fully integrated into the automated support process of the tunneling and anchoring machine. From anchor drilling and tray installation to sensor installation and locking, the entire process requires no manual intervention, completely replacing manual installation work in the unsupported area. This eliminates safety risks such as falling people, falling objects, roof collapse, and roof fall caused by unsupported operations, meeting the inherent safety requirements of coal mines. The wired communication connection is simple and convenient, requiring no complicated operations and reducing the intensity of underground work for workers.

[0021] 3. Improved Installation and Monitoring Accuracy: The anchor bolt stress sensor employs a dual positioning design of "V-shaped positioning notch + annular magnetic attraction band" to ensure precise and stable gripping by the integrated excavator and anchorer, preventing gripping deviation. An elastic centering ring enables automatic alignment of the sensor with the anchor bolt and tray, ensuring uniform force distribution. An anchor bolt installation trigger mechanism and automatic calibration with "installation equals zero position" eliminate initial value errors caused by manual installation, improving the accuracy and reliability of monitoring data. The 485 / CAN wired communication offers low transmission latency and strong anti-interference capabilities, avoiding signal loss and interference in wireless transmission, further enhancing data continuity and accuracy.

[0022] 4. Improve monitoring efficiency and reduce overall costs: A typical coal mine working face (equipped with 300 sets of sensors) can reduce the number of full-time monitoring personnel by 2-3 after adopting this system, saving labor and construction costs annually; at the same time, automated installation efficiency is more than 80% higher than manual installation, shortening the support cycle and improving roadway excavation efficiency; the sensor functions are simplified, manufacturing costs are reduced, and the service life is long and maintenance costs are low, further reducing overall investment.

[0023] 5. High system integration, filling a technological gap: This invention integrates four major modules: sensor hardware, automated installation adaptation, monitoring signal acquisition and transmission, and ground monitoring and early warning, forming a complete "perception-transmission-analysis-early warning" closed loop. This fills the gap in existing technologies where anchor stress monitoring is not integrated into the automated support process, has redundant functions, and has unstable transmission. At the same time, it solves the industry pain point that existing sensors cannot be adapted to the automatic installation of the tunneling and anchoring machine.

[0024] 6. High stability and adaptability to complex underground working conditions: The sensor adopts a sealed encapsulation and explosion-proof design with an IP68 protection level. The communication interface is sealed, making it suitable for complex underground environments such as humidity, dust, high temperature, and high pressure. The housing is made of high-strength alloy steel, which can withstand the instantaneous torque when the lock is tightened and is not easily damaged. The 485 / CAN wired communication has strong anti-interference ability and stable transmission. The data acquisition instrument has a data buffering function to ensure the long-term stable operation of the monitoring system.

[0025] 7. Facilitates large-scale integration and management: The sensor's shape and gripping interface adopt a standardized design, which is compatible with mainstream tunneling and anchoring machines, enabling large-scale integration; each sensor has a unique ID, which facilitates the traceability of installation location, data matching and equipment management; the data acquisition instrument centrally stores and manages data in a unified manner, realizing precise and intelligent control of anchor bolt monitoring.

[0026] 8. Facilitating the Construction of Intelligent Mines: This system achieves full automation and intelligence in anchor bolt stress monitoring, and seamlessly integrates with the automated process of the integrated tunneling and anchoring machine. It conforms to the national policy orientation of "intelligent mines, mechanization to replace manpower, and automation to reduce manpower," and can promote the transformation of coal mine roadway support monitoring from "manual operation" to "intelligent perception," thereby improving the level of intelligent safety production in coal mines. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of an intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine according to the present invention; Figure 2 This is a front view of the upper surface of the anchor stress sensor of the present invention.

[0028] Figure 3This is a front view of the lower surface of the anchor stress sensor of the present invention.

[0029] Figure 4 This is a schematic diagram of the structure of an intelligent anchor stress monitoring system applicable to the automatic installation of an integrated tunneling and anchoring machine according to the present invention.

[0030] Figure 5 This is a schematic diagram of the application method of the intelligent anchor stress monitoring system for automatic installation of tunneling and anchoring machines according to the present invention.

