Concrete spraying machine and method for managing tunnel excavation and concrete spraying

Abstract

To provide a concrete spraying machine capable of suppressing the occurrence of a dead angle region during measurement when measuring a peripheral surface which is an excavation surface of a tunnel, and a management method of tunnel excavation and concrete spraying using the concrete spraying machine.SOLUTION: A concrete spraying machine 100 for spraying concrete onto a working face K and a peripheral surface S of a tunnel includes a self-propelled spraying carriage 10, a nozzle device 20 including a nozzle boom 21 that is attached to the spraying carriage 10 in a turnable manner and is extendable and retractable, and a nozzle 29 that is attached to a tip of the nozzle boom 21 and discharges concrete, and a control device 50 that specifies at least coordinates of a measurement point on the peripheral surface S. Two 3D scanners 61 are attached to the right and left positions in front of the blowing truck 10, and the scanning center axes L1 and L2 of the 3D scanners 61 positioned on the right and left are set in the direction of the peripheral surface S on the opposite side from the center P1 of the working face.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a concrete spraying machine and a method for controlling tunnel excavation and concrete spraying. [Background technology]

[0002] In the construction of mountain tunnels, after a specified length of excavation and excavation, a series of construction cycles are carried out, including the primary spraying of concrete (primary spraying) onto the periphery (arch surface) and face of the completed tunnel, followed by the secondary spraying (secondary spraying) (primary spraying and secondary spraying are collectively referred to as sprayed concrete). Here, for example, if the ground is relatively soft or the tunnel being constructed is a large-section tunnel, the erection of shoring may precede the secondary spraying, and furthermore, rock bolts may be driven in after the secondary spraying. By applying this sprayed concrete, it is possible to prevent collapses and skin falls from the tunnel face and periphery, ensuring safe construction of mountain tunnels.

[0003] Incidentally, sprayed concrete is a means of preventing the above-mentioned surface from falling off, and at the same time, together with the lining concrete applied inside the sprayed concrete, it also functions as a structural component of the mountain tunnel, so a minimum sprayed thickness (design sprayed thickness) is set at, for example, about 100 mm. Furthermore, the lining concrete is also set to a minimum lining thickness (design lining thickness) of, for example, 300 mm, and the interior dimensions of the tunnel inside the lining concrete are also set, so it is necessary to confirm that the excavation surface (or bare excavation surface) on the circumferential surface before the sprayed concrete is applied is not on the tunnel interior side of the designed excavation surface before the sprayed concrete is applied. More precisely, tunnel excavation and concrete spraying must be managed in such a way that the excavation surface on the periphery is confirmed to be no further inside the tunnel than the designed excavation surface before spraying the concrete, and the finished sprayed surface of the sprayed concrete is confirmed to be no further inside the tunnel than the designed finished sprayed surface before proceeding to the construction of the lining concrete.

[0004] When confirming that the excavation surface on the periphery is not further into the tunnel than the design excavation surface, one possible approach, instead of direct measurements by workers from the perspective of measurement safety, is to determine the absolute coordinates of the concrete sprayer installed on the tunnel entrance side of the face, and then use a measuring device attached to the concrete sprayer to determine the relative coordinates of, for example, multiple points (point cloud) on the excavation surface relative to the concrete sprayer.Since the absolute coordinates of the concrete sprayer have been determined, the absolute coordinates of each point cloud can be determined by determining the relative coordinates of each point cloud relative to the concrete sprayer. However, when measuring the excavation surface using a measuring device attached to a concrete sprayer, a blind spot occurs during measurement due to the sprayed concrete (and shoring) that has already been applied on the tunnel entrance side, and if the distance between the tunnel entrance side of the concrete sprayer and the tunnel face is long or if the thickness of the sprayed concrete is thick, the blind spot becomes wider, which is undesirable.

[0005] For these reasons, when installing a concrete sprayer at the tunnel entrance side of the tunnel face to measure the excavated surface, which is the circumferential surface, it is desirable to have a concrete sprayer that can reduce the occurrence of blind spots during measurement, and a method for managing tunnel excavation and concrete spraying using this concrete sprayer.

[0006] Patent Document 1 proposes a concrete material spraying device that sprays concrete material onto the inner wall surface of a tunnel. This concrete material spraying device includes a measuring unit that measures the cross-sectional shape of the inner wall surface, a sprayer that sprays concrete material from a nozzle onto the inner wall surface, and a control unit that controls the measuring unit and the sprayer, and the control unit calculates the required spray thickness for each of a plurality of predetermined sections based on the cross-sectional shape measured by the measuring unit and a predetermined cross-sectional shape of the designed inner wall surface of the tunnel, and controls the sprayer based on the calculated required spray thickness. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Publication No. 2020-33723 Summary of the Invention [Problem to be solved by the invention]

[0008] The concrete spraying device described in Patent Document 1 is said to be able to ensure a certain spray thickness while smoothing the finished surface with a certain degree of precision. However, Patent Document 1 does not disclose any means for addressing the above-mentioned problem, that is, a means for preventing blind spots from occurring when measuring the excavated surface of the tunnel periphery by installing a concrete sprayer on the tunnel entrance side of the tunnel face.

[0009] The present invention aims to provide a concrete sprayer that can suppress the occurrence of blind spots when measuring the circumferential surface, which is the excavation surface of a tunnel, by installing the concrete sprayer on the tunnel entrance side of the tunnel face, and a method for managing tunnel excavation and concrete spraying using this concrete sprayer. [Means for solving the problem]

[0010] In order to achieve the above object, one aspect of the concrete sprayer according to the present invention is as follows: A concrete sprayer that sprays concrete onto the tunnel face and periphery, which are the concrete spraying surface and the excavation surface, A self-propelled spraying cart, a nozzle device including a nozzle boom that is rotatably attached to the spraying cart and is extendable and contractible, and a nozzle that is attached to the tip of the nozzle boom and that ejects concrete; a control device that determines coordinates of at least the measurement points on the peripheral surface; Two 3D scanners are attached to the left and right positions in front of the spraying cart. The scanning center axes of the 3D scanners located on the left and right are each set in the direction of the peripheral surface on the opposite side of the center of the face.

