Handling system and segment installation method

Abstract

This invention provides a handling system and a segment installation method that enable efficient segment installation inside existing tunnels without interfering with obstacles. [Solution] The handling system 400 is for gripping a segment 60 and installing it inside an existing tunnel 10, and comprises a handling machine 200 and an operating terminal 300. The handling machine 200 comprises a base machine 230 equipped with an operating room 212 and a self-propelled means 220, a plurality of booms 240, 250, 260 that are movably supported relative to the base machine 230 and are rotatably connected to each other via a plurality of joints, and a gripping device 270 attached to the tip of a boom 260 for gripping a segment 60. The operation of the booms 240, 250, 260 is controlled by an operating panel 215 installed in the operating room 212, and the gripping device 300 is operated wirelessly from an operating terminal 300 located away from the operating room 212.

Description

Technical Field

[0001] The present invention relates to a handling system and a method for installing segments.

Background Art

[0002] In order to prevent existing tunnels used for subways and underpasses from collapsing due to large-scale earthquakes, seismic reinforcement work is being carried out everywhere, in which a secondary lining is constructed inside the primary lining that forms the existing tunnel. Taking the structure of an existing tunnel to be reinforced that has been in existence for decades as an example, a primary lining formed by a plurality of concrete segments or the like, having a circular or horseshoe-shaped cross-sectional shape as a basic structure, has a concrete invert (invert concrete) provided below the inside of the primary lining, a concrete trough (trough concrete) provided on the invert, shotcrete provided on the inner wall surface of the primary lining above the trough concrete, a track bed laid on the invert, and a track provided on the track bed. When constructing a secondary lining inside an existing tunnel, the aged trough concrete and shotcrete are removed, and after installing a waterproof sheet or the like on the inner wall surface of the primary lining, the secondary lining is constructed.

[0003] When the existing tunnel to be reinforced is, for example, a railway tunnel (operating line tunnel), overhead lines, high-voltage lines, arrestor lines, etc. are suspended above the inside of this railway tunnel and extend in the axial direction of the tunnel. Therefore, when constructing the secondary lining within a limited construction time (nighttime line closure and power outage time) while the railway tunnel is in service, it is necessary to construct the secondary lining while preventing interference with these various overhead lines. Also, in order to efficiently construct the secondary lining within such a limited construction time, instead of the method of constructing the secondary lining by casting concrete on site, a method of transporting factory-produced segments to the site and assembling them on site to construct the secondary lining is preferable. However, even when precast segments are assembled on-site, installing them in an environment where various overhead wires and other obstacles hang down inside the existing tunnel lining (primary lining) is not easy.

[0004] Therefore, when installing segments inside existing tunnels, there is a need for a handling system and a segment installation method that can efficiently install segments without interfering with obstacles.

[0005] Here, Patent Document 1 proposes a segment handling device. This segment handling device is used when installing reinforcing segments on the inner wall surface of an existing tunnel, and comprises a base that can be mounted on a trolley that travels on a track laid inside the existing tunnel, a slewing driver's cab that is movably supported on the base, a moving mechanism that moves the slewing driver's cab in the tunnel axis direction and the tunnel cross-sectional direction, a multi-joint boom that is supported on the slewing driver's cab and can be operated from the inside, and a segment gripping part that is attached to the multi-joint boom and directly grips the reinforcing segments. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2001-254598 [Overview of the project] [Problems that the invention aims to solve]

[0007] According to the segment handling device described in Patent Document 1, construction efficiency can be improved by ensuring ease of alignment. However, even with the segment handling device described in Patent Document 1, since the segments are installed by an operator inside the driver's cab operating a boom, it is extremely difficult for the operator to operate the boom, etc., to move and install the segments to the installation site while preventing interference with multiple overhead wires and other obstacles, and thus the installation process is extremely time-consuming.

[0008] The present invention aims to provide a handling system and a method for installing segments that can efficiently install segments inside an existing tunnel without interfering with obstacles. [Means for solving the problem]

[0009] To achieve the aforementioned objective, one aspect of the handling system according to the present invention is: A handling system for gripping segments and installing them inside existing tunnels, It has a handling machine and an operating terminal, The aforementioned handling machine is A base machine equipped with a control room and self-propelled means, Multiple booms are movably supported on the base machine and are rotatably connected to each other via multiple joints, The boom is equipped with a gripping device that is attached to the tip of the boom and grips the segment, The operation of the boom is controlled by a control panel installed in the control room. The gripping device is characterized by being operated wirelessly from the operating terminal located away from the operating room.

[0010] According to this embodiment, the operation of multiple booms of the handling machine is controlled by an operator in the base machine's control room via a control panel, and the operation of the gripping device, which is attached to the tip of the boom and grips the segment, is controlled by a worker other than the operator in the control room via an operating terminal at a position where the segment can be seen. This ensures that interference with obstacles inside the existing tunnel is reliably prevented, and the segment can be efficiently installed in the installation position. Here, for example, the gripping device is equipped with a control panel, and the drive unit of the gripping device is controlled by the control panel upon receiving command signals from the operating terminal.

[0011] For example, an operator can move the boom to bring the segment close to the vicinity of overhead wires or other structures near the segment's installation location. Then, a worker positioned to see the segment can rotate the gripping device via a control terminal to change the segment's orientation to prevent interference with overhead wires or other structures. By further operating the gripping device, the segment can be installed in its designated location.

[0012] Furthermore, in another embodiment of the handling system according to the present invention, The gripping device is equipped with an electric cylinder. The operation of the electric cylinder is controlled by a command signal from the control terminal, thereby adjusting the orientation of the segment to be installed.

[0013] According to this embodiment, the gripping device is equipped with an electric cylinder, and the operation of the electric cylinder is controlled by a command signal from an operating terminal, thereby eliminating the need for wired operation of the gripping device. For example, if the gripping mechanism of the gripping device is a conventional hydraulic jack (hydraulic control system), a hydraulic hose is connected to the hydraulic jack, and a manual lever device for operating the jack is connected to the hydraulic hose. Therefore, in addition to the operator of the base machine, a worker is required to manually operate the hydraulic jack, and another worker is required to guide the hydraulic hose to prevent it from getting caught on various equipment in the tunnel. When guiding the hydraulic hose, the worker may have to stand directly beneath the segment gripped by the hydraulic jack, and there is also a risk of the worker tripping and falling when moving to guide the hose, so there are issues regarding work safety.

