Concrete spraying machine and concrete spraying method

Abstract

To provide a concrete spraying machine and a concrete spraying method capable of spraying concrete while efficiently and highly accurately specifying spraying thickness on both a face and a circumferential surface, which are spraying surfaces.SOLUTION: A concrete spraying machine 100 that sprays concrete onto a face K and a circumferential surface S of a tunnel T has a nozzle mechanism 50 that includes a self-propelled spraying truck 10, a nozzle boom 20 attached to the spraying truck 10, and a nozzle 40, an erector 60 that is attached to the spraying truck 10 and grips the shoring, and a control device 80 that specifies at least the relative coordinates of measurement points on the face K and the circumferential surface S with respect to the spraying truck 10. The front of the spraying truck 10 is equipped with a 3D scanner A (90A), and the erector 60 is equipped with a 3D scanner B (90C).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a concrete spraying machine and a concrete spraying method.

Background Art

[0002] In the construction of mountain tunnels, after excavation and overbreak of a predetermined length, primary spraying (primary shotcrete) of concrete is performed on the peripheral surface and the face of the constructed tunnel, temporary supports are built, secondary spraying (secondary shotcrete) is performed, and then rock bolts are installed as necessary in a series of construction cycles. In primary and secondary spraying, a concrete spraying machine is generally applied, in which a nozzle boom having a nozzle for discharging concrete at its tip and an erector for gripping a temporary support and installing it on the peripheral surface of the tunnel are equipped on a self-propelled spraying carriage. The above-mentioned nozzle boom is equipped with various sensors such as a rotary encoder, an angle sensor, and a stroke sensor, and the spraying carriage is equipped with a target. Surveying means such as a total station is installed at a position where the surveying reference point on the portal side of the tunnel can be surveyed relative to the concrete spraying machine, and the three-dimensional coordinates of the spraying carriage are specified by the surveying means. Then, the horizontal angle of the nozzle boom is specified by the rotary encoder provided in the nozzle boom, the inclination angle of the nozzle boom is specified by the angle sensor, and the length of the nozzle boom to, for example, the tip position (nozzle position) is specified by the stroke sensor. Therefore, the three-dimensional coordinates of the tip of the nozzle boom are specified by the three-dimensional coordinates of the spraying carriage and the specified information based on the horizontal angle, inclination angle of the nozzle boom, and the length to its tip, and the three-dimensional coordinates of the nozzle attached to the tip are specified. Distance sensors such as millimeter wave radars are provided at the tip of the nozzle boom and the nozzle to measure the distance to the face and the peripheral surface of the tunnel, which is the concrete spraying surface.

[0003] By determining the three-dimensional coordinates of the nozzle and measuring the distance between the nozzle and the sprayed surface before and after concrete spraying onto the tunnel face and surrounding surface, the three-dimensional coordinates of the sprayed surface can be determined. Therefore, by determining the three-dimensional coordinates of the sprayed surface before and after concrete spraying, the sprayed thickness can be determined from the difference. By performing concrete spraying while determining the sprayed thickness at multiple locations on both the face and surrounding surface, it is possible to achieve concrete spraying with highly precise control of the sprayed thickness. However, in reality, while distance sensors such as millimeter-wave radar equipped on the tip of the nozzle boom or on the nozzle can determine the spraying thickness at the face located in front of the concrete spraying machine, it is extremely difficult to determine the spraying thickness on the circumferential surface located to the side of the concrete spraying machine using distance sensors equipped on the tip of the nozzle boom or on the nozzle.

[0004] As described above, the spraying trolley that makes up a concrete spraying machine has a nozzle boom that can rotate freely attached to the front, for example, the center, and erectors that can rotate freely attached to the left and right of the nozzle boom. Furthermore, it may also be equipped with a mancage boom with a mancage at its tip. The erectors and other components located on the sides of the nozzle boom tend to obstruct the determination of the spraying thickness on the circumferential surface by distance sensors equipped on the tip of the nozzle boom or the nozzle, and one of the reasons is that it naturally becomes difficult to determine the spraying thickness while avoiding the erectors and other components. Therefore, there is a need for a concrete spraying machine that can efficiently and accurately determine the spraying thickness on both the face and the surrounding surface, which are the spraying surfaces, while spraying concrete, and a concrete spraying method that can efficiently and accurately determine the spraying thickness while spraying concrete.

[0005] Here, Patent Document 1 proposes a concrete material spraying device for spraying concrete material onto the inner wall surface of a tunnel. This concrete material spraying device comprises a measuring unit for measuring the cross-sectional shape of the inner wall surface, a spraying machine for spraying concrete material onto the inner wall surface by injecting it from a nozzle, and a control unit for controlling the measuring unit and the spraying machine. The control unit calculates the required spraying thickness for each predetermined number of sections based on the cross-sectional shape measured by the measuring unit and the predetermined cross-sectional shape of the tunnel's designed inner wall surface, and controls the spraying machine based on the calculated required spraying thickness. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2020-33723 [Overview of the project] [Problems that the invention aims to solve]

[0007] According to the concrete material spraying apparatus described in Patent Document 1, it is possible to ensure the spraying thickness while making the finished surface smooth with a certain degree of accuracy. However, as described above, this concrete material spraying apparatus does not disclose a means for accurately determining the spraying thickness over the entire circumferential surface of the tunnel, while avoiding erectors and other components on both sides of the nozzle boom, not just the tunnel face, that is, for efficiently and accurately determining the spraying thickness at both the tunnel face and the circumferential surface.

