A tunnel lining system

Abstract

A tunneling system comprising an automatic tunnel construction vehicle to remove material and apply lining to a tunnel created by the removal of the material and concurrently with material removal. The system comprises a lining applicator to automatically apply a cementitious mixture to the tunnel, and a slip shield trowel to press the cementitious mixture against a wall of the tunnel while the cementitious mixture is curing, thereby creating a completed tunnel.

Description

A TUNNEL LINING SYSTEMRELATED CASES

[0001] The present application claims priority to U.S. Provisional Application No. 63 / 512,565, filed on July 7, 2023, which is incorporated herein in its entirety.FIELD

[0002] The present invention relates to automatic tunnel lining, and more particularly to automatic tunnel lining that can seal and support the tunnel walls and ceiling at the same penetration rate as a boring robot.BACKGROUND

[0003] Increasing demand for electricity, the need to integrate vast “landlocked” U.S. solar and wind energy resources into the power supply to reduce CO2 emissions, the potential for natural disasters or malicious threats in remote locations, and the risk of climate change-induced extreme weather, severe storms, and wildfires have raised alarm about the reliability, security, and resilience of the already stressed and fragile U.S. electric grid. Studies have shown that undergrounding electric power lines can protect them from many of these vulnerabilities. However, the current cost of undergrounding using existing technologies is not economical, with costs ranging from 4 to 14 times more than overhead lines of the same voltage and same distance.

[0004] Current techniques for tunneling are slow and expensive.BRIEF DESCRIPTION OF THE FIGURES

[0005] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:

[0006] Figure 1 is a side view of one embodiment of the automatic tunneling system including the tunnel borer, lining applicator, and vacuum component.

[0007] Figure 2A is a perspective view of one embodiment of the lining applicator including a plurality of stationary sprayers and showing the slip shield trowel.

[0008] Figure 2B is a front view of one embodiment of the lining applicator including the plurality of stationary sprayers.

[0009] Figure 2C is the front view of one embodiment of the lining applicator, including a plurality of moving sprayers.

[0010] Figure 2D is a front view of another embodiment of the lining applicator including a plurality of stationary fan sprayers, which inject the cementitious mixture across a wider area.

[0011] Figure 2E is a is front view of another embodiment of the lining applicator including a smaller number of moving sprayers.

[0012] Figure 2F is an illustration of one embodiment of a tractor including the lining applicator.

[0013] Figures 3A-3B show one embodiment of a controllable valve which adjusts the volume of injection of the cementitious mixture based on data from a mechanical sensor.

[0014] Figure 3C-3D show another embodiment of a controllable valve which adjusts the volume of the cementitious mixture based on data from an electronic sensor interpreted using a processor.

[0015] Figure 4A is a view of one embodiment of the slip shield trowel, with extended pistons to press the trowel against the cementitious mixture, while it sets.

[0016] Figure 4B is a view of one embodiment of the slip shield trowel, with contracted pistons to pull in the slip shield trowel, enabling the component to move without touching the tunnel walls.

[0017] Figure 4C is a view of one embodiment of a hydraulic piston that may be used to support the slip shield trowel.

[0018] Figure 4D is a view of one embodiment of the slip shield trowel, with overlapping components.

[0019] Figure 4E is a view of one embodiment of the front of a portion of the slip shield trowel, showing the beveled front of the slip shield trowel, to collect the cementitious mixture from the nozzles, and press them against the tunnel walls.

[0020] Figure 5A is view of one embodiment a drip collector unit to collect overflow cementitious mixture and apply it to the ground.

[0021] Figure 5B is a view of another embodiment of a drip collector unit to collect overflow cementitious mixture and apply it to the edges of the tunnel.

[0022] Figure 6 is an overview flowchart of utilizing the system.

[0023] Figure 7 is a flowchart of one embodiment of applying the cementitious mixture to the tunnel walls.

[0024] Figure 8 is a flowchart of one embodiment of mixing the cementitious mixture based on the usage.

[0025] Figure 9 is a flowchart of one embodiment of a two-stage application.

[0026] Figure 10 is a block diagram of one embodiment of the system.

[0027] Figure 11 is a block diagram of one embodiment of a computer system that may be used with the present invention.DETAILED DESCRIPTION

[0028] The present system describes a tunnel boring system, which in one embodiment includes a plasma tunnel boring robot and an automated tunnel lining applicator. In one embodiment, the plasma tunnel boring system of U.S. Patent No. 11 ,136,886 is used, which is incorporated by reference in its entirety. However, alternative tunnel boring mechanisms may be used.

[0029] One embodiment of the present system is a tunnel casement solution that can seal and support the tunnel walls and ceiling at the same penetration rate (-135 ft. / hr.) as the plasma boring robot described in U.S. Patent No. 11,136,886. No current system can support the plasma drilling system, because of the speed of advance. Generally, tunnel lining is a slow laborious process. In contrast, the described lining system can provide a tunnel casement solution which keeps up with the plasma boring robot and matches its speed in lining the tunnel created. Thus, the automated tunnel lining applicator addresses the problem of concurrent tunnel lining, to ensure that the plasma boring robot’s tunnel is correctly stabilized. Because no such system exists today, the problem recognized by the inventors of this system is novel, and recognition of the problem is part of the novelty of this application.