[0011] According to this embodiment, the scanning center axes of the two 3D scanners attached to the left and right positions in front of the spraying cart are each set in the direction of the peripheral surface on the opposite side of the center of the face (therefore, in a plan view, both scanning center axes intersect), which makes it possible to suppress the occurrence of blind spots when measuring the peripheral surface, which is the excavation surface, using each 3D scanner, and in some cases to completely eliminate the occurrence of blind spots.

[0012] Here, "the scanning central axes of the 3D scanners located on the left and right are set in the direction of the circumferential surface on the opposite side of the center of the face" means that the scanning central axis of the left 3D scanner is set on the face or circumferential surface on the opposite side of the center of the face to measure the circumferential surface (or face) on the right side opposite the center of the face, and the scanning central axis of the right 3D scanner is set on the face or circumferential surface on the opposite side of the center of the face to measure the circumferential surface (or face) on the left side opposite the center of the face. In this invention, "right side" and "left side" define the left and right directions when viewing the face from the minehead, but the opposite definition method may also be used.

[0013] A target (prism) is attached to the spraying cart, and the three-dimensional coordinates (absolute coordinates) of the spraying cart are determined by a surveying device such as a total station located in a position that allows surveying of a survey reference point closer to the tunnel entrance than the spraying cart. The survey data obtained by the surveying device may be transmitted to or input into a control device. Here, the control device may be equipped on the spraying cart or may be housed in, for example, a management facility located outside the tunnel. The absolute coordinates of each point cloud on the excavated surface of the peripheral surface are determined based on the measured three-dimensional coordinates (absolute coordinates) of the spraying cart and the relative coordinates with respect to the spraying cart based on the measurement data of each of the multiple measurement points (point clouds) on the peripheral surface measured by a 3D scanner.

[0014] The concrete sprayer of this embodiment may be equipped with only a nozzle device including a boom, or may be equipped with an erector device (erector) that grips and assembles the support in addition to the nozzle device. In tunnel construction in hard ground or tunnel construction with a relatively small cross section, the erector device may not be necessary.

[0015] In addition to the spraying cart having two 3D scanners attached to the left and right positions at the front, this also includes a configuration in which a separate 3D scanner is attached to the front, for example in the center position, so that there are three 3D scanners in total, and a configuration in which there is an additional separate 3D scanner, so that there are four or more 3D scanners. In a configuration in which the measurement ranges of the two 3D scanners partially overlap at the face, the two 3D scanners can measure the entire area of ​​the face and the left and right peripheral surfaces.In a configuration in which the measurement ranges of the two 3D scanners do not overlap at the face, or in which the overlapping area at the face is narrow even when they do overlap, it is preferable to have a 3D scanner specialized for measuring the face located in front of the spraying cart, for example in a central position.

[0016] Another aspect of the concrete sprayer according to the present invention is Two erectors that are rotatably attached to the spraying cart, are extendable and retractable in their axial direction, and grip the support are attached to the left and right positions in front of the spraying cart, respectively. The 3D scanner is attached near the mounting position of each of the two erectors relative to the spraying cart.

[0017] According to this aspect, when two erectors are attached to the left and right positions in front of the spraying cart, 3D scanners are attached near the attachment positions of each of the two erectors relative to the spraying cart (the base of the erector), thereby preventing each of the erector booms from becoming an obstacle when measuring the surrounding surface (excavated surface) or the sprayed finished surface using the 3D scanner.

[0018] In another aspect of the concrete sprayer according to the present invention, The 3D scanner measures a point cloud, which is a plurality of measurement points on the peripheral surface, and each measurement data of the point cloud is transmitted from the 3D scanner to the control device, The control device Create coordinate data for each point cloud based on the received measurement data for each point cloud, storing point cloud data relating to the design excavation surface; storing first coordinates on the excavation surface and second coordinates on the sprayed finish surface corresponding to each point cloud; If the first coordinate is located on the tunnel interior side of the design excavation surface, it is determined that there is a hit portion, If the first coordinate is located closer to the natural ground than the design excavation surface, it is determined that there is no impact, and the thickness of the concrete sprayed is calculated based on the first coordinate and the second coordinate.

[0019] According to this aspect, if the first coordinate on the excavation surface corresponding to each point group, which is a plurality of measurement points on the circumferential surface, is located closer to the tunnel interior than the design excavation surface, it is determined that there is a hit area, and if the first coordinate is located closer to the natural ground than the design excavation surface, it is determined that there is no hit area.By calculating the concrete spray thickness based on the first coordinate and the second coordinate, the concrete spray thickness can be calculated and identified on the assumption that there is no hit area. This allows for the construction of a concrete sprayed to a thickness greater than the design thickness after confirming that the excavation surface on the periphery is not closer to the tunnel interior than the design excavation surface. If it is determined that there is a rough spot, the rough spot must be re-excavated to eliminate the rough spot before the concrete is applied.

[0020] By ensuring that there are no rough spots on the entire peripheral surface, which is the excavation surface, and then spraying the finished sprayed concrete so that the finished sprayed surface is on the designed finished sprayed surface or closer to the natural ground than the designed finished sprayed surface, it is possible to guarantee that the sprayed thickness will be equal to or greater than the designed sprayed thickness, and that the lining thickness of the lining concrete will be equal to or greater than the designed lining thickness. Here, in addition to ensuring a sprayed thickness equal to or greater than the designed sprayed thickness and a lining thickness equal to or greater than the designed lining thickness, it is essential to ensure the specified tunnel interior dimensions.

[0021] In another aspect of the concrete sprayer according to the present invention, The control device A feature of this method is that the amount of concrete sprayed is calculated by multiplying the spray thickness of each point group by the spray area that covers each point group.

[0022] According to this aspect, the amount of concrete sprayed can be calculated with high accuracy by calculating the product of the spraying thickness of each point cloud and the spraying area covering each point cloud. Here, the spraying thickness of each point cloud can be calculated by finding the difference (three-dimensional difference) between the second coordinate and the first coordinate for each point cloud.

[0023] In another aspect of the concrete sprayer according to the present invention, The control device For each point group, coordinate data for the intermediate spraying stage is created based on one or more intermediate measurements during the spraying process up to the designed sprayed finish surface, The current amount of concrete sprayed during the spraying process is calculated by multiplying the coordinate data of each point group during the spraying process by the spraying area covering each point group. The remaining concrete spraying volume is calculated by the difference between the planned total volume of concrete sprayed, calculated by multiplying the coordinate data on the design sprayed finished surface corresponding to each point group by the spraying area covering each point group, and the current concrete spraying volume.

