Mobile factory system and factory-based construction method for cut-and-cover project

Abstract

NOT VISIBLE DUE TO STATUS OF PATENT

Description

Mobile factory system and prefabricated construction method for open-cut and buried engineering projects Technical Field

[0001] This invention relates to the field of cut-and-cover construction engineering. More specifically, this invention relates to a mobile factory system and a factory-based construction method for cut-and-cover engineering. Background Technology

[0002] Open-cut and tunneling is an engineering method that combines surface excavation and underground structure construction, widely used in the construction of underground facilities such as tunnels and subway stations. This method involves first excavating the surface, then constructing the required underground structure, such as a tunnel or station, within the excavated area, and finally covering it to restore the original surface. Due to its advantages in quality, controllable construction period, and relatively low cost, the open-cut method is generally considered the preferred construction method when there are no nearby traffic or environmental restrictions. However, although existing open-cut and tunneling construction technologies have achieved mechanization in some processes, such as using rebar tying trolleys and lining formwork trolleys, the specialization and intelligence of traditional construction equipment are not high, and effective assembly line operations are not formed between different processes, resulting in poor construction efficiency and safety, leading to increased construction time and costs. Summary of the Invention

[0003] One object of the present invention is to solve at least the above-mentioned problems and to provide at least the advantages that will be described later.

[0004] To achieve these objectives and other advantages according to the present invention, a mobile factory system for open-cut and buried-underground engineering projects is provided, wherein the open-cut and buried-underground engineering projects are divided into multiple sections along the construction direction, and multiple construction processes are carried out sequentially in the foundation pit of each section, including a remote control system and construction equipment for each of the aforementioned processes; each of the aforementioned construction equipment is equipped with a positioning device and an image acquisition device, respectively used to acquire the location information of the construction equipment and the current construction image.

[0005] The remote control system is communicatively connected to each of the construction equipment, each of the positioning devices, and each of the image acquisition devices. It receives the location information and construction images of each of the construction equipment, and determines the construction section where each of the construction equipment is located and the construction progress of the current process. After determining that the target section has completed the construction work of the target process and the next section has completed the construction work of the previous process, it controls the construction equipment of the target section to move to the next section to carry out the construction work of the target process.

[0006] Preferably, the process includes waterproofing membrane construction, invert arch construction, lining reinforcement binding, lining concrete pouring and curing; all the construction equipment is movable, specifically including:

[0007] Concrete spraying equipment and waterproof membrane laying equipment used in the construction process of waterproof membrane;

[0008] Invert arch pouring trolley used for invert arch construction process;

[0009] Reinforcement binding trolley, reinforcement workshop and formwork trolley used for the reinforcement binding process of lining;

[0010] External curing trolley, internal curing trolley, and end-sealing trolley used for concrete lining pouring and curing processes.

[0011] Another objective of this invention is to provide a factory-based construction method for open-cut and buried-underground engineering projects. This method employs a mobile factory system for open-cut and buried-underground engineering projects, where each section sequentially performs the waterproofing membrane construction, invert arch construction, lining reinforcement binding, and lining concrete pouring and curing processes. A remote control system controls the construction equipment corresponding to each process to perform the construction operations. Furthermore, the remote control system determines the section where each construction equipment is located and the progress of the current process based on the location information and construction images of each piece of equipment. When any construction equipment completes the current process of the current section, the remote control system determines whether it can enter the next section, and whether the construction equipment from the previous section performing the next process can enter the current section.

[0012] Preferably, the remote control system controls the concrete spraying device and the waterproof membrane laying device to carry out the waterproof membrane construction, specifically including: controlling the concrete spraying device and the waterproof membrane laying device to move along the length of the foundation pit within the section, spraying a certain thickness of concrete onto the side wall of the foundation pit through the concrete spraying device; then laying the waterproof membrane onto the side wall of the foundation pit through the waterproof membrane laying device, and inspecting the quality of the waterproof membrane laying; if the laying quality does not meet the requirements, controlling the waterproof membrane laying device to return to the corresponding position and re-laying.

[0013] Preferably, the remote control system controls the invert arch pouring trolley to carry out invert arch construction. The invert arch pouring trolley spans across the foundation pit. Specifically, after the invert arch reinforcement and invert arch formwork of the current section are completed, the invert arch pouring trolley is controlled to move along the top of the foundation pit to the top of the current section, and concrete is poured into the invert arch formwork through the invert arch pouring trolley.

[0014] Preferably, the remote control system controls the rebar tying trolley, rebar workshop, and formwork trolley to perform lining rebar tying. Specifically, this includes: when the invert arch construction process of the current section has been completed, first controlling the rebar tying trolley and the rebar workshop to enter the current section, and tying the lining rebar skeleton of the current section on the rebar tying trolley; then controlling the rebar workshop to lift the lining rebar skeleton, and then controlling the rebar tying trolley to leave the current section; controlling the formwork trolley to enter the current section and move to below the lining rebar skeleton, releasing the lifting of the lining rebar skeleton through the rebar workshop, with the formwork trolley supporting the lining rebar skeleton, and controlling the rebar workshop to move away from the current section.

[0015] Preferably, the remote control system controls the external curing trolley to pour lining concrete. The external curing trolley spans across the foundation pit. Specifically, it includes controlling the external curing trolley to enter the current section and move it above the template trolley, and using the external curing trolley to pour and vibrate the lining concrete in the current section.