[0031] In the diagram: 1-Anchor bolt stress sensor; 2-Data acquisition device; 3-Data aggregation base station; 4-Underground industrial ring network; 5-Ground monitoring center; 6-Early warning terminal; 7-Anchor bolt body; 8-Pattern; 9-Locking nut; 11-Tunnel roof; 101-Annular body; 102-Anchor bolt perforation; 103-Stress sensing unit; 104-Communication interface; 105-V-shaped positioning notch; 106-Annular magnetic attraction strip; 107-Elastic centering ring; 108-Miniature pressure sensor; 109-Annular anti-slip texture; 110-Storage module. Detailed Implementation

[0032] 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.

[0033] Example 1 Please see Figure 1 , Figure 2 , Figure 3 As shown, this invention provides an embodiment of an intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine. In this embodiment, the intelligent anchor bolt includes an anchor bolt body 7, a tray 8, a locking nut 9, and an anchor bolt stress sensor 1. The anchor bolt stress sensor 1 is disposed between the fixing disc 8 and the locking nut 9 of the anchor bolt. The tray 8 and the anchor bolt stress sensor 1 are sequentially sleeved on the bolt body 7. The tray 8 abuts against the tunnel roof wall 11. The locking nut 9 is threadedly connected to the bolt body 7, pressing the anchor bolt stress sensor 1 upwards. The anchor bolt stress sensor 1 includes a sensor body 101, which is an annular structure with an anchor bolt through hole 102 at its center matching the outer diameter of the anchor bolt body 7. An elastic centering ring 107 is disposed along the inner edge of the anchor bolt through hole 102 at its center. The elastic centering ring 107 is made of polyurethane elastomer material, and its inner diameter is 2-3 mm smaller than the diameter of the bolt body 7.

[0034] The sensor body 101 has a shell thickness controlled at 8-12mm, made of high-strength materials such as 40Cr alloy steel, and its hardness can reach HRC38-42 after heat treatment. The annular body features a uniform stress distribution design, capable of withstanding installation torque ≥500N·m. A stress-sensing unit 103 is embedded near the center of the upper surface of the sensor body 101 shell. The stress-sensing unit 103 is arranged in a ring, housing a resistance strain gauge or fiber optic grating sensor, employing a full-bridge circuit design with a range of 0-400kN / 0-800kN and an accuracy of ±1%, ensuring accurate sensing of the anchor bolt's axial stress. An annular magnetic attraction band 106 is also embedded radially outside the stress-sensing unit 103 on the upper surface of the shell. Additionally, two symmetrical V-shaped positioning notches 105 for gripping are formed near the edge of the upper surface of the sensor body 101 shell. The sensor body 101 has a communication interface 104 on its side for connecting a 485 / CAN communication cable. The interface is sealed with an IP68 protection rating to prevent dust and moisture from entering and damaging it. A built-in storage module 110 stores a unique identification code. Four miniature pressure sensors 108 are symmetrically embedded circumferentially on the lower surface of the sensor body 101's housing. The upper and lower surfaces of the sensor body 101's housing are also provided with anti-slip textures 109.

[0035] Example 2 Please see Figure 4 As shown, the present invention provides an embodiment of an intelligent anchor stress monitoring system suitable for automatic installation of a tunneling and anchoring machine. In this embodiment, the intelligent anchor stress monitoring system includes an intelligent anchor as described in Embodiment 1, an automated installation adapter module, a data acquisition and transmission module, a ground monitoring center 5, and an early warning terminal 6. The automated installation adapter module includes a sensor gripping self-adaptive unit and a locking process torque transmission unit. The sensor gripping self-adaptive unit includes a positioning notch 105 between the end positioning claw of the manipulator of the integrated excavator and anchor and the sensor body 101, and an electromagnetic chuck of the manipulator and a magnetic attraction band 106 between the manipulator and the sensor body 101. The locking process torque transmission unit includes anti-slip textures 109 on the upper and lower surfaces of the housing of the sensor body 101. The data acquisition and transmission module includes a data acquisition unit 2, which is deployed in a safe area near the tunneling face. It has a 485 / CAN wired communication interface and connects to the anchor stress sensor 1 via a 485 / CAN wired communication line. The data acquisition unit 2 has a built-in signal conditioning circuit that amplifies, filters, and performs analog-to-digital conversion on the stress signal transmitted from the sensor to ensure data accuracy. Simultaneously, it receives the sensor's "installation in place" signal, triggering the system to automatically complete zero-point calibration and binding the calibration data with the sensor ID for storage, facilitating subsequent traceability. The data acquisition unit 2 has a built-in large-capacity storage module, supporting at least three months of historical data storage. The data acquisition unit features an explosion-proof design, meeting the coal mine underground explosion-proof standard (Exib I Mb), and is suitable for the complex underground environment.

