Concrete spraying machine and concrete spraying method

Abstract

To provide a concrete spraying machine and a concrete spraying method capable of carrying out spraying construction while controlling the spraying thickness of concrete sprayed on a face.SOLUTION: A concrete spraying machine 100 that sprays concrete on at least face K of a tunnel T has a self-propelled spraying cart 10, a nozzle mechanism 50 comprising a nozzle boom 20 and a nozzle 40, and a control device 80 that specifies the relative coordinates of the measurement point at the face K with respect to the spraying cart 10. A 3D scanner 90A and a camera 95 are installed in front of the spraying cart 10. A cabin 13 is equipped with a monitor 15. On the monitor 15, a face image captured by the camera 95 and an outline of a surface area around each measurement point are displayed in an overlapping manner, and the concrete spraying thickness calculated by the control device 80 based on the distance data before and after concrete spraying to the measurement point is displayed as the spraying thickness of the surface area.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, falsework is erected, 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 falsework and installing it on the peripheral surface of the tunnel are equipped on a self-propelled spraying carriage. The above-described 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 a surveying reference point on the portal side of the tunnel relative to the concrete spraying machine can be surveyed, 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, and the length to its tip of the nozzle boom, 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 or 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 specifying the spraying thickness at multiple locations on both the tunnel face and the surrounding surface, it is possible to achieve concrete spraying with highly precise control over the spraying thickness.

[0004] Here, Patent Document 1 proposes a concrete spraying thickness management system for managing the thickness of concrete material sprayed onto the excavation surface of a tunnel. This concrete spraying thickness management system includes a distance detector capable of measuring the distance to the excavation surface, a display device capable of displaying predetermined information on the sprayed surface of the excavation surface to which the concrete material is sprayed, and a control device that controls the display device based on the detected value of the distance detector. The control device sets a target spraying thickness of the concrete material to be sprayed onto the excavation surface, measures a reference distance to the excavation surface where concrete material has not been sprayed using a distance detector, measures the surface distance to the sprayed surface of the excavation surface where concrete material has been sprayed using a distance detector, calculates the difference between the measured reference distance and the surface distance, and displays predetermined information on the sprayed surface using a display device based on the result of comparing the calculated difference with the target spraying thickness. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2021-95716 [Overview of the project] [Problems that the invention aims to solve]

[0006] According to the concrete spraying thickness management system described in Patent Document 1, the surface distance to the sprayed surface before and after spraying on the excavation face is measured by a distance detector, and the spraying thickness can be calculated by finding the difference between the two. However, while this measurement method can calculate and manage the spraying thickness at multiple points on a face that spreads out over a surface, it is extremely difficult to manage the spraying thickness over the entire surface of the face, and there is no description of means for managing the spraying thickness over the entire surface.

[0007] The present invention aims to provide a concrete spraying machine and a concrete spraying method that can perform spraying work while controlling the spraying thickness of concrete sprayed on the tunnel face over a surface area. [Means for solving the problem]

[0008] To achieve the above objective, one embodiment of the concrete spraying machine according to the present invention is: A concrete spraying machine for spraying concrete onto at least the face of a tunnel, 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, The system includes at least a control device that identifies the relative coordinates of the measurement points at the tunnel face with respect to the spraying trolley, The front of the aforementioned spraying trolley is equipped with a 3D scanner and a camera. The cabin of the aforementioned spraying trolley is equipped with a monitor. The monitor displays, superimposed, the image of the tunnel face captured by the camera and the contour lines of the surface areas around each of the measurement points. The concrete spraying thickness calculated by the control device based on distance data before and after concrete spraying to the measurement point acquired by the 3D scanner is displayed as the spraying thickness of the surface area.