[0024] According to this aspect, coordinate data for each point cloud during spraying is created based on measurements taken during the spraying process up to the designed sprayed surface, the current concrete sprayed volume for the spraying process is calculated by multiplying the coordinate data for each point cloud during spraying by the sprayed area covering each point cloud, the planned total concrete volume is calculated by multiplying the coordinate data for the designed sprayed surface corresponding to each point cloud by the sprayed area covering each point cloud, and the remaining concrete volume is calculated by the difference between the planned total concrete volume and the current concrete volume, thereby enabling the remaining concrete volume during the spraying process to be determined with high accuracy. This eliminates the risk of running out of concrete during the construction process and reduces the occurrence of unused remaining concrete.

[0025] In another aspect of the concrete sprayer according to the present invention, The control device The amount of concrete currently used at the intermediate spraying stage is stored; Calculate the rebound rate based on the difference between the amount of sprayed concrete at the intermediate stage of spraying and the amount of used concrete at the current time; The method is characterized in that the rebound rate is taken into consideration when calculating the remaining amount of concrete to be sprayed.

[0026] According to this embodiment, the rebound rate (the proportion of concrete that is not used in the sprayed concrete due to concrete rebound) is calculated based on the difference between the current amount of concrete sprayed at the intermediate spraying stage (the amount of concrete actually sprayed on the surrounding surface) and the current amount of concrete used (the amount of concrete actually used), and by taking the rebound rate into account when calculating the remaining amount of concrete sprayed, the remaining amount of concrete sprayed can be determined with even greater accuracy. Here, by calculating the rebound rate once, the same rebound rate can be used in calculating the remaining amount of concrete sprayed in a series of other calculations, so the rebound rate may be calculated only once. Additionally, a past rebound rate, such as a rebound rate calculated when the shotcrete was applied the previous day, may also be applied.

[0027] Furthermore, one aspect of the tunnel excavation and concrete spraying management method according to the present invention is to A method for managing tunnel excavation and concrete spraying, which determines whether or not there is a bump on the circumferential surface when spraying concrete onto the face and circumferential surface of a tunnel after excavation, which are the concrete spraying surface and the excavation surface, and calculates the thickness of the concrete sprayed, A concrete sprayer is used, which is equipped with a self-propelled spraying cart, a nozzle device that is rotatably attached to the spraying cart and that discharges concrete, and two 3D scanners that are installed on the left and right positions in front of the spraying cart, and the scanning central axes of the 3D scanners located on the left and right are each set in the direction of the peripheral surface that is on the opposite side from the center of the face, The 3D scanner measures a point cloud that is a plurality of measurement points on the peripheral surface before the concrete is sprayed; Create coordinate data for each point cloud based on the measurement data for each point cloud, Prepare point cloud data relating to the design excavation surface, first coordinates on the excavation surface corresponding to each point cloud, and second coordinates on the sprayed finish surface that is constructed so as to be located closer to the natural ground than the design sprayed finish surface; If the first coordinates corresponding to each point group are located on the tunnel interior side of the design excavation surface, it is determined that there is a hit, and the hit is to be re-excavated, If the first coordinate corresponding to each point cloud is located on the natural ground side of the design excavation surface, it is determined that there is no impact, and the concrete spray thickness is calculated based on the first coordinate and the second coordinate.

[0028] According to this aspect, the scanning central axes of the two 3D scanners attached to the left and right positions in front of the spraying cart are respectively set in the direction of the circumferential surface on the opposite side of the center of the face, thereby suppressing the occurrence of blind spots when measuring the excavation surface of the circumferential surface using each 3D scanner, and in some cases completely eliminating the occurrence of blind spots. Furthermore, if the first coordinate on the excavation surface corresponding to each point cloud, which is a plurality of measurement points on the circumferential surface, is located closer to the tunnel interior than the design excavation surface, it is determined that there is a hit, and the hit is re-excavated. If the first coordinate is located closer to the natural ground than the design excavation surface, it is determined that there is no hit, and the concrete spraying thickness is calculated based on the first and second coordinates. By applying the shotcrete to the excavation surface without a hit, the spraying thickness to the finished sprayed surface can be calculated and identified. Furthermore, by ensuring that there are no rough spots on the entire excavation surface of the periphery, and by spraying the concrete so that the finished sprayed surface is closer to the ground than the designed finished sprayed surface, it is possible to guarantee that the sprayed thickness will be equal to or greater than the designed sprayed thickness, and that the lining thickness of the lining concrete will be equal to or greater than the designed lining thickness. [Effects of the Invention]

[0029] The concrete sprayer of the present invention can be installed on the tunnel entrance side of the tunnel face to measure the circumferential surface, which is the excavation surface of the tunnel, and can suppress the occurrence of blind spots during measurement. Furthermore, the tunnel excavation and concrete spraying management method of the present invention can ensure that the concrete spray thickness is equal to or greater than the design spray thickness, and that the lining concrete lining thickness is equal to or greater than the design lining thickness. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 is a plan view of an example of a concrete sprayer according to an embodiment. [Figure 2] 2 is a view taken in the direction of the arrow II in FIG. 1 and is a side view of an example of a concrete sprayer according to an embodiment. FIG. [Figure 3A] FIG. 2 is a front view of an example of a measurement device, showing a state in which a slide shutter is closed. [Figure 3B] 3B is a view taken in the direction of the arrow B in FIG. 3A and is a side view of an example of a measuring device. [Figure 3C] FIG. 2 is a front view of an example of a measurement device, showing a state in which the slide shutter is open. [Figure 4] This figure compares the blind spot area when measuring the right side of the tunnel, which is the excavation surface, using a 3D scanner attached to the front left side of the spraying cart, and the blind spot area when measuring using a 3D scanner attached to the front right side of the spraying cart. [Figure 5] FIG. 2 is a diagram illustrating an example of the hardware configuration of a control device that constitutes a concrete sprayer. [Figure 6] FIG. 2 is a diagram illustrating an example of the functional configuration of a control device that constitutes a concrete sprayer. [Figure 7] FIG. 10 is a diagram showing an example of a display on a monitor screen on an operator's control panel. [Figure 8] FIG. 10 is a schematic diagram illustrating rules regarding the presence or absence of a contact portion. [Figure 9] FIG. 1 is a schematic diagram illustrating rules regarding spray thickness. [Figure 10] FIG. 10 is a diagram showing an example of the flow and required time from setting up the spray machine to the end of spraying and the movement of the spray machine. DETAILED DESCRIPTION OF THE INVENTION

[0031] Hereinafter, a concrete sprayer and a method for managing tunnel excavation and concrete spraying according to an embodiment will be described with reference to the accompanying drawings. Note that in this specification and drawings, substantially identical components will be designated by the same reference numerals, and redundant explanations may be omitted.