[0008] The present invention aims to provide a concrete spraying machine capable of efficiently and accurately specifying the spraying thickness on both the face and the surrounding surface that will be sprayed, and a concrete spraying method capable of efficiently and accurately specifying the spraying thickness while spraying concrete. [Means for solving the problem]

[0009] To achieve the above objective, one embodiment of the concrete spraying machine according to the present invention is: A concrete spraying machine that sprays concrete onto the tunnel face and surrounding surface, A self-propelled spraying trolley, A nozzle mechanism comprising a nozzle boom that is rotatably mounted to the aforementioned spraying trolley and is extendable and retractable in its own axial direction, and a nozzle attached to the tip of the nozzle boom for discharging concrete, An erector is rotatably mounted to the aforementioned spraying trolley, is extendable and retractable in its own axial direction, and grips the support structure. The system includes at least a control device that identifies the relative coordinates of the measuring points on the face and the circumferential surface with respect to the spraying trolley, A 3D scanner A is mounted at the front of the aforementioned spraying trolley. The aforementioned erector is characterized by being equipped with a 3D scanner B.

[0010] According to this embodiment, in a concrete spraying machine in which a nozzle boom and an erector are rotatably mounted on the front of a spraying trolley, a 3D scanner A is equipped on the front of the spraying trolley and a separate 3D scanner B is equipped on the erector. For example, the relative coordinates of multiple measurement points (points for measuring spraying thickness) at the face directly facing the front of the spraying trolley can be measured by 3D scanner A, and the relative coordinates of multiple measurement points on the circumferential surface can be measured by 3D scanner B equipped on the erector. By performing this before and after concrete spraying, it becomes possible to efficiently and accurately determine the spraying thickness at multiple measurement points on both the face and the circumferential surface. In other words, since the 3D scanner B equipped on the Erector determines the thickness of the spray coating on the surrounding surface, the Erector does not become an obstacle in this determination process. Here, 3D scanner A can also measure the relative coordinates of multiple measurement points on both the tunnel face and the surrounding surface. In this case, 3D scanner B, which is equipped on the erector, functions as a backup scanner to measure relative coordinates when 3D scanner A is unusable due to dust such as rebound during concrete spraying onto the tunnel face, by having the erector move closer to the surrounding surface and the tunnel face. A target may be provided on the spraying trolley, and the three-dimensional coordinates of the spraying trolley may be determined by a surveying means such as a total station located in a position that allows for the measurement of a surveying reference point on the tunnel portal side of the spraying trolley, and the surveying data from the surveying means may be transmitted to or input to a control device. Here, the control device may be mounted on the spraying trolley, or it may be housed in a management facility located outside the tunnel, for example. The erectors are mounted, for example, on either side of the nozzle boom, which is positioned in the center of the front of the spraying trolley, and each erector is equipped with its own 3D scanner B. This configuration allows each 3D scanner B to determine the spraying thickness for, for example, the left and right halves of an arc-shaped circumferential surface.

[0011] The nozzle boom and erector may be equipped with various sensors such as rotary encoders, angle sensors, and stroke sensors. Based on data such as the horizontal angle and tilt angle identified by the rotary encoder, and the distance to the installation position of the 3D scanner B on the erector, the relative coordinates (three-dimensional coordinates) of the 3D scanner B with respect to the spraying trolley can be determined. Alternatively, the absolute coordinates of each measurement point may be determined based on the three-dimensional coordinates (absolute coordinates) of the spraying trolley measured by a surveying means such as a total station, and the relative coordinates of multiple measurement points on the tunnel face and surrounding surface measured by a 3D scanner A. The spraying thickness may then be determined from the difference in absolute coordinates of each measurement point before and after concrete spraying.

[0012] Furthermore, in another embodiment of the concrete spraying machine according to the present invention, The nozzle boom is equipped with a first target, and the erector is equipped with a second target. The tip of the nozzle boom or the nozzle is equipped with a laser rangefinder for measuring the distance from the nozzle to the spraying surface. The measurement position data of the first target and the measurement position data of the second target, measured by the 3D scanner A, are acquired by the control device, and the control device updates or corrects the relative coordinates of both the nozzle and the installation position of the 3D scanner B on the erector with respect to the spraying trolley.

[0013] According to this embodiment, a first target is mounted on the tip of the nozzle boom, and a second target is mounted on the erector. The positions of the first and second targets are measured by 3D scanner A, and the relative coordinates (three-dimensional coordinates) of the first and second targets with respect to the spraying trolley are measured. This makes it possible to accurately determine the relative coordinates of both the nozzle and the erector with respect to the spraying trolley using 3D scanner B. When determining the relative coordinates of the 3D scanner B with respect to the spraying trolley at the nozzle and erector based on data from rotary encoders, angle sensors, etc., equipped on the nozzle boom and erector, the accuracy may decrease compared to this embodiment because the relative coordinates are determined indirectly based on sensor data. However, in this embodiment, the position of the tip of the nozzle boom, etc., is measured directly, so the accuracy of the three-dimensional coordinates of the nozzle boom tip, etc., that are measured is significantly improved.

[0014] Here, "updating or correcting relative coordinates" means updating the relative coordinates to each spraying trolley as needed, or correcting currently identified relative coordinates to new relative coordinates, considering that the nozzle position and the installation position of 3D scanner B on the erector change moment by moment. By updating or correcting relative coordinates in this way, it is possible to suppress the accumulation of errors related to relative coordinates, etc., which would result in errors in the specific value of the spraying thickness.