[0014] In contrast, in this embodiment, since an electric cylinder is applied to the gripping mechanism, the need for hydraulic hose assistance is eliminated, preventing the dangers associated with assistance, reducing the number of workers required for hydraulic hose assistance and manual operation of hydraulic jacks, and allowing workers to remotely operate the gripping device via an operating terminal from a safe position away from the gripped segment while still being able to see the segment.

[0015] Furthermore, in another embodiment of the handling system according to the present invention, The aforementioned boom included, A mast that can be raised and lowered relative to the base machine, An arm is rotatably mounted to the mast via the joint, The tilt mechanism is rotatably mounted to the arm via the joint, The gripping device is attached to the end of the tilt mechanism.

[0016] According to this aspect, the boom of the handling machine includes a mast that can be raised and lowered, an arm that is rotatably attached to the mast, and a tilt that is rotatably attached to the arm. Since a gripping device is attached to the tilt, it is possible to install segments at various installation positions in an existing tunnel while avoiding obstacles such as overhead lines.

[0017] Also, in another aspect of the handling system according to the present invention, at least one of the arm and the tilt is provided with a telescopic mechanism, and the tilt is characterized by having a rotation mechanism that rotates around its axis.

[0018] According to this aspect, by providing a telescopic mechanism for one or both of the arm and the tilt, and further providing a rotation mechanism for the tilt to rotate around its axis, the handling performance of the segment can be further enhanced.

[0019] Also, in another aspect of the handling system according to the present invention, the gripping device has a pair of gripping parts that grip a steel plate having a first bolt hole that constitutes the segment, and each of the pair of gripping parts is provided with a second bolt hole, and a rod is inserted through the pair of mutually aligned second bolt holes and the first bolt hole, and the segment is fixed to the pair of gripping parts.

[0020] According to this aspect, one of the main girder, joint plate, and vertical rib made of a steel plate that constitutes the segment is sandwiched by a pair of gripping parts provided in the gripping device, and a rod is inserted through the first bolt hole of the steel plate and the second bolt hole of the gripping part that are mutually aligned to fix the segment to the gripping part. Therefore, both smooth gripping of the segment by the gripping part and smooth removal of the segment from the gripping part can be achieved by fixing with the insertion of the rod and removal by pulling out the rod.

[0021] Furthermore, one embodiment of the segment installation method according to the present invention is: A method for installing segments, which involves installing segments inside an existing tunnel where an obstacle exists above the interior space, A base machine equipped with a control room and self-propelled means, Multiple booms are movably supported on the base machine and are rotatably connected to each other via multiple joints, A handling machine comprising a gripping device attached to the tip of the boom for gripping the segment, wherein the operation of the boom is controlled by an operating panel installed in the control room, Preparation steps include preparing an operating terminal located away from the operating room for wirelessly operating the gripping device, The present invention is characterized by comprising a segment installation step, in which the gripping device grips the segment and, while operating the plurality of booms, installs the segment at the inner installation position without interfering with the obstacle.

[0022] According to this embodiment, the operation of multiple booms of the handling machine is controlled by an operator in the base machine's control room via a control panel, and the operation of the gripping device attached to the tip of the boom that grips the segment is controlled by a worker other than the operator in the control room via an operating terminal at a position where the segment can be seen. This ensures that interference with obstacles inside the existing tunnel is reliably prevented, and the segment can be efficiently installed in the installation position, resulting in a highly safe and efficient segment installation process. Therefore, the segment installation method of this embodiment is suitable for the construction of secondary lining in railway tunnels where construction time is limited by nighttime track closures and power supply shutdowns.

[0023] Here, various types of precast segments can be used for installation, including steel segments, concrete segments, and composite segments with concrete filled inside a steel shell. However, steel segments are suitable for installation in environments where construction time is limited, as they possess high rigidity while being as lightweight as possible, offer excellent handling, and allow for flexible processing to wrap around the inside of the primary lining to conform to its shape.

[0024] Furthermore, in another aspect of the segment installation method according to the present invention, The gripping device is equipped with an electric cylinder. The system is characterized by transmitting a command signal from the control terminal to operate the electric cylinder and adjust the orientation of the segment to be installed.

[0025] According to this embodiment, the gripping device is equipped with an electric cylinder, and the operation of the electric cylinder is controlled by a command signal from an operating terminal. For example, if the gripping mechanism of the gripping device is a conventional hydraulic jack (hydraulic control system) and a hydraulic hose is connected to the hydraulic jack, it becomes unnecessary to require a worker to manually operate the hydraulic jack and a worker to manage the hydraulic hose inside the tunnel. This reduces the number of workers required, thereby improving construction safety inside the tunnel and dramatically improving the operability of the gripping device. [Effects of the Invention]

[0026] According to the handling system and segment installation method of the present invention, segments can be installed efficiently inside an existing tunnel without interfering with obstacles. [Brief explanation of the drawing]