[0036] The data acquisition unit 2 is connected to each anchor bolt stress sensor 1 via a 485 / CAN communication cable. The communication cable is a mining-grade flame-retardant, waterproof, and tensile-resistant cable, suitable for working conditions such as dampness, dust, and mechanical impact in the mine. The communication distance is ≥100m and the transmission delay is ≤1 second, ensuring real-time transmission of stress data and installation signals, and avoiding the problem of unstable signal in the complex underground environment.

[0037] The data acquisition unit 2 uploads stored stress data and equipment status data (such as whether sensor communication is normal) to the data aggregation base station 3 in real time via a wireless transmission module. The data aggregation base station 3 is deployed at the entrance of the roadway, receives stress data from multiple sensors, and uploads it to the ground monitoring center 5 through the underground industrial ring network 4. If the industrial ring network is interrupted, the data acquisition unit 2 automatically caches the data and automatically retransmits it after the network is restored, ensuring that no data is lost.

[0038] The main functions of ground monitoring center 5 and early warning terminal 6 include: 1. Data reception and storage: Receive stress data uploaded from downhole in real time and store it in a time-series database.

[0039] 2. Data Analysis Module: Performs trend analysis and anomaly detection on stress data, and calculates the stress change rate.

[0040] 3. Early warning module: When the stress value exceeds the preset threshold (such as 80% of the design anchoring force) or the rate of change is abnormal, an audible and visual alarm will be automatically issued and an early warning message will be pushed to the relevant responsible persons.

[0041] 4. Visualization: Displays the stress state of each anchor bolt in the form of curves, heat maps, etc., and supports historical data query and report export.

[0042] 5. Equipment Management Module: It can monitor the communication status between the sensor and the data acquisition instrument in real time. When the sensor experiences communication interruption or data abnormality, it will automatically issue an alert, which will help the staff to troubleshoot the fault in time (such as loose cable or damaged interface) and ensure the continuous and stable operation of the monitoring system.

[0043] The intelligent anchor bolt stress monitoring system also includes an anchor bolt installation in place triggering mechanism. The triggering mechanism consists of four miniature pressure sensors 108 set on the lower surface of the sensor body 101. The miniature pressure sensors 108 monitor the pressure of the anchor bolt stress sensor 1 being clamped by the tray 8 and the locking nut 9 during the installation process, and the pressure data is collected in real time by the data acquisition instrument 2. When the pressure reaches the preset threshold, the installation in place signal is triggered, and the data acquisition instrument 2 records the current stress value of the anchor bolt stress sensor as the initial value for automatic calibration.

[0044] Combination Figure 5 As shown in the figure, the specific steps of the application method of the intelligent anchor bolt stress monitoring system suitable for automatic installation of tunneling and anchoring machines provided in this embodiment are as follows: Step 1: Drilling preparation. After the tunnel cutting machine completes the roadway cutting, the anchor drilling machine moves to the preset anchor hole position and completes the drilling operation according to the preset parameters (hole diameter, hole depth). The rock powder in the anchor hole is cleaned to ensure smooth anchor installation. This step can be implemented with reference to the existing intelligent anchor protection control technology without changing the original operation process.

[0045] Step 2: Anchor bolt and pallet installation. The robotic arm of the tunneling and anchoring machine grabs the anchor bolt, completes the filling of anchoring agent (if applicable), inserts the anchor bolt into the anchor hole, then grabs a standard mining pallet, puts the pallet on the exposed end of the anchor bolt, and presses it tightly against the surface of the roadway rock wall to ensure that the pallet fits tightly against the rock wall. This step is consistent with the existing tunneling and anchoring machine operation process and does not add any additional procedures.

[0046] Step 3: Automatic sensor gripping. The automatic anchor drilling machine of the integrated tunneling and anchoring machine moves to the anchor stress sensor storage location. The robotic arm aligns its end-positioning claw with the V-shaped positioning notch on the outer circumference of the upper surface of the anchor stress sensor. At the same time, the electromagnetic chuck is activated to attract the magnetic attraction strip on the upper surface of the anchor stress sensor, achieving stable gripping of the sensor. The gripping force is controlled at 50-80N to avoid damage to the anchor stress sensor or communication interface due to excessive gripping force, or detachment due to insufficient gripping force.

