TBM Shotcrete Nozzle with Dynamic Oscillation for Rebound Reduction
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Solution Overview
Problem
Manual shotcrete spraying in tunnel boring machines results in high rebound, large concrete loss, poor collection, and serious dust pollution, necessitating a more efficient and environmentally friendly solution.
Innovation Solution
A new-type TBM shotcrete machine featuring a concrete inlet pipe, four-way pipe, nozzle, brush motor, longitudinal and lateral oscillating cylinders, flow mixer, and controller, allowing for intelligent regulation and real-time adjustment of nozzle spacing and angle to minimize rebound and optimize spraying efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual shotcrete spraying is used, then operation flexibility is maintained, but concrete rebound increases and material loss increases
Solution Approach 1:
The system uses sensors to automatically detect tunnel wall distance and spray concrete without continuous manual control, allowing the machine to serve itself in maintaining optimal spraying parameters while reducing material loss
Solution Approach 2:
The shotcrete machine incorporates telescopic arms and adjustable nozzles that can dynamically change position and angle during operation, maintaining flexibility while optimizing spray delivery to reduce rebound and material waste
2Device complexity
If manual shotcrete spraying is used, then equipment complexity is reduced, but dust pollution increases and environmental protection deteriorates
Solution Approach 1:
The system uses pneumatic conveying to deliver concrete through pipes to the spray nozzle, containing the material in a closed system that prevents dust escape to the environment while maintaining operational capability
Solution Approach 2:
The patent introduces an automated control system with sensors and controllers as intermediaries between the operator and the spraying process, managing dust containment and material delivery while reducing direct manual exposure to harmful environments
3Use of energy by moving object
If manual shotcrete spraying is used, then energy consumption is lower, but spray efficiency decreases and concrete collection worsens
Solution Approach 1:
The system uses dynamically adjustable telescopic arms and rotating nozzles that can optimize spray direction and distance in real-time, improving concrete placement accuracy and collection efficiency while maintaining energy-efficient operation through automated control
Solution Approach 2:
Sensors provide feedback on tunnel wall distance and spray conditions to the control system, which automatically adjusts spraying parameters to optimize efficiency and concrete collection while maintaining energy-efficient operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The machine reduces concrete rebound and loss, minimizes dust pollution, and enhances environmental protection by enabling energy-saving, intelligent, and adaptive shotcrete spraying.
Implementation Method 1
the concrete inlet pipe is connected to the nozzle and the bent pipes through the flow mixer
Implementation Method 2
an eccentric block is provided at an output terminal of the brush motor, the eccentric block cooperates with the supporting arm
Implementation Method 3
the longitudinal oscillating cylinder has a swing angle of 120°, and the lateral oscillating cylinder has a swing angle is 60°
Implementation Method 4
a measuring sensor is provided inside the air inlet pipe, the measuring sensor and the controller are connected to each other
Data Source
AI summary
Disclosed is a mixing and guniting device of a new type for a TBM, wherein the device comprises a concrete inlet pipe (1), a four-way pipe (15), a nozzle (4), an agitator motor (5), a longitudinal swing oil cylinder (6), a flow mixer, a lateral swing oil cylinder (16), a telescopic oil cylinder (7) connected to a big arm, and a controller, one end of the telescopic oil cylinder (7) being provided with a connection plate (12), the four-way pipe (15) being fixed on the upper part of the connecting plate (12), two interfaces in the upper part of the four-way pipe (15) being respectively provided with an air inlet pipe (2) and an accelerator inlet pipe, a measuring sensor connected to the controller being provided in the air inlet pipe (2), two interfaces in the lower part of the four-way pipe (15) being respectively provided with bent pipes (8), the other ends of the bent pipes (8) being in communication with the flow mixer, the nozzle (4) being provided in the upper part of the flow mixer, the concrete inlet pipe (1) being provided in the lower part of the flow mixer, and the concrete inlet pipe (1) being in communication with the nozzle (4) and the bent pipe (8) via the flow mixer. The mixing and guniting device can adjust the distance and the angle between the nozzle and a sprayed face intelligently and in real time according to the air flow, so as to ensure a suitable distance at which the rebound rate is lowest and the best angle at which the nozzle is always perpendicular to the sprayed face, such that the rebound rate is effectively reduced with less loss of concrete, energy conservation and environmental protection.