[0016] Preferably, the external curing trolley is equipped with a movable vibrating device; the remote control system is communicatively connected to the vibrating device to obtain vibration data and control the movement of the vibrating device; the remote control system generates a pouring quality cloud map based on the vibration data, determines the under-vibrated area of ​​the lining in the current section through the pouring quality cloud map, and controls the vibrating device to move to the under-vibrated area to vibrate again.

[0017] Preferably, the remote control system controls the inner curing trolley and the end sealing trolley to perform lining concrete curing, specifically including: controlling the outer curing trolley to close the top space of the current section lining, then controlling the inner curing trolley and the end sealing trolley to move into the current section lining, closing both ends of the current section lining through the end sealing trolley, and performing inner curing of the lining through the inner curing trolley.

[0018] Preferably, temperature and humidity sensors are installed on the inner curing trolley and on the surface and inside of the lining concrete of the current section. The remote control system is communicatively connected to each of the temperature and humidity sensors to obtain temperature and humidity data at the corresponding locations. The remote control system adjusts the position of the inner curing trolley and the curing temperature and humidity according to the temperature and humidity data at each location.

[0019] The present invention has at least the following beneficial effects:

[0020] 1. The mobile factory system and factory-style construction method for open-cut and buried-construction projects provided by this invention, by employing mobile construction equipment, can quickly adapt to the specific construction needs of each section. The remote control system enables real-time monitoring of the construction progress of each section and centralized intelligent management of construction equipment, enhancing the efficiency and accuracy of construction management. This allows construction equipment to smoothly execute different construction processes in different sections, effectively achieving continuity and automation of the construction process, forming a highly efficient factory-like assembly line operation mode. This method significantly reduces reliance on manpower, thereby improving construction efficiency.

[0021] 2. The mobile factory system and factory construction method for open-cut and buried engineering provided by this invention can accurately control the construction process of each construction equipment through a remote control system, ensuring the structural stability of waterproofing membrane laying, invert arch construction, steel reinforcement cage, and uniform pouring and full vibration of concrete, thereby ensuring the overall quality of the project.

[0022] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0023] Figure 1 is a schematic diagram of the structure of the mobile factory system described in this invention;

[0024] Figure 2 is a schematic diagram of the multi-section construction process of the factory construction method described in this invention;

[0025] Figure 3 is a structural schematic diagram of the integrated waterproof membrane laying tool described in this invention;

[0026] Figure 4 is a side structural schematic diagram of the integrated waterproof membrane laying tool described in this invention;

[0027] Figure 5 is a structural schematic diagram of the inverted arch casting trolley described in this invention;

[0028] Figure 6 is a structural schematic diagram of the rebar binding trolley described in this invention;

[0029] Figure 7 is a structural schematic diagram of the steel reinforcement workshop described in this invention;

[0030] Figure 8 is a structural schematic diagram of the template trolley described in this invention;

[0031] Figure 9 is a structural schematic diagram of the external curing trolley described in this invention;

[0032] Figure 10 is a schematic diagram of the installation position of the vibrating device of the present invention;

[0033] Figure 11 is a schematic diagram of the structure of the maintenance shed described in this invention;

[0034] Figure 12 is a structural schematic diagram of the end-sealing gate trolley described in this invention;

[0035] Figure 13 is a structural schematic diagram of the internal curing trolley described in this invention; Detailed Implementation

[0036] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0037] It should be noted that, unless otherwise specified, the experimental methods described in the following embodiments are all conventional methods, and the reagents and materials described are all commercially available unless otherwise specified. In the description of this invention, the terms "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0038] As shown in Figure 1, the present invention provides a mobile factory system for open-cut and buried-underground engineering projects. The open-cut and buried-underground engineering projects are divided into multiple sections along the construction direction. Multiple construction processes are carried out sequentially in the foundation pit of each section. The system includes a remote control system and construction equipment for each of the aforementioned processes. Each of the aforementioned construction equipment is equipped with a positioning device and an image acquisition device, which are used to acquire the location information of the construction equipment and the current construction image, respectively.

[0039] The remote control system is communicatively connected to each of the construction equipment, each of the positioning devices, and each of the image acquisition devices. It receives the location information and construction images of each of the construction equipment, and determines the construction section where each of the construction equipment is located and the construction progress of the current process. After determining that the target section has completed the construction work of the target process and the next section has completed the construction work of the previous process, it controls the construction equipment of the target section to move to the next section to carry out the construction work of the target process.

[0040] In this technical solution, the remote control system is an intelligent control center, a computing unit with computational and analytical capabilities, including servers and large terminal devices. The remote control system controls each construction device to perform corresponding construction operations, acquires location information to determine the section position of each construction device, and acquires current construction images to determine the construction progress of each construction device. Based on the section position and construction progress of each construction device, it controls the movement of each construction device between different sections, allowing each section to operate independently, and different sections to perform different procedures simultaneously. This provides overall management of all construction equipment, improving factory construction efficiency and equipment utilization. Construction sections can be divided according to the actual construction situation of construction equipment and personnel, ensuring efficient implementation of each procedure within each section. This allows for rapid transition to the next procedure after the completion of the current procedure in a target section, and enables the construction equipment for the current procedure to quickly move to the next section to perform the current procedure.