[0032] [Concrete sprayer according to the embodiment, and method for managing tunnel excavation and concrete spraying] 1 to 10, a concrete sprayer according to an embodiment and an example of a method for managing tunnel excavation and concrete spraying will be described. Here, FIG. 1 is a plan view of an example of a concrete sprayer according to an embodiment, and FIG. 2 is a side view of an example of a concrete sprayer according to an embodiment, taken along the arrow II in FIG. 1. Also, FIG. 3A is a front view of an example of a measuring device, showing a state in which the sliding shutter is closed. FIG. 3B is a side view of an example of a measuring device, taken along the arrow B in FIG. 3A. FIG. 3C is a front view of an example of a measuring device, showing a state in which the sliding shutter is open. Furthermore, FIG. 4 is a diagram comparing the blind spot area when the right side of the tunnel, which is the excavation surface, is measured using a 3D scanner attached to the front left of the spraying cart with the blind spot area when measured using a 3D scanner attached to the front right of the spraying cart.

[0033] In the following description, the left and right directions when viewing the face K from the entrance side in FIG. 1 will be referred to as the left and right sides.

[0034] The concrete sprayer 100 is a heavy machine that sprays concrete at a predetermined spray thickness onto the face K and peripheral surface S, which are the concrete spraying surface and excavation surface of a tunnel T (mountain tunnel) being constructed in the ground G.

[0035] The construction of a mountain tunnel T involves a series of construction cycles: excavation and excavation to a specified length, the primary spraying of concrete onto the periphery S (arch surface) and face K of the constructed tunnel T, the erection of steel supports M (an example of supports) made of H-shaped steel beams, etc., and secondary spraying. This construction cycle is repeated as the tunnel is excavated. Here, there is also a construction method in which rock bolts are installed as needed after the secondary spraying. In addition, in the case of small-section tunnels or hard ground, erecting supports may not be necessary.

[0036] Figures 1 and 2 show that excavation and removal has been completed for a range of about 1 to 3 meters beyond the section where the erection of shoring M and the construction of shotcrete C (primary and secondary spraying) have been completed, and the tunnel face K and periphery S of that section are exposed. Of this exposed area, shotcrete and lining concrete, which will become the structural components of the tunnel, will be applied to the periphery S in particular, and shotcrete will be applied while managing the excavation surface (excavation shape) and the sprayed thickness of the lining concrete that will be applied on top of the excavation surface.

[0037] The concrete spraying machine 100 comprises a self-propelled spraying carriage 10, a control device 50 mounted on the spraying carriage 10, a nozzle device 20 attached to a central position in front of the spraying carriage 10 (towards the face K), and two erector devices 30 attached to the left and right positions in front of the spraying carriage 10.

[0038] The nozzle device 20 is attached to the spraying truck 10 so as to be freely rotatable in the vertical direction (X2 direction) and horizontal direction (X3 direction), and comprises a nozzle boom 21 which is freely extendable and retractable in the X1 direction along its own axial direction, a rotary mechanism 25 mounted at the tip of the nozzle boom 21, and a nozzle 29 which ejects sprayed concrete while rotating horizontally in the X4 direction by the rotary mechanism 25.

[0039] The end of a concrete pressure hose or concrete pressure piping (not shown) is attached to the end of the nozzle 29 opposite the discharge port, and the concrete pressure hose or the like leads to a hopper to which concrete is supplied from a mixer truck (not shown) or to a concrete pump that pressure-feeds the concrete. By driving the concrete pump, concrete is supplied to the nozzle 29 via the concrete pressure hose or the like, and is then discharged from the nozzle 29 onto the surface to be sprayed.

[0040] The erector device 30 is attached to the spraying cart 10 so as to be freely rotatable in the vertical direction (X2 direction) and horizontal direction (X3 direction), and is equipped with a nozzle boom 31 that is freely extendable in the X1 direction along its own axial direction.It grasps the support M, which is divided into two parts at its tip, and erects the support M at the specified erection position.

[0041] Two measuring devices 60A, 60B are attached to the left and right positions in front of the spraying cart 10, more precisely, near the respective mounting positions 15 of the two erectors 30 in front of the spraying cart 10. Furthermore, a separate measuring device 60C is attached to the center position in front of the spraying cart 10.

[0042] Each measuring device 60 is equipped with a 3D scanner 61 as shown in Figure 3. Here, it is preferable to use a 3DLiDER as the 3D scanner 61. This is because the 3DLiDER is resistant to vibrations and is suitable for installation on heavy machinery, and is a relatively inexpensive measuring instrument compared to general 3D scanners.

[0043] As shown in Fig. 1, the 3D scanner 61 of the measuring device 60B on the front left side of the spraying cart 10 has its scanning central axis L1 set in the direction of the right peripheral surface S on the opposite side of the center P1 of the face K. More precisely, while the scanning central axis L1 is set in the area of ​​the face K on the right side of the center P1 of the face K, the range between the scanning lines L1' on the left and right of the scanning central axis L1, which is the scanning range of the 3D scanner 61, is set to the right peripheral surface S, and a point cloud, which is a plurality of measurement points on the right peripheral surface S, is measured.

[0044] Meanwhile, the 3D scanner 61 of the measuring device 60A located on the front right side of the spraying cart 10 has its scanning central axis L2 set in the direction of the left peripheral surface S on the opposite side of the center P1 of the face K. More precisely, while the scanning central axis L2 is set in the area of ​​the face K on the left side of the center P1 of the face K, the range between the scanning lines L2' on the left and right of the scanning central axis L2, which is the scanning range of the 3D scanner 61, is set to the left peripheral surface S, and a point cloud, which is a plurality of measurement points on the left peripheral surface S, is measured.