[0047] Step 4: Automatic insertion and positioning. The robotic arm picks up the anchor stress sensor, moves it to the anchor position on the installed tray, aligns the center hole of the anchor stress sensor with the exposed end of the anchor (above the tray), and slowly inserts it. The elastic centering ring in the center of the sensor automatically guides the sensor to align with the center of the anchor and the tray, ensuring that the anchor stress sensor is subjected to uniform force and avoiding displacement. At the same time, it ensures that the communication interface faces the direction that facilitates subsequent cable connection.

[0048] Step 5: Automatically tighten the lock. The robotic arm releases the anchor stress sensor, moves it to the lock storage, grabs the lock, and fits it onto the exposed end of the anchor (above the anchor stress sensor). The drilling rig rotates the nut to the preset torque value (300-500 N·m) to sequentially tighten the lock nut, anchor stress sensor, and tray, ensuring that the anchor stress sensor is firmly clamped between the tray and the lock, and that the tightening torque of the lock nut meets the design requirements without damaging the internal components and communication interface of the anchor stress sensor.

[0049] Step 6: Wired Connection and Automatic Calibration (Installation and Zero Position). The operator connects one end of the 485 / CAN communication cable to the communication interface of the anchor stress sensor and the other end to the data acquisition unit, completing the wired communication link setup. When the tightening torque of the locking nut reaches the preset value, the miniature pressure sensor on the lower surface of the anchor stress sensor is clamped by the tray and the locking nut. When the pressure reaches the preset threshold, a "installation in place" signal is triggered. This signal is transmitted to the data acquisition unit via 485 / CAN wired communication. The data acquisition unit reads the unique ID (identification code) of the anchor stress sensor, records the installation location (provided by the integrated anchor-digging machine positioning system), installation time, and current stress value, and records the current stress value as the initial value (i.e., the "zero position reference"), completing automatic calibration, eliminating stress deviations during installation, and ensuring the accuracy of the monitoring data.

[0050] Step 7: Real-time monitoring and data transmission. The anchor bolt stress sensor enters the working state, continuously sensing changes in the axial stress of the anchor bolt. The stress sensing unit is only responsible for collecting stress signals and transmitting them to the data acquisition unit in real time via 485 / CAN wired communication. The data acquisition unit conditions and converts the received signals and stores them in the built-in storage module, while simultaneously uploading the data to the data aggregation base station in real time. The data acquisition unit synchronously monitors the communication status of the anchor bolt stress sensor and promptly issues a fault alert if a communication interruption occurs.

[0051] Step 8: Data aggregation and uploading. The data aggregation base station receives stress data and status signals sent by each data acquisition instrument, performs temporary caching and data verification, removes abnormal data, and uploads it to the ground monitoring center in real time through the underground industrial ring network. If the underground industrial ring network is interrupted, the data acquisition instrument automatically caches the data, and automatically re-uploads the cached data to the ground after the network is restored to ensure that no data is lost.

[0052] Step 9: Data Analysis and Early Warning. The ground monitoring center stores, analyzes, and visualizes the received time-series stress data, performs trend analysis and anomaly detection on the stress data, and calculates the stress change rate. When the stress value exceeds a preset threshold (such as 80% of the design anchoring force) or the change rate is abnormal, the system automatically issues an audible and visual alarm and notifies the relevant responsible persons via SMS, APP push, etc. After receiving the warning, the responsible persons can view the location and stress data of the specific abnormal anchor bolts through the platform and take timely and targeted measures (such as reinforcement support, shutdown inspection) to prevent roof safety risks.

[0053] Step 10: Post-maintenance and data traceability. The ground monitoring center monitors the communication status of the anchor stress sensor and the data acquisition instrument in real time, as well as the working status of the data acquisition instrument. When communication interruption or data abnormality occurs, a maintenance reminder is issued. Staff can accurately locate the faulty anchor stress sensor based on its ID and installation location, troubleshoot cable and interface problems, and repair or replace it. At the same time, historical data stored on the data acquisition instrument and the ground platform can be queried and exported at any time, facilitating the analysis and summary of the stability of the surrounding rock in the tunnel and the optimization of the support plan.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine, characterized in that, The intelligent anchor bolt includes a rod body, a tray, a lock, and an anchor bolt stress sensor. The anchor bolt stress sensor is disposed between the fixing disc of the anchor bolt and the lock, and includes a sensor body. The sensor body has a ring structure with a through hole in the center that matches the outer diameter of the anchor bolt. A stress sensing unit is embedded on the upper surface of the sensor body, and a communication interface and a built-in storage module are provided on the side of the sensor body.