[0030] The automatic tunnel lining applicator includes 1) a concrete / cementitious material formulation for the tunnel lining material that flows through the delivery system and sets quickly, achieves the required structural breaking point, and adapts to site environmental conditions, 2) a continuous mixing and application system, 3) a slip shield trowel to protect the tractors and to support the tunnel lining material until it is fully set. In one embodiment, the present system utilizes a transformative undergrounding construction system that simultaneously bores the tunnel and applies a tunnel casing. The system is designed to be useablewith a variety of mixtures for application to the tunnel surfaces, so that the mixture can be defined by the engineer of record based on the local conditions and requirements for the tunnel. The automatic tunnel lining applicator is flexible enough to accommodate the various mixtures and layers specified. In one embodiment, the system uses concrete admixes designed for high heat, and can use rock aggregate created during the robot’s plasma tunneling efforts (recycling). In one embodiment, concrete mix is sprayed as a slurry on the newly exposed tunnel walls, which still retain considerable residual heat helping set the concrete. In one embodiment, slurry material is continuously sprayed to a sufficient casing depth on the tunnel walls and ceiling as the casement system component moves forward, allowing the attached slip form to smooth and form the slurry material into a finished tunnel ceiling and wall.

[0031] The system includes several components, in one embodiment. In one embodiment, a casing delivery system also referred to as lining applicator, in one embodiment is on a tractor that follows behind a plasma boring tractor. The casing delivery tractor includes a mixing chamber and control system and sprayer(s) to apply a cementitious mixture to the tunnel. In one embodiment, the system also includes a ground sensor, and tracks to move the casing delivery tractor. The casing delivery tractor may use wheels, tracks, continuous track, or other movement mechanism. In one embodiment, a reverse slip, or slip shield trowel, forms on the sides of the casing delivery tractor, to smooth the composite casing mixture, as the sprayers apply it to the walls. The casing delivery tractor, in one embodiment, may be the same tractor as the plasma boring tractor and / or a vacuum tractor. In one embodiment, a completed tunnel may be used for transmission cables, various power lines and other cables, and may include a human-sized service space allowing maintenance.

[0032] While there are well-known tunneling technologies that incorporate various methods of casing (such as horizontal directional digging, micro-tunneling, open cut, and horizontal augur boring), there was no existing tunnel casement system to match the boring speed of the robotic system until the present automatic tunnel lining system.

[0033] The following detailed description of embodiments of the invention make reference to the accompanying drawings in which like references indicate similar elements, showing by way of illustration specific embodiments of practicing the invention. Description of these embodiments is in sufficient detail to enable those skilled in the art to practice the invention. One skilled in the art understands that other embodiments may be utilized, and that logical, mechanical, electrical, functional, and other changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.

[0034] Figure 1 is a side view of one embodiment of the automatic tunneling system 100 including the tunnel borer, lining applicator, and vacuum component. The automatic tunneling system includes one or more tractors, to move the automatic tunneling system forward to drill or excavate a tunnel. The front of the automatic tunneling system includes the borer 110, which includes a plurality of plasma torches 115 and a shield 120. The shield 120 reflects heat from the plasma torches 115. The size of the shield 120 defines the size of the tunnel 105. The plasma torches 115 are used to bore the tunnel, by melting and / or gasifying, breaking up and / or spallating the earthen material being tunneled through. In one embodiment, most of the material is gasified or melted, but some gravel and melted rock remains.

[0035] The lining applicator 130 includes one or more sprayers 135 which are used to spray a mixture onto the ceiling and walls (surfaces) of the newly dug tunnel. In one embodiment, the mixture is a cementitious mixture. In one embodiment, the residual heat from the plasma torches in the surfaces helps set the cementitious mixture.

[0036] In one embodiment, there is a second lining applicator 140 which includes a second set of sprayers 145. In one embodiment, if there are two lining applicators 130, 140, the system includes a first set of one or more sprayers to spray a waterproofing or other initial layer, and a second set of one or more sprayers to spray the cementitious mixture. In one embodiment, the waterproofing layer, or water impervious layer, is applied prior to applying the cementitious mixture. The first set and the second set of sprayers may be on the same tractor or may be on separate tractors. In another embodiment, two layers of cementitious material may be applied by first lining applicator 130 and second lining applicator 140.

[0037] In one embodiment, there is a slip shield trowel 150 over one or more tractors. The slip shield trowel 150 after the lining applicator 130 pushes the cementitious mixture against the tunnel surfaces, until the mixture sets. In one embodiment, there is also a canopy 155 over the borer 110, to protect it against rocks. In one embodiment, the canopy 155 may be identical in design to the slip shield trowel but is not pressed against the tunnel surfaces. In one embodiment, the slip shield trowel 150 extends over one or more tractors. In one embodiment, the length of the slip shield trowel is based on the type of material used for the cementitious mixture. In one embodiment, the slip shield trowel extends the full length of the automatic tunneling system 100.