[0015] Further, according to this aspect, the 3D scanner A measures the tip position of the nozzle boom, the installation position of the 3D scanner B on the erector, and further the relative coordinates of a plurality of measurement points on the face (or both the face and the peripheral surface). The 3D scanner B measures the relative coordinates of a plurality of measurement points on the peripheral surface. Since the spraying of concrete, the update and correction of the relative coordinates of the nozzle and the 3D scanner B before and after the concrete spraying, and the measurement of the relative coordinates of a plurality of measurement points on the face and the peripheral surface can be automatically performed, an operator or the like is not required, and a complete automatic spraying construction of concrete including the specification of the spraying thickness can be realized.

[0016] Further, in another aspect of the concrete spraying machine according to the present invention, A rotary mechanism for swinging the nozzle is provided at the tip of the nozzle boom, and the nozzle is attached to the rotary mechanism.

[0017] According to this aspect, by providing a rotary mechanism for swinging the nozzle at the tip of the nozzle boom, so-called rotary spraying can be realized, in which concrete is sprayed while swinging (or rotary rotating) the nozzle in a horizontal plane. For example, in a conventional concrete spraying machine, there is only swinging for moving the nozzle closer to or farther from (or up and down) the spraying surface, and there is no device that swings (rotates) while keeping the distance constant with respect to the spraying surface. By such rotary spraying in which the nozzle is swung while keeping the distance constant with respect to the spraying surface, it becomes possible to spray concrete evenly on the spraying surface while keeping the spraying pressure and the spraying amount of the concrete with respect to the spraying surface uniform.

[0018] Further, in another aspect of the concrete spraying machine according to the present invention, The rotary mechanism includes a housing attached to the nozzle, a motor housed in the housing, and an eccentric plate that is stepwise displaced in position with respect to the housing. By driving the motor in a state where the eccentric plate is displaced to a predetermined position, the housing is swung, and the nozzle is swung via the housing.

[0019] According to this aspect, the rotary mechanism includes a housing attached to the nozzle, a motor housed in the housing, and an eccentric plate that gradually displaces its position with respect to the housing. By driving the motor in a state where the eccentric plate is displaced to a predetermined position, the nozzle can be swung in a desired swinging mode. Here, the stepwise displacement adjustment of the eccentric plate can be performed manually or automatically.

[0020] In another aspect of the concrete spraying machine according to the present invention, In the vicinity of the nozzle in the nozzle boom, an accelerometer or a speedometer for measuring the speed of the nozzle is further provided.

[0021] According to this aspect, the moving speed of the nozzle can be measured, and among factors important in rotary spraying, such as the distance to the spraying surface, the moving speed of the nozzle, the rotation speed (rotational speed) of the nozzle, and the swing angle, it is possible to confirm whether the moving speed of the nozzle is the desired moving speed, and if it deviates from the desired moving speed, it is possible to correct the moving speed.

[0022] Also, one aspect of the concrete spraying method according to the present invention is A concrete spraying method for spraying concrete onto the face and the peripheral surface of a tunnel face, The concrete spraying machine is characterized by having a nozzle mechanism comprising a self-propelled spraying cart, a nozzle boom that is rotatably mounted to the spraying cart and is extendable and retractable in its own axial direction, a nozzle attached to the tip of the nozzle boom for discharging concrete, and an erector that is rotatably mounted to the spraying cart and is extendable and retractable in its own axial direction for gripping the shoring, and having step A, which involves spraying concrete onto the tunnel face and the surrounding surface, and before and after this spraying, measuring the relative coordinates of a plurality of measurement points on the tunnel face and the surrounding surface using a 3D scanner A equipped in front of the spraying cart to determine the spraying thickness.

[0023] According to this embodiment, by having step A, in which a 3D scanner A mounted on the front of the spraying trolley measures the relative coordinates of multiple measurement points on the tunnel face and the surrounding surface to determine the spraying thickness, it becomes possible to spray concrete while efficiently and accurately determining the spraying thickness on both the tunnel face and the surrounding surface which will be the spraying surface.

[0024] Furthermore, other embodiments of the concrete spraying method according to the present invention include: A concrete spraying method for spraying concrete onto the tunnel face and surrounding surface, Step A1 involves using a concrete spraying machine that includes a self-propelled spraying cart, a nozzle mechanism comprising a nozzle boom rotatably mounted to the spraying cart and extendable in its own axial direction, a nozzle attached to the tip of the nozzle boom for discharging concrete, and an erector rotatably mounted to the spraying cart and extendable in its own axial direction for gripping the shoring, to spray concrete onto the tunnel face, and before and after this spraying, measuring the relative coordinates of multiple measurement points on the tunnel face with a 3D scanner A mounted in front of the spraying cart to determine the spraying thickness. The invention is characterized by having step A2, which involves spraying concrete onto the circumferential surface, and before and after this spraying, measuring the relative coordinates of multiple measurement points on the circumferential surface using a 3D scanner B equipped on the erector to determine the spraying thickness.

[0025] According to this embodiment, the invention includes step A1, in which a 3D scanner A mounted on the front of the spraying trolley measures the relative coordinates of multiple measurement points at the tunnel face to determine the spraying thickness, and step A2, in which a 3D scanner B mounted on the erector measures the relative coordinates of multiple measurement points on the circumferential surface to determine the spraying thickness. This makes it possible to spray concrete while efficiently and accurately determining the spraying thickness at both the tunnel face and the circumferential surface, which are the spraying surfaces.

