Grouting operation automatic control method based on multi-stage timing cooperation

Abstract

The present application relates to grouting operation technical field, and disclose a kind of grouting operation automatic control method based on multi-stage timing cooperation, comprising: completing equipment self-checking, authorization and grouting parameter reception;Automatic navigation to target area and adjust platform car platform;Unfold functional components, high-precision alignment orifice;Under the parallel of multiple units, dynamically select idle non-interference unit, complete the automatic connection of stop plug and pipeline;According to specification, automatically execute washing, water pressure, grouting, screen, waiting for condensation and sealing, and adjust process according to water pressure or grouting response;Automatic flushing, release resources to support continuous operation.The scheme realizes the automation timing cooperation of grouting operation whole process by unified state driving scheduling engine, effectively integrates heterogeneous subsystem, supports multi-unit dynamic scheduling and anti-interference coordination, has visual auxiliary precision alignment, resource automatic release and continuous operation ability, fusion real-time exception detection mechanism, improves the coherence, safety and operating efficiency of grouting process.

Description

Technical Field

[0001] This invention relates to the field of grouting operation technology, and in particular to an automatic control method for grouting operations based on multi-stage time-series coordination. Background Technology

[0002] Tunnel grouting (also known as injection grouting) is a mature but constantly evolving key process, widely used in water conservancy, transportation (railway / highway), mining, and underground engineering. Its basic principle is to inject a cementitious grout (such as cement grout, chemical grout, or a mixture of grouts) into fissures, cavities, or loose areas of rock or soil through drilling to achieve reinforcement, seepage prevention, and water plugging.

[0003] Current grouting techniques heavily rely on manual experience, resulting in a lack of unified time-series coordination and intelligent scheduling mechanisms throughout the entire process. Specifically, this manifests as: independent operation of each subsystem, severe information silos, and reliance on manual judgment and switching between processes by operators. This makes it difficult to achieve high-precision, high-efficiency automated closed-loop control. Especially in scenarios with multiple units operating in parallel, key coordination issues such as idle equipment selection and interference prevention for robotic arm movements lack systematic solutions, easily leading to equipment collisions, pipeline blockages, or process interruptions. Furthermore, anomaly detection is mostly reactive, lacking real-time early warning and adaptive adjustment capabilities deeply integrated with the main control process. This segmented, passive, and manually controlled operation mode is not only inefficient and prone to quality fluctuations but also poses safety hazards, severely hindering the intelligent upgrading of grouting construction under complex geological conditions. Therefore, there is an urgent need for an automated control method capable of multi-stage, full-process, and highly collaborative control of heterogeneous subsystems to fundamentally solve the core problems of time-series fragmentation and scheduling mismatch in grouting operations. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing an automatic control method for grouting operations based on multi-stage temporal coordination.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] The automatic control method for grouting operations based on multi-stage time-series collaboration includes: System initialization and task setting stage: completing equipment self-checks, operation authorization, and receiving structured grouting task parameters; Autonomous movement and platform leveling stage: automatically navigating to the target area based on task location information and adjusting the trolley platform attitude to a high-precision horizontal state; Operation preparation and borehole alignment stage: deploying functional components, integrating design coordinates and on-site visual perception data to achieve high-precision spatial alignment of the end effector with the target grouting borehole; Multi-unit intelligent scheduling and automatic connection stage: dynamically selecting the optimal idle and interference-free unit under the parallel configuration of multiple grouting units, and completing the fully automatic physical connection and sealing verification of the grout stop plug and pipeline; Full-process grouting and real-time control stage: automatically executing the sub-processes of borehole washing, water pressure, grouting, grout shielding, waiting for setting, and borehole sealing according to specifications, and dynamically adjusting the process strategy based on water pressure results or grouting response; Resource release and data closed-loop stage: automatically flushing the equipment after the operation is completed, releasing the occupied resources to support continuous operation, and generating a quality report with process curves and uploading it to the engineering management platform.

[0007] As a preferred technical solution of the present invention, in the system initialization and task setting stage: after the system is powered on, hardware self-test, communication link verification and no-load test run of the actuator are performed in parallel; encrypted task packages from the remote engineering management platform or work orders input by the local HMI are received, the task packages include hole position geometry information, grouting process parameters and safety constraints; the task packages are digitally signed and verified, and it is checked whether the grouting process parameters exceed the current equipment capability boundary. If they exceed the boundary, the subsequent stage is prohibited; the parameters that pass the verification are distributed to the positioning module, grouting pump controller and process state machine according to the functional domain, and the operator ID and parameter version number are recorded.

[0008] As a preferred technical solution of the present invention, in the operation preparation and hole alignment stage, the system executes the following steps in a preset sequence: unlocking and unfolding the robotic arm protective cover, extending the grouting hose reel bracket, starting the grout circulation preheating circuit, moving the robotic arm to the standby posture, and starting the grouting unit in self-circulation mode; after each step is completed, a feedback signal is required, and if any link times out or gets stuck, the process is paused and an alarm is triggered.