[0041] Specifically, the positioning device can employ a Global Navigation Satellite System (GNSS) to acquire the location information of each construction device. The remote control system can then determine the location of the construction device within a work section based on this location information. The image acquisition device can be a video surveillance device to acquire current construction images of the construction equipment. The remote control system can then determine the construction progress of the construction equipment based on these current construction images. After determining the work section location of any construction device, the remote control system can perform process detection on the construction images acquired by the image acquisition device on that construction device using a target detection algorithm. This process image is then used as the Region of Interest (ROI) for process identification. The ROI is then processed using CNN (Convolutional Neural Network) and LSTM (Long Short-Term Memory) algorithms to determine the construction progress of the target process.

[0042] Furthermore, the procedures for each section of the open-cut and buried-underground engineering project include waterproofing membrane construction, invert arch construction, lining reinforcement binding, lining concrete pouring, and curing; all the construction equipment is movable, specifically including:

[0043] Concrete spraying equipment and waterproof membrane laying equipment used in the construction process of waterproof membrane;

[0044] Invert arch pouring trolley used for invert arch construction process;

[0045] Reinforcement binding trolley, reinforcement workshop and formwork trolley used for the reinforcement binding process of lining;

[0046] External curing trolley, internal curing trolley, and end-sealing trolley used for concrete lining pouring and curing processes.

[0047] As shown in Figure 2, section 201 involves the construction of the waterproofing membrane, section 202 involves the construction of the invert arch, section 203 involves the binding of the lining reinforcement, and section 204 involves the pouring and curing of the lining concrete. The lining concrete pouring for section 203 only begins after the curing of the lining concrete in section 204 is completed. The mobile factory system uses mobile construction equipment, enabling rapid adaptation to the specific construction needs of each section. The remote control system achieves real-time monitoring of the construction progress of each section and centralized intelligent management of the construction equipment, enhancing the efficiency and accuracy of construction management. This allows the construction equipment to smoothly execute different construction processes in different sections, effectively achieving continuity and automation of the construction process, forming a highly efficient factory-like assembly line operation mode. This method significantly reduces reliance on manpower, thereby improving construction efficiency; furthermore, the factory-like construction environment provides workers with more convenient and safer working conditions, reducing the negative impact of environmental factors on construction. Furthermore, each of the construction devices is equipped with sensors for monitoring equipment operation and the construction environment. The remote control system can construct a digital twin model based on the construction data received from the construction devices, and control the construction devices to perform construction operations based on the digital twin model, thereby achieving unified management and centralized control of each construction device.

[0048] This invention also provides a factory-based construction method for open-cut and buried-underground engineering projects. Utilizing the mobile factory system, each section sequentially performs the waterproofing membrane construction, invert arch construction, lining reinforcement binding, and lining concrete pouring and curing processes. The remote control system controls the construction equipment corresponding to each process to perform the construction operations. Furthermore, the remote control system determines the section where each construction equipment is located and the current construction progress of the current process based on the location information and construction images of each construction equipment. When any construction equipment completes the current process of the current section, the remote control system determines whether it can enter the next section, and whether the construction equipment in the previous section performing the next process can enter the current section. Taking the i-th section and its currently constructed process as the target section and target process, when the current process of the i-th section is completed, and the i+1-th section completes the previous process of the target process, the remote control system controls the construction equipment of the current process of the i-th section to enter the i+1-th section for construction.

[0049] In another technical solution, the remote control system controls the concrete spraying device and the waterproof membrane laying device to carry out the waterproof membrane construction. Specifically, it includes: controlling the concrete spraying device and the waterproof membrane laying device to move along the length of the foundation pit within the work section; spraying a certain thickness of concrete onto the side wall of the foundation pit through the concrete spraying device; then laying the waterproof membrane onto the side wall of the foundation pit through the waterproof membrane laying device; and inspecting the quality of the waterproof membrane laying. If the laying quality does not meet the requirements, controlling the waterproof membrane laying device to return to the corresponding position and re-lay it.

[0050] The construction process for the waterproofing membrane includes shotcrete leveling of the sidewalls and the laying of the waterproofing membrane. Shotcrete leveling of the sidewalls involves: attaching reinforcing mesh to the sidewalls of the excavated foundation pit, and then spraying concrete onto the sidewalls using a shotcrete device to initially reinforce the sidewalls and achieve a certain degree of flatness, providing a stable and flat working surface for subsequent construction. Preferably, low-resilience concrete can be used, with a slump of 210-230mm, a spread of 500-600mm, and a slump emptying time of 3-8 seconds. The concrete is in a continuous fluid state during emptying, making construction operations more convenient, improving work speed and efficiency, ensuring the uniformity and continuity of concrete pouring, and guaranteeing the absence of defects such as honeycomb and air bubbles within the structure. After the shotcrete leveling of the sidewalls is completed, the waterproofing membrane is laid. The waterproofing membrane laying device includes a hot-melt washer positioning device and an integrated waterproofing membrane laying fixture.