[0009] According to this embodiment, a 3D scanner and camera are mounted on the front of the spraying trolley, and a monitor is mounted in the cabin of the spraying trolley. The face image of the tunnel taken by the camera and the contour lines of the surface area around each measurement point are displayed superimposed. Furthermore, the sprayed concrete thickness calculated based on the distance data of the concrete before and after spraying to each measurement point acquired by the 3D scanner is displayed as the sprayed thickness of each surface area. As a result, the operator riding in the cabin of the spraying trolley can check the sprayed thickness corresponding to multiple surface areas into which the entire face image is divided, making it possible to perform spraying work while managing the sprayed concrete thickness on the tunnel face in a surface manner. For example, a design spray thickness may be set, and the difference between the current spray thickness and the design spray thickness may be displayed on a monitor. The system may then spray concrete equivalent to the displayed difference for areas where the concrete spraying is insufficient.

[0010] Here, "surface area around the measurement point" refers to a single surface area defined by contour lines, for example, a rectangular (square or rectangular) area in plan view, or a circular area in plan view, under the assumption that the sprayed thickness is approximately the same within a certain range centered on the measurement point. The face image of a tunnel face that extends spatially can be divided into multiple areas by the contour lines of multiple superimposed surface areas. Within each surface area, the sprayed thickness calculated by the control device is displayed as the sprayed thickness for the entire surface area.

[0011] Furthermore, in another embodiment of the concrete spraying machine according to the present invention, The aforementioned spray thickness is assigned multiple display colors depending on the thickness. Multiple surface regions are formed by multiple meshes, The monitor is characterized in that it displays the interior of a plurality of meshes, the outline of a mesh, or a numerical value indicating the spraying thickness in a mesh, in a display color corresponding to the spraying thickness.

[0012] According to this embodiment, multiple surface areas are formed by multiple meshes, and therefore the tunnel face image is divided by multiple meshes, making it possible to divide the tunnel face image with meshes that are regularly aligned vertically and horizontally. Furthermore, on the monitor, the inside of the multiple meshes, the outlines of the meshes, or numerical values ​​indicating the spraying thickness in the meshes are displayed in display colors corresponding to the spraying thickness, thereby improving the accuracy of surface management of the spraying thickness at the tunnel face. Moreover, it becomes easier to identify surface areas with insufficient spraying thickness, and it becomes possible to quickly perform additional spraying on the identified surface areas.

[0013] Furthermore, in another embodiment of the concrete spraying machine according to the present invention, When the inside of the mesh is displayed in the aforementioned display color, the inside of the mesh is displayed in a colored, semi-transparent manner, and the corresponding face image inside the mesh can be seen.

[0014] According to this embodiment, when the inside of the mesh is displayed in a display color, the inside of the mesh is displayed as a colored semi-transparent material, thereby enabling the visibility of the tunnel face image while allowing the spraying thickness in each mesh to be identified by the display color.

[0015] Furthermore, in another embodiment of the concrete spraying machine according to the present invention, The operator is able to easily check both the position of the nozzle in the face image and the mesh to be sprayed using the monitor.

[0016] According to this embodiment, the operator can confirm both the nozzle position in the face image and the mesh to be sprayed on the monitor, making it possible to accurately and quickly position the nozzle to the desired spraying position and perform concrete spraying. Since the face image can be displayed on the monitor as a moving image in addition to the still image, in the moving image, the moving nozzle can be monitored at any time, and it is possible to confirm at any time that the nozzle is at the desired spraying position.

[0017] In another aspect of the concrete spraying machine according to the present invention, The control device is characterized in that it executes magnification adjustment of the face image based on the distance data.

[0018] According to this aspect, for example, when there is a deviation between the aiming of the camera and the front view dimension of the face depending on the positional relationship (relative distance) between the face and the camera, based on the distance data specified by the control device, magnification adjustment of the face image (enlargement, reduction, trimming, etc. of the face image) or movement adjustment of the spraying carriage (and the camera) is executed, so that correction can be made to properly overlap the aiming of the camera over the entire area of the face.