[0026] Furthermore, in another embodiment of the concrete spraying method according to the present invention, The nozzle boom is equipped with a first target and a laser rangefinder, and the erector is equipped with a second target. In step A1, the 3D scanner A measures the first target to determine the relative coordinates of the nozzle, and the laser rangefinder determines the distance to the working face. In step A2, the 3D scanner A measures the second target to determine the relative coordinates of the mounting position of the 3D scanner B on the erector.

[0027] According to this embodiment, a second target is equipped on the tip of the nozzle boom, a third target is equipped on the erector, and the relative coordinates of the first and second targets are measured by 3D scanner A. This makes it possible to accurately determine the relative coordinates of 3D scanner B with respect to the spraying trolley at the nozzle and erector, and to update and correct each three-dimensional coordinate as needed.

[0028] Furthermore, other embodiments of the concrete spraying method according to the present invention include: In steps A, A1, and A2, concrete is sprayed while the nozzle is oscillating.

[0029] According to this embodiment, by rotary spraying, in which the nozzle is oscillated while maintaining a constant distance from the spraying surface, it becomes possible to evenly spray concrete onto the spraying surface while maintaining uniform spraying pressure and amount of concrete onto the spraying surface. [Effects of the Invention]

[0030] According to the concrete spraying machine and concrete spraying method of the present invention, concrete can be sprayed while efficiently and accurately determining the spraying thickness on both the face and the surrounding surface that will be sprayed. [Brief explanation of the drawing]

[0031] [Figure 1] This is a side view of an example of a concrete spraying machine according to an embodiment. [Figure 2] This is a plan view of an example of a concrete spraying machine according to an embodiment. [Figure 3] This is an enlarged view of part III in Figure 1, and is an enlarged side view of an example of a nozzle mechanism. [Figure 4] Figure 3 is a perspective view of an example of a nozzle mechanism, seen from a diagonal rearward angle. [Figure 5] This is a perspective view of an example of a rotary mechanism, seen from a diagonal downward angle. [Figure 6] This is a perspective view of an example of a rotary mechanism, seen from diagonally above. [Figure 7] This figure shows an example of the hardware configuration of a control device that makes up a concrete spraying machine. [Figure 8] This diagram shows an example of the functional configuration of the control device that makes up a concrete spraying machine. [Modes for carrying out the invention]

[0032] The concrete spraying machine and concrete spraying method according to the embodiment will be described below with reference to the attached drawings. In this specification and drawings, substantially identical components may be denoted by the same reference numerals to avoid redundant explanations.

[0033] [Concrete spraying machine and concrete spraying method according to this embodiment] An example of a concrete spraying machine and concrete spraying method according to an embodiment will be described with reference to Figures 1 to 8. Here, Figures 1 and 2 are a side view and a plan view, respectively, of an example of a concrete spraying machine according to an embodiment. Figure 3 is an enlarged view of part III of Figure 1, and is an enlarged side view of an example of a nozzle mechanism. Figure 4 is a perspective view of the example of the nozzle mechanism shown in Figure 3, viewed from the rear at an oblique angle. Furthermore, Figures 5 and 6 are perspective views of an example of a rotary mechanism, viewed from the lower and upper angles at an oblique angle, respectively.

[0034] In Figures 1 and 2 below, the axial direction of the tunnel T is defined as the X direction, the horizontal direction perpendicular to the X direction as the Y direction, and the vertical direction perpendicular to the X direction as the Z direction. As explained below, for example, the relative coordinates of multiple measurement points at the tunnel face K with respect to the spraying trolley 10 can be determined by (Xi, Yi, Zi) using these three directions.

[0035] The concrete spraying machine 100 is a heavy machine that sprays concrete with a predetermined spraying thickness onto the face K and surrounding surface S, which are the concrete spraying surfaces in a tunnel T (mountain tunnel) constructed on the ground G.

[0036] In the construction of the mountain tunnel T, the construction cycle consists of excavation and mowing of a predetermined length, primary concrete spraying on the circumferential surface S and tunnel face K of the constructed tunnel T, installation of shoring, and secondary spraying. This cycle is repeated as excavation progresses. In some cases, rock bolts are installed after the secondary spraying as needed. Figures 1 and 2 show the state where excavation and mowing have been completed in a range of approximately 1m to 3m beyond the section where the sprayed concrete C with a spraying thickness t has been completed, and the tunnel face K and circumferential surface S of that section are exposed. On this exposed tunnel face K and circumferential surface S, sprayed concrete is applied while controlling the spraying thickness.

[0037] The concrete spraying machine 100 includes a self-propelled spraying trolley 10, a control device 80 mounted on the spraying trolley 10, and a nozzle boom 20 that is rotatably mounted vertically (Y1 direction) and horizontally (Y2 direction) at the center of the front (face K side) of the spraying trolley 10, and is extendable and retractable in the Y3 direction in its axial direction. The concrete spraying machine 100 further includes a pair of erectors 60 that are similarly rotatably mounted in the Y1 and Y2 directions at left and right positions of the nozzle boom 20 in front of the spraying trolley 10, and are extendable and retractable in the Y4 direction in its axial direction, and a pair of man cage booms 70 that are similarly rotatably mounted in the Y1 and Y2 directions near the left and right erectors 60 in front of the spraying trolley 10, and are equipped with man cages 72 at their ends.

[0038] The nozzle boom 20 has a boom 21 extending from the spraying trolley 10 and an arm 22 that is rotatably and extendably attached to the tip of the boom 21. A rotary mechanism 30 is attached to the tip of the arm 22, and a nozzle 40 is attached to the rotary mechanism 30. The nozzle boom 20, the rotary mechanism 30, and the nozzle 40 constitute the nozzle mechanism 50.