[0038] In one embodiment, if the first lining applicator 130 applies a waterproofing layer, or another layer rather than a cementitious layer, then thecorresponding slip shield trowel acts as a canopy only and does not press the material against the tunnel surfaces. The slip shield trowel 150 is used with cementitious mixtures only, in one embodiment.

[0039] In one embodiment, a vacuum component 160 includes one or more vacuum hoses 165 which vacuum up the gravel and melted rock from the plasma torches.

[0040] The lining applicator 130 may be part of a first tractor 170, a second tractor 180, or a third tractor 190, in one embodiment. In one embodiment, the lining applicator 130 may be part of the first tractor 170 which includes the borer 110. In that embodiment, the lining applicator 130 is on the back of the first tractor. In one embodiment, the lining applicator 130 may be part of a second tractor 180. On the second tractor 180 the lining applicator 130 may be on the front and / or the back of the second tractor. In one embodiment, if the lining applicator 130 is on the back of the second tractor 180, a vacuum component 160 and may be on the front of the second tractor 180. In one embodiment, there may be a vacuum hose 165 on the first tractor 170 and the second or subsequent tractor. In one embodiment, the vacuum component 160 may be on the second tractor 180, and the lining applicator 130 may be on a third tractor 190. Alternatively, the lining applicator 130 may be on a second tractor 180, and the vacuum component 160 may be on the third tractor. Additional tractors may be added.

[0041] In one embodiment, there may be two lining applicators 130, 140 on separate tractors. For example, a first lining applicator 130 may apply a waterproof layer or a gluing layer, and a second lining applicator 140 may apply the cementitious mixture. In another embodiment, the first lining applicator 130 may apply a first layer, and the second lining applicator 140 may apply a second layer of cementitious mixture. In one embodiment, the distance between the first liningapplicator 130 and the second lining applicator 140 is sufficient to allow the first layer of material to fully cure before the second layer is applied.

[0042] In one embodiment, a waterproof layer may be applied only when sensor data indicates that water impingement is a risk for the tunnel segment. In one embodiment, the specific order and composition of each layer is determined by an engineer based on sensor data. Because the automatic tunneling system is configurable, the system can be set to use whatever layers are preferred, in the order set.

[0043] In one embodiment, the automatic tunneling system may include multiple lining applicators 130, 140 each of which applies a cementitious mixture, or another mixture. In one embodiment, the mixtures may vary by application. For example, the first layer may be a smoother and thinner layer, with a second thicker and more gravely mixture. There may be one or more additional layers as well. In one embodiment, the number of layers, and material used for the layers is set when the composition of the material into which the tunnel is bored is determined. Depending on what is being tunneled-through, there may be different compositions of the cementitious material(s). The specific composition of the mixtures is set by an engineer familiar with the local conditions and requirements for the tunnel. The automatic tunneling system can accommodate a variety of specific mixtures. In one embodiment, the automatic tunnel lining system can adjust the mixture based on instructions from the engineer during the tunneling process. This flexibility is made possible because in one embodiment, the cementitious material is mixed in-situ by the lining applicator. In one embodiment, the lining applicator has materials available for the various potential mixtures.

[0044] Figure 2A is a perspective view of one embodiment of the lining applicator including a plurality of stationary sprayers and showing the slip shieldtrowel. The lining applicator 210 includes control and mixing components (not shown) within tractor 215. The dispersing portion of the lining applicator 210 is shown with stationary sprayers 220. The stationary sprayers 220 dispense a cementitious mixture, in one embodiment. In one embodiment, the stationary sprayers 220 may dispense a waterproof layer or another material. The amount of mixture coming from stationary sprayers 220 in one embodiment are controlled by a controllable valve, which adjusts the volume of the spray. The view further illustrates the slip shield trowel 225, which ensures that the cementitious mixture stays attached to the tunnel surface as it cures.

[0045] Figure 2B is a front and / or back of the embodiment of the lining applicator including a plurality of stationary sprayers. As can be seen, the stationary sprayers 220 cover the surfaces of the tunnel 230 with the mixture.

[0046] Figure 2C is a front and / or back of the embodiment of the lining applicator including a plurality of moving sprayers 240. The moving sprayers 240 rotate as they apply a mixture along a segment of tunnel. In one embodiment, the movement speed of the moving sprayers 240 is controlled along with the volume being dispensed, to apply the correct amount of mixture. In one embodiment, there may be three to ten moving sprayers. Figure 2E illustrates three moving sprayers 250, where each sprayer covers 1 / 3 of the tunnel arc. Figure 2B illustrates seven moving sprayers.

[0047] Figure 2D is a view of another embodiment of the lining applicator including a plurality of stationary fan sprayers, which inject the cementitious mixture across a wider area. In this embodiment, the fan sprayers 255 have a wide outlet, referred to as a “fan” spraying, such that the material is sprayed across a wider surface without any movement by the sprayers 255. In one embodiment, the system may include two to five fan sprayers to cover the tunnel surfaces.

[0048] Figure 2F is a simplified interior view of a tractor including the lining applicator. The lining applicator 260 may be on the front or back of tractor 265, as discussed above. In one embodiment, the lining applicator 260 includes one or more sprayers 270, which output a mixture. In one embodiment, the mixture is output from mixing chamber 275. Mixing chamber 275 creates a cementitious mixture from dry mix 280, 282, 284 and water 285. In one embodiment, there may be multiple dry mixes 280, 282, 284.