[0009] As a preferred technical solution of the present invention, in the operation preparation and hole position fine alignment stage, the hole position fine alignment adopts a coordinate-vision dual closed-loop mechanism: First, the global coordinates of the hole position provided by BIM are transformed to the coordinate system of the robot arm base through the current pose of the trolley to obtain the preliminary target pose; after the robot arm moves to the vicinity of the pose, the industrial camera is triggered to capture the hole opening area, and the actual hole center position is identified by ORB feature matching and RANSAC to eliminate mismatches; the actual hole center coordinates are back-projected to the robot arm base system through the hand-eye calibration matrix to generate a correction amount and superimpose it on the preliminary target pose as the final approximation target.

[0010] As a preferred technical solution of the present invention, the autonomous movement and platform leveling stage includes: planning the global travel path of the trolley according to the center coordinates of the target hole group, and adaptively switching the positioning mode according to environmental characteristics during the movement; after reaching the target area, adjusting the height of the four hydraulic outriggers in two stages of coarse adjustment and fine adjustment based on feedback from a high-precision dual-axis tilt sensor; and simultaneously using a laser level to cross-verify the four corners of the platform during the leveling process. If multiple adjustments still fail to meet the accuracy requirements, the current terrain is marked as unlevelable.

[0011] As a preferred technical solution of the present invention, the process of dynamically selecting the optimal unit in the multi-unit intelligent scheduling and automatic connection stage includes: constructing a unit-task matching matrix, comprehensively evaluating the idle status of each grouting unit, the Euclidean distance to the target hole, and the matching degree of the current grout type; based on the current pose and predicted trajectory of all active robotic arms, using fast bounding boxes and GJK algorithms to perform real-time collision detection; modeling the grouting hose as a discrete elastic rod, calculating its bending energy, and if it exceeds a set threshold, instructing the corresponding robotic arm to perform a small swing straightening action; after confirming that there is no spatial interference and no risk of pipe entanglement, locking the selected unit resources and issuing a connection command.

[0012] As a preferred embodiment of the present invention, the automatic connection includes two sub-processes: insertion of the grout stop plug and locking of the quick connector. First, a first robotic arm holds the grout stop plug and inserts it along the hole axis to a specified depth, controlled in real-time by a depth encoder. After the grout stop plug is in place, its sealing cavity is inflated. A pressure sensor monitors the pressure inside the cavity; when the pressure reaches a set threshold and is maintained for a preset time, the seal is considered successfully established. Second, a second robotic arm grasps the grout quick connector and, guided by an industrial camera, aligns it with the grout inlet of the grout stop plug, performing a combined axial advancement and rotational locking action. A six-dimensional force sensor monitors the contact force in real-time; if lateral off-center loading is detected, the end posture is automatically fine-tuned. A torque sensor monitors the locking torque; when a preset value is reached, the mechanical connection is considered complete.

[0013] As a preferred technical solution of the present invention, the full-process grouting and real-time control stage includes: sequentially executing the sub-processes of hole washing, simple water pressure, grouting, grout shielding, waiting for setting, and hole sealing, each process being driven by a finite state machine; during the simple water pressure process, the stable water absorption is recorded; if the water absorption exceeds a preset threshold, grouting is not skipped, but the process is switched to abnormal grouting mode, adjusting the initial water-cement ratio or initiating the pre-grouting thick grout sub-step; during the grouting process, the pressure of the hole and adjacent holes is monitored in real time; if the pressure rise rate of adjacent holes exceeds a set threshold, cross-grouting is determined to have occurred and the current grouting is paused; key parameters of all processes, including pressure, flow rate, time, and event logs, are sampled and stored at high frequency to form a time-stamped process curve.

[0014] As a preferred technical solution of the present invention, in the resource release and data closure stage: after the grouting and pipeline flushing of the current hole are completed, the main control unit automatically releases the occupied grouting unit, robotic arm and auxiliary pipeline resources, and updates their status to idle; at the same time, it polls the task queue of the hole to be processed. If there are unassigned tasks, it automatically jumps to the work preparation and hole alignment stage, triggers the work process of the next hole, and reuses the established platform leveling status and walking positioning results; if the task queue is empty, it summarizes the process data of the whole process, generates a structured report containing hole information, operation records and process curves, and uploads it to the engineering management platform through an encrypted API.

[0015] As a preferred technical solution of the present invention, in the synchronous activation phase of the system operation enable and anomaly detection function, the anomaly detection engine includes: after the operator triggers the operation enable command through identity authentication, the system immediately starts the multimodal anomaly detection engine, which includes four parallel subsystems: signal-level anomaly detection, equipment health assessment, spatial interference prediction, and process deviation identification; the anomaly detection results are output in terms of risk level, and high-risk events directly trigger the state machine to jump to the safety degradation mode; the anomaly detection runs through all stages to ensure that the entire process is under control.