[0019] One aspect of the concrete spraying method according to the present invention is A concrete spraying method for spraying concrete at least on the face of a tunnel, Using a self-propelled spraying carriage, a nozzle boom that is rotatably attached to the spraying carriage and is telescopable in its own axial direction, and a nozzle that is attached to the tip of the nozzle boom and discharges concrete, a nozzle mechanism, and at least a control device that specifies the relative coordinates of the measurement points on the face with respect to the spraying carriage, with a 3D scanner and a camera installed in front of the spraying carriage, and a monitor installed in the cab of the spraying carriage, spraying concrete on the face using the concrete spraying machine, before and after this spraying, obtaining distance data of the concrete before and after spraying to the face with the 3D scanner, calculating the spraying thickness of the concrete with the control device, and displaying on the monitor by overlapping the face image of the face captured by the camera, the contour lines of the surface areas around the respective measurement points, and the calculated spraying thicknesses of the respective measurement points, and performing additional spraying on the surface area where the spraying thickness is insufficient.

[0020] According to this aspect, a 3D scanner and a camera are equipped in front of the spraying carriage, a monitor is equipped in the cabin of the spraying carriage, the face image of the heading face imaged by the camera and the contour lines of the surface areas around each measurement point are displayed superimposed, and further, the spraying thickness of the concrete calculated based on the distance data before and after spraying of the concrete to each measurement point acquired by the 3D scanner is displayed as the spraying thickness of each surface area. Thus, the operator boarding the cabin of the spraying carriage can check the spraying thickness corresponding to the plurality of surface areas into which the face image of the entire heading face is divided, and perform the spraying construction while managing the spraying thickness of the concrete sprayed on the heading face in terms of surface. Such monitor display facilitates identification of the surface area with insufficient spraying thickness, so that additional spraying can be promptly performed on the identified surface area, and concrete spraying with the spraying thickness accurately managed over the entire heading face can be realized.

Advantages of the Invention

[0021] According to the concrete spraying machine and the concrete spraying method of the present invention, the spraying construction can be performed while managing the spraying thickness of the concrete sprayed on the heading face in terms of surface.

Brief Description of the Drawings

[0022] [Figure 1] It is a side view of an example of the concrete spraying machine according to the embodiment. [Figure 2] It is a plan view of an example of the concrete spraying machine according to the embodiment. [Figure 3] It is a diagram showing an example of the hardware configuration of the control device constituting the concrete spraying machine. [Figure 4] It is a diagram showing an example of the functional configuration of the control device constituting the concrete spraying machine together with peripheral devices. [Figure 5] It is a diagram showing an example of a countermeasure when there is a deviation between the aiming of the camera and the front view dimension of the heading face according to the position of the camera with respect to the heading face. [Figure 6] This figure shows an example of a monitor display screen, specifically an example of the display in reference value measurement mode. [Figure 7] This figure shows another example of the monitor's display screen, specifically an example of the display in spray value measurement mode. [Figure 8] This figure shows an example of a display on a monitor screen where the tunnel face image and a mesh colored according to the spraying thickness are overlaid. [Modes for carrying out the invention]

[0023] 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.

[0024] [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.

[0025] 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.

[0026] 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.

[0027] In the construction of mountain tunnel T, the process involves excavating a predetermined length, removing excavated material, applying primary concrete spraying to the surrounding surface S and face K of the constructed tunnel T, erecting support structures, and applying secondary concrete spraying. This construction cycle is repeated as excavation progresses. In some cases, rock bolts are installed after the secondary concrete spraying, if necessary.

[0028] Figures 1 and 2 show that excavation and spoil removal have been completed in a range of approximately 1m to 3m beyond the section where the sprayed concrete C with a sprayed thickness t has been applied, and the face K and surrounding surface S of that section are exposed. The sprayed concrete is then applied to this exposed face K and surrounding surface S while controlling the sprayed thickness.

[0029] 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 mounted at the center of the front (face K side) of the spraying trolley 10 so as to be able to rotate vertically (Y1 direction) and horizontally (Y2 direction), and is able to extend and retract in the Y3 direction in its own axial direction.