[0027] [Figure 1] This figure shows a cross-sectional view perpendicular to the axis of an example of a renewed tunnel according to the embodiment, and following Figure 5, is a process diagram of an example of a construction method for the renewed tunnel according to the embodiment. [Figure 2]This figure shows a cross-sectional view perpendicular to the axis of an example of an existing tunnel before its renewal. [Figure 3] This is a process diagram of an example of a construction method for a renewed tunnel according to the embodiment. [Figure 4A] This is an enlarged view of section IV in Figure 3. [Figure 4B] This diagram illustrates the track bed retaining wall before the construction of the foundation concrete shown in Figure 4A. [Figure 5] Following Figure 3 is a process diagram illustrating an example of a construction method for a renewed tunnel according to this embodiment. [Figure 6A] This is an enlarged view of section VI in Figure 5. [Figure 6B] This is a view from arrow BB in Figure 6A. [Figure 6C] This is a view from the CC arrow in Figure 6A. [Figure 7] This is a perspective view of an example of a steel segment forming a secondary lining. [Figure 8A] This diagram shows the setup of guide materials to which surveying targets are attached. [Figure 8B] This diagram shows the process of measuring the coordinates of each position on the guide material using surveying equipment. [Figure 9] This diagram illustrates the construction section and construction sequence in the construction method for a renewed tunnel according to the embodiment. [Figure 10] This diagram outlines the design concept and design method of a renewal tunnel according to an embodiment. [Figure 11] This figure shows an example of a handling system according to an embodiment, and also shows an example of a method for installing a segment according to the embodiment. [Figure 12] This diagram shows the state before and after tilt extension, and also illustrates the change in the segment's orientation by the gripping device. [Figure 13] This is a side view showing an example of a handling machine before the gripping device is attached. [Figure 14A] This figure shows the gripping device gripping a steel segment. [Figure 14B]This is a view from the direction of arrow B in Figure 11A. [Figure 15] This figure shows the installation of steel segments by a handling machine, and also illustrates an example of a segment installation method according to the embodiment. [Figure 16] This figure shows an example of the hardware configuration of an operation panel, control panel, and operation terminal. [Figure 17] This diagram shows an example of the functional configuration of an operation panel, a control panel, and an operation terminal. [Modes for carrying out the invention]

[0028] The following describes the renewed tunnel according to the embodiment, its construction method, the handling system, and the segment installation method, with reference to the attached drawings. In this specification and the drawings, substantially identical components are denoted by the same reference numerals to avoid redundant explanations.

[0029] [Renewal tunnel according to an embodiment, its construction method, handling system, and segment installation method] Referring to Figures 1 to 17, an example of a renewed tunnel according to an embodiment, its construction method, handling system, and segment installation method will be described. Here, Figure 1 shows a cross-sectional view perpendicular to the axis of an example of a renewed tunnel according to the embodiment, and Figure 2 shows a cross-sectional view perpendicular to the axis of an example of an existing tunnel before renewal. Also, Figures 3, 5, and 1 are, in order, process diagrams of an example of a construction method for a renewed tunnel according to the embodiment. Furthermore, Figure 4A is an enlarged view of part IV of Figure 3, Figure 4B is a diagram explaining the retaining wall of the track bed before the construction of the foundation concrete shown in Figure 4A, Figure 6A is an enlarged view of part VI of Figure 5, Figure 6B is a view from arrow BB in Figure 6A, and Figure 6C is a view from arrow CC in Figure 6A. Furthermore, Figure 7 is a perspective view of an example of a steel segment forming a secondary lining, Figure 8A shows the installation of a guide material to which a surveying target is attached, and Figure 8B shows the measurement of the coordinates of each position of the guide material using surveying equipment. Furthermore, Figure 9 is a diagram illustrating the construction section and construction sequence in the construction method of the renewed tunnel according to the embodiment, and Figure 10 is a diagram outlining the design concept and design method of the renewed tunnel according to the embodiment.

[0030] As shown in Figure 1, the renewed tunnel 100 is formed by constructing a secondary lining 70 inside the primary lining 11 that forms the existing tunnel 10, as shown in Figure 2.

[0031] The existing tunnel 10 in the illustrated example is a railway tunnel that was constructed underground G and has been in operation for several decades. Its basic structure consists of a primary lining 11, which is formed by assembling multiple concrete segments in the circumferential direction via segment joints to form segment rings, and then joining multiple segment rings in the axial direction (longitudinal direction) of the tunnel via ring joints.

[0032] In order to prevent the primary lining 11 from collapsing due to a large earthquake, a secondary lining is constructed inside the primary lining 11 as seismic reinforcement, thereby forming the renewed tunnel 100.

[0033] In the illustrated example, the cross-sectional shape of the primary lining 11 perpendicular to the axis is arc-shaped, with an invert 13 (invert concrete) provided below the inside, trough concrete 18 provided at the left and right ends of the upper surface of the invert 13, a track bed 15 laid on the upper surface of the invert 13, and rails 17 for up-line and down-line vehicles laid axially on the track bed 15. In addition, drainage facilities such as a drainage ditch extending axially are provided at the central position above the invert 13.

[0034] The inner wall surface of the primary lining 11 is coated with sprayed concrete 19, and various ancillary equipment is installed inside the sprayed concrete 19. These ancillary facilities are all axially extending, and the overhead lines B1, lighting equipment B2, low-voltage lines B3, high-voltage lines B4, leaky coaxial cable B5 (LCX), handrails B6, and water supply pipes B7 are shown as examples of ancillary equipment for a railway tunnel.

[0035] In the tunnel renovation method described below, the existing tunnel 10 to be renovated is a railway tunnel (operational line tunnel), and the construction will be carried out under restricted working hours, such as during nighttime track closures and power supply shutdowns, while continuing railway operations during business hours. When constructing the secondary lining inside the primary lining 11, these various ancillary facilities will be maintained without being removed.

[0036] Therefore, various ancillary facilities become obstacles during construction, and the construction requires efficient and safe construction within the limited construction time as described above, without interfering with these obstacles, and a reduction in the construction period.

[0037] As is clear from comparing Figure 2 and Figure 1, the trough concrete 18 in the existing tunnel 10 is chipped away and removed, and the shotcrete 19 is similarly chipped away and removed, after which the secondary lining 70 is formed inside the primary lining 11.

[0038] More specifically, a waterproof sheet 30 is laid on the inner wall surface of the primary lining 11, foundation concrete 20 is formed in the areas where the trough concrete 18 is removed at the left and right ends of the upper surface of the invert 13, height adjustment segment pieces 50 are provided on top of the foundation concrete 20, and multiple steel segment pieces 60 are assembled on top of the left and right height adjustment segment pieces 50 to form the secondary lining 70. The space behind the secondary lining 70 (the space between the secondary lining 70 and the waterproof sheet 30) is filled with a backfill material such as mortar to form the renewed tunnel 100.

[0039] An example of a construction method for a renewed tunnel is as follows:

[0040] As shown in Figure 3, the trough concrete 18 is chipped away and the lower portion of the sprayed concrete 19 is chipped away and removed from the existing tunnel 10 shown in Figure 2.