2. The intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine according to claim 1, characterized in that, The upper surface of the sensor body housing has 2-4 symmetrically arranged gripping positioning notches, and the upper surface of the sensor body housing is fitted with an annular magnetic attraction strip.

3. The intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine according to claim 2, characterized in that, Multiple miniature pressure sensors are symmetrically embedded in the lower surface of the sensor body housing along the circumference.

4. The intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine according to claim 3, characterized in that, The sensor body has an elastic centering ring along the inner edge of its central perforation. The elastic centering ring is made of polyurethane elastomer material and its inner diameter is 2-3 mm smaller than the diameter of the rod.

5. The intelligent anchor bolt suitable for automatic installation by a tunneling and anchoring machine according to claim 4, characterized in that, The thickness of the sensor body shell is controlled at 8-12mm, and it is made of high-strength material. After heat treatment, the hardness is not less than HRC38-42.

6. An intelligent anchor bolt stress monitoring system suitable for automatic installation by a tunneling and anchoring machine, characterized in that, The intelligent anchor stress monitoring system includes the intelligent anchor as described in claim 5, an automated installation adapter module, a data acquisition and transmission module, and a ground monitoring and early warning platform. The automated installation adapter module includes a sensor gripping self-adaptation unit and a locking process torque transmission unit. The sensor gripping self-adaptation unit includes a positioning notch between the end-positioning claw of the manipulator of the integrated excavator and anchor and the positioning notch of the sensor body, and an electromagnetic chuck of the manipulator and a magnetic attraction band between the electromagnetic chuck of the manipulator and the sensor body. The locking process torque transmission unit includes anti-slip textures on the upper and lower surfaces of the housing of the sensor body. The data acquisition and transmission module includes a data acquisition instrument, which is connected to the anchor bolt stress sensor via a 485 / CAN wired communication line. After amplifying, filtering and converting the stress signal transmitted by the sensor to analog-to-digital, the data is uploaded to the data aggregation base station in real time via a wireless transmission module. The data aggregation base station uploads the acquired data to the ground monitoring and early warning platform through the underground industrial ring network. The ground monitoring and early warning platform receives and stores data, analyzes the received data, and automatically issues an audible and visual alarm when the stress value exceeds a preset threshold or the rate of change is abnormal. It also visualizes the data in the form of graphics and charts and monitors the communication status of each anchor stress sensor and data acquisition instrument in real time.

7. The intelligent anchor bolt stress monitoring system for automatic installation of a tunneling and anchoring machine according to claim 6, characterized in that: The intelligent anchor bolt stress monitoring system also includes an anchor bolt installation in place triggering mechanism, which consists of multiple miniature pressure sensors set on the lower surface of the sensor body. The miniature pressure sensors monitor the pressure of the anchor bolt stress sensor being clamped by the tray and lock during the installation process, and the pressure data is collected in real time by the data acquisition instrument. When the pressure reaches a preset threshold, the installation in place signal is triggered, and the data acquisition instrument records the current stress value of the anchor bolt stress sensor as the initial value for automatic calibration.

8. The intelligent anchor bolt stress monitoring system for automatic installation of a tunneling and anchoring machine according to claim 7, characterized in that: The smart anchor bolt's stress sensor stores a unique identification code, which is transmitted to the data acquisition unit via 485 / CAN wired communication after installation.