[0016] The present invention has the following beneficial effects:

[0017] This solution provides a multi-stage, time-sequential, and automated control method for intelligent integrated grouting trolleys. By constructing a unified state-driven scheduling engine, it integrates disparate operation units such as walking, leveling, positioning, connecting, grouting, and cleaning into a logically coherent, condition-triggered automated process. After the task starts, the system can autonomously complete equipment self-checks, parameter verification, path planning, and platform leveling, and achieve high-precision hole alignment based on coordinate transformation and visual feedback. In multi-unit parallel operation scenarios, it dynamically selects idle resources and simultaneously performs anti-interference and pipeline anti-entanglement checks to ensure safe and efficient scheduling. The entire grouting process is driven by a finite state machine, with key parameters recorded in real time. After the operation is completed, resources are automatically released and seamlessly connected to the next hole task, supporting continuous unmanned operation. At the same time, the anomaly detection mechanism is deeply coupled with the main control process, providing real-time risk perception and response capabilities throughout the entire operation cycle. This method effectively improves the time-sequential coordination, resource utilization efficiency, and overall operational reliability of grouting operations. Attached Figure Description

[0018] Figure 1 This is a timing diagram of the automatic control method for grouting operations based on multi-stage temporal coordination proposed in this invention.

[0019] Figure 2 Flowchart for the process parameter setting stage;

[0020] Figure 3 A flowchart for the walking and positioning phase;

[0021] Figure 4 This is a flowchart of the posture adjustment phase;

[0022] Figure 5 A flowchart for achieving the work position stage;

[0023] Figure 6 A flowchart for the selection and interference-free scheduling phase of grouting units;

[0024] Figure 7 This is a flowchart for the connection phase. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0026] Reference Figure 1 This paper proposes an automated control method for grouting operations based on multi-stage temporal coordination. Targeting the integrated construction equipment, the intelligent integrated grouting trolley, this method proposes an automated control strategy covering the entire process and connecting multiple subsystems. It constructs a unified state-driven scheduling engine, transforming the originally dispersed, asynchronous grouting process, which relies on manual intervention, into a highly integrated automated processing flow triggered by logical conditions, coordinated by spatiotemporal constraints, and featuring real-time feedback loops. By deeply integrating robot motion control, platform posture adjustment, spatial coordinate mapping, fluid process execution, and multi-source sensing data, it achieves precise coordination of complex operation units such as walking, leveling, positioning, connecting, grouting, and cleaning along the time axis and task chain. This not only ensures the orderly connection of actions at each stage and efficient resource utilization but also, through embedded anomaly detection and self-recovery mechanisms, endows the system with the ability to make autonomous decisions and operate safely in dynamic construction environments. Thus, it upgrades grouting operations from the traditional human-controlled equipment mode to a system-autonomous intelligent processing. The method includes the following stages:

[0027] Phase 1: Startup and System Self-Test: Establishing the initial reliable state of the entire automated process, this phase verifies the integrity of key hardware, communication links, and basic control functions, laying the foundation for subsequent high-reliability operation. It ensures that all participating execution and sensing units are in a predictable and controllable working state, preventing global process interruptions or safety incidents due to underlying faults. Specifically, after system power-on, the main control logic immediately initiates a parallel self-test sequence, first verifying the connectivity and redundancy switching capabilities of industrial buses such as CANopen and EtherCAT with wireless communication; subsequently, it performs zero-point calibration and response measurement on sensing devices such as tilt sensors, pressure transmitters, encoders, and vision cameras. In terms of the actuators, the hydraulic outriggers, robotic arm servo system, and grouting pump frequency converter respectively perform limit reset and no-load test runs. For example, if the pump body idles for 3 seconds, the current is monitored for abnormality. At the software level, the integrity of the control algorithm library is checked synchronously, the process parameter template index is loaded, and the safety rule engine is initialized. All sub-item results are summarized in the central status register. If any critical item, such as positioning module failure or emergency stop circuit disconnection, fails, the system is locked in the fault pending state, and the fault code is highlighted through the HMI. Only when all non-fatal items pass and no critical items fail can the next stage be entered. This stage is superior to the traditional manual item-by-item inspection method and provides a high-availability starting point for full-process automation.

[0028] Phase Two, Process Parameter Setting: Please refer to the appendix. Figure 2 This mechanism enables the semantic conversion from engineering design intent to physical execution instructions. It serves as a crucial interface connecting BIM models or construction plans with automated control systems. Through structured parameter reception and consistency verification, it ensures that all subsequent collaborative actions are based on accurate and feasible process objectives, preventing equipment exceeding limits or process failures due to data mismatches. Specifically, parameter setting supports two modes:

[0029] Remote configuration: Push encrypted JSON task packages via the project management platform;

[0030] On-site setup: The operator selects a preset work order or manually enters a task package in the HMI;

[0031] Furthermore, remote commands have higher priority than local commands to prevent command conflicts. The task package includes:

[0032] Hole location geometry information, including X / Y / Z coordinates, dip angle, depth, etc.;

[0033] Grouting process parameters, including design pressure, flow rate, water-cement ratio, and grouting / setting time;

[0034] Safety constraints include maximum permissible deviations and pipeline bending radius thresholds.

[0035] After receiving the parameters, the main control unit first verifies the digital signature to ensure that the data has not been tampered with, and then performs a capability matching verification. For example, if the grouting pressure is set to 6 MPa, but the current grouting pump's rated pressure is only 5 MPa, the system will immediately issue an alarm and disable the function.