[0041] After removing the trough concrete 18 and the lower portion of the sprayed concrete 19, the trough concrete 18 is removed and foundation concrete 20 is poured onto the left and right ends of the upper surface of the invert 13 that is exposed.

[0042] Here, as shown in Figure 4B, when constructing the foundation concrete 20, a retaining wall 15A is installed at the end of the track bed 15. The retaining wall 15A in the illustrated example is formed by angle steel extending in the axial direction.

[0043] The installation of this track bed retaining wall 15A prevents the track bed 15 from collapsing laterally when construction vehicles such as heavy machinery travel on the rails 17 during the construction period from the removal of the trough concrete 18 to the construction of the foundation concrete 20.

[0044] When installing the waterproof sheet 30, the inner wall surface of the primary lining 11 is smoothed by scraping or other means, and the waterproof sheet 30 of the specified size is laid out. The ends of the waterproof sheets 30 overlap each other and are fixed to the primary lining 11 with anchors (not shown), and the overlapping parts are joined by welding or other means. In addition, in areas where localized waterproofing is required, a separate waterproof sheet 30A is laid out as shown in Figure 4B.

[0045] Furthermore, as shown in Figure 4B, the upper surfaces of the left and right ends of the invert 13 are shaped into cut surfaces 13a with a predetermined inclination angle θ1. Foundation concrete 20 will be poured onto the cut surfaces 13a, and the inclination angle θ1 of the cut surfaces 13a is set to a predetermined angle that allows the axial force acting from the secondary lining installed above to be sufficiently transmitted to the invert 13 via the foundation concrete 20, and prevents the foundation concrete 20 from shifting laterally.

[0046] Next, as shown in Figure 4A, the lower part of the fixing anchor 25 is driven into the invert 13 through the cut surface 13a of the invert 13, and the upper part of the fixing anchor 25 is made to protrude. Then, the foundation reinforcement bars 23 are placed and concrete is poured, thereby constructing the foundation concrete 20 while joining it to the invert 13. The upper surface of the foundation concrete 20 is constructed on a horizontal surface, for example, as shown in the example.

[0047] In this way, by constructing foundation concrete 20 on top of the invert 13 and then constructing secondary lining 70 on top of the foundation concrete 20, the legs of the secondary lining 70 are supported by the newly constructed foundation concrete 20 and are not directly supported by the invert 13, which is a component of the existing tunnel 10. This allows for the formation of a renewed tunnel 100 in which the legs of the secondary lining are stably supported (the above describes the foundation concrete construction process).

[0048] Next, as shown in Figures 3 and 4A, a waterproof sheet 30 is laid below the inner wall surface of the primary lining 11 (part of the waterproof sheet installation process), the lower part of the fixing anchor 43 is driven into the upper surface of the foundation concrete 20, and the upper part of the fixing anchor 43 is made to protrude. Then, a height adjustment plate 41 is placed with a gap from the upper surface of the foundation concrete 20, and the upper part of the fixing anchor 43 is inserted through a bolt hole (not shown) provided in the height adjustment plate 41 to secure it.

[0049] Because the primary lining 11 is aging, there is a possibility that groundwater in the ground G may seep into the interior of the primary lining 11 through cracks and other openings in the primary lining 11. Therefore, a drainage pipe 35 made of PVC pipe or the like is installed, which runs from the primary lining 11 through the gap between the foundation concrete 20 and the height adjustment plate 41 and leads to the drainage facility 16 (see Figure 1, etc.) located above the invert 13. Leakage water flowing from the back of the primary lining 11 in the X1 direction is drained to the drainage facility 16 via the drainage pipe 35. This drainage pipe 35 will remain in place not only during construction but also after the completion of the renewed tunnel 100, and will be used for the continuous drainage of leakage water from the primary lining 11.

[0050] Next, as shown in Figure 5, a height adjustment segment piece 50 is installed on a height adjustment plate 41 which is placed on top of the foundation concrete 20 with a gap between them.

[0051] More specifically, as shown in Figure 6A, the gap between the foundation concrete 20 and the height adjustment plate 41 is filled with non-shrink mortar 45 to close the gap, and then the height adjustment segment piece 50 is installed on the upper surface of the height adjustment plate 41.

[0052] As shown in Figures 6A to 6C, the height-adjusting segment piece 50 comprises an outer main girder 51 and an inner main girder 52, a base plate 53, a joint plate 56, and a skin plate 54 joined to these. The base plate 53 is provided with a plurality of bolt holes 55, and fixing anchors 43 are inserted through each bolt hole 55.

[0053] Thus, instead of directly installing steel segment pieces on the upper surface of the foundation concrete 20, a height adjustment plate 41 and height adjustment segment pieces 50 are installed above the foundation concrete 20, and the steel segment pieces 60 are installed on top of the height adjustment segment pieces 50. This allows for smooth adjustment of the installation height of the secondary lining during construction, and the height adjustment segment pieces 50 are installed on a highly flat installation surface (the surface of the height adjustment plate 41). As a result, a secondary lining 70 and a renewed tunnel 100 with high construction accuracy can be constructed under excellent workability conditions.

[0054] After installing the height-adjusting segment pieces 50, the upper sprayed concrete 19 (see Figure 5) remaining on the inner wall surface of the primary lining 11 is removed, and the waterproof sheet 30 is installed over the entire inner wall surface of the primary lining 11 (waterproof sheet installation process).

[0055] Next, a segment ring is formed by installing a steel segment piece 60 on top of the height-adjusting segment piece 50, and the secondary lining 70 shown in Figure 1 is constructed by joining multiple segment rings in the axial direction.

[0056] As shown in Figure 7, the steel segment pieces 60 that form the secondary lining 70 include, for example, a pair of outer main girders 61 and inner main girders 62, a pair of joint plates 63 (segment joint plates), longitudinal ribs 67 that connect the main girders, and skin plates 65 that are joined to these.

[0057] The outer main girder 61 and joint plate 63 are provided with bolt holes 68 through which bolts (not shown) are inserted to form ring joints or segment joints with other adjacent steel segment pieces 60, and the inner main girder 62 is also provided with bolt holes 68.