[0030] The concrete spraying machine 100 further includes a pair of erectors 60 that are similarly rotatable in the Y1 and Y2 directions and extendable in the Y4 direction in their own axial direction, mounted on the left and right positions of the nozzle boom 20 in front of the spraying trolley 10, and a pair of man cage booms 70 that are similarly rotatable in the Y1 and Y2 directions and mounted near the left and right erectors 60 in front of the spraying trolley 10, and are equipped with man cages 72 at their ends.

[0031] 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.

[0032] Here, the end of a concrete pumping hose (or concrete pumping piping) not shown is attached to the end of the nozzle 40 opposite to the discharge port (the lower end of the nozzle 40 in Figure 1), and this concrete pumping hose is connected to a hopper to which concrete is supplied from a mixer truck not shown, and to a concrete pump that pumps the concrete.

[0033] By driving the concrete pump with the control device 80, concrete is supplied to the nozzle 40 via the concrete pumping hose, and the 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, and concrete with the quick-setting agent added may be discharged onto the spraying surface.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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).

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] Although not shown in the diagram, the rotary mechanism 30 comprises a pair of housings, a motor housed in the housings, a storage unit mounted above the motor, and a nozzle mounting cylinder that extends laterally from one of the housings and has a nozzle installed inside. Inside the other housing, a laser distance meter 90B is installed, which irradiates a laser onto the spraying surface in the direction of concrete spraying, acquires the reflected laser, and measures the distance to the spraying surface in real time. A nozzle 40 and a concrete pumping hose are attached to the nozzle mounting cylinder, and concrete supplied by the drive of a concrete pump (not shown) is supplied to the nozzle via the concrete pumping hose and discharged from the nozzle 40.

[0045] The rotary mechanism 30 is configured such that an eccentric plate protrudes laterally from the storage body in stages, and the motor rotates with the eccentric plate displaced to one side, causing the nozzle 40 to oscillate. 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.

[0046] In this configuration, one housing is equipped with a proximity sensor (not shown) that detects the approach of a permanent magnet housed within a rotor (not shown) that constitutes the motor, and measures the rotational speed of the rotor. The other housing is equipped with an acceleration sensor (not shown) that measures the movement speed of the rotary mechanism 30 and the nozzle 40.

[0047] A camera 95 is further mounted at the center of the front of the spraying trolley 10, and the camera 95 is configured to capture still and moving images of the tunnel face K in front. The image data captured by the camera 95 is transmitted to the control device 80.

[0048] At the front of the spraying trolley 10 is a cabin 13 where the operator sits, and the cabin 13 is equipped with a monitor 15 that allows the operator to perform concrete spraying while controlling the spraying thickness.

[0049] Monitor 15 is connected to the control device 80 so that it can receive data transmitted from the control device 80. As described below, the monitor 15 receives image data of the front view of the tunnel face K captured by the camera 95 via the control device 80 and displays it on the display screen. On Monitor 15, the image of the tunnel face K and multiple meshes M (see Figure 8) are displayed superimposed, and the spraying thickness within each mesh M is further displayed. An example of the display on Monitor 15 will be described in detail below.

[0050] Next, with reference to Figures 3 to 8, the control device 80 constituting the concrete spraying machine 100 will be described, along with an example of the display on the monitor 15's display screen and an example of a concrete spraying method in which concrete spraying is performed while referring to this display screen. Here, Figure 3 is a diagram showing an example of the hardware configuration of the control device, and Figure 4 is a diagram showing an example of the functional configuration of the control device constituting the concrete spraying machine, along with peripheral equipment. Figure 5 is a diagram showing an example of countermeasures when there is a discrepancy between the camera's aiming and the front view dimension of the tunnel face, depending on the camera's position relative to the tunnel face. Figure 6 is a diagram showing an example of the monitor's display screen, specifically an example of the reference value measurement mode display, and Figure 7 is a diagram showing another example of the monitor's display screen, specifically an example of the spraying value measurement mode display. Furthermore, Figure 8 is a diagram showing an example of the monitor's display screen where the tunnel face image and a mesh colored according to the spraying thickness are superimposed.