[0036] After verification, the parameters are distributed to the corresponding functional domains: coordinate data is sent to the positioning and coordinate transformation module, pressure / flow rate setpoints are sent to the grouting pump controller, and time parameters are injected into the process state machine; all parameter changes are recorded with version number and operator ID, supporting full traceability; this mechanism effectively eliminates the risk of operating beyond limits and ensures the process feasibility of multi-unit collaboration.

[0037] Phase 3: System operation enablement and anomaly detection function are activated simultaneously: an authorization-monitoring dual-track mechanism is introduced. While granting the system execution permissions, a full-dimensional anomaly perception capability is deployed simultaneously to build a dynamic security protection network. This enables the system to have real-time risk identification and response capabilities during operation, rather than relying solely on pre-emptive static checks. This anomaly detection runs through all subsequent phases to ensure that the entire process evolves under controlled conditions.

[0038] Specifically, the operator triggers the run enable command through authentication such as fingerprint or electronic token. Once authorization is successful, the system releases the software emergency stop locks on all actuators and immediately starts the multimodal anomaly detection engine, which contains four parallel subsystems:

[0039] (1) Signal-level anomaly detection: Based on wavelet packet decomposition and sliding window statistics, real-time identification of sudden changes, oscillations or drifts in pressure and flow signals;

[0040] (2) Equipment health assessment: LSTM network is used to model time series data such as pump body vibration and motor temperature to predict the remaining service life and provide early warning of potential failures;

[0041] (3) Spatial interference prediction: Combining the current pose of the robotic arm with the planned trajectory, a fast collision detection algorithm such as GJK is used to predict whether there will be interference between the robotic arms or with the environment in the future, such as within 5 seconds;

[0042] (4) Process deviation identification: Compare the real-time injection volume with the theoretical curve. If the unit water absorption volume is continuously higher than the threshold, it is determined that there may be cross-contamination or large cracks.

[0043] All detection results are output in terms of risk level (low / medium / high). High-risk events directly trigger safety degradation or emergency shutdown. In this stage, the initialization of the anomaly detection function and the system operation enable operation are executed synchronously to ensure that there is complete real-time monitoring capability at the initial moment of the automated process. This avoids the safety blind spots caused by the traditional control process of running first and then monitoring. It also prevents the failure to identify early faults or abnormal conditions in time due to the delayed activation of the detection module. At the same time, the activation status of anomaly detection is forcibly associated with the enable permission. Automatic operation mode is only allowed when all safety conditions are met, thereby improving the overall functional safety and operational reliability of the system.

[0044] Phase Four: Navigation and Positioning. This phase enables the trolley to autonomously navigate from its current location to the target grouting area. It integrates multi-source positioning information to overcome signal blockage and accuracy degradation issues in complex construction site environments. Through robust positioning and path planning, it ensures the trolley efficiently and safely reaches the starting point of the operation, laying a spatial benchmark for subsequent precise positioning. Please refer to the appendix. Figure 3 The process includes the following steps:

[0045] Target position analysis and global path planning: The main control unit extracts the center coordinates (X, Y, Z) of the target hole group from the pre-set process parameters, and combines them with the current pose of the trolley to call an A or RRT class algorithm to generate an optimal travel path that avoids known static obstacles. The path planning takes into account kinematic constraints such as the minimum turning radius and maximum climbing ability of the trolley.

[0046] Multimodal positioning mode adaptive switching: The system automatically selects or merges positioning sources according to the current environment. For example, in open areas such as dam top platforms, RTK-GNSS is used first, which can achieve a horizontal positioning accuracy of better than ±2 cm. After entering tunnels, corridors or areas with dense steel structures, it automatically switches to a local positioning mode with laser SLAM as the main mode and UWB ultra-wideband assistance, with a typical positioning error controlled within ±5 cm.

[0047] Dynamic obstacle avoidance and local trajectory replanning: During the walking process, the LiDAR continuously scans the front and identifies dynamic obstacles. When a potential collision risk is detected, the system adjusts the speed and heading in real time based on the dynamic window method to generate a local obstacle avoidance trajectory. If the obstacle blocks the original path for a long time, global path replanning is triggered.

[0048] Target area approach and precise stopping control: When the trolley enters a certain range of the target area, the system reduces the travel speed and activates high-frequency pose feedback with an update rate of ≥10 Hz. After stopping at the preset parking point, the system performs millimeter-level position correction based on the positioning residual, such as a slight forward or backward movement of ±5 cm. Finally, the electronic parking brake is activated and the travel motor is locked.

[0049] Positioning Completion Confirmation and Reporting: The system comprehensively judges whether the following conditions are met: the deviation between the actual position of the trolley and the target parking point is less than a threshold, for example, ≤ ±5 cm laterally and ≤ ±8 cm longitudinally; the platform has no significant slippage, verified by cross-verification of the wheel speed encoder and IMU; and the parking mechanism has been effectively locked. After all conditions are met, a positioning completion signal is sent to the main control state machine, and the final parking pose is recorded for coordinate transformation in the subsequent attitude adjustment stage.