[0051] After the sidewall of the foundation pit is leveled with shotcrete, geotextile is hung. The position of the hot-melt gasket is automatically determined by the waterproof membrane hot-melt gasket positioning device. Then, according to the position of the hot-melt gasket, the waterproof membrane is welded to the hot-melt gasket using an integrated waterproof membrane laying fixture. Specifically, the hot-melt gasket positioning device is equipped with a laser rangefinder and a leveling device. After leveling the device, the height L1 of the positioning device and the distance L2 between the positioning device and the waterproof membrane (sidewall) are obtained using the laser rangefinder. The spacing of the hot-melt gasket arrangement (e.g., quincunx arrangement) L3 is input into the positioning device. The planar coordinates of the hot-melt gasket on the sidewall of the foundation pit can be obtained using L1 and L3. The laser emission angle can be obtained by combining these coordinates with L2, thus achieving automatic positioning of the hot-melt gasket. As shown in Figures 3 and 4, the integrated waterproof membrane laying fixture includes a frame. A walking structure 305 is installed at the bottom of the frame to move the frame within the foundation pit. A winch 301 and pulleys 302 are installed on the frame to hoist the waterproof membrane 303. A waterproof membrane laying quality inspection module is also installed on the frame, positioned behind the waterproof membrane 302 along the laying direction. The waterproof membrane laying quality inspection module includes an image acquisition device 304 and a display screen 305. The image acquisition device 304 can be a wireless camera. A slide rail is installed on the frame, and a displacement device is installed at the bottom of the image acquisition device 304. The displacement device moves the image acquisition device 304 along the slide rail, and the length of the slide rail ensures that the image acquisition range can cover at least one waterproof membrane 303 when the image acquisition device moves along it. The image acquisition device 304 takes pictures of the laid waterproof membrane to collect image data. The remote control system is connected to the image acquisition device 304. After acquiring the image data, it performs image processing and recognition to determine the flatness of the waterproof membrane, the width and straightness of the overlap of the waterproof membrane, and feeds the recognition results back to the display screen 305 for display, so as to facilitate on-site management and correction.

[0052] The specific steps of the remote control system controlling the waterproof membrane laying device to perform waterproof membrane laying construction include:

[0053] SA1, the waterproof membrane hot melt gasket positioning equipment positions the hot melt gasket on the working surface;

[0054] SA2. The integrated waterproof membrane laying tooling is moved to the current work surface to hoist the waterproof membrane, and the waterproof membrane is manually welded according to the position of the hot melt gasket.

[0055] SA3, the integrated tooling for laying waterproof membrane is moved to the next working surface to hoist the waterproof membrane, while the image acquisition equipment takes pictures of the waterproof membrane on the previous working surface from all angles to check the quality of the waterproof membrane.

[0056] SA4. If the waterproof membrane installation quality inspection fails, the integrated waterproof membrane installation tooling is moved to the unqualified work surface to repair the unqualified waterproof membrane. In another technical solution, the remote control system controls the invert arch pouring trolley to carry out invert arch construction. The invert arch pouring trolley spans across the foundation pit. Specifically, after the invert arch reinforcement and invert arch formwork of the current section are completed, the invert arch pouring trolley is controlled to move along the top of the foundation pit to above the current section, and concrete is poured into the invert arch formwork through the invert arch pouring trolley.

[0057] The invert arch is the bottom structure that provides stability and load-bearing capacity for the underground structure. Concrete pouring typically occurs after the invert arch reinforcement cage and formwork are prepared. As shown in Figure 5, the frame 505 of the invert arch pouring trolley spans across the foundation pit. The frame 505 is equipped with an inlet 501, a conveying device 502, and a discharge port 503. The inlet 501 is connected to the discharge port 503 via the conveying device 502. Concrete trucks unload concrete into the inlet 501, and the concrete is then conveyed to the discharge port 503 via the conveying device 502. The concrete is then transported into the invert arch formwork 504 through the discharge port 503. Multiple discharge ports 503 are provided, each equipped with a discharge valve, allowing concrete to be poured at multiple points via the conveying device 502. The conveying device 502 can be a screw conveyor or a belt conveyor, and the discharge ports 503 can be connected to a tremie pipe or a guide pipe equipped with an anti-segregation device. The frame 505 of the invert arch casting trolley is equipped with a walking module at its bottom, which allows it to move above the foundation pit. The frame 505 is equipped with a lifting device 506 that lifts the guide pipe of the discharge port 503. The lifting device 506 can lift the guide pipe of the discharge port 503 upward, thereby allowing the invert arch casting trolley to move through the area provided with supports 507 (such as concrete supports or steel supports).

[0058] In another technical solution, the remote control system controls the rebar tying trolley, rebar workshop, and formwork trolley to perform lining rebar tying. Specifically, this includes: when the invert arch construction process of the current section has been completed, first controlling the rebar tying trolley and the rebar workshop to enter the current section, and tying the lining rebar skeleton on the rebar tying trolley; then controlling the rebar workshop to lift the lining rebar skeleton, and then controlling the rebar tying trolley to leave the current section; controlling the formwork trolley to enter the current section and move to below the lining rebar skeleton, releasing the lifting of the lining rebar skeleton through the rebar workshop, allowing the formwork trolley to support the lining rebar skeleton, and controlling the rebar workshop to move away from the current section. (Rebar tying trolley)

[0059] Specifically, after the remote control system determines that the invert construction of the current section is completed and the invert strength meets the requirements, it controls the rebar tying trolley and the rebar workshop to move to the target section. The rebar tying trolley moves onto the invert, and the rebar workshop, spanning above the foundation pit, moves above the rebar tying trolley. The lifting device in the rebar workshop can then be used to place the lining rebar onto the rebar tying trolley for binding the lining rebar skeleton of the target section.