[0045] In addition, the 3D scanner 61 of the measuring device 60C located at the center of the front of the spraying cart 10 has the range between the scanning lines L3' on the left and right sides set to the central area or almost the entire area of ​​the face K, and mainly measures a point cloud which is a plurality of measurement points at the face K.

[0046] Here, in the illustrated example, the scanning range of the 3D scanner 61 of the measuring device 60B and the scanning range of the 3D scanner 61 of the measuring device 60A partially overlap at the face K, and therefore the entire area of ​​the face K and the left and right peripheral surfaces S can be covered by the two measuring devices 60A, 60B, so for example, the central measuring device 60C may be omitted. However, by providing the central measuring device 60C as in the illustrated example, it can be used as a substitute when, for example, one of the left and right measuring devices 60A, 60B becomes unusable, and further, since it is located in a position that makes it easy to measure the entire area of ​​the face K, more accurate measurements of the face K are possible.

[0047] 3A and 3B, the measurement device 60 includes a heat sink housing 62, a leveling stand 63 below the heat sink housing 62, and a magnet fixing jig 64 below the leveling stand 63. A 3D scanner 61 and a two-axis inclinometer 67 are built into the heat sink housing 62. A cross-shaped marking laser 68 is also provided on the top of the heat sink housing 62. The marking laser may be a triple laser or the like in addition to a cross-shaped laser.

[0048] As shown in Figure 3C, a slide shutter 66 that slides in the X5 direction by an electric actuator 65 is provided on the front of the heat sink housing 62, and sliding the slide shutter 66 opens the 3D scanner 61, making it ready for measurement.

[0049] In this way, by opening the 3D scanner 61 only when it is performing measurements, the 3D scanner 61 can be protected from flying concrete, dust, etc.

[0050] When erecting the shoring and spraying the shotcrete, the spraying cart 10 is positioned at a predetermined position on the tunnel entrance side of the tunnel face K, and as shown in Figure 2, the positioning posture is fixed by the outriggers 17, and then a series of construction works are carried out. Furthermore, if the measurement of the peripheral surface S determines that there is a bump (a part that protrudes into the tunnel interior) that is located on the tunnel interior side of the designed excavation surface, it will not be possible to ensure the specified spraying thickness and further the specified lining thickness, so holes will be drilled in the bump before the spraying work is carried out, which prevents work from having to be reworked.

[0051] Targets 12A, 12B, and 12C are attached to three locations on the rear (portion entrance side) of the spraying cart 10. Meanwhile, a permanent total station E (TS, an example of a surveying means) is installed at a predetermined position on the applied shotcrete C. The total station E is installed at a position on the port entrance side of the tunnel T where it can survey a survey reference point (not shown), and its own three-dimensional coordinates (absolute coordinates) are determined by surveying the survey reference point.

[0052] The total station E is used to collimate each of the targets 12A, 12B, and 12C, and to measure the distance and angle, thereby measuring the three-dimensional coordinates (absolute coordinates) of the spraying cart 10.

[0053] Although not shown in the figures, each of the targets 12A, 12B, and 12C is equipped with a collimation enable / disable means, and sequential control is performed so that each of the targets 12A, 12B, and 12C is collimated one by one in order, with only one target being made collimation enable and the other collimation targets being made uncollimation enable, and then the collimation enable target being made uncollimation enable, thereby effectively preventing the accidental collimation of a target other than the target to be collimated when sequentially collimating multiple targets 12A, 12B, and 12C with one total station E. For example, examples of the aiming enabling / disabling means include a configuration in which the aiming target is housed in a cover to make it impossible to aim, and the aiming target is raised and lowered by an actuator so that it protrudes from the cover to make it possible to aim, a configuration in which the cover surrounding the aiming target is raised and lowered by an actuator to make the aiming target possible or impossible to aim, and even a configuration in which each target is equipped with a shutter and only the shutter of the aiming target opens.

[0054] When measuring each target using the total station E, the control device 50 controls the sequential opening and closing of the shutters of each target, and the three-dimensional coordinate data of the spraying cart 10 measured by the total station E is transmitted to or input into the control device 50.

[0055] In addition, instead of the illustrated example in which three targets 12A, 12B, and 12C are attached to the rear of the spraying cart 10, the three-dimensional coordinates of the spraying cart may be determined using two targets and one inclinometer.

[0056] Here, with reference to FIG. 4, the effect of measuring the peripheral surface S on the opposite side of the center P1 of the working face K by each measuring device 60 as in the illustrated example will be described.

[0057] In Figure 4, scanning line L1' is a line that allows measurement of the peripheral surface S by the left-hand measuring device 60B shown in Figure 1 without interfering with the already constructed support M on the right-hand side of the face K. Of the total length t1 of the peripheral surface S between the support M and the face K, the unmeasurable length Δt1 (blind spot area) is very small, and the remaining length t2 is the measurable range.

[0058] In contrast, if the right-side peripheral surface S is measured using the measuring device 60A located on the right side of the spraying cart 10, the scanning line L2' that can measure the peripheral surface S without interfering with the already constructed support M on the right-side face K side will be as shown in Figure 3, and the unmeasurable length Δ2 (blind spot area) will be significantly longer than Δ1, and accordingly the measurable length t3 will be significantly shorter.

[0059] From the above, since the scanning center axes L2, L1 of each of the 3D scanners 61 of the two measuring devices 60A, 60B attached to the left and right positions in front of the spraying cart 10 are each set in the direction of the peripheral surface S on the opposite side of the center P1 of the face K, the occurrence of blind spots can be suppressed when each 3D scanner 61 measures the peripheral surface S, which is the excavation surface, and in some cases it is even possible to completely eliminate the occurrence of blind spots.

[0060] Next, the control device 50 constituting the concrete sprayer 100 will be described with reference to Figures 5 and 6. Here, Figure 5 is a diagram showing an example of the hardware configuration of the control device, and Figure 6 is a diagram showing an example of the functional configuration of the control device.

[0061] As shown in Fig. 5, the control device 50 is configured by an information processing device such as a control panel made up of a computer. The computer constituting the control device 50 includes a CPU (Central Processing Unit) 51, a main memory device 52, an auxiliary memory device 53, a communication IF 54, and an input / output IF (interface) 55, which are interconnected by a connection bus 56. The main memory device 52 and the auxiliary memory device 53 are computer-readable recording media. Note that the above components may be provided separately, or some of the components may not be provided.