[0039] Here, the end of a concrete pumping hose 42 (or concrete pumping pipe) is attached to the end of the nozzle 40 opposite to the discharge port (the lower end of the nozzle 40 in Figure 1), as shown in Figures 3 and 4. This concrete pumping hose 42 is connected to a hopper from which concrete is supplied from a mixer truck (not shown) and to a concrete pump that pumps the concrete. By driving the concrete pump with the drive control of the control device 80, concrete is supplied to the nozzle 40 via the concrete pumping hose 42, and concrete is discharged from the nozzle 40 onto the spraying surface. Here, a quick-setting agent may be supplied directly to the nozzle 40, or to a position near the nozzle 40 in the concrete pumping hose 42, and concrete with the quick-setting agent added may be discharged onto the spraying surface.

[0040] Of the spraying trolley 10, a third target 12A is mounted at the rear on the tunnel entrance side, and separate third targets 12B and 12C are mounted at the left and right positions in the center, with each of the third targets 12A, 12B, and 12C being installed at different height levels.

[0041] A surveying device consisting of a total station (not shown) is provided at a location on the tunnel T portal side of the concrete spraying machine 100 where surveying control points can be measured. The total station sights each of the third targets 12A, 12B, and 12C, and distance and angle measurements are performed to measure the three-dimensional coordinates (absolute coordinates) of the spraying trolley 10. The three-dimensional coordinate data of the spraying trolley 10 measured by the total station is transmitted to or input into the control device 80.

[0042] Furthermore, the concrete spraying machine 100 does not necessarily apply the absolute coordinates of the spraying trolley 10 when measuring the spraying thickness on the spraying surface. However, the absolute coordinates of the measurement points may be determined based on the absolute coordinates of the spraying trolley 10 and the relative coordinates of the measurement points on the spraying surface measured by the 3D scanner A(90A) or the like, as described below, and the spraying thickness may be determined based on the absolute coordinates of the measurement points before and after concrete spraying.

[0043] 3D scanners A (90A) are mounted on the left and right ends of the front of the spraying trolley 10. Here, it is preferable to use 3DRiDER as 3D scanner A (90A) and 3D scanner B (90C), which will be described below. This is because 3DRiDER is resistant to vibrations and is suitable for installation on heavy machinery, and is a relatively inexpensive measuring instrument compared to general 3D scanners.

[0044] Of the nozzle boom 20, the boom 21 and arm 22 are equipped with first targets 28C and 28B, respectively, and the rotary mechanism 30 is equipped with a separate first target 28A.

[0045] The nozzle boom 20 is also equipped with multiple angle sensors 25A, 25B, and 25C, as well as a rotary encoder 26 and a stroke sensor 27. The angle sensors 25A, 25B, and 25C determine the inclination angle at each position, the rotary encoder 26 determines the horizontal angle, and the stroke sensor 27 determines the length of the nozzle boom 20 from the spraying trolley 10 at a predetermined position (for example, the tip of the arm 22).

[0046] A laser rangefinder 90B is equipped on the rotary mechanism 30 at the tip of the nozzle boom 20. This laser rangefinder 90B measures the distance between the nozzle 40 and the spraying surface in real time, ensuring a constant distance while spraying concrete. When spraying concrete with the distance between the nozzle 40 and the spraying surface set to, for example, about 1.5m, problems such as the ground surface crumbling and the sprayed surface peeling may occur. Furthermore, the surface irregularities of the sprayed surface are generally large. Therefore, it is desirable to extend or retract the nozzle boom 20 based on the measurement value from the laser rangefinder to maintain a constant distance between the nozzle 40 and the spraying surface.

[0047] Furthermore, the Erecta 60 is equipped with multiple angle sensors 65A, 65B, as well as a second target 68, a 3D scanner B (90C), and a stroke sensor 67. The Erecta 60 may also be further equipped with a rotary encoder.

[0048] 3D scanners A (90A) located at the left and right ends of the front of the spraying trolley 10 measure the relative coordinates of multiple measurement points (points for measuring spray thickness) on the spraying surface, the face K, and the surrounding surface S, with respect to the spraying trolley 10.

[0049] The 3D scanner A (90A) further sights the first targets 28A, 28B, and 28C equipped on the nozzle mechanism 50 and the second target 68 equipped on the erector 60, identifies the relative position of the nozzle 40 with respect to the spraying trolley 10 and the relative position of the 3D scanner B (90C), and transmits the respective relative position data to the control device 80.

[0050] As shown in Figures 5 and 6, the rotary mechanism 30 includes a pair of housings 31 and 32, a motor 33 housed in the housings 31 and 32, a storage unit 34 mounted above the motor 33, and a nozzle mounting cylinder 36 that extends laterally from one of the housings 32 and on which the nozzle 40 is installed.

[0051] Inside the other housing 32, a laser distance meter 90B is installed. This meter irradiates the spraying surface in the direction of concrete spraying with a laser in the X2 direction, acquires the reflected laser, and measures the distance to the spraying surface in real time.

[0052] As shown in Figures 5 and 6, a nozzle 40 and a concrete pumping hose 42, indicated by a dashed line, are attached to the nozzle mounting cylinder 36. Concrete supplied by the drive of a concrete pump (not shown) is supplied to the nozzle 40 via the concrete pumping hose 42 and discharged from the nozzle 40 in the direction of X1.

[0053] As shown in Figure 6, the eccentric plate 35 is configured to protrude in stages from the storage body 34 in the X3 direction.