[0060] As shown in Figure 6, the bottom of the main body of the rebar tying trolley is equipped with a walking module 701, which includes moving wheels and a rail clamp for rail-clamping movement. Multiple adjustment mechanisms 702 are provided along the tunnel cross-section on the main body of the rebar tying trolley, and these adjustment mechanisms 702 are connected to the support structure 703. The adjustment mechanism 702 can be a hydraulic cylinder equipped with a displacement sensor. When the adjustment mechanism 702 supports the support structure 703, the displacement sensor can accurately detect the displacement of the hydraulic cylinder and is connected to the remote control system. This allows the remote control system to compare the hydraulic cylinder displacement with a preset displacement and control the adjustment mechanism 702 to achieve automatic opening and closing of the support structure 703. The lining rebar skeleton includes inner ring rebar and outer ring rebar; the support structure 703 is equipped with comb-tooth grooves. When tying the rebar, the inner ring rebar can be placed into the comb-tooth grooves to achieve precise rebar positioning. The inner ring circumferential rebar is tied first, followed by the inner ring longitudinal rebar. After the inner ring reinforcement is tied, the outer ring reinforcement is tied using the inner ring reinforcement as support. The outer ring longitudinal reinforcement can be tied first, followed by the outer ring circumferential reinforcement. Finally, hook reinforcement is tied between the inner and outer ring reinforcements to complete the lining reinforcement skeleton. A retractable platform 704 is installed on the side of the main body of the reinforcement trolley. After the retractable platform 704 extends laterally, it is used to tie the reinforcement at the bottom of the side. The main body of the reinforcement trolley is also equipped with multiple laser rangefinders 705. The laser rangefinders 705 are used to measure the distance between the sensor point and the invert arch. The remote control system receives data from each laser rangefinder 705. By acquiring multiple distances, the attitude information of the reinforcement trolley can be determined to ensure the stability of the reinforcement trolley and that the lining reinforcement tying meets design specifications. Using the reinforcement trolley for full-section coverage and high-density arrangement of the lining reinforcement can effectively improve the construction efficiency of the lining reinforcement tying.

[0061] As shown in Figure 7, the rebar workshop can be a semi-enclosed mobile workshop, including a top structure 901 and side structures 902 located on both sides of the foundation pit. The rebar workshop spans above the foundation pit, and the bottom of its main structure can be moved above the foundation pit via a traveling mechanism 903, moving to the top of the rebar tying trolley. Preferably, the rebar workshop can cover the top of the rebar tying trolley to provide a comfortable construction environment, avoiding the impact of weather factors such as scorching sun and rain / snow on construction, and effectively shortening the construction period. The rebar workshop can also be equipped with a cantilever gantry crane 904, with one side set as semi-enclosed. The cantilever of the cantilever gantry crane 904 can extend from the opening on this side, enabling material transportation inside and outside the workshop, such as hoisting loose rebar from outside the site to the rebar tying trolley inside the foundation pit for rebar tying.

[0062] The steel reinforcement workshop is equipped with a lifting point device 905, which is arranged in a matrix to form multiple lifting points. Each lifting point can independently control the tension. After the lining steel reinforcement skeleton is tied, it can be suspended by the lifting point device 905 in the steel reinforcement workshop. The lifting point device 905 provides the tension to maintain the structural stability of the lining steel reinforcement skeleton. The steel reinforcement tying trolley no longer provides support for the lining steel reinforcement skeleton. At this time, the support structure 703 can be disengaged from the lining steel reinforcement skeleton by adjusting the retraction mechanism 702, so that the steel reinforcement tying trolley can move to the next section to carry out the lining steel reinforcement tying process of the next section.

[0063] The specific construction steps for lining reinforcement binding controlled by the remote control system, including controlling the rebar binding trolley, rebar workshop, and formwork trolley, include:

[0064] SB1. Control the rebar binding trolley and the rebar workshop to enter the current section, and perform inner ring rebar binding on the rebar binding trolley for the current section;

[0065] SB2. Control the lifting device of the steel bar workshop to suspend the inner ring steel bar, and control the steel bar binding trolley to move away from the current section and enter the next section;

[0066] SB3. Control the template trolley to enter the target section and move it to the bottom of the inner ring reinforcement. Release the inner ring reinforcement from suspension through the lifting device so that the template trolley supports the inner ring reinforcement. Bind the outer ring reinforcement on the template trolley.

[0067] SB4. After the lining reinforcement of the target section is tied, control the steel reinforcement plant to move away from the target section and enter the next section.