[0062] The CPU 51 is also called an MPU (Microprocessor) or a processor, and may be a single processor or a multiprocessor. The CPU 51 is a central processing unit that performs overall control of the control device 50, which is a computer. The CPU 51, for example, deploys a program stored in the auxiliary storage device 53 in an executable manner in a working area of ​​the main storage device 52, and controls peripheral devices through the execution of the program, thereby providing functions that meet a predetermined purpose.

[0063] The main memory device 52 stores computer programs executed by the CPU 51, data processed by the CPU 51, and the like. The main memory device 52 includes, for example, a flash memory, a random access memory (RAM), and a read-only memory (ROM). The auxiliary memory device 53 stores various programs and various data on a readable and writable recording medium and is also referred to as an external memory device. The auxiliary memory device 53 stores, for example, an operating system (OS), various programs, various tables, and the like. The OS includes, for example, a communication interface program that exchanges data with external devices connected via the communication IF 54. Examples of external devices include the total station E, the targets 12A, 12B, and 12C (their shutter mechanisms), the electric actuator 65 and the 3D scanner 61 included in the measuring device 60, and a personal computer (not shown) for construction management in a management facility (construction station) connected to a network.

[0064] The auxiliary storage device 53 is used, for example, as a storage area that supplements the main storage device 52, and stores computer programs executed by the CPU 51, data processed by the CPU 51, etc. The auxiliary storage device 53 is a silicon disk including nonvolatile semiconductor memory (flash memory, EPROM (Erasable Programmable ROM)), a hard disk drive (HDD: Hard Disk Drive), a solid state drive, etc. Examples of the auxiliary storage device 53 include drives for removable recording media such as CD drives, DVD drives, and BD drives, and examples of the removable recording media include CDs, DVDs, BDs, USB (Universal Serial Bus) memories, and SD (Secure Digital) memory cards.

[0065] The input / output IF 55 is an interface for inputting and outputting data between devices connected to the control device 50. For example, a pointing device such as a touch panel, and an input device such as a microphone are connected to the input / output IF 55. The control device 50 receives operation instructions and the like from an operator who operates the input device via the input / output IF 55.

[0066] In addition, the input / output IF 55 is connected to display devices such as a liquid crystal panel (LCD: Liquid Crystal Display) or an organic EL panel (EL: Electroluminescence), and output devices such as a speaker. For example, the display devices display the coordinate data of the spraying cart 10 from the total station E, the absolute coordinates of each point cloud based on the measurement data of each point cloud of the peripheral surface S, which is the excavation surface, measured by the 3D scanner 61, a cross-sectional view of the excavation surface (a cross-sectional view perpendicular to the tunnel axis) based on the absolute coordinates of each point cloud, point cloud data on the design excavation surface stored in advance in the control device 50, a cross-sectional view of the design excavation surface based on the point cloud data, the determination result of whether or not there is a hit, the coordinate data of the hit if there is a hit, the thickness of the sprayed concrete for each point cloud, a cross-sectional view of the finished sprayed surface, etc.

[0067] The communication IF 54 is an interface with a cable or network to which the control device 50 is connected. The communication IF 54 receives measurement data from the measuring device 60, the total station E, etc. via various networks, such as a public network like the Internet, a wireless network like a mobile phone network, a dedicated network like a VPN (Virtual Private Network), or a LAN (Local Area Network), and transmits coordinate data of each point cloud forming the excavation surface, the presence or absence of a hit area, coordinate data when a hit area is present, data on the thickness of the concrete sprayed on each point cloud, etc. to a personal computer for construction management in the management facility.

[0068] 6, the control device 50, through the execution of a program by the CPU 51, provides various functions, such as at least an acquisition unit 102, a measurement device drive unit 104, a coordinate data creation unit 106, a determination unit 108, a spraying thickness calculation unit 110, a spraying amount calculation unit 112, a rebound rate calculation unit 114, a remaining concrete spraying amount calculation unit 116, a display unit 118, and a storage unit 120. Here, at least some of the above processing functions may be provided by a DSP (Digital Signal Processor), a GPU (Graphics Processing Unit), or the like, and similarly, at least some of the above processing functions may be provided by dedicated LSIs (Large Scale Integration), such as an FPGA (Field-Programmable Gate Array), a numerical calculation processor, an image processing processor, or other digital circuits.

[0069] The acquiring unit 102 acquires coordinate data relating to the three-dimensional coordinates (absolute coordinates) of the spraying cart 10 measured by the total station E, and stores (stores) the coordinate data in the memory unit 120. The acquiring unit 102 also acquires measurement data of a point cloud, which is a plurality of measurement points on the peripheral surface S, which is the excavation surface before concrete is sprayed, measured by the 3D scanner 61, and stores the measurement data in the memory unit 120.

[0070] When the measurement device driving unit 104 performs measurement of each point group on the peripheral surface S using the measurement device 60, it operates the electric actuator 65 to open the slide shutter 66, operates the 3D scanner 61 to acquire measurement data of each point group, and after acquiring the measurement data, it operates the electric actuator 65 to close the slide shutter 66.

[0071] As already explained, the right measuring device 60B is operated when acquiring measurement data for each point cloud on the left side peripheral surface S, and the left measuring device 60A is operated when acquiring measurement data for each point cloud on the right side peripheral surface S. Furthermore, the central measuring device 60C may be operated when acquiring measurement data for each point cloud in the central region of the working face K.

[0072] The coordinate data creation unit 106 creates relative coordinates for each point cloud based on the measurement data of each point cloud stored in the memory unit 120, and combines these with the absolute coordinates of the spraying cart 10 stored in the memory unit 120 to create absolute coordinates for each point cloud, which are then stored in the memory unit 120 as first coordinates.

[0073] The memory unit 120 also stores point cloud data relating to the design excavation surface and the design finished sprayed surface. Here, the design excavation surface is the excavation surface that satisfies all of the specified tunnel inner diameter, specified lining concrete lining thickness (for example, a lining thickness of 300 mm or more), and specified lining concrete sprayed thickness (for example, a sprayed thickness of 100 mm or more), and the area that protrudes further into the tunnel interior than the design excavation surface is treated as a rough area and is subject to re-excavation. The design finished sprayed surface is the finished sprayed surface that satisfies the specified tunnel inner diameter and specified lining concrete lining thickness (for example, a lining thickness of 300 mm or more).