[0051] As shown in Figure 3, 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.

[0052] 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.

[0053] 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), 3D scanner B (90C), laser distance meter 90B, camera 95, 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.

[0054] 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.

[0055] 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.

[0056] Furthermore, the input / output IF85 can be connected to display devices such as liquid crystal displays (LCDs) or 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. The spraying thickness at each measurement point is also transmitted to the monitor 15 mounted in the cabin 13 and displayed on the monitor 15's display screen. If a certain threshold is set for the spraying thickness, the threshold may also be displayed on the monitor 15's display screen, and an alarm may be displayed when the identified spraying thickness exceeds the threshold.

[0057] 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.

[0058] 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.

[0059] As shown in Figure 4, 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 magnification adjustment unit 112, the display unit 114, and the storage unit 116. 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.

[0060] 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 116.

[0061] 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 116.

[0062] Furthermore, the acquisition unit 102 acquires, for example, motion data of a front view of the tunnel face K captured by the camera 95. This motion data also includes the nozzle 40, which is close to the tunnel face K for spraying concrete, in a movement pattern corresponding to the operator's actions.

[0063] 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 116, 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.

[0064] Furthermore, 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).

[0065] 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.

[0066] 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.

[0067] The magnification adjustment unit 112 determines the distance from the camera 95 to the tunnel face K based on the relative coordinates of each measurement point at the tunnel face K, which have been determined by the relative coordinate determination unit 104, and compares the distance from the camera 95 to the tunnel face K with a suitable imaging distance (or imaging angle) for which the tunnel face K is clearly imaged by the camera 95.

[0068] As shown in Figure 5, if the camera 95 is too far from the tunnel face K, the magnification adjustment unit 112 calculates the amount of magnification adjustment based on the current distance and the focal length within the camera 95, and then controls the camera 95 to focus based on the calculated magnification adjustment amount.

[0069] On the other hand, if the camera 95 is too close to the tunnel face K, the camera 95's focus control is insufficient. Therefore, the magnification adjustment unit 112 identifies a suitable imaging distance (e.g., a retreat distance) and displays it on the display unit 114. The operator can then retract the spraying trolley 10 (and camera 95) by the displayed retreat distance to position the camera 95 in an appropriate location where the entire tunnel face K can be imaged.

[0070] In this way, the magnification adjustment unit 112 adjusts the magnification of the tunnel face image (enlargement, reduction, cropping, etc.) and the movement of the spraying trolley 10 (and camera 95) based on the distance data to the tunnel face K identified by the control device 80, in case there is a discrepancy between the aiming of the camera 95 and the front view dimension of the tunnel face K, thereby correcting the aiming of the camera 95 to properly overlap the entire area of ​​the tunnel face K.

[0071] Returning to Figure 4, the display unit 114 displays relative coordinate data of each measurement point before and after concrete spraying at the 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.

[0072] The display unit 114 displays the spray thickness at each measurement point, along with the image captured by the camera 95 regarding the tunnel face K, on ​​the display screen of the monitor 15 mounted in the cabin 13.

[0073] The display screen of the monitor 15 can be freely switched between images related to the reference value measurement mode shown in Figure 6 and images related to the spray value measurement mode shown in Figure 7 by pressing the switch button on the screen (indicated by (7) in the figure).

[0074] In the display screen showing the reference value measurement mode as shown in Figure 6, "(1) Spraying thickness progress" is displayed for the front view image of the tunnel face K taken by camera 95, and multiple measurement points are displayed within rectangular frames. As shown in Figure 8, multiple rectangular meshes M, formed by spreading out the multiple measurement points, are superimposed on this image of the tunnel face K.