[0049] A computing system 290 controls the mixture, including selection of the dry mixes 280, 282, 284, and water 285, as well as mixing chamber 275. Dry mixes 280, 282, 284 may include all of the components for various cementitious mixtures, including sand, gravel, fibers, and / or other materials. In one embodiment, one or more of the dry mixes 280, 282, 284 may be partially or completely made up of aggregate (gravel) from the material removed by the plasma torches. In one embodiment, the dry mixes, water, and aggregate are received via umbilicals 292 from outside the tunnel.

[0050] In one embodiment, material collected from the spoils is collected by a vacuum component and sent out of the tunnel. The material is then sifted, and processed, and a portion of the dry mix that is returned to the lining applicator 260 via an umbilical 292 may include such spoils as aggregate for use in the cementitious mixture. In one embodiment, the computing system 290 includes a processor and receives data from one or more sensors 295. The sensors 295 may be used to analyze the material that the tunneling system is moving through, and adjust the mixture used. The sensors 295 may also be used to analyze the air, the ground, the distance between the system and the ground, etc. Sensors may include sensor such as LIDAR sensors to map rough tunnel shapes, distances, etc., temperature sensors, sensors to detect possible detachment of cementitiousmaterial or possible cave in, air quality sensors, etc. Additional sensors may be present, on other components of the automatic tunnel lining system, the boring system, or elsewhere,

[0051] In one embodiment, the computing system 290 may be a distributed computing system, with a portion on tractor 265, and other portions of the computing system 290 elsewhere. For example, the computing system 290 may include one or more processors that are local and / or remote from the lining applicator 260. In one embodiment, the computing system 290 is a distributed system located in various portions of the automatic tunnel lining system. In another embodiment, there may be separate computing systems 290 controlling various aspects of the system. In one embodiment, the separate computing systems 290 may communicate via a network. The network may be wireless or wired via the umbilicals connecting the components together.

[0052] In one embodiment, a transfer system propels dry mixture to the mixing system, the mixing chamber 275 combines the dry mixture with water, and then pumps and manages the flow rate of the mixture through sprayer 270. The transfer system is controlled by computing system 290.

[0053] Figures 3A and 3B illustrate one embodiment of a controllable valve which adjusts the volume of injection of the cementitious mixture based on data from a mechanical sensor. The nozzle 310 outputs the cementitious mixture, in one embodiment. The mechanical controller 320 in one embodiment is a wheel 330 coupled via a spring-adjusted handle, which travels along the tunnel surface in close proximity to the nozzle 310. The spring 335 compresses as the wheel 330 travels over a portion of the tunnel, which is closer to the nozzle 310, and thus should take less of the cementitious mixture. The compression of the spring 335 controls a gate 315, which controls how much mixture exits the nozzle. In this way, the volume ofthe cementitious mixture applied to the tunnel surface is automatically adjusted to account for the unevenness of the tunnel. The resulting casing or lining will be even.

[0054] Figure 3C and 3D illustrate one embodiment of a controllable valve which adjusts the volume of the cementitious mixture based on data from an electronic sensor interpreted using a processor. Instead of a mechanical controller, the system receives data from sensor 360, indicating the distance to the tunnel surface, which is used by processor 370, to set the controller 380 to adjust the volume of mixture dispensed by nozzle 350. In one embodiment, the adjustment may be how open the nozzle is, as shown in Figures 3C and 3D, a gate as shown in Figures 3A and 3B, or another type of controller that adjusts the volume of cementitious mixture. In one embodiment, the processor 370 is part of the computing system of the lining applicator.

[0055] Figure 4A is a view of one embodiment of the slip shield trowel, with extended pistons to press the trowel against the cementitious mixture, while it sets. In one embodiment, the slip shield trowel 410 is on the same tractor as the lining applicator 400. The shield trowel 410 is pressed against the tunnel surface in one embodiment using hydraulics 450. In one embodiment, each segment 415-445 is supported by a plurality of hydraulics 450, which press the segments against the tunnel surfaces. In one embodiment, the slip shield trowel 410 can also be retracted, as shown in Figure 4B, using the hydraulics 450. The slip shield trowel is retracted, in one embodiment, to enable the automatic tunneling system to move without scraping the tunnel walls. Figure 4B illustrates one embodiment of the retracted slip shield trowel 410. This may be useful in backing out the tunneler, for example. The slip shield trowel 410 acts as a canopy over one or more tractors, protecting them from drips or damage from the cementitious mixture. Additionally, in oneembodiment, the slip shield trowel can be used as a simple canopy to protect other tractors / equipment as well.

[0056] Figure 4C is a view of one embodiment of a hydraulic piston that may be used to support the slip shield trowel. The piston 450 supports the slip shield trowel 410 and can be retracted to retract the slip shield trowel.