[0054] The rotary mechanism 30 is a mechanism that causes the nozzle 40 to oscillate in the X4 direction by rotating the motor 33 with the eccentric plate 35 displaced to one side. By rotary spraying, which discharges concrete from the oscillating nozzle 40, the distance of the nozzle 40 to the spraying surface is kept constant, and it is possible to spray concrete evenly onto the spraying surface while maintaining equal spraying pressure and amount of concrete on the spraying surface.

[0055] By adjusting the amount of displacement of the eccentric plate 35, the oscillation pattern of the nozzle 40 can be varied in various ways. Here, the stepwise adjustment of the displacement amount of the eccentric plate 35 can be performed manually or automatically.

[0056] One housing 32 is equipped with a proximity sensor 37, which detects the approach of a permanent magnet housed in a rotor (not shown) that constitutes the motor 33 and measures the rotational speed of the rotor. The other housing 31 is equipped with an acceleration sensor 29, which measures the movement speed of the rotary mechanism 30 and the nozzle 40.

[0057] In rotary spraying, the distance of the nozzle 40 to the spraying surface, the movement speed of the nozzle 40, the rotation speed of the nozzle 40, and the oscillation angle are all important factors. Furthermore, by checking whether the movement speed of the nozzle 40 is the desired speed using the acceleration sensor 29, it becomes possible to correct the movement speed if it deviates from the desired speed.

[0058] Next, with reference to Figures 7 and 8, the control device 80 that constitutes the concrete spraying machine 100 will be described. Here, Figure 7 is a diagram showing an example of the hardware configuration of the control device, and Figure 8 is a diagram showing an example of the functional configuration of the control device.

[0059] As shown in Figure 7, the control device 80 is composed of an information processing device (computer) such as a personal computer (PC). The computers constituting the control device 80 are interconnected by a connection bus 86 and include a CPU (Central Processing Unit) 81, main memory 82, auxiliary storage 83, communication IF 84, and input / output IF (interface) 85. The main memory 82 and auxiliary storage 83 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.

[0060] The CPU 81, also known as an MPU (Microprocessor) or processor, may be a single processor or a multiprocessor. The CPU 81 is a central processing unit that controls the entire control unit 80, which consists of a computer. For example, the CPU 81 expands a program stored in the auxiliary storage device 83 into an executable format in the working area of ​​the main memory device 82, and controls peripheral devices through the execution of the program, thereby providing a function that matches a predetermined purpose.

[0061] The main memory 82 stores computer programs executed by the CPU 81 and data processed by the CPU 81. The main memory 82 includes, for example, flash memory, RAM (Random Access Memory), and ROM (Read Only Memory). The auxiliary memory 83 stores various programs and various data on a recording medium that can be read and written freely, and is also called an external memory. The auxiliary memory 83 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 84. External devices include, for example, 3D scanner A (90A) and 3D scanner B (90C), laser distance meter 90B, angle sensors 25A, 25B, 25C, rotary encoder 26, stroke sensor 27, total station, etc., as well as, for example, a personal computer (not shown) for construction management located in a management facility (construction office) connected to a network.

[0062] The auxiliary storage device 83 is used, for example, as a storage area that assists the main memory 82, and stores computer programs executed by the CPU 81, data processed by the CPU 81, etc. The auxiliary storage device 83 is a silicon disk containing non-volatile semiconductor memory (flash memory, EPROM (Erasable Programmable ROM)), a hard disk drive (HDD), a solid-state drive, etc. Examples of auxiliary storage devices 83 include drives for removable recording media such as CD drives, DVD drives, and BD drives, and examples of removable recording media include CDs, DVDs, BDs, USB (Universal Serial Bus) memory, SD (Secure Digital) memory cards, etc.

[0063] The input / output IF85 is an interface for inputting and outputting data between the control device 80 and the connected devices. For example, keyboards, pointing devices such as touch panels and mice, and input devices such as microphones can be connected to the input / output IF85. The control device 80 receives operation instructions from the operator operating the input device via the input / output IF85.

[0064] Furthermore, the input / output IF85 can be connected to display devices such as liquid crystal displays (LCDs) and electroluminescent (EL) panels, as well as output devices such as printers and speakers. For example, relative coordinate data of each measurement point before and after concrete spraying at the tunnel face K and surrounding surface S, transmitted from 3D scanner A (90A) and 3D scanner B (90C), is displayed, and the spraying thickness at each measurement point identified based on this relative coordinate data is displayed.

[0065] If a certain threshold is set for the spray thickness, the threshold may also be displayed, and an alarm may be displayed when the specified spray thickness exceeds the threshold.

[0066] Furthermore, the distance between the nozzle 40 and the spraying surface, measured by the laser distance meter 90B, is displayed in real time, and if a distance threshold is set within a control standard value (e.g., 1.5m), an alarm may be displayed when the specified distance exceeds the threshold.

[0067] The communication IF84 is an interface between the control device 80 and the cables and networks to which it is connected. The communication IF84 receives measurement data from the 3D scanner A (90A) etc. via various networks such as public networks like the internet, wireless networks like mobile phone networks, dedicated networks like VPNs (Virtual Private Networks), and LANs (Local Area Networks), and transmits specific data such as the spray thickness at multiple measurement points on the sprayed surface to a personal computer for construction management located in the management facility.