[0075] As shown in Figures 6 and 8, the image of the tunnel face K displays a "(2) Legend" which shows the display color corresponding to the spray thickness and the range of spray thickness. Also, to the left of the image of the tunnel face K, "(3) Extracted Mesh Information" is displayed, showing the reference coordinates of each mesh, and other information is displayed, including "(4) Current Time", "(5) Reference Value Acquisition Time", "(6) Spray Value Update Time (Latest Data Acquisition Time)", "(7) Measurement Mode Display, where "Reference Value Measurement Mode" is selected in Figure 6", "(8) Button to select manual or automatic measurement", "(9) Status display showing whether it is in standby or measuring", "(10) Screenshot Save Button to save screenshots of each state as needed to save the basis for progress management", and "(11) Report Output Button to output the reference value, the last updated value data, and the final spray thickness data calculated from them".

[0076] In contrast to the reference value measurement mode shown in Figure 6, the sprayed value measurement mode shown in Figure 7 identifies the sprayed thickness in each mesh M, and the current sprayed thickness in each mesh M is entered into the extracted mesh information. The multiple mesh Ms shown in Figure 8, which are overlaid on the captured image of the face K, display colors corresponding to the sprayed thickness. In addition, the sprayed thickness is also displayed numerically within each mesh M. Although the drawing is displayed in black and white, the actual monitor 15 displays colors such as blue, green, yellow, red, orange, and purple, corresponding to the range of sprayed thicknesses.

[0077] Here, in addition to the form in which the inside of the mesh M is displayed in a color corresponding to the spraying thickness as shown in the illustrated example, the outline of the mesh M and the numerical value indicating the spraying thickness within the mesh M may also be displayed in a color corresponding to the spraying thickness.

[0078] On the display screen of monitor 15, the nozzle 40, which moves as needed by the operator, will also be included in the image of the tunnel face K. In this case, the display color within each mesh M is displayed semi-transparently so that the images of the nozzle 40 and the tunnel face K can be seen.

[0079] In this way, multiple meshes M, which define the surface area around multiple measurement points, are superimposed on the captured image of the tunnel face K. The captured image of the tunnel face K can be viewed while the area within the meshes M is displayed in a color corresponding to the spraying thickness. This makes it possible to accurately and comprehensively manage the spraying thickness across the entire area of ​​the tunnel face K.

[0080] At the tunnel face K, in addition to managing the entire area with a uniform spray thickness, the tunnel face K may also be divided into multiple areas depending on the possibility of surface collapse (degree of risk), and the spray thickness may be varied for each area. In either case, the image of the tunnel face K is divided into multiple regions (mesh M), and the spray thickness for each region is specified. As a result, the difference between the design spray thickness and the actual spray thickness in each region can be calculated, and the operator can easily determine the spray thickness required for further spraying in each region.

[0081] Furthermore, since the image of the tunnel face K includes the nozzle 40 which is constantly moving, the operator can check on the monitor 15 whether the nozzle 40 is directly facing the mesh M to be sprayed, and then perform the concrete spraying operation after aligning the nozzle 40 with the mesh M to be sprayed.

[0082] Here, it is preferable that the spraying trolley 10 is equipped with a rotating light (Patlite® registered trademark) not shown, and that the rotating light is illuminated while the spray thickness is being measured to notify the operator that measurement is in progress. This allows the operator to stop the spraying work during measurement and to quickly resume spraying work after the measurement is completed. This rotating light may also be equipped with a buzzer, so that in addition to the visual warning from the rotating light, an audible warning from the buzzer can be added.

[0083] With the concrete spraying machine 100 and the concrete spraying method using it, the relative coordinates of multiple measurement points on the face K and the surrounding surface S, the tip position of the nozzle boom 20 and the relative coordinates of the installation position of the 3D scanner B (90C) on the erector 60 are measured by the 3D scanner A (90A), or the relative coordinates of multiple measurement points on the surrounding surface S are measured by the 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, thus eliminating the need for operators and enabling completely automated concrete spraying construction, including the determination of the spraying thickness.