[0058] The gripping device 270 (see Figure 11, etc.) of the handling machine 200 described below grips a suitable member (steel plate) from among the main girders 61, 62 and joint plates 63, aligns the second bolt hole 278 (see Figures 14A, 14B) of the gripping device 270 with the bolt hole 68 (first bolt hole), inserts the rod 279 to fix the steel segment piece 60 to the gripping device 270, and then moves and installs the steel segment piece 60 to the installation position.

[0059] The secondary lining forming the renewed tunnel is not constructed using cast-in-place concrete, but rather by transporting and assembling multiple factory-fabricated steel segment pieces 60 on-site. This significantly shortens the construction period. Because construction can be completed in such a short time, this segment is suitable for situations where the existing tunnel 10 is a railway tunnel used for commercial purposes, as shown in the illustrated example, and where construction time is limited due to nighttime track closures and power outages.

[0060] Furthermore, by using steel segment pieces 60, it is possible to eliminate issues that arise when using concrete segment pieces, which are also precast products, such as quality degradation due to chipping of corners during construction and reduced handling due to the heavy weight of the pieces (the above describes the secondary lining construction process).

[0061] The steel segment piece 60 further comprises a filling pipe 69, and a filling hole (not shown) is provided in the skin plate 65 at a position corresponding to the filling pipe 69.

[0062] After the steel segment pieces 60 are installed in their respective locations, the renewed tunnel 100 is constructed by filling the back of the steel segment pieces 60 with a backfill material 80 such as mortar from inside the tunnel through the filling pipes 69 of any of the steel segment pieces 60.

[0063] By filling the back of the secondary lining 70 with backfill material 80, any voids that may occur behind the secondary lining 70 can be eliminated. For example, when the primary lining 11 collapses during an earthquake and the secondary lining 70 resists the surrounding earth pressure and soil water pressure, the earth pressure and soil water pressure acting on the secondary lining 70 can be equalized (backfill material filling process).

[0064] The refurbished tunnel 100 to be constructed will have a double waterproofing structure formed by the waterproof sheet 30 and backfill material 80 on the inner wall surface of the primary lining 11, and if waterproofing materials such as gaskets (not shown) are installed on the outer surface (ring joint surface) of the outer main girder 61 and the outer surface (segment joint surface) of the joint plate 63 of the steel segment piece 60, it will have a triple waterproofing structure, thus resulting in a refurbished tunnel with excellent waterproofing.

[0065] In the secondary lining construction process, as shown in Figures 8A and 8B, when constructing the first steel segment ring formed at the front, a guide material 90 is installed inside the primary lining 11 to define the position where the secondary lining 70 should be constructed.

[0066] A target 92 is attached to the guide material 90, and as shown in Figure 8B, multiple guide materials 90 are assembled in the circumferential direction, and the first steel segment ring is installed adjacent to them.

[0067] Here, the positions of the targets 92 of the multiple guide materials 90 assembled in the circumferential direction are measured in the X5 direction using surveying equipment 95 such as a total station installed inside the tunnel, and the three-dimensional coordinates of each target 92 are identified, thereby enabling measurement and management of the secondary lining 70 that will be constructed thereafter.

[0068] Although not shown in the diagram, during the construction of the secondary lining 70, the width of the spring line of the secondary lining is measured with a measuring tape, and the height from the spring line to the top of the secondary lining 70 is measured, thereby determining the three-dimensional coordinates of each part of the secondary lining 70, as well as the internal space.

[0069] Furthermore, in the construction of the secondary lining 70, as shown in Figure 9, the construction section of the secondary lining 70 (renewal tunnel construction section) of a predetermined length, which consists of multiple segment rings 60A connected in the axial direction, is divided into three construction sections with different construction timings: the first phase (section 1-1, section 1-2, section 1-3, ...), the second phase (section 2-1, section 2-2, section 2-3, ...), and the third phase (section 3-1, section 3-2, ...). The first and second phase construction sections are set alternately, and the third phase construction section is set between the first and second phase construction sections, with the first, second, and third phase construction sections being constructed in that order. Note that in Figure 9, the axial width of one segment ring 60A is, for example, about 1m to 1.5m.

[0070] First, in order to carry out construction on sections 1-1, 1-2, 1-3, etc., which are included in the first phase of construction, various facilities that were installed in the first phase of construction (fixing members for temporarily fixing overhead line B1, etc.) will be moved to the second phase of construction sections, such as sections 2-1, 2-2, 2-3, etc., and then construction on the first phase of construction will be carried out after the move.

[0071] After the construction of the first phase section is completed, the sections included in the second phase section, such as sections 2-1, 2-2, 2-3, etc., will be constructed simultaneously. In doing so, various facilities that were installed in the second phase section before construction (including facilities that were relocated and installed before construction of the first phase section) will be moved to the first phase section where the secondary lining has been completed, and then construction of the second phase section will proceed after the relocation.

[0072] After the construction of the first construction section is completed and the construction of the second construction section is finished, when constructing the third construction section, the width between the first and second construction sections is measured and one or more segment rings 60A are installed (two segment rings 60A are installed in the third construction section shown in the illustration) to connect the first, second, and third construction sections and construct the secondary lining 70 over the entire area of ​​the renewal tunnel construction section.

[0073] This construction method allows for the construction of the secondary lining 70 while continuously adjusting it throughout the entire construction period, without having to remove any equipment.

[0074] Furthermore, by having the third construction section, which is set between the first and second construction sections, be constructed last, the width between the first and second construction sections can be measured during the construction of the third construction section, and one or more segment rings 60A can be installed. This allows for a smooth continuity between the first, second, and third construction sections, making it possible to construct the renewal tunnel 100 efficiently.

[0075] Next, referring to Figure 10, we will outline the design philosophy and design method of the illustrated example of the Renewal Tunnel 100.

[0076] The primary lining 11 of the existing tunnel 10, which was constructed several decades ago, may lose its ability to withstand soil and water pressure due to a Level 2 earthquake.

[0077] Based on the design philosophy and design methods shown in Figure 10, a renewed tunnel including secondary lining will be designed, taking into account the tunnel's condition during a Level 2 earthquake, its condition under normal circumstances after a Level 2 earthquake, and its condition when subjected to a Level 1 earthquake after a Level 2 earthquake.