[0057] Figure 4D is a view of one embodiment of the slip shield trowel, with overlapping segments. In one embodiment, the shield trowel 410 is made up of a plurality of segments 415, 420, 425, 430, 435, 440, 445, each overlapping so that the shield trowel forms a solid form, which is used to press the cementitious mixture into the tunnel surface. In one embodiment, the shield trowel 410 includes five segments, a top portion, two curved sides, and the side portion. In one embodiment, the shield trowel 410 includes between three and twelve segments. In one embodiment, the shield trowel 410 covers the top 2 / 3 of the tunnel but does not reach to the base. In another embodiment, the shield trowel 410 may extend near the ground. In one embodiment, shield trowels 410 may be extended by having a second slip shield trowel 460 overlapping the first shield trowel.

[0058] Figure 4E is a view of one embodiment of the front of a portion of the slip shield trowel, showing a beveled front 470 of the slip shield trowel 410, to collect the cementitious mixture from the nozzles, and press them against the tunnel walls.

[0059] Figure 5A is view of one embodiment a drip collector to collect overflow cementitious mixture and apply it to the ground. In one embodiment, at the front of the lining applicator 510, the system includes a scoop or drip collector 520 to collect the cementitious mixture overflow and plow it into the center of the tunnel. As the system passes, in one embodiment, smoothing bars 530 spread the materialacross the center and form it into a smooth surface to serve as a floor. In one embodiment, the system is designed to minimize waste of materials.

[0060] Figure 5B is a view of another embodiment of a drip collector to collect overflow cementitious mixture and apply it to the edges of the tunnel. In one embodiment, the lining applicator 550 includes a drip collector 560, which collects the cementitious mixture overflow and applies it to the corners of the tunnel to reinforce them.

[0061] Figure 6 is an overview flowchart of utilizing the system. The process starts at block 610. At block 615, the system identifies the material that will be tunneled through, and based on the identification identifies the components of the automatic tunneling system and sets up the tractors and components. In one embodiment, the automatic tunneling system always includes a borer and a lining applicator, and at least one tractor to provide movement. Optionally, the automatic tunneling system may also include one or more additional lining applicators, one or more vacuum components, and any number of tractors. The set-up also includes positioning the components on the tractors. As discussed above, the lining applicator may be on the front or the back of a tractor. There may be a vacuum hose on the first tractor, or not.

[0062] At block 620, the cementitious mixture is selected, based on the material to be tunneled-through, and potential environmental factors. In one embodiment, the cementitious mixture selection may be based on the density, solidity, type, and environment of the tunnel, as well as its depth. In one embodiment, the mixture selection may select a plurality of potential mixtures, based on expected environmental factors. For example, the system may select a first mixture for a first segment, and potentially a second mixture for a second segment. The system may potentially also select multiple layers, with separate mixtures.Furthermore, in one embodiment, the selection may include a determination whether to include a waterproof layer under the cementitious layer.

[0063] At block 625, the tunnel boring system is started, to remove material and build a tunnel. In one embodiment, the tunnel boring system uses a set of one or more plasma torches to remove material and create the tunnel. In one embodiment, the automatic tunneling system described above is used.

[0064] At block 630, the lining applicator is used to apply cementitious material to the tunnel surface as it is being dug out. In one embodiment, the lining application may apply one or more layers of cementitious material. In one embodiment, a first waterproof layer may be applied by lining applicator. In one embodiment, there may be multiple lining applicators.

[0065] At block 635, the slip shield trowel is used to press the cementitious material against the tunnel surfaces. In one embodiment, the slip shield trowel is used to compress the cementitious material and hold it in place as it cures.

[0066] At block 640, the process determines whether conditions have changed, which may include changes in the material through which the automatic tunneling system is boring has changed. Such changes may include changes in the rock / earthen materials, the presence or absence of water, depth, etc. If so, at block 645, the lining mixture may be adjusted for the updated conditions. In one embodiment, if the conditions are within the planned range, the adjustment may be done without requiring any external input, by the computing system that is part of the automatic tunneling system. The process then returns to block 625 to continue to use the tunnel boring system.

[0067] If there is no change to the conditions at block 640, the process determines whether the tunnel is done, at block 650. If not, the process continues to block 625 to use tunnel boring system. If the tunnel is done, in one embodiment atblock 655 the slip shield trowel is lowered, and the tunnel boring system is backed out of the tunnel. By lowering the slip shield trowel, the slip shield trowel does not scrape against the tunnel wall, as it is backed out. In some embodiments this step may be skipped, if the tunnel exit is reached on the other hand, and there is no need to back up. The process then ends at block 660.

[0068] Figure 7 is a flowchart of one embodiment of applying the cementitious mixture to the tunnel walls. The process starts at block 710. At block 715, one or more environmental sensors are used to detect issues. Issues can include water leaking into the tunnel, the rock walls being fragile or friable, etc.

[0069] At block 720, the lining mixture is adjusted based on the environment and detected issues. In one embodiment, the lining mixture adjustment adjusts how many layers are sprayed, and what the layers are.

[0070] At block 730, a sensor is used to detect the distance to the tunnel surface, for each nozzle.

[0071] At block 740, the nozzle output volume is adjusted based on the sensor data. In one embodiment, the sensor may be a mechanical sensor controlling a valve or gate or nozzle size, to adjust the volume. The purpose of this adjustment is to create a level tunnel surface when the surface post-boring is uneven.