[0068] As shown in Figure 8, the control device 80, through the execution of a program by the CPU 81, provides various functions, at least including the acquisition unit 102, the relative coordinate identification unit 104, the spraying thickness calculation unit 106, the concrete pump drive unit 108, the boom drive unit 110, the display unit 112, and the storage unit 114. Here, at least a portion of the above processing functions may be provided by a DSP (Digital Signal Processor), a GPU (Graphics Processing Unit), etc. Similarly, at least a portion of the above processing functions may be provided by a dedicated LSI (large scale integration) such as an FPGA (Field-Programmable Gate Array), a numerical processing processor, an image processing processor, or other digital circuits.

[0069] The acquisition unit 102 acquires three-dimensional coordinate data of multiple measurement points on the sprayed surface, the face K, and the surrounding surface S, which are measured by 3D scanner A (90A) and 3D scanner B (90C). The acquired three-dimensional coordinate data is stored (remembered) in the storage unit 114.

[0070] Furthermore, the acquisition unit 102 acquires three-dimensional coordinate data when the first targets 28A, 28B, 28C and the second target 68 are sighted, as measured by the 3D scanner A (90A), and this data is stored (remembered) in the storage unit 114.

[0071] The relative coordinate identification unit 104 identifies the relative coordinates of each measurement point with respect to the spraying trolley 10 based on the three-dimensional coordinate data of each measurement point on the spraying surface stored in the storage unit 114, and identifies the relative coordinates of the nozzle 40 and the 3D scanner B (90B) based on the three-dimensional coordinate data of the first targets 28A, 28B, 28C and the second target 68. The relative coordinate identification unit 104 can also identify the relative coordinates of the measurement points with respect to the spraying trolley 10 based on the relative coordinates of the 3D scanner B (90C) and the relative coordinates of the measurement points on the spraying surface (e.g., the circumferential surface S) measured by the 3D scanner B (90C).

[0072] The spraying thickness calculation unit 106, for example, calculates the difference in relative coordinates before and after concrete spraying at each measurement point, and uses the difference value as the spraying thickness.

[0073] The concrete pump drive unit 108 controls the operation of the concrete pump in conjunction with the operation control of the nozzle boom 20 by the boom drive unit 110. Once the nozzle 40 is positioned at a certain distance from the spraying surface, the boom drive unit 110 stops the operation of the nozzle boom 20, and then drives the concrete pump to discharge concrete onto the spraying surface for a certain period of time. At this time, the boom drive unit 110 controls the rotation of the motor 33 of the rotary mechanism 30, causing the nozzle 40 to oscillate while discharging concrete.

[0074] The display unit 112 displays relative coordinate data of each measurement point before and after concrete spraying at the tunnel face K and the surrounding surface S, and displays the spraying thickness at each measurement point calculated by the spraying thickness calculation unit 106 based on this relative coordinate data.

[0075] With the concrete spraying machine 100, the relative coordinates of multiple measurement points on the face K and the surrounding surface S are measured by 3D scanner A (90A), and the relative coordinates of the tip position of the nozzle boom 20 and the installation position of 3D scanner B (90C) on the erector 60 are measured. Alternatively, the relative coordinates of multiple measurement points on the surrounding surface S are measured by 3D scanner B (90C). As a result, automatic concrete spraying, measurement of the relative coordinates of multiple measurement points on the face K and surrounding surface S before and after concrete spraying, and updating and correction of the relative coordinates of the nozzle 40 and 3D scanner B (90C) are performed automatically, eliminating the need for operators and enabling fully automated concrete spraying construction, including the determination of the spraying thickness.

[0076] Furthermore, by performing rotary spraying, which discharges concrete from the oscillating nozzle 40, the distance of the nozzle 40 from the spraying surface is kept constant, and the spraying pressure and amount of concrete applied to the spraying surface are kept uniform, allowing concrete to be sprayed evenly onto the spraying surface, thus enabling the construction of high-quality sprayed concrete.

[0077] Furthermore, by continuously updating or correcting the relative coordinates of the nozzle 40 with respect to the spraying trolley 10, and the absolute coordinates of the nozzle 40 using a total station, it is possible to eliminate cumulative errors in the coordinates of each measurement point on the spraying surface.

[0078] Next, we will outline the concrete spraying method according to the embodiment.

[0079] This concrete spraying method includes step A, in which concrete is sprayed onto the tunnel face K and the surrounding surface S using a concrete spraying machine 100, and before and after this spraying, the relative coordinates of multiple measurement points on the tunnel face K and the surrounding surface S are measured using a 3D scanner A (90A) mounted on the front of the spraying trolley 10 to determine the spraying thickness.

[0080] In concrete spraying, rotary spraying is performed, in which concrete is sprayed while the nozzle 40 is oscillated. For example, the spraying thickness of one layer is set to about 50 mm, and the relative coordinates of the sprayed surface are obtained using 3D scanner A (90A) or 3D scanner B (90C) after the first layer has been sprayed. For concrete spraying on the tunnel face K, the concrete spraying is completed after spraying one layer (e.g., 50 mm), while for concrete spraying on the surrounding surface S, multiple layers are sprayed in stages. In this rotary spraying, the distance between the nozzle 40 and the sprayed surface is measured continuously using the laser distance meter 90B, and concrete spraying is performed while maintaining a constant distance.

[0081] This concrete spraying method allows for the efficient and highly accurate determination of the spraying thickness of the concrete at the excavation face K and the surrounding surface S, while simultaneously constructing the sprayed concrete.