[0074] If the first coordinates stored in the memory unit 120 are located on the tunnel interior side of the designed excavation surface, the determination unit 108 determines that there is a hit area, and designates the area as a target area for re-excavation as described above.

[0075] On the other hand, if the first coordinate is on the natural ground side of the design excavation surface, the determining unit 108 determines that there is no hit portion.

[0076] If there is a region with a hit portion, the hit portion is excavated again, and the entire peripheral surface S becomes a region without a hit portion.

[0077] When the entire peripheral surface S is free of any imperfections, the nozzle device 20 applies sprayed concrete to the peripheral surface S.

[0078] For example, if the design sprayed thickness is set to 100 mm, the sprayed concrete is applied until the sprayed thickness reaches 100 mm or more. The measurement device 60 measures the finished sprayed surface corresponding to each point cloud and stores the measured values ​​in the memory unit 120 as second coordinates.

[0079] When spraying concrete, one or more intermediate measurements are taken during the spraying process up to the designed sprayed finish surface, and the coordinate data creation unit 106 creates coordinate data for each point group at the intermediate spraying stage based on the intermediate measurements and stores it in the memory unit 120.

[0080] The spraying amount calculation unit 112 calculates the amount of sprayed concrete as it is during the spraying process by multiplying the coordinate data of each point cloud during the spraying process by the spraying area that covers each point cloud.

[0081] The sprayed concrete thickness calculation unit 110 calculates the sprayed concrete thickness from the difference between the first coordinates relating to the excavation surface and the second coordinates relating to the finished sprayed surface in each point cloud.

[0082] By confirming that the sprayed concrete thickness of each point group is equal to or greater than the design sprayed concrete thickness and that the coordinates of the finished sprayed surface corresponding to each point group are closer to the natural ground than the design finished sprayed concrete surface, the construction of the sprayed concrete will satisfy all control standards.The lining concrete will then be constructed to the specified lining thickness.

[0083] The rebound rate calculation unit 114 calculates the rebound rate based on the difference between the amount of sprayed concrete at the current spraying stage and the amount of used concrete at that stage.

[0084] The remaining concrete spraying volume calculation unit 116 calculates the remaining concrete spraying volume by the difference between the planned total volume of concrete to be sprayed, calculated by multiplying the coordinate data of the design spraying finished surface corresponding to each point cloud by the spraying area covering each point cloud, and the current concrete spraying volume. This calculation takes into account the rebound rate calculated by the rebound rate calculation unit 114. Based on the calculated remaining concrete spraying volume, the remaining required spraying volume is calculated with high accuracy, and the concrete required for the remaining shotcrete application is prepared.

[0085] The display unit 118 displays whether or not there is a contact area on the peripheral surface S, the amount of contact (amount of protrusion from the designed excavation surface) if there is a contact area, and the sprayed thickness of the shotcrete, and displays these on a monitor screen such as a control panel in the operator's cabin of the spraying cart 10. Fig. 7 shows an example of a display on a monitor screen. Here, the monitor screen may be installed in various locations where the operator can check it, such as being mounted on the control panel in the operator's cabin, being mounted on the spraying machine, being attached to the nozzle operation remote control, being fixed to the wrist or arm of the operator holding the remote control, or being worn around the neck.

[0086] While checking the monitor screen, the operator can check the presence or absence of hit areas in each point group on the excavation surface, the amount of hit areas if any, and the thickness of the sprayed concrete based on the color display on the circumferential surface.

[0087] In the example shown, the upper row shows measurement data for the amount of contact, and the lower row shows measurement data for the sprayed thickness. In the tunnel cross-section diagram at the bottom, the central horizontal line is designated as SL (spring line), the central vertical line is designated as CL (center line), and the measurement results of the peripheral surface S at a certain position in the tunnel axial direction are shown in different colors.

[0088] Regarding the amount of hits, for example, white is considered to have no hits, and colors other than white, such as blue, yellow, green, and red, are considered to have hits with increasing amounts of hits in that order.

[0089] On the other hand, the spray thickness decreases in the order of green, blue, and white, with dark green and darker black being considered to be excessively thick. Even if the spray thickness is excessive, it does not pose a structural problem because it meets the design spray thickness, and is merely a warning that an excessive amount of concrete has been used.

[0090] An example of the rules regarding the amount of impact is shown in Figure 8. For example, if the design spraying thickness is 100 mm and a margin of 40 mm is allowed, by managing the as-built shape of the excavation surface so that the periphery, which is the excavation surface, is 140 mm to 100 mm toward the natural ground from the designed spraying finished surface, the designed spraying finished surface can be secured, and the excavation surface can ensure a design spraying thickness of 100 mm or more.

[0091] For example, if the excavation surface is located more than 140 mm toward the natural ground from the designed sprayed finish surface, the resulting spray thickness will be excessive, resulting in an excessive spray volume. Therefore, in this example, a margin of approximately 40 mm is set in order to keep the spray volume within an appropriate range.

[0092] Furthermore, in this example, the cross-sectional radius of the tunnel is 6700 mm and the lining thickness of the lining concrete is set to 300 mm, so it is essential to meet these set values, and then manage the finished shape of the peripheral surface S, which is the excavation surface for applying sprayed concrete that meets the spraying thickness of 100 mm.

[0093] At the initial measurement stage (measurement of the unexcavated surface before spraying), the operator checks that there are no excavation marks on the constructed circumferential surface S, and at the final measurement stage (measurement after spraying construction), the operator checks that there are no red areas on the finished sprayed surface that extend beyond the designed finished sprayed surface toward the tunnel interior, and carries out construction and management with the aim of turning green (a color that indicates a range of 0mm to 40mm of margin, with 0mm above the designed finished sprayed surface).This type of construction management ensures quality and smooth construction progress.

[0094] An example of rules regarding spray thickness is shown in Figure 9. In relation to the above-mentioned thickness, the operator should carry out construction and management aiming for a green color in the range of 100 mm to 140 mm (150 mm in the figure).

[0095] FIG. 10 shows an example of the flow and required time from setting up the spray machine until spraying is completed and the spray machine moves.

[0096] Each measurement is triggered by manually pressing a button. After the button is pressed, the automatic total station performs "TS attitude measurement," which aims the prism of the spraying machine to calculate the position of the spraying machine, followed by "LiDAR face measurement," which measures the periphery of the face using two installed LiDARs, and "arithmetic processing," which calculates the tunnel coordinates and spraying thickness of the point cloud on the periphery based on the attitude measurement information and LiDAR acquired data, and the measurement results are then automatically processed in sequence and displayed on the monitor.