[0072] At block 745, material is sprayed through the one or more nozzles onto the tunnel surface.

[0073] At block 750, the slip shield trowel is used to press the material against the tunnel surface. The slip shield trowel pushes a cementitious mixture against the tunnel surface, enabling it to cure while it is supported by the slip shield trowel.

[0074] At block 755, the process determines whether the tunnel segment is complete. If so, the process ends at block 760. Otherwise, the process returns to block 715 to continue monitoring environmental conditions and issues.

[0075] Figure 8 is a flowchart of one embodiment of mixing the cementitious mixture based on the usage. The process starts at block 810.

[0076] At block 815, the material that will be tunneled through is identified. In one embodiment, one or more sensors are used to determine the material. In one embodiment, some material is removed and separately analyzed.

[0077] At block 820, the moisture content is determined. In one embodiment, moisture sensors are used.

[0078] At block 830, water impingement is determined. Water impingement is the proximity of water sources that are likely to result in water entering the tunnel. Determining water impingement may include determine ground water levels.

[0079] At block 840, the optimum aggregate content is determined. The optimum aggregate content defines the percentage of a cementitious mix that is aggregate from the spoils removed by the automatic tunneling system. In one embodiment, the optimum aggregate content includes the percentage of aggregate material and the particle size of the aggregate. The optimum aggregate content may be set by an engineer based on environmental, local, zoning, and other factors such as the material being removed, moisture content, and likely water impingement.

[0080] At block 845, the mix is selected based on the conditions. The mix includes one or more dry mixes mixed with water by the lining applicator. At block 850, the cementitious mixture is created in real-time, as it is applied. The process then ends at block 855.

[0081] Figure 9 is a flowchart of one embodiment of a two-stage application. The process starts at block 910. At block 915, the first layer of material is applied. The fixing material may be spray epoxy, rubber, or another material.

[0082] At block 920, the process determines whether the first layer needs a trowel. If so, the first layer is pressed with the slip shield trowel against the tunnel surfaces, at block 925. The process then continues to block 930. If troweling is not needed, at block 930 the slip shield trowel is used to protect the tractors and sensors from dropping rocks or other materials, but the slip shield trowel is not pressed against the tunnel surfaces.

[0083] At block 935, a second layer is applied. In one embodiment the second layer is a cementitious material. However, in one embodiment, the second layer may also be a non-cementitious material.

[0084] At block 940, the second layer is pressed against the tunnel surfaces using a second slip shield trowel. The process then ends at block 950. The actual application process may include anywhere between one and five layers of various materials. In one embodiment, the materials which require setting, such as the cementitious layer, may have the slip shield trowel used to press them against the tunnel surfaces for curing. Other layers may not need such trowel features.

[0085] Figure 10 is a block diagram of one embodiment of the system. The system includes a computing system 1010 which controls the various aspects of the automatic tunnel lining system. In one embodiment, the computing system comprises a set of one or more computers including processors, and software programs. In one embodiment, the computing system is a special-purpose device which includes one or more processors. In one embodiment, the computing system 1010 comprises a plurality of separate processing systems which may or may not communicate with each other. The computing system 1010 receives data from oneor more sensors 1015. The sensors 1015 may include one or more of a: ground sensor, distance sensor, air sensor.

[0086] In one embodiment, the computing system 1010 controls the plasma controller 1020, which controls the plasma torch head 1025. The control may include setting the power level, cooling spray (cold air or cold water used with the plasma torch to increase effectiveness), offset distance from the ground, etc.

[0087] In one embodiment, the computing system 1010 controls the tractor controller 1070 for each of the tractors 1075 which move the system. As discussed above, the system includes one or more tractors to provide motive power, and support via an umbilical to the various components.

[0088] In one embodiment, the computing system 1010 controls the mix controller 1030, which controls a cementitious material mixer 1035 and / or fixing layer mixer 1045. The control includes the volume of material output, as well as the composition of the material. In one embodiment, the system carries multiple dry mixes, and the mix controller 1030 controls the specific mixture that is used. In one embodiment, mix controller 1030 also controls the aggregate inflow controller 1040, which determines how much of the aggregate is used in the cementitious material. The aggregate is the removed material from the tunnel. In one embodiment, the aggregate is processed outside the tunnel, so the aggregate inflow controller 1040 controls how much and what size aggregate is returned to the lining applicator.

[0089] In one embodiment, the computing system 1010 also controls the spray nozzle controller 1050, which controls the output of spray nozzles 1055. The spray nozzles 1055 apply the fixing layer(s) and / or cementitious material layer(s) onto the tunnel surfaces.

[0090] In one embodiment, the computing system 1010 also controls the reverse slip trowel controller 1060, which controls the reverse slip trowel(s) and / orcanopies over the tractors 1075. The reverse slip trowel controller 1060 controls the extension and retraction of the reverse slip trowel 1065.

[0091] As should be clear to one of skill in the art, the computing system 1010 may include a plurality of different processors, some of which may be remote from each other. Thus, the “computing system 1010” need not be a single unified system.

[0092] Figure 11 is a block diagram of one embodiment of a computer system that may be used with the present invention. It will be apparent to those of ordinary skill in the art, however that other alternative systems of various system architectures may also be used.