[0068] In the above process, each lifting point of the lifting device 905 is equipped with a tension sensor and a servo system. The tension sensor can detect the magnitude of the tension at the lifting point. The remote control system acquires the current actual tension value detected by the tension sensor and controls the distribution and tension of the lifting device 905 to ensure that the steel reinforcement cage will not deform due to suspension, thereby achieving a system conversion without load difference. Specifically, the remote control system can determine the number, location, and tension value of the lifting points of the lifting device 905 based on the structural information of the lining steel reinforcement cage. For example, the structural information of the lining steel reinforcement cage can be acquired through the image acquisition device, and the structural stress analysis of the steel reinforcement cage can be provided through the steel reinforcement system conversion calculation model to determine the preset number, location, and tension value of the lifting points, ensuring that the deformation of the lining steel reinforcement cage is controllable. Then, the lifting device 905 is arranged according to the preset number and location of the lifting points, and the preset tension value of the lifting points is sent to the servo system of each lifting point, so that the servo system controls the actual tension value of each lifting point according to the preset tension value to maintain the structural stability of the steel reinforcement cage.

[0069] As shown in Figure 8, the main body of the template trolley is equipped with a walking device 1001 at its bottom. The walking device 1001 includes moving wheels and rail clamps for rail-clamped movement. Multiple template adjustment mechanisms 1002 are installed along the tunnel section on the main body of the template trolley, and these mechanisms are connected to the template 1003. Each template adjustment mechanism 1002 can be a hydraulic cylinder equipped with a displacement sensor. When the template adjustment mechanism 1002 supports the template 1003, the displacement of the hydraulic cylinder can be accurately detected. The remote control system receives data monitored by the displacement sensor, compares the hydraulic cylinder displacement with a preset displacement, and automatically and accurately controls the supporting state to achieve automatic mold closing and retraction of the template 1003. The template material of the template 1003 can be stainless steel composite template. Multiple laser rangefinders 1004 are also installed on the main body of the template trolley. The laser rangefinders 1004 can be used to measure the distance between the sensor points and the invert arch. The remote control system can determine the posture information of the template trolley by acquiring multiple distances to ensure the stability of the template trolley's posture and that the template installation conforms to design specifications. Meanwhile, the laser rangefinder 1004 can also be configured on the side of the formwork trolley to facilitate verification that the bottom side formwork is properly supported after the formwork is closed. The formwork trolley can be used to install and close the lining formwork for the lining concrete pouring process.

[0070] In another technical solution, the remote control system controls an external curing trolley to pour lining concrete. The external curing trolley spans the foundation pit, specifically including: controlling the external curing trolley to enter the current section and move it above the formwork trolley, and using the external curing trolley to pour and vibrate the lining concrete in the current section. Further, the external curing trolley is equipped with a movable vibrating device; the remote control system is communicatively connected to the vibrating device to obtain vibration data and control the movement of the vibrating device; the remote control system generates a pouring quality cloud map based on the vibration data, determines the under-vibrated areas of the target section lining through the pouring quality cloud map, and controls the vibrating device to move to the under-vibrated areas for re-vibration.

[0071] As shown in Figures 9 and 10, the external curing trolley is straddling the foundation pit, and its main body is equipped with a walking drive device 1101 at the bottom, allowing it to move above the foundation pit. The vibration device is installed on the longitudinal beam 1102 of the main body of the external curing trolley. The vibration device includes a distance measuring device 1103 and a vibrator 1104. The distance measuring device 1103 includes multiple laser rangefinders for detecting the concrete liquid level height of the lining; the vibrator 1104 includes multiple vibrating rods for vibrating the poured concrete, eliminating air bubbles, improving concrete density, and enhancing the overall performance of the concrete.

[0072] The specific construction steps for the remote control system to control the external curing trolley to pour lining concrete include:

[0073] SC1. Obtain the concrete liquid level height of the current section lining through the ranging device 1103, and determine the current concrete liquid level height as the first height H1;

[0074] SC2. Pour the lining concrete.

[0075] SC3, Increase the concrete liquid level by a second height H2 or reach the maximum height H. max When the time comes, stop pouring the lining concrete and control the vibrator 1103 to vibrate the concrete.

[0076] SC4. After vibration is complete, update the first height H1 based on the current concrete liquid level, and continue pouring or stop pouring until the first height H1 reaches the maximum height H. max until.

[0077] The above process employs layered pouring and vibration. By continuously repeating the measurement, pouring, and vibration processes, continuous layered pouring and vibration of concrete are achieved, ensuring the consistency of quality throughout the entire concrete structure from bottom to top. The first height H1 represents the initial height of the concrete surface, and the second height H2 represents the height of a single pour. This second height can be adjusted according to the specific construction environment of the lining pouring, such as setting it to 50cm. During a single pouring operation, the measuring device 1103 continuously monitors the concrete surface height. When the concrete surface height is increased by the second height H2 from the first height H1, it indicates the end of the single-layer concrete pouring. Pouring is stopped, and vibration begins. After vibration is complete, the first height H1 is updated with the current concrete surface height, and the next layer of concrete pouring begins. When the concrete surface reaches its maximum height H... max When the time comes, stop pouring and begin vibration. After vibration, if the measured first height H1 is different from the maximum height H... max If they are the same, it means the pouring task has been completed.

[0078] Preferably, the vibration system of the external curing trolley also includes indicator lights. These indicator lights can be used to provide feedback on the pouring and stopping signals issued by the remote control system. The remote control system can display different signals to provide feedback on the pouring status based on the concrete level height detected by the ranging device 1103. For example, if the concrete level height is detected to be continuously rising, a pouring signal is issued, and the indicator light turns green, indicating that pouring is in progress. If the concrete level height is detected to have reached the upper limit of a single pouring height or the maximum height, a stopping signal is issued, and the indicator light turns red, indicating that pouring has stopped.