[0082] Another aspect of the concrete spraying method involves using a concrete spraying machine 100 to spray concrete onto the tunnel face K, and before and after this spraying, performing step A1, in which the relative coordinates of multiple measurement points on the tunnel face K are measured using a 3D scanner A (90A) to determine the spraying thickness. Next, concrete is sprayed onto the surrounding surface S, and before and after this spraying, a 3D scanner B (90C) is used to measure the relative coordinates of multiple measurement points on the surrounding surface S to determine the spraying thickness, and this is performed in step A2.

[0083] In this setup, the nozzle boom 20 is equipped with first targets 28A, 28B, and 28C, and the erector 60 is equipped with a second target 68. In step A1, the 3D scanner A (90A) measures the first targets 28A, 28B, and 28C to determine the relative coordinates of the nozzle 40. Meanwhile, in step A2, the 3D scanner A (90A) measures the second target 68 to determine the relative coordinates of the mounting position of the 3D scanner B (90C). In this way, concrete spraying is performed while continuously updating or correcting the relative coordinates of the nozzle 40 and the 3D scanner B (90C). Rotary spraying is also performed in this spraying method.

[0084] With this concrete spraying method, the 3D scanner B (90C) equipped on the erector 60 is used when measuring the relative coordinates of the measurement points on the circumferential surface S, thus eliminating the problem of the erector 60 interfering with the measurement.

[0085] 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]

[0086] 10: Spraying cart 12A, 12B, 12C: Third target 20: Nozzle boom 21: Boom 22: Arm 25A, 25B, 25C: Angle sensors 26: Rotary encoder 27: Stroke sensor 28A, 28B, 28C: First target 29: Accelerometer 30: Rotary mechanism 31,32: Enclosure 33: Motor 34: Storage Unit 35: Eccentric plate 36: Nozzle mounting tube 37: Proximity sensor 40: Nozzle 42: Concrete pumping hose 50: Nozzle mechanism 60: Erecta 65A, 65B: Angle sensor 67: Stroke sensor 68: Second Target 70: Man Cage Boom 72: Man Cage 80: Control device 90A: 3D Scanner A 90B: Laser distance meter 90C: 3D Scanner B 100: Concrete spraying machine G: Ground T: Tunnel (mountain tunnel) K: Face (sprayed surface) S: Surrounding surface (sprayed surface) C: Sprayed concrete t: Spray thickness

Claims

1. A concrete spraying machine that sprays concrete onto the tunnel face and surrounding surface, A self-propelled spraying trolley, A nozzle mechanism comprising a nozzle boom that is rotatably mounted to the aforementioned spraying trolley and is extendable and retractable in its own axial direction, and a nozzle attached to the tip of the nozzle boom for discharging concrete, An erector is rotatably mounted to the aforementioned spraying trolley, is extendable and retractable in its own axial direction, and grips the support structure. The system includes at least a control device that identifies the relative coordinates of the measuring points on the face and the circumferential surface with respect to the spraying trolley, A 3D scanner A is mounted in front of the spraying trolley, which is used to identify the relative coordinates at multiple measurement points on the tunnel face. The erector is equipped with a 3D scanner B used to determine the relative coordinates at multiple measurement points on the circumferential surface. The nozzle boom is equipped with a first target, and the erector is equipped with a second target. The tip of the nozzle boom or the nozzle is equipped with a laser rangefinder for measuring the distance from the nozzle to the spraying surface. A concrete spraying machine characterized in that the measurement position data of the first target and the measurement position data of the second target measured by the 3D scanner A are acquired by the control device, and the control device updates or corrects the relative coordinates of both the nozzle and the installation position of the 3D scanner B on the erector with respect to the spraying trolley.

2. The concrete spraying machine according to claim 1, characterized in that a rotary mechanism for oscillating the nozzle is provided at the tip of the nozzle boom, and the nozzle is attached to the rotary mechanism.

3. The rotary mechanism comprises a housing attached to the nozzle, a motor housed in the housing, and an eccentric plate that shifts its position in stages relative to the housing. The concrete spraying machine according to claim 2, characterized in that the housing is oscillated and the nozzle is oscillated via the housing by driving the motor while the eccentric plate is displaced to a predetermined position.

4. The concrete spraying machine according to claim 3, further characterized in that an accelerometer or velocity meter for measuring the speed of the nozzle is provided near the nozzle in the nozzle boom.

5. A concrete spraying method for spraying concrete onto the tunnel face and surrounding surface, Step A1 involves using a concrete spraying machine that includes a self-propelled spraying cart, a nozzle mechanism comprising a nozzle boom rotatably mounted to the spraying cart and extendable in its axial direction, a nozzle attached to the tip of the nozzle boom for discharging concrete, and an erector rotatably mounted to the spraying cart and extendable in its axial direction for gripping the shoring, to spray concrete onto the tunnel face, and before and after this spraying, measuring the relative coordinates of multiple measurement points on the tunnel face with respect to the spraying cart using a 3D scanner A mounted in front of the spraying cart to determine the spraying thickness. Step A2 involves spraying concrete onto the circumferential surface, and before and after this spraying, measuring the relative coordinates of multiple measurement points on the circumferential surface with respect to the spraying trolley using a 3D scanner B equipped on the erector to determine the spraying thickness. The nozzle boom is equipped with a first target and a laser rangefinder, and the erector is equipped with a second target. In step A1, the 3D scanner A measures the first target to determine the relative coordinates of the nozzle, and the laser rangefinder determines the distance to the cutting face. A concrete spraying method characterized in that, in step A2, the second target is measured by the 3D scanner A to determine the relative coordinates of the mounting position of the 3D scanner B in the erector.

6. The concrete spraying method according to claim 5, characterized in that concrete is sprayed while the nozzle is oscillating in steps A1 and A2.

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