9. An application method of the intelligent anchor bolt stress monitoring system as described in claim 8, applicable to the automatic installation of an integrated tunneling and anchoring machine, characterized in that: The specific steps of the application method are as follows: Step 1: Drilling preparation. After the tunnel cutting machine completes the roadway cutting, the anchor drilling machine moves to the preset anchor hole position and completes the drilling operation according to the preset hole diameter and hole depth parameters. Step 2: Anchor bolt and pallet installation. The robotic arm of the tunneling and anchoring machine grabs the anchor bolt and inserts it into the anchor hole. Then, it grabs a standard mining pallet, puts the pallet on the exposed end of the anchor bolt, and presses it tightly against the surface of the roadway rock wall to ensure that the pallet fits tightly against the rock wall. Step 3: Automatic sensor grabbing. The automatic anchor drilling machine of the integrated tunneling and anchoring machine moves to the anchor stress sensor storage location. The robotic arm aligns the end positioning claw with the V-shaped positioning notch on the upper surface of the anchor stress sensor housing. At the same time, the electromagnetic chuck is activated to attract the magnetic attraction strip on the upper surface of the anchor stress sensor, realizing the stable grabbing of the anchor stress sensor. The grabbing force of the robotic arm is controlled at 50-80N. Step 4: Automatic insertion and positioning. The robotic arm picks up the anchor stress sensor, moves it to the anchor position on the installed tray, aligns the center hole of the anchor stress sensor with the exposed end of the anchor, and slowly inserts it. The elastic centering ring in the center of the anchor stress sensor automatically guides the anchor stress sensor to align with the center of the anchor and the tray, while ensuring that the communication interface of the anchor stress sensor faces the direction that facilitates subsequent cable connection. Step 5: Automatic locking. The robotic arm releases the anchor stress sensor, moves it to the locking storage, grabs the locking nut, and inserts it onto the exposed end of the anchor. The drilling rig rotates the locking nut according to the preset torque value, pressing the locking nut, anchor stress sensor, and tray in sequence to ensure that the anchor stress sensor is firmly clamped between the tray and the locking nut, and that the tightening torque of the locking nut meets the design requirements without damaging the internal components and communication interface of the anchor stress sensor. The preset torque value of the drilling rig is 300-500 N·m. Step 6: Wired Connection and Automatic Calibration. Connect the anchor bolt stress sensor and the data acquisition unit using a 485 / CAN communication cable. When the locking torque reaches the preset value, the miniature pressure sensor on the lower surface of the sensor is clamped by the tray and the locking unit. When the pressure reaches the preset threshold, it triggers the "installation in place" signal. This signal is transmitted to the data acquisition unit via 485 / CAN wired communication. The preset pressure threshold is 100-150kN. The data acquisition unit reads the unique identification code of the sensor, records the installation position, installation time, and current stress value, and records the stress value detected by the anchor bolt stress sensor as the initial value, i.e., the "zero reference". This completes the automatic calibration, eliminates stress deviations during the installation process, and ensures the accuracy of the monitoring data.

10. The application method of the intelligent anchor bolt stress monitoring system for automatic installation of a tunneling and anchoring machine according to claim 9, characterized in that: The application method also includes, Step 7: Real-time monitoring and data transmission. The anchor bolt stress sensor enters the working state, continuously sensing changes in the axial stress of the anchor bolt. The stress sensing unit is only responsible for collecting stress signals and transmitting them to the data acquisition unit in real time via 485 / CAN wired communication. The data acquisition unit conditions and converts the received signals and stores them in the built-in storage module, while simultaneously uploading the data to the data aggregation base station in real time. The data acquisition unit synchronously monitors the communication status of the anchor bolt stress sensor and promptly issues a fault alert if a communication interruption occurs. Step 8: Data aggregation and uploading. The data aggregation base station receives stress data and status signals sent by each data acquisition unit, performs temporary caching and data verification, removes abnormal data, and uploads it to the ground monitoring center in real time through the underground industrial ring network. If the underground industrial ring network is interrupted, the data acquisition unit automatically caches the data and automatically re-uploads the cached data to the ground after the network is restored to ensure that no data is lost. Step 9: Data Analysis and Early Warning. The ground monitoring center stores, analyzes, and visualizes the received time-series stress data, performs trend analysis and anomaly detection on the stress data, and calculates the stress change rate. When the stress value exceeds the preset threshold or the rate of change is abnormal, the system will automatically issue an audible and visual alarm and notify the relevant responsible persons via SMS, APP push, and other means. Step 10: Post-maintenance and data traceability. The ground monitoring center monitors the communication status of the anchor stress sensor and the data acquisition instrument in real time, as well as the working status of the data acquisition instrument. When communication interruptions or data anomalies occur, maintenance reminders are issued. Staff can accurately locate faulty sensors based on the unique identification code and installation location of the anchor stress sensor, troubleshoot cable and interface problems, and repair or replace them. At the same time, historical data stored in the data acquisition instrument and the ground platform can be queried and exported at any time, facilitating the analysis and summary of the stability of the surrounding rock in the tunnel and the optimization of support schemes.

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