[0079] Furthermore, the external curing trolley includes at least two sets of vibrating devices, located on both sides of the lining of the current section. These devices can be installed on at least two longitudinal beams 1102 on both sides of the external curing trolley. The vibration system of the external curing trolley can simultaneously vibrate and pour concrete onto the sidewalls of the lining of the current section. It should be noted that during the pouring process, each set of vibrating devices can independently detect the concrete level, and the concrete level can be taken as the average value detected by each measuring device 1103 within the set.

[0080] The vibratory compactor is equipped with a displacement device at its bottom, allowing it to move along the longitudinal beam 1103 to different positions for concrete compaction. For example, a slide rail is installed on the longitudinal beam 1102, allowing the measuring device 1103 and the vibrator 1104 to move along the slide rail. When detecting the concrete level, if the laser line of the measuring device 1103 is blocked by reinforcing bars, it can move along the slide rail to avoid them. The vibrator 1104 can be moved along the slide rail to different areas for compaction.

[0081] The remote control system can acquire the vibration data of the vibrating device and determine the under-vibrated area of ​​the lining in the current section based on the vibration data. The vibration data may include the lowering depth of the vibrating rod, the lifting and lowering speed, the vibration frequency, the vibration time, and the vibration position. By analyzing the vibration data, a casting quality cloud map can be formed. Based on the casting quality cloud map, the under-vibrated area can be determined. If there is under-vibration or missed vibration in the under-vibrated area, it is necessary to control the vibrator 1104 to move there for vibration or to perform manual vibration.

[0082] In another technical solution, the remote control system controls the inner curing trolley and the end sealing trolley to perform lining concrete curing, specifically including: controlling the outer curing trolley to close the top space of the current section lining, then controlling the inner curing trolley and the end sealing trolley to move into the current section lining, closing both ends of the current section lining through the end sealing trolley, and performing inner curing of the lining through the inner curing trolley.

[0083] Furthermore, temperature and humidity sensors are respectively installed on the inner curing trolley and on the surface and inside of the lining concrete of the target section. The remote control system is communicatively connected to each of the temperature and humidity sensors to obtain temperature and humidity data at the corresponding locations. The remote control system adjusts the position of the inner curing trolley and the curing temperature and humidity according to the temperature and humidity data at each location.

[0084] Specifically, after the concrete pouring and vibration of the current lining section are completed, the top space of the target lining section can be sealed off using the external curing trolley. As shown in Figure 11, the external curing trolley is equipped with a curing shed 1105, which is mounted on the longitudinal beams 1106 and transverse beams 1107 of the main body of the external curing trolley. The curing shed 1105 is enclosed on the left and right sides and top of the external curing trolley, and has a roll-up telescopic structure at the front and rear ends. When the external curing trolley is moving, the front and rear ends of the curing shed 1105 are retracted. After the external curing trolley completes the lining pouring and vibration, the front and rear ends of the curing shed 1105 are extended below the top of the lining, sealing off the top space of the lining to provide a suitable environment for the external curing of the lining.

[0085] After the remote control system controls the external curing trolley to close the top space of the target section lining, it also needs to control the internal curing trolley and the end sealing trolley to move into the current section lining. The end sealing trolley closes both ends of the current section lining, and the internal curing trolley performs internal curing of the lining.

[0086] As shown in Figure 12, the main body of the end-sealing trolley is equipped with a walking module 1401, an adjusting device 1402, and insulation material 1403. The end-sealing trolley moves within the lining via the walking module 1401. When the current section requires curing, two end-sealing trolleys can be deployed, moving to both ends of the lining respectively. The top-support cylinders of the adjusting device 1402 support the insulation material 1403, sealing the lining and achieving temperature and humidity control inside the lining. The insulation material 1403 is a roll material that can be rolled up while the end-sealing trolley is moving and unfolded after the end-sealing trolley is in place.

[0087] As shown in Figure 13, the internal curing trolley includes a trolley body 1501 and a curing trolley 1502. A moving module 1503 is installed at the bottom of the trolley body 1501 to allow it to move inside the lining. A temperature and humidity sensor 1504 is installed on the trolley body 1501 to detect the temperature and humidity of the environment inside the lining. A trolley traveling module 1505 is installed at the bottom of the curing trolley 1502. The trolley traveling module 1505 can be longitudinally moving wheels, allowing the curing trolley 1502 to move longitudinally on the platform above the trolley body 1501. The curing trolley 1502 also includes an annular spray pipe 1506 and an infrared temperature sensor 1507. The annular spray pipe 1506, in conjunction with atomizing fan-shaped nozzles, can spray and cure the lining arch and sidewalls. The infrared temperature sensor 1507 can detect the temperature of the concrete in the lining arch and sidewalls.

[0088] The remote control system acquires concrete temperature parameters and ambient temperature and humidity parameters at different locations of the lining in the current section, such as concrete pouring temperature, internal concrete temperature, concrete surface temperature, ambient temperature and humidity, and internal-to-surface temperature difference. It then controls the internal curing trolley to move within the lining and adjusts the curing temperature and humidity through the curing trolley.