[0078] First, regarding the modeling of the tunnel during the design process, the tunnel is modeled as an equivalent stiffness beam (not shown), and when the tunnel passes through a fault, the fault displacement load is applied to the equivalent stiffness beam to perform a cross-sectional check of the tunnel.

[0079] Regarding the analysis of Level 2 earthquakes, the design will be carried out using the limit state design method, assuming that soil and water pressure will be borne by the primary lining, and that only Level 2 loads will act on the secondary lining.

[0080] Regarding the normal state after a Level 2 earthquake, the design will be carried out using the allowable stress design method. The primary lining will be assumed to have lost its load-bearing capacity due to the Level 2 earthquake, and the secondary lining will be designed based on the design concept that only the secondary lining will bear the soil and water pressure.

[0081] Regarding the consideration of what happens when a Level 1 earthquake occurs after a Level 2 earthquake, the design will be carried out using the allowable stress design method. The primary lining will be assumed to have lost its load-bearing capacity due to the Level 2 earthquake, and the secondary lining will be designed based on the design concept that only the secondary lining will bear the soil and water pressure and seismic loads.

[0082] Based on the above design philosophy and design method, the aging primary lining 11 does not have the capacity to withstand soil and water pressure caused by a Level 2 earthquake, while the secondary lining 70 has the capacity to withstand a Level 2 earthquake and is designed to withstand soil and water pressure after a Level 2 earthquake. Thus, the secondary lining 70 and the renewed tunnel 100 equipped with it can be designed under a rational design philosophy.

[0083] Next, with reference to Figures 11 to 17, a handling system according to an embodiment applied to the construction method of a renewal tunnel, and a method for installing segments using this handling system will be described.

[0084] The handling system 400 comprises a handling machine 200 and an operating terminal 300 carried by a worker (not shown) who is in a safe and visible position within the tunnel, away from the handling machine 200, where the steel segment piece 60 gripped by the handling machine 200 can be seen.

[0085] The handling machine 200 has a base machine 230 and a plurality of booms 240, 250, and 260 that are movably supported relative to the base machine 230, and a gripping device 270 for gripping steel segment pieces 60 is attached to the tip of the boom 260.

[0086] Referring to Figure 13, the configuration of the base machine 230 will be explained in detail. The illustrated base machine 230 has a self-propelled means 220 consisting of caterpillar tracks or the like, and an upper rotating body 210 that is mounted above the self-propelled means 220 so as to be rotatable in the Y1 direction.

[0087] The upper slewing body 210 is provided with a control room 212 equipped with a control panel 215 from which an operator (not shown) can operate the drives of the upper slewing body 210 and each of the booms 240, 250, and 260.

[0088] The boom 240, which is directly attached to the upper slewing body 210, is a mast, and the mast 240 is mounted so as to be able to move up and down in the Y2 direction relative to the upper slewing body 210.

[0089] The boom 250, which is rotatably mounted on the joint 245 of the mast 240, is an arm, and the lower end of the arm 250 and the upper slewing body 210 are connected by a hydraulic cylinder 218, and the arm 250 rotates in the Y4 direction with the joint 245 as the pivot point due to the sliding of the cylinders that make up the hydraulic cylinder 218.

[0090] The arm 250 is configured to extend and retract freely in the Y5 direction, with two components joined together via an extension mechanism 252 consisting of a hydraulic cylinder.

[0091] The arm 250 is equipped with a separate hydraulic cylinder 254, which is rotatably mounted on the joint 256. One end of the hydraulic cylinder 254 is attached to the boom 260 (tilt).

[0092] Driven by the hydraulic cylinder 254, the tilt 260 rotates in the Y6 direction around the pivot point 264.

[0093] The tilt 260 is configured to be extendable and retractable in the Y7 direction, with two components joined together via an extension mechanism 262 consisting of a hydraulic cylinder.

[0094] The base of the Tilt 260 is equipped with a servo motor 266, which is a rotation mechanism. The Tilt 260 rotates in the Y8 direction when driven by the servo motor 266. In other words, the Tilt 260, which is located at the tip of the boom, is capable of both extension and rotation.

[0095] A gripping device 270, which is illustrated in detail in Figures 14A and 14B, is attached to the tip (end portion 268) of the tilt 260.

[0096] In this way, the base machine 230 enables the transfer of steel segment pieces 60 to predetermined installation locations within the narrow interior of the existing tunnel 10, while avoiding interference with obstacles such as overhead power lines B1, by having multiple booms 240, 250, and 260 move up and down, rotate, extend and retract, and rotate.

[0097] The handling machine 200, configured as described above, is installed at a construction site inside the existing tunnel 10. Inside the tunnel, away from the handling machine 200, a worker carries an operating terminal 300 and completes preparations for operating the gripping device 270 (preparation step for segment installation method).

[0098] As shown in Figures 14A and 14B, the gripping device 270 includes an electric cylinder 275 and a control panel 272. As shown in Figure 11, the control panel 272 receives a command signal transmitted in the Z1 direction from an operating terminal 300 carried by a worker located away from the base machine 230. As shown in Figure 14B, the electric cylinder 275 is operated to extend and retract in the Y10 direction based on the received command signal, and the steel segment piece 60 to be installed is rotated in the Y11 direction around the pivot point 271 to adjust its posture.

[0099] Here, the gripping device 270 has a pair of gripping parts 277, and in the illustrated example, the pair of gripping parts 277 grip the inner main girder 62 that constitutes the steel segment piece 60.

[0100] Each of the pair of gripping parts 277 is provided with a second bolt hole 278. When the pair of gripping parts 277 grips the inner main girder 62, the first bolt hole 68 and the two second bolt holes of the inner main girder 62 are aligned with each other, and a rod 279 such as a bolt is inserted through each of the bolt holes 278, 68, thereby gripping and fixing the steel segment piece 60 to the gripping device 270.