[0084] 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.

[0085] 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.

[0086] Furthermore, multiple meshes M defining the surface area around multiple measurement points are superimposed on the image of the tunnel face K displayed on the display screen of the monitor 15 mounted in the cabin 13 of the spraying trolley 10. The image of the tunnel face K can be viewed while the inside of the meshes M is displayed in a color corresponding to the spraying thickness, thereby enabling accurate and surface-level control of the spraying thickness across the entire area of ​​the tunnel face K.

[0087] Furthermore, since the nozzle 40 is also included in this image, the operator can visually check the monitor 15 to correctly position the nozzle 40 relative to the mesh M to be sprayed, and then perform the concrete spraying operation.

[0088] 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]

[0089] 10: Spraying cart 12A, 12B, 12C: Third target 13: Cabin 15: Monitor 20: Nozzle boom 21: Boom 22: Arm 25A, 25B, 25C: Angle sensors 26: Rotary encoder 27: Stroke sensor 28A, 28B, 28C: First target 30: Rotary mechanism 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 (3D Scanner) 90B: Laser distance meter 90C: 3D Scanner B (3D Scanner) 95: Camera 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 M: Mesh (surface area)

Claims

1. A concrete spraying machine for spraying concrete onto at least the face of a tunnel, 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, The system includes at least a control device that identifies the relative coordinates of the measurement points at the tunnel face with respect to the spraying trolley, The spraying trolley is equipped with a 3D scanner and a camera at its front. The cabin of the aforementioned spraying trolley is equipped with a monitor. The monitor displays, superimposed, the image of the tunnel face captured by the camera and the contour lines of the surface areas around each of the measurement points. A concrete spraying machine characterized in that the concrete spraying thickness calculated by the control device based on distance data before and after concrete spraying to the measurement point acquired by the 3D scanner is displayed as the spraying thickness of the surface area.

2. The aforementioned spray thickness is assigned multiple display colors depending on the thickness. Multiple surface regions are formed by multiple meshes, The concrete spraying machine according to claim 1, characterized in that the monitor displays the interior of a plurality of meshes, the outline of the meshes, or a numerical value indicating the spraying thickness in the meshes, in the display color corresponding to the spraying thickness.

3. The concrete spraying machine according to claim 2, characterized in that when the inside of the mesh is displayed in the display color, the inside of the mesh is displayed in a colored semi-transparent manner, and the face image corresponding to the inside of the mesh can be seen.

4. The concrete spraying machine according to claim 2 or 3, characterized in that the operator can easily confirm both the position of the nozzle in the face image and the mesh to be sprayed using the monitor.

5. The concrete spraying machine according to any one of claims 1 to 3, characterized in that the control device performs magnification adjustment of the face image based on the distance data.

6. A concrete spraying method for spraying concrete onto at least the face of a tunnel, A concrete spraying method is characterized by using a concrete spraying machine that has at least a self-propelled spraying cart, a nozzle mechanism comprising a nozzle mechanism having a nozzle boom that is rotatably attached to the spraying cart and is extendable and retractable in its axial direction, and a nozzle attached to the tip of the nozzle boom for discharging concrete, and a control device that identifies the relative coordinates of measurement points at the tunnel face with respect to the spraying cart, a 3D scanner and a camera mounted in front of the spraying cart, and a monitor mounted in the cabin of the spraying cart, to spray concrete onto the tunnel face, and before and after the spraying, distance data of the concrete to the tunnel face before and after spraying is acquired by the 3D scanner, the control device calculates the sprayed concrete thickness, and the monitor displays the tunnel face image captured by the camera, the contour lines of the surface areas around each of the measurement points, and the calculated sprayed concrete thickness for each of the measurement points superimposed on the monitor, and additional spraying is performed on the surface areas where the sprayed thickness is insufficient.

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