[0093] The computer system illustrated in Figure 11 includes a bus or other internal communication means 1140 for communicating information, and a processing unit 1110 coupled to the bus 1140 for processing information. The processing unit 1110 may be a central processing unit (CPU), a digital signal processor (DSP), or another type of processing unit 1110.

[0094] The system further includes, in one embodiment, a random access memory (RAM) or other volatile storage device 1120 (referred to as memory), coupled to bus 1140 for storing information and instructions to be executed by processor 1110. Main memory 1120 may also be used for storing temporary variables or other intermediate information during execution of instructions by processing unit 1110.

[0095] The system also comprises in one embodiment a read only memory (ROM) 1150 and / or static storage device 1150 coupled to bus 1140 for storing static information and instructions for processor 1110. In one embodiment the system also includes a data storage device 1130 such as a magnetic disk or optical disk and its corresponding disk drive, or Flash memory or other storage which is capable ofstoring data when no power is supplied to the system. Data storage device 1130 in one embodiment is coupled to bus 1140 for storing information and instructions.

[0096] The system may further be coupled to an output device 1170, such as a cathode ray tube (CRT) or a liquid crystal display (LCD) coupled to bus 1140 through bus 1160 for outputting information. The output device 1170 may be a visual output device, an audio output device, and / or tactile output device (e.g. vibrations, etc.)

[0097] An input device 1175 may be coupled to the bus 1160. The input device 1175 may be an alphanumeric input device, such as a keyboard including alphanumeric and other keys, for enabling a user to communicate information and command selections to processing unit 1110. An additional user input device 1180 may further be included. One such user input device 1180 is cursor control device 1180, such as a mouse, a trackball, stylus, cursor direction keys, or touch screen, may be coupled to bus 1140 through bus 1160 for communicating direction information and command selections to processing unit 1110, and for controlling movement on display device 1170.

[0098] Another device, which may optionally be coupled to computer system 1100, is a network device 1185 for accessing other nodes of a distributed system via a network. The communication device 1185 may include any of a number of commercially available networking peripheral devices such as those used for coupling to an Ethernet, token ring, Internet, or wide area network, personal area network, wireless network or other method of accessing other devices. The communication device 1185 may further be a null-modem connection, or any other mechanism that provides connectivity between the computer system 1100 and the outside world.

[0099] Note that any or all of the components of this system illustrated in Figure 11 and associated hardware may be used in various embodiments of the present invention.

[0100] It will be appreciated by those of ordinary skill in the art that the particular machine that embodies the present invention may be configured in various ways according to the particular implementation. The control logic or software implementing the present invention can be stored in main memory 1120, mass storage device 1130, or other storage medium locally or remotely accessible to processor 1110.

[0101] It will be apparent to those of ordinary skill in the art that the system, method, and process described herein can be implemented as software stored in main memory 1120 or read only memory 1150 and executed by processor 1110. This control logic or software may also be resident on a computer readable medium having computer readable program code embodied therein and being readable by the mass storage device 1130 and for causing the processor 1110 to operate in accordance with the methods and teachings herein.

[0102] The present invention may also be embodied in a handheld or portable device containing a subset of the computer hardware components described above. For example, the handheld device may be configured to contain only the bus 1140, the processor 1110, and memory 1150 and / or 1120.

[0103] The handheld device may be configured to include a set of buttons or input signaling components with which a user may select from a set of available options. These could be considered input device #1 1175 or input device #2 1180. The handheld device may also be configured to include an output device 1170 such as a liquid crystal display (LCD) or display element matrix for displaying information to a user of the handheld device. Conventional methods may be used to implementsuch a handheld device. The implementation of the present invention for such a device would be apparent to one of ordinary skill in the art given the disclosure of the present invention as provided herein.

[0104] The present invention may also be embodied in a special purpose appliance including a subset of the computer hardware components described above. For example, the appliance may include a processing unit 1110, a data storage device 1130, a bus 1140, and memory 1120, and no input / output mechanisms, or only rudimentary communications mechanisms, or a networked connection to provide control signals. In general, the more special purpose the device is, the fewer of the elements need be present for the device to function. In some devices, communications with the user may be through a touch-based screen, or similar mechanism. In one embodiment, the device may not provide any direct input / output signals but may be configured and accessed through a website or other network-based connection through network device 1185. The computing system described above may include one or more such computer systems, including some with no input / output capabilities.

[0105] It will be appreciated by those of ordinary skill in the art that any configuration of the particular machine implemented as the computer system may be used according to the particular implementation. The control logic or software implementing the present invention can be stored on any machine-readable medium locally or remotely accessible to processor 1110. A machine-readable medium includes any mechanism for storing information in a form readable by a machine (e.g. a computer). For example, a machine readable medium includes read-only memory (ROM), random access memory (RAM), magnetic disk storage media, optical storage media, flash memory devices, or other storage media which may be used for temporary or permanent data storage. In one embodiment, the control logicmay be implemented as transmittable data, such as electrical, optical, acoustical or other forms of propagated signals (e.g. carrier waves, infrared signals, digital signals, etc.).

[0106] In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.