[0101] For example, as shown in Figures 11 and 12, an operator in the control room 212 of the base machine 230 operates the mast 240, arm 250, and tilt 260 via the control panel 215 while checking the position of obstacles such as the overhead line B1. This moves the mast 240 upward by a predetermined length, changes the position of the arm 250 and tilt 260 to a perpendicular position to the mast 240, and extends the tilt 260 via its telescopic mechanism 262. During this operation, interference between each boom 240, 250, 260 and the steel segment piece 60 and obstacles such as the overhead line B1 is avoided, and the steel segment piece 60 is moved to the vicinity of its installation position.

[0102] Next, a worker who is in a position where the steel segment piece 60 is visible and safe (for example, not below the steel segment piece 60 or each boom) transmits a command signal in the Z1 direction to the control panel 272 of the gripping device 270 via a portable operating terminal 300.

[0103] Upon receiving the command signal, the control panel 272 drives the electric cylinder 275 in the Y10 direction, fine-tunes the orientation of the steel segment piece 60 by driving the electric cylinder 275, and then installs the steel segment piece 60 in the installation position (segment installation step of the segment installation method).

[0104] In this way, the operation of the multiple booms 240, 250, and 260 of the handling machine 200 is controlled by an operator in the control room 212 of the base machine 230 via the control panel 215, and the operation of the gripping device 270, which is attached to the tip 268 of the tilt 260 and grips the steel segment piece 60, is controlled by a worker other than the operator in the control room 212 via the operation terminal 300 from a position where the steel segment piece 60 can be seen. This ensures that interference with obstacles B1 and other objects inside the existing tunnel 10 is reliably prevented, while efficiently installing the steel segment piece 60 in the installation position.

[0105] Furthermore, since the gripping device 270 is equipped with an electric cylinder 275 and the operation of the electric cylinder 275 is controlled by a command signal from the operation terminal 300, the need for wired operation of the gripping device can be eliminated.

[0106] For example, if the gripping mechanism of the gripping device is a conventional hydraulic jack (hydraulic control system), a hydraulic hose is connected to the hydraulic jack, and a manual lever device for operating the jack is connected to the hydraulic hose. Therefore, in addition to the base machine operator, a worker to manually operate the hydraulic jack and a worker to guide the hydraulic hose to prevent it from getting caught on various equipment in the tunnel are required. When guiding the hydraulic hose, the worker may have to stand directly beneath the segment gripped by the hydraulic jack, and there is also a risk of the worker tripping and falling when moving to guide the hose, so there are issues regarding work safety.

[0107] In contrast, since the gripping device 270 in the illustrated example is fitted with an electric cylinder 275, the need for hydraulic hose handling is eliminated, preventing the dangers associated with handling the hose, reducing the number of workers required for handling the hydraulic hose and manually operating the hydraulic jack, and allowing a worker to remotely operate the gripping device 270 via the operating terminal 300 from a safe position away from the gripped steel segment piece 60, while still being able to see the segment.

[0108] Next, with reference to Figures 16 and 17, we will outline an example of the hardware and functional configuration of the operation panel 215, the control panel 272, and the operation terminal 300, all of which consist of computers.

[0109] As shown in Figure 16, the operation panel 215, the control panel 272, and the operation terminal 300 are composed of an information processing device consisting of a computer. The computer comprising the operation panel 215, the control panel 272, and the operation terminal 300 is equipped with a CPU (Central Processing Unit) 502, main memory 504, auxiliary storage 506, communication interface 508, and input / output interface 510, all of which are interconnected by a connection bus 512. The main memory 504 and auxiliary storage 506 are recording media that can be read by the computer. Note that each of the above components may be provided individually, or some of the components may be omitted.

[0110] The CPU 502, also known as an MPU (Microprocessor) or processor, is a central processing unit that controls the entire system, including the computer-based operation panel 215, control panel 272, and operation terminal 300. For example, the CPU 502 expands a program stored in the auxiliary storage device 506 into an executable format in the working area of ​​the main memory device 504, and controls peripheral devices through program execution, thereby providing functions that meet predetermined purposes.

[0111] The main memory 504 stores computer programs executed by the CPU 502 and data processed by the CPU 502. The main memory 502 includes, for example, flash memory, RAM (Random Access Memory), and ROM (Read Only Memory). The auxiliary storage device 506 stores various programs and various data on a recording medium that can be read and written freely, and is also called an external storage device. The auxiliary storage device 506 stores, for example, the OS (Operating System), various programs, various tables, etc. The OS includes, for example, a communication interface program that exchanges data with external devices connected via the communication IF 508.

[0112] External devices for the control panel 215 include hydraulic cylinders 218, 252, 254, and 262, and servo motor 266, etc. External devices for the control panel 272 include the operating terminal 300, and conversely, external devices for the operating terminal 300 include the control panel 272.

[0113] The auxiliary storage device 506 is used, for example, as a storage area that assists the main memory 504, and stores computer programs executed by the CPU 502, data processed by the CPU 502, etc. The auxiliary storage device 506 is a silicon disk containing non-volatile semiconductor memory (flash memory, EPROM (Erasable Programmable ROM)), a hard disk drive (HDD), or the like.

[0114] The input / output IF510 is an interface for inputting and outputting data between the operation panel 215, the control panel 272, and the devices connected to the operation terminal 300. For example, pointing devices such as touch panels and input devices such as microphones are connected to the input / output IF510. The operation panel 215, the control panel 272, and the operation terminal 300 receive operation instructions from operators operating the input devices via the input / output IF510.

[0115] Furthermore, the input / output IF510 can be connected to display devices such as liquid crystal displays (LCDs) and electroluminescent (EL) panels, as well as output devices such as speakers.

[0116] For example, the display device on the control panel 215 displays two-dimensional and three-dimensional images of the inner wall surface of the primary lining 11 and various obstacles in the vicinity, the three-dimensional coordinates of the installation location where the steel segment piece 60 will be installed next, and the current position of the gripping device 270 when various booms are driven.

[0117] Meanwhile, the display device of the operating terminal 300 displays the installation location of the steel segment piece 60 and the locations of various obstacles, as well as the current position of the steel segment piece 60 being gripped by the gripping device 270.

[0118] The communication IF508 is the interface between the operation panel 215, the control panel 272, and the operation terminal 300, and the cables and networks that connect them. The communication IF508 transmits and receives data to and from each other via various networks, such as wireless networks like mobile phone networks, dedicated networks like VPNs (Virtual Private Networks), and LANs (Local Area Networks).