[0050] Phase 5, Attitude Adjustment: Eliminate attitude deviations of the trolley platform caused by uneven ground or vibrations during movement, establish a high-precision horizontal reference plane, and based on closed-loop feedback control, adjust the height of multiple support points to ensure the platform's tilt angle meets the accuracy requirements of subsequent robotic arm operations, guaranteeing accurate hole alignment; for details, please refer to the appendix. Figure 4 After attitude adjustment is initiated, the high-precision dual-axis tilt sensor adjusts at 100 degrees. The system uses a Hz sampling rate to acquire the current pitch and roll angles. The main controller reads the initial tilt data provided by the sensors to determine if the current platform tilt is within the allowable range, such as ±0.5°. If the initial tilt meets the requirements, it directly enters the fine-tuning stage; otherwise, coarse-tuning is required. During coarse-tuning, based on the kinematic model of the four hydraulic outriggers, the system calculates the required extension and retraction of each outrigger and performs corresponding adjustments to quickly bring the platform tilt angle close to the target value. When the platform tilt error is reduced to within the coarse-tuning threshold, the system switches to fine-tuning mode, using a PID control algorithm combined with feedforward compensation to gradually fine-tune the position of each outrigger until the tilt angle stabilizes within the final target range. In addition, during the entire leveling process, a laser level cross-verifies the four corners of the platform to ensure that all points meet the set accuracy requirements. If the target cannot be met after multiple attempts, the system marks the area as unlevelable terrain and prompts for manual intervention. Once the required leveling accuracy is achieved, the hydraulic locking valve automatically closes, fixing the outrigger position to prevent platform settlement or movement during operation due to grouting reaction force or other factors. This stage utilizes closed-loop feedback control, employing high-precision dual-axis tilt sensors and laser levels, combined with coarse and fine adjustment strategies. This not only improves the accuracy of hole alignment and reduces posture deviations caused by uneven ground or walking vibrations, but also enhances the stability and reliability of multi-robotic arm collaborative operations.

[0051] Phase 6, Work Preparation: By orderly unfolding various functional components, a complete grouting operation topology is constructed, completing the transition from "transportation state" to "operation state". Fluid pathways are established in advance, the degrees of freedom of the actuators are released, and key systems are preheated, shortening the preparation time before formal operation and improving overall efficiency. Specifically, the system executes the following steps in a preset sequence: (1) Unlock and unfold the robotic arm protective cover and release the joint brakes; (2) Extend the grouting hose reel bracket to the working position; (3) Start the slurry circulation preheating circuit (automatically activated when the ambient temperature is below 5℃); (4) The robotic arm performs the "standby posture" movement and returns the end quick-change tool to the visual calibration position; (5) The grouting unit starts the self-circulation mode, discharges the air in the pipeline and establishes the initial pressure. After each step is completed, a feedback signal is required. If any link is overdue or stuck, the process is suspended and an alarm is triggered. This phase compresses the traditional manual preparation time, avoids human error, and provides a rapid readiness guarantee for the parallel operation of multiple units.

[0052] Phase Seven: Reaching the Working Position: Achieving high-precision spatial alignment from the trolley platform coordinate system to the target grouting hole. Through multi-source coordinate fusion and vision-assisted precision positioning, this resolves the issue of inaccurate docking of the end effector caused by trolley positioning residuals and hole construction deviations. Please refer to the appendix. Figure 5 First, the main control unit reads the target hole design coordinates from the pre-set process parameters, typically including three-dimensional position and orientation angle. Based on the current pose of the trolley platform determined during the posture adjustment phase, including position offset and attitude angle, this global coordinate is transformed into the robot arm base coordinate system as the initial motion target, establishing the initial reference point for the robot arm's motion planning. After the robot arm moves to the field of view above the estimated hole, a high-definition industrial camera is triggered to capture an image of the hole area. The system uses feature point extraction and template matching algorithms, such as SIFT and ORB combined with RANSAC robust estimation, to identify the actual hole center position and calculate its two-dimensional or three-dimensional deviation relative to the design coordinates. The actual hole center position and orientation information obtained from visual recognition are superimposed on the initial transformation result to form the corrected final target pose. This pose comprehensively considers the design intent and the actual situation on site, significantly improving the physical feasibility of docking. For collision-free path planning and low-speed approximation, based on the corrected target pose, the path planning module generates a safe trajectory that avoids the trolley structure, pipelines, and other obstacles. The robot arm follows this trajectory at a low speed, for example, not exceeding 0.2 km / h. The system moves smoothly at a speed of meters per second, ensuring minimal dynamic disturbance. When the end effector approaches the orifice to a preset distance, such as 5 centimeters, it automatically pauses movement and enters a ready-to-connect state. Subsequently, the system checks whether the following conditions are met:

[0053] The deviation between the current position of the end effector and the corrected target pose is less than a threshold, for example, ±2 mm;

[0054] The vision system continuously locks onto the opening without obstruction;

[0055] No new obstacles were added to the work area.