[0097] The prototype took approximately two minutes to complete the series of measurements above, and it was necessary to reduce the time required to reduce the impact on the construction cycle. Therefore, the program that currently processes "TS attitude measurement" and "LiDAR face measurement" in series was changed to parallel processing, and the specifications were also changed so that "TS attitude measurement" was only performed during the initial measurement.

[0098] This change has made it possible to reduce the measurement time by one minute for the initial measurement and by one minute and 30 seconds for the intermediate and final measurements.

[0099] It should be noted that the present invention is not limited to the configurations shown here, and other embodiments may be possible in which other components are combined with the configurations described in the above embodiments. In this regard, the present invention can be modified within the scope of the present invention, and can be appropriately determined depending on the application form. [Explanation of symbols]

[0100] 10: Spraying cart 12A, 12B, 12C: Target (prism) 15:Installation position 17: Outrigger 20: Nozzle device 21: Nozzle boom 25: Rotary mechanism 29: Nozzle 30: Erector device (Erector) 31: Boom 40: Mancage device 41: Boom 42: Mancage 50: Control device 60, 60A, 60B, 60C: Measuring equipment 61: 3D scanner 62: Housing (heat sink housing) 63: Standard stand 64:Magnet fixing jig 65: Electric actuator 66: Slide shutter 67:2-axis inclinometer 68: Laser for specifying 70:Monitor screen 100: Concrete sprayer (sprayer) 102: Acquisition Department 104: Measuring device drive unit 106: Coordinate data creation unit 108: Judgment section 110: Spray thickness calculation unit 112: Spray amount calculation unit 114: Rebound rate calculation section 116: Remaining concrete spraying amount calculation section 118:Display section 120: Storage section G: Ground T: Tunnel (mountain tunnel) K: Face (blasting surface, excavation surface) S: Peripheral surface (sprayed surface, excavated surface) C: Shotcrete M: Shoring (steel shoring) E: Total Station (TS)

Claims

1. A concrete sprayer that sprays concrete onto the tunnel face and periphery, which are the concrete spraying surface and the excavation surface, A self-propelled spraying cart, a nozzle device including a nozzle boom that is rotatably attached to the spraying cart and is extendable and contractible, and a nozzle that is attached to the tip of the nozzle boom and that ejects concrete; a control device that determines coordinates of at least the measurement points on the peripheral surface; Two 3D scanners are attached to the left and right positions in front of the spraying cart, A concrete sprayer characterized in that the scanning central axes of the 3D scanners located on the left and right are each set in the direction of the circumferential surface on the opposite side of the center of the face.

2. Two erectors that are rotatably attached to the spraying cart, are extendable and retractable in their axial directions, and grip the supports are attached to the left and right positions in front of the spraying cart, respectively.

2. The concrete sprayer according to claim 1, wherein the 3D scanner is attached near the attachment position of each of the two erectors relative to the spraying carriage.

3. The 3D scanner measures a point cloud which is a plurality of measurement points on the peripheral surface, and each measurement data of the point cloud is transmitted from the 3D scanner to the control device, The control device Create coordinate data for each point cloud based on the received measurement data for each point cloud, storing point cloud data relating to the design excavation surface; storing first coordinates on the excavation surface and second coordinates on the sprayed finish surface corresponding to each point cloud; If the first coordinate is located on the tunnel interior side of the design excavation surface, it is determined that there is a hit portion; A concrete sprayer as described in claim 2, characterized in that if the first coordinate is located on the natural ground side of the design excavation surface, it is determined that there is no impact, and the thickness of the concrete sprayed is calculated based on the first coordinate and the second coordinate.

4. The control device 4. The concrete sprayer according to claim 3, wherein the amount of concrete sprayed is calculated by multiplying the spray thickness of each point group by the spray area that covers each point group.

5. The control device For each point group, coordinate data for the intermediate stage of spraying is created based on one or more intermediate measurements during the spraying process up to the designed sprayed finish surface, The current amount of concrete sprayed during the spraying process is calculated by multiplying the coordinate data of each point group during the spraying process by the spraying area covering each point group. A concrete sprayer as described in claim 4, characterized in that the remaining concrete spraying volume is calculated by the difference between the planned total volume of concrete to be sprayed, which is calculated by multiplying the coordinate data on the designed sprayed finished surface corresponding to each point group by the spraying area covering each point group, and the current concrete spraying volume.

6. The control device The amount of concrete currently used at the intermediate spraying stage is stored; Calculate the rebound rate based on the difference between the amount of sprayed concrete at the intermediate stage of spraying and the amount of used concrete at the current time; 6. The concrete sprayer according to claim 5, wherein the rebound rate is taken into consideration when calculating the remaining amount of concrete to be sprayed.

7. A method for managing tunnel excavation and concrete spraying, which determines whether or not there is a bump on the circumferential surface when spraying concrete onto the face and circumferential surface of a tunnel after excavation, which are the concrete spraying surface and the excavation surface, and calculates the thickness of the concrete sprayed, A concrete sprayer is used, which includes a self-propelled spraying cart, a nozzle device that is rotatably attached to the spraying cart and that sprays concrete, and two 3D scanners that are installed on the left and right positions in front of the spraying cart, and the scanning central axes of the 3D scanners located on the left and right are each set in the direction of the peripheral surface that is on the opposite side from the center of the face, The 3D scanner measures a point cloud that is a plurality of measurement points on the peripheral surface before spraying the concrete, Create coordinate data for each point cloud based on the measurement data for each point cloud, Prepare point cloud data relating to a design excavation surface, first coordinates on the excavation surface corresponding to each point cloud, and second coordinates on a sprayed finish surface that is constructed so as to be located closer to the natural ground than the design sprayed finish surface; If the first coordinates corresponding to each point group are located on the tunnel interior side of the design excavation surface, it is determined that there is a hit, and the hit is to be re-excavated; A method for managing tunnel excavation and concrete spraying, characterized in that if the first coordinates corresponding to each point cloud are on the natural ground side of the design excavation surface, it is determined that there is no contact area, and the thickness of the concrete sprayed is calculated based on the first coordinates and the second coordinates.

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