[0089] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A mobile factory system for a cut-and-cover project, the cut-and-cover project being divided into a plurality of sections in a construction direction, and a plurality of work processes being sequentially performed in a foundation pit of each section, characterized in that, The remote control system and construction equipment for each of the construction processes are included; each of the construction equipment is provided with a positioning device and an image acquisition device, respectively, to acquire position information and current construction images of the construction equipment; The remote control system is in communication connection with each of the construction equipment, each of the positioning devices and each of the image acquisition devices, receives position information and construction images of each of the construction equipment, and determines the construction process progress of the construction equipment in the work section and the current process; after determining that the target work section completes the construction of the target process and the next work section completes the construction of the previous process, the construction equipment of the target work section is controlled to move to the next work section for the construction of the target process.

2. The mobile factory system for open-cut and underground construction projects as described in claim 1, characterized in that, The processes include waterproof board construction, inverted arch construction, lining steel binding, lining concrete pouring and maintenance; each of the construction equipment is movable and specifically includes: a concrete spraying device and a waterproof board laying device for waterproof board construction process construction; an inverted arch pouring trolley for inverted arch construction process construction; a steel binding trolley, a steel factory and a formwork trolley for lining steel binding process construction; an external maintenance trolley, an internal maintenance trolley and an end sealing door trolley for lining concrete pouring and maintenance process construction.

3. A method for factory construction of open cut and cover works, using the mobile factory system for open cut and cover works as claimed in claim 2, characterized in that, Each work section sequentially performs waterproof board construction process, inverted arch construction process, lining steel binding process, lining concrete pouring and maintenance process; the remote control system controls the construction equipment corresponding to each process to perform the construction of each process; and the remote control system determines the construction process progress of the construction equipment in the work section and the current process according to the position information and construction images of each of the construction equipment; when any of the construction equipment completes the current process construction of the current work section, the remote control system determines whether it can enter the next work section and whether the construction equipment of the previous process in the previous work section can enter the current work section.

4. The method for factory construction of open-deep concealed engineering according to claim 3, characterized in that, The remote control system controls the concrete spraying device and the waterproof board laying device to perform waterproof board construction, specifically including: controlling the concrete spraying device and the waterproof board laying device to move along the length direction of the foundation pit in the work section, spraying a certain thickness of concrete to the side wall of the foundation pit through the concrete spraying device; then laying a waterproof board on the side wall of the foundation pit through the waterproof board laying device, and detecting the laying quality of the waterproof board, if the laying quality does not meet the requirements, controlling the waterproof board laying device to return to the corresponding position to re-lay.

5. The method for factory construction of open-deep cover project according to claim 3, characterized in that, The remote control system controls the inverted arch pouring trolley to perform inverted arch construction, and the inverted arch pouring trolley is transverse to the foundation pit, specifically including: after the inverted arch steel and inverted arch formwork construction of the current work section is completed, the inverted arch pouring trolley is controlled to move above the current work section along the top of the foundation pit, and the inverted arch pouring trolley pours concrete into the inverted arch formwork.

6. The method for factory construction of open-deep cover project according to claim 3, characterized in that, The remote control system controls the steel binding trolley, the steel factory building and the formwork trolley to carry out lining steel binding, specifically including: when the current work section has completed the inverted arch construction process, first control the steel binding trolley and the steel factory building to enter the current work section, and carry out the lining steel framework binding of the current work section on the steel binding trolley; then control the steel factory building to hoist the lining steel framework, and then control the steel binding trolley to leave the current work section; control the formwork trolley to enter the current work section and move to below the lining steel framework, release the hoisting of the lining steel framework by the steel factory building, support the lining steel framework by the formwork trolley, and control the steel factory building to move away from the current work section.

7. The method for factory construction of open-deep cover project according to claim 6, characterized in that, The remote control system controls the external curing trolley to carry out lining concrete pouring, and the external curing trolley is transversely arranged on the foundation pit, specifically including: control the external curing trolley to enter the current work section and move to above the formwork trolley, and carry out the lining concrete pouring and vibrating of the current work section by the external curing trolley.

8. The method for factory construction of open-deep concealed engineering according to claim 7, characterized in that, A movable vibrating device is arranged on the external curing trolley; the remote control system is in communication connection with the vibrating device to obtain vibrating data and control the vibrating device to move; the remote control system forms a pouring quality cloud chart according to the vibrating data, determines the under-vibrated area of the current work section through the pouring quality cloud chart, and controls the vibrating device to move to the under-vibrated area again for vibrating.

9. The method for factory construction of open-deep cover project according to claim 7, characterized in that, The remote control system controls the internal curing trolley and the end sealing door trolley to carry out lining concrete curing, specifically including: after the external curing trolley seals the top space of the current work section lining, control the internal curing trolley and the end sealing door trolley to move to the current work section lining, seal the two ends of the current work section lining by the end sealing door trolley, and carry out the internal curing of the lining by the internal curing trolley.

10. The method for factory construction of open-deep concealed engineering according to claim 9, characterized in that, The internal curing trolley, the surface and the inner part of the current work section lining concrete are respectively provided with temperature and humidity sensors, and the remote control system is in communication connection with each temperature and humidity sensor to obtain the temperature and humidity data of the corresponding position; the remote control system adjusts the position, curing temperature and humidity of the internal curing trolley according to the temperature and humidity data of each position.