[0056] Once all conditions are met, a "reached work position" signal is sent to the main control state machine, preparing to enter the next stage of automatic connection operation. This stage utilizes a "coordinate-vision" dual closed-loop positioning mechanism to improve docking accuracy and lay the foundation for a highly reliable connection.

[0057] Phase 8, Grouting Unit Selection and Interference Prevention Scheduling: In scenarios involving multiple units operating in parallel, this phase utilizes intelligent resource allocation and spatial conflict prediction. Based on combinatorial optimization and kinematic simulation, it dynamically selects the optimal unit while mitigating the risks of robotic arm trajectory interference and pipe entanglement, achieving the dual goals of maximizing operational efficiency and ensuring physical safety. Please refer to the appendix. Figure 6 This includes the following steps:

[0058] The system constructs a unit-task matching matrix, comprehensively considering factors such as unit idle status, Euclidean distance to the target orifice, and current slurry type matching degree, and uses a weighted scoring method to initially select candidate units;

[0059] Initiate an anti-interference check. Based on the current pose and future trajectory prediction of all active robotic arms, use the fast bounding box algorithm and GJK algorithm to perform real-time collision detection. If the minimum distance is less than the safety threshold such as 30 cm, then reassign tasks or adjust the work order.

[0060] In addition, the system models the hose as a discrete elastic rod and calculates its bending energy. If it exceeds the threshold, it instructs the robotic arm to perform a small swing straightening action to release the pipeline stress. After the action is completed, it performs another winding evaluation. If the risk cannot be eliminated after multiple attempts, the unit is marked as currently unavailable and the system returns to the candidate list to select the next unit. This step helps prevent pipeline damage or blockage caused by excessive bending.

[0061] Once the unit is selected, the system locks its resources and issues a connection command. The unit then enters a ready state, awaiting subsequent operation commands. This process avoids the equipment idleness problem of the traditional one-machine-one-hole mode and improves the utilization rate of the trolley.

[0062] Phase Nine, Connection: Please refer to the appendix. Figure 7This system achieves fully automated physical connection between the grout stop plug and the grouting orifice, as well as the quick-connect fittings in the grouting pipeline, establishing a fluid pathway. Through force control, position control, and multi-source sensor feedback, it ensures alignment accuracy, sealing reliability, and mechanical locking strength during the connection process, preventing leakage, detachment, or seal failure during subsequent high-pressure grouting. Specifically, the robotic arm grips the grout stop plug and slowly inserts it along the orifice axis. The insertion depth is controlled in real-time by a depth encoder to ensure it reaches the specified process position, such as 200 mm to 500 mm below the orifice. Once in place, the system inflates the grout stop plug's sealing cavity, and a pressure sensor monitors the pressure inside. When the pressure reaches a set threshold, such as 0.5 MPa, and remains stable for several seconds, the seal is considered effectively established. If the threshold is not met, the seal is considered to have failed, and the process proceeds to retry or manual intervention.

[0063] After the seal is confirmed, another robotic arm grabs the grouting quick connector and aligns it with the grout inlet of the stop plug under the guidance of an industrial camera. The system calculates the positional deviation through image recognition and performs a combined action of axial propulsion and rotational locking: a six-dimensional force sensor monitors the contact status in real time, and automatically fine-tunes the posture if lateral load is detected; a torque sensor monitors the locking process, and when the output torque reaches the preset value, it is determined that the mechanical connection has been reliably locked.

[0064] After connection is complete, the system opens the solenoid valve, injects low-pressure fluid into the pipeline, and maintains the pressure for a period of time to determine if there is a leak. If there is no significant pressure drop during the pressure holding period, the connection is considered successful; otherwise, it is considered a failure. After successful connection, the main control unit sends a "connection complete" signal to the state machine and records key data throughout the process, including the slurry plug inflation pressure, locking torque, pressure holding test results, and number of retry attempts. This data is used for quality traceability, equipment health assessment, and subsequent process optimization. This stage integrates the sealing-connection-verification process, significantly reducing the connection failure rate and ensuring continuous execution of multiple processes.

[0065] Phase Ten, Full-Process Grouting: The process automatically executes sub-processes such as borehole washing, water pressure, grouting, grout shielding, setting, and borehole sealing according to standard specifications. Based on state machine-based process logic control and real-time process feedback adjustment, it ensures that each operation strictly conforms to technical regulations and can dynamically adjust parameters according to on-site responses. The entire grouting process is driven by a finite state machine, with each sub-process activated sequentially. Each sub-process includes, in sequence:

[0066] Orifice flushing: The system starts the clean water pump and flushes the orifice at a low pressure, such as 0.3 MPa, for 5 minutes. The turbidity sensor monitors the water quality changes in real time until the turbidity drops below the set threshold, such as NTU < 10. After flushing, the system automatically opens the drain valve to discharge the sewage in the orifice.

[0067] Simple water pressure test: Close the drain valve, inject water into the hole and gradually increase the pressure to the design pressure value. The pressure holding time is usually 10 minutes. During this period, the system records the water absorption. If the water absorption exceeds the preset threshold, it is determined that there is a large crack or leakage in the hole wall. The system will automatically adjust the subsequent grouting process parameters, such as adjusting the initial water-cement ratio, to enhance the filling capacity of the grout.