[0119] As shown in Figure 17, the operation panel 215, the control panel 272, and the operation terminal 300 all provide various functions, at least the communication unit 550, the drive control unit 552, the display unit 554, and the storage unit 556, through the execution of a program by the CPU 502.

[0120] The communication units 550 of the operation panel 215, the control panel 272, and the operation terminal 300 mutually transmit and receive command signals.

[0121] The drive control unit 552 of the control panel 215 performs drive control for hydraulic cylinders 218, 252, 254, 262 and servo motor 266, etc., while the drive control unit 552 of the operation terminal 300 performs drive control for the electric cylinder 275 via the control panel 272.

[0122] The display units 554 of the control panel 215 and the control terminal 300 respectively display the contents of the display devices described above.

[0123] The memory unit 556 of the control panel 215 stores various information, such as the three-dimensional coordinates of each construction section, the three-dimensional coordinates of various obstacles, construction sections where secondary lining has been completed, and construction sections where secondary lining is scheduled to be constructed next.

[0124] The segment installation method using the handling system 400 allows for efficient installation of steel segment pieces 60 at the installation location while reliably preventing interference with obstacles B1 and other objects present inside the existing tunnel 10. This enables segment installation with high construction safety and excellent construction efficiency. For this reason, it is a suitable method for the construction of secondary lining in railway tunnels where construction time is limited due to nighttime track closures and power supply shutdowns.

[0125] Furthermore, other embodiments may be used in which other components are combined with the configurations listed in the above embodiments, and the present invention is not limited in any way to the configurations shown herein. In this regard, modifications can be made without departing from the spirit of the present invention, and can be appropriately determined according to the application form. [Explanation of Symbols]

[0126] 10: Existing tunnels 11: Primary lining 13: Invert 13a: Cut surface 15: Road bed 15A: Track bed retaining wall 16: Drainage equipment 17: Rails 18: Trough concrete 19: Sprayed concrete 20: Foundation concrete 23: Reinforcement bars for foundations 25: Fixing anchors 30: Waterproof sheet 41: Height adjustment plate 43: Fixing anchors 50: Segment piece for height adjustment 51: Outer main girder 52: Inner main girder 53: Bottom plate 54: Skin Plate 55: Bolt hole 56: Joint plate 60: Steel segment piece (segment) 60A: Steel segment ring 61: Outer main girder (main girder) 62: Inner main beam (main beam) 63: Joint plate 65: Skin Plate 67: Vertical Ribs 68: Bolt hole (1st bolt hole) 69: Filling pipe 70: Secondary lining 80: Backfill material 90: Guide material 92: Target 95: Surveying equipment 100: Renewal Tunnel 200: Handling Machine 210: Upper rotating body 212: Control room 215: Control panel 218: Hydraulic Cylinder 220:Self-propelled means 230: Base machine 240: Mast (boom) 242: Hydraulic Cylinder 245: Joint 250: Arm (boom) 252: Hydraulic cylinder (extension mechanism) 254: Hydraulic Cylinder 256: Joints 260: Tilt (Boom) 262: Hydraulic cylinder (extension mechanism) 264: Pivot point 266: Servo motor (rotation mechanism) 268: End (tip) 270: Gripping device 271: Pivot point 272: Control Panel 275: Electric Cylinder 277: Grip part 278: Bolt hole (2nd bolt hole) 279: Rod (bolt) 300: Operating terminal 400: Handling System G: underground, ground B1: Overpass (obstacle) B2: Lighting equipment (obstacles) B3: Low-voltage lines (obstacles) B4: High-voltage power lines (obstacles) B5: Leaky coaxial cable (LCX, obstruction) B6: Handrail (obstacle) B7: Water pipe (obstacle)

Claims

1. A handling system for gripping segments and installing them inside existing tunnels, It has a handling machine and an operating terminal, The handling machine is A base machine equipped with a control room and self-propelled means, Multiple booms are movably supported on the base machine and are rotatably connected to each other via multiple joints, The boom is equipped with a gripping device that is attached to the tip of the boom and grips the segment, The operation of the boom is controlled by a control panel installed in the control room. A handling system characterized in that the gripping device is operated wirelessly from the operating terminal located away from the operating room.

2. The gripping device is equipped with an electric cylinder. The handling system according to claim 1, characterized in that the operation of the electric cylinder is controlled by a command signal from the operating terminal, thereby adjusting the posture of the segment to be installed.

3. The aforementioned boom included, A mast that can be raised and lowered relative to the base machine, An arm is rotatably mounted to the mast via the joint, The tilt mechanism is rotatably mounted to the arm via the joint, The handling system according to claim 2, characterized in that the gripping device is attached to the end of the tilt.

4. At least one of the arm and the tilt is equipped with an extension / retraction mechanism, The handling system according to claim 3, characterized in that the tilt is provided with a rotation mechanism that rotates around its axis.

5. The gripping device has a pair of gripping parts for gripping a steel plate having a first bolt hole that constitutes the segment, Each of the pair of gripping portions is provided with a second bolt hole. The handling system according to claim 1, characterized in that a rod is inserted through a pair of mutually aligned second bolt holes and first bolt holes, and the segment is fixed to the pair of gripping portions.

6. A method for installing segments, which involves installing segments inside an existing tunnel where an obstacle exists above the interior space, A base machine equipped with a control room and self-propelled means, Multiple booms are movably supported on the base machine and are rotatably connected to each other via multiple joints, A handling machine comprising a gripping device attached to the tip of the boom for gripping the segment, wherein the operation of the boom is controlled by an operating panel installed in the control room, Preparation steps include preparing an operating terminal located away from the operating room for wirelessly operating the gripping device, A method for installing a segment, comprising the steps of: gripping the segment with the gripping device and installing the segment at the inner installation position without interfering with the obstacle while operating the plurality of booms.

7. The gripping device is equipped with an electric cylinder. The method for installing a segment according to claim 6, characterized in that a command signal is transmitted from the operating terminal to operate the electric cylinder and adjust the posture of the segment to be installed.

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