Claims

CLAIMSWe claim:1 . An automatic tunneling system to remove material and apply lining to a tunnel created by the removal of the material and concurrently with material removal, the automatic tunneling system comprising: a lining applicator to automatically apply a cementitious mixture to the tunnel; a slip shield trowel to press the cementitious mixture against a surface of the tunnel while the cementitious mixture is curing, thereby creating a completed tunnel.

2. The system of claim 1 , further comprising: a tunnel borer to removes the material using a plurality of plasma torches.

3. The system of claim 1 , wherein the lining applicator comprises a sprayer to spray the cementitious mixture on the surface of the tunnel.

4. The system of claim 3, wherein the sprayer has an adjustable valve such that a volume of cementitious mix injected is adjusted based on a depth of the tunnel surface.

5. The system of claim 4, further comprising: a spring controlled valve adjuster to automatically adjust the volume, based on a compression of the spring.

6. The system of claim 4, further comprising: a sensor to determine a distance to the tunnel surface, and automatically adjust the volume based on the distance.

7. The system of claim 1 , wherein the slip shield trowel covers a tractor including the lining applicator on a front of the tractor.

8. The system of claim 7, wherein the slip shield trowel extends over one or more additional tractors.

9. The system of claim 6, wherein the slip shield trowel comprises a plurality of parts overlapping to provide a continuous surface.

10. The system of claim 9, wherein the slip shield trowel is segmentally retractable, to enable reversing.11 . The system of claim 9, further comprising a plurality of hydraulic pistons to press the slip shield trowel against the surface of the tunnel.

12. The system of claim 1, wherein: a first tractor removes the material to form the tunnel; a second tractor includes the lining applicator to apply the cementitious mixture to the tunnel surface, to form a finished tunnel.

13. The system of claim 12, wherein: the second tractor further includes the slip shield trowel, covering the second tractor.

14. The system of claim 12, wherein: a third tractor to vacuum residue from the material removal is positioned between the first tractor and the second tractor.

15. The system of claim 1 , further comprising: a drip collector to collect overflow of the cementitious mixture; and a smoothing bar to apply the overflow to the tunnel.

16. The system of claim 1 , further comprising: a second lining applicator, to apply a second layer of cementitious mixture to the tunnel surface.

17. The system of claim 1 , further comprising:a second lining applicator to apply a water impervious layer prior to applying the cementitious mixture.

18. The system of claim 1 , wherein the lining applicator comprises a plurality of sprayers to apply the cementitious mixture.

19. The system of claim 18, wherein the sprayers rotate.

20. The system of claim 1 , wherein the automatic lining is applied at a speed that the system excavates, enabling continuous excavation and building of the tunnel.21 . The system of claim 1 , wherein the cementitious mixture is mixed at the automatic tunneling system, and a composition of the cementitious mixture is determined based on conditions in the tunnel.

22. The system of claim 21 , wherein the cementitious mixture includes aggregate from spoils removed from the tunnel.

23. A method comprising: removing material using an automatic tunneling system to create a tunnel; automatically applying a cementitious mixture to a tunnel surface; pressing the cementitious mixture against the tunnel surface while the cementitious mixture is curing using a slip shield trowel, thereby creating a completed tunnel.

24. The method of claim 23, further comprising: removing the material using a plurality of plasma torches.

25. The method of claim 23, wherein automatically applying the cementitious mixture comprises spraying the cementitious mixture on the surface of the tunnel.

26. The method of claim 25, further comprising:adjusting a valve to control a volume of cementitious mix based on a depth of the tunnel surface.

27. The method of claim 26, wherein the adjusting comprises: using a compression of a spring in a spring controlled valve adjuster to automatically adjust the volume.

28. The method of claim 26, wherein the adjusting comprises: determining a distance to a tunnel surface using a sensor; and automatically adjusting the volume based on the distance.

29. The method of claim 23, wherein the slip shield trowel covers a tractor including a lining applicator on a front of the tractor.

30. The method of claim 29, wherein the slip shield trowel extends over one or more additional tractors.31 . The method of claim 23, wherein the slip shield trowel comprises a plurality of segments overlapping to provide a continuous surface.

32. The method of claim 23, further comprising: segmentally retracting the slip shield trowel, to enable reversing.

33. The method of claim 23, further comprising: pressing the slip shield trowel against the surface of the tunnel using a plurality of hydraulic pistons to.

34. The method of claim 23, further comprising: collecting overflow of the cementitious mixture using a drip collector; and applying the overflow to the tunnel.

35. The method of claim 23, further comprising: applying a second layer of cementitious mixture to the tunnel surface.

36. The method of claim 23, further comprising: applying a water impervious layer prior to applying the cementitious mixture.

37. The method of claim 23, wherein the applying of the cementitious mixture uses a plurality of sprayers to apply the cementitious mixture.

38. The method of claim 23, wherein applying of the cementitious mixture is at a speed of the removing of the material to create the tunnel, enabling continuous excavation and building of the tunnel.

39. The method of claim 23, further comprising: determining a composition of the cementitious mixture based on conditions in the tunnel; and mixing the cementitious mixture at the automatic tunneling system.

40. The method of claim 23, wherein the cementitious mixture includes aggregate from spoils removed from the tunnel.

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