[0068] Grouting: The mixing system prepares the grout according to the set water-cement ratio, and the grouting pump implements a staged pressure increase strategy, monitoring the pressure and flow rate in real time. If the pressure of adjacent holes suddenly increases, it is determined that the grout is cross-linked and the process is suspended.

[0069] After reaching the designed injection volume, maintain the pressure for 10-30 minutes. The process is considered complete when the flow rate approaches zero.

[0070] Waiting for solidification: Turn off the pump, start the timer, keep the pipeline closed, and allow the slurry to stand and solidify in the hole;

[0071] Sealing: After the curing process is complete, the system injects thick slurry into the orifice and simultaneously lifts the slurry stop plug to ensure a tight seal at the orifice.

[0072] The entire grouting process is driven by a finite state machine, supporting conditional branching and mode switching between each step. All operational events and process parameters are sampled and stored at a high frequency to generate complete time-stamped process curves for quality assessment, digital delivery, and other purposes.

[0073] Phase 11, Equipment and Pipeline Flushing: A combination of high-pressure backflushing and mechanically assisted shaking is used to thoroughly clean the inner walls of the pipelines, preventing solidification and blockage, and extending equipment lifespan. After the entire grouting process is completed, the system switches to a clean water circuit, starts the high-pressure flushing pump, and backflushes the main grouting pipeline; simultaneously, the robotic arm executes a preset shaking program, applying periodic small-amplitude oscillations to the bends in the hoses to peel off adhering grout; the flushing water is discharged after three stages of sedimentation to meet standards.

[0074] Finally, all valves are reset to standby mode, the system self-checks whether the pipeline pressure is zero, and then the main control unit automatically releases the grouting unit, robotic arm and auxiliary pipeline resources occupied by this operation and updates their status to idle; at the same time, the system polls the task queue of the holes to be processed. If there are unassigned tasks, the operation process of the next hole is automatically triggered, that is, a new round of scheduling starts from stage seven; if the task queue is empty, the system moves to the results summary stage.

[0075] Phase Twelve: Data Comparison, Result Judgment, Outcome Summary, and Data Transmission: Through intelligent comparison and rule-based reasoning, the system automatically generates quality judgment and outcome reports, seamlessly integrating with the engineering management system to support digital acceptance and measurement, achieving a data closed loop in the grouting process. Specifically, the system collects time-series data throughout the entire process, including pressure, flow rate, time, and event logs, comparing it with design parameters from multiple dimensions. Based on an industry-standard built-in judgment rule engine, it outputs qualified / acceptable / unqualified conclusions. It automatically generates PDF reports containing process curves, borehole location information, and operation records, and uploads them to the cloud-based BIM platform via an encrypted API, providing a solid basis for quality traceability.

[0076] In summary, this method constructs a programmable, monitorable, and optimizable automated grouting operation processing system through precise timing coordination of the above stages. This system integrates heterogeneous units such as a walking chassis, leveling mechanism, multiple robotic arms, and parallel grouting unit into a unified intelligent execution entity, realizing autonomous operation of the entire process from task reception to result archiving.

[0077] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An automatic control method for grouting operations based on multi-stage temporal coordination, characterized in that, The steps are as follows: System initialization and task setting phase: Complete equipment self-check, operation authorization, and receive structured grouting task parameters; Autonomous movement and platform leveling phase: Based on the task location information, automatically navigate to the target area and adjust the trolley platform attitude to a high-precision level state; Operation preparation and hole alignment stage: unfold functional components, integrate design coordinates and on-site visual perception data to achieve high-precision spatial alignment of the end effector with the target grouting hole; Multi-unit intelligent scheduling and automatic connection stage: Under the parallel configuration of multiple grouting units, the optimal idle and interference-free unit is dynamically selected, and the fully automatic physical connection and sealing verification of the grout plug and pipeline are completed. Full-process grouting and real-time control stage: Automatically execute the processes of hole washing, water pressure, grouting, grout shielding, waiting for setting and hole sealing according to specifications, and dynamically adjust the process strategy based on the water pressure results or grouting response; Resource release and data closure phase: After the operation is completed, the equipment is automatically flushed, the occupied resources are released to support continuous operation, and a quality report with process curves is generated and uploaded to the engineering management platform.

2. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 1, characterized in that, The system initialization and task loading phase includes: After the system is powered on, hardware self-test, communication link verification and no-load test run of the actuator are performed in parallel. Receive encrypted task packages from a remote engineering management platform or work orders input from a local HMI. The task packages contain hole location geometry information, grouting process parameters, and safety constraints. The task package is digitally signed and verified, and it is checked whether the grouting process parameters exceed the current equipment capacity limit. If they do, the subsequent stages are prohibited. The parameters that pass the verification are distributed to the positioning module, grouting pump controller and process state machine according to their functional domains, and the operator ID and parameter version number are recorded.

3. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 1, characterized in that, During the work preparation and hole alignment stages, the system executes the tasks sequentially according to a preset time sequence: Unlock and unfold the robotic arm protective cover, extend the grouting hose reel bracket, start the grout circulation preheating circuit, move the robotic arm to the standby posture, and start the grouting unit in self-circulation mode; After each step is completed, a feedback signal must be sent. If any step times out or gets stuck, the process will be paused and an alarm will be triggered.

4. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 3, characterized in that, In the preparation and hole alignment stages, the hole alignment employs a coordinate-vision dual closed-loop mechanism: First, the global coordinates of the hole positions provided by BIM are transformed to the coordinate system of the robot arm base through the current pose of the trolley to obtain the preliminary target pose; After the robotic arm moves to the vicinity of this pose, it triggers the industrial camera to capture the area of ​​the hole. The actual hole center position is identified by ORB feature matching and RANSAC to eliminate mismatches. The actual hole center coordinates are back-projected onto the robotic arm base system through the hand-eye calibration matrix, generating correction values ​​and superimposing them onto the initial target pose as the final approximation target.

5. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 1, characterized in that, The autonomous mobility and platform leveling phase includes: The trolley's global travel path is planned based on the center coordinates of the target hole group, and the positioning mode is adaptively switched according to environmental characteristics during the travel process. Upon reaching the target area, the height of the four hydraulic outriggers is adjusted in two stages—coarse and fine—based on feedback from a high-precision dual-axis tilt sensor. During the leveling process, a laser level is used simultaneously to cross-verify the four corners of the platform. If multiple adjustments still fail to meet the accuracy requirements, the current terrain is marked as unlevelable.

6. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 3, characterized in that, In the multi-unit intelligent scheduling and automatic connection phase, the process of dynamically selecting the optimal unit includes: Construct a unit-task matching matrix to comprehensively evaluate the idle status of each grouting unit, its Euclidean distance to the target hole, and the matching degree of the current grout type; Based on the current pose and predicted trajectory of all active robotic arms, real-time collision detection is performed using fast bounding box and GJK algorithm; The grouting hose is modeled as a discrete elastic rod, and its bending energy is calculated. If it exceeds the set threshold, the corresponding robotic arm is instructed to perform a small swing straightening action. After confirming that there is no spatial interference and no risk of pipeline entanglement, the selected unit resources are locked and connection instructions are issued.

7. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 4, characterized in that, The automatic connection includes two sub-processes: insertion of the anti-slurry plug and locking of the quick-connect coupling. The first robotic arm holds the grout stop plug and inserts it along the hole axis to the specified process depth. This depth is controlled by a depth encoder in real time. After the grout stop plug is in place, air is injected into its sealing cavity. The pressure sensor monitors the pressure inside the cavity. When the pressure reaches the set threshold and is maintained for a preset time, the seal is determined to be successfully established. The second robotic arm grabs the grouting quick connector and, guided by an industrial camera, aligns it with the grout inlet of the grout stop plug, performing a combined axial pushing and rotating locking action. A six-dimensional force sensor monitors the contact force in real time. If a lateral load is detected, the end posture is automatically fine-tuned. A torque sensor monitors the locking torque. When the preset value is reached, the mechanical connection is determined to be complete.

8. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 1, characterized in that, The full-process grouting and real-time control stage includes: The process of hole washing, simple water pressure, grouting, grout shielding, waiting for setting and hole sealing is executed in sequence, and each process is driven by a finite state machine; During the simple water pressure process, the stable water absorption is recorded. If the water absorption exceeds the preset threshold, the grouting is not skipped, but the abnormal grouting mode is switched to adjust the initial water-cement ratio or start the pre-grouting thick grout sub-step. During the grouting process, the pressure of the current hole and adjacent holes are monitored in real time. If the pressure of the adjacent hole rises at a rate exceeding the set threshold, it is determined that cross-grouting has occurred and the current grouting is suspended. All key parameters of the process, including pressure, flow rate, time, and event logs, are sampled and stored at high frequency to form time-stamped process curves.

9. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 1, characterized in that, During the resource release and data closure phase: After the grouting and pipeline flushing of the current hole are completed, the main control unit automatically releases the occupied grouting unit, robotic arm and auxiliary pipeline resources, and updates their status to idle; At the same time, the queue of pending hole positions is polled. If there are unassigned tasks, the process will automatically jump to the work preparation and hole position alignment stage, trigger the work process of the next hole, and reuse the established platform leveling status and walking positioning results. If the task queue is empty, the entire process data is aggregated to generate a structured report containing hole location information, operation records, and process curves, and then uploaded to the engineering management platform via an encrypted API.

10. The automatic control method for grouting operations based on multi-stage temporal coordination according to claim 1, characterized in that, During the system operation enable and anomaly detection function synchronous activation phase, the anomaly detection engine is deeply coupled with the main control process, including: After the operator triggers the run enable command through identity authentication, the system immediately starts the multimodal anomaly detection engine, which includes four parallel subsystems: signal-level anomaly detection, equipment health assessment, spatial interference prediction, and process deviation identification. Anomaly detection results are output as risk levels. High-risk events directly trigger the state machine to jump to the security degradation mode. The anomaly detection is performed at all stages to ensure that the entire process is under control.

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