Tunnel Lining Segment Placement via Time-of-Flight Sensing
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Solution Overview
Problem
The manual and hazardous process of installing tunnel lining segments using a manipulator, which requires precise positioning and alignment, is inefficient due to environmental conditions and the complexity of movements, leading to inaccuracies in placement and alignment.
Innovation Solution
A device equipped with a manipulator, tool position sensors, and time-of-flight cameras for accurate 3D sensing and alignment, allowing for automated and precise placement of tunnel lining segments by controlling actuators based on real-time measurement data and installation plans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation of the erector is used to place tunnel lining segments, then the operator can visually monitor the process, but the operator must work in hazardous conditions with restricted movement speed and high complexity
Solution Approach 1:
The automated erector system performs the segment placement operation autonomously without human intervention in the hazardous zone. The system uses sensors to detect segment positions, calculates optimal placement trajectories, and executes movements automatically, allowing the system to serve itself rather than requiring human operators to work in dangerous conditions
Solution Approach 2:
The patent replaces manual mechanical operation with an automated control system that uses sensors, processors, and actuators. The control system substitutes human operators by integrating data from multiple sensors and automatically controlling the erector's movements, thereby eliminating the need for operators to work in hazardous environments while managing operational complexity
2Reliability
If the manipulator moves with restricted speed to ensure safety, then human operators can monitor the process, but the productivity of segment placement is reduced
Solution Approach 1:
The automated system monitors its own operation through integrated sensors and control systems, eliminating the need for human operators who would require restricted speeds for safety. The system can operate at higher speeds while maintaining safety through automated detection and control
Solution Approach 2:
The patent implements feedback mechanisms using sensors that continuously monitor the position of tunnel lining segments and the erector's movements. This real-time feedback allows the control system to adjust operations dynamically, enabling faster movement speeds while maintaining safety through automated correction and monitoring
3Productivity
If automated operation is implemented to improve safety and productivity, then human error is reduced, but precise sensing and alignment of tunnel lining segments becomes more challenging
Solution Approach 1:
The patent combines multiple sensing technologies (laser scanners, cameras, distance sensors) into an integrated sensing system. By merging these different detection methods, the system overcomes the limitations of individual sensors and achieves high-precision measurement of segment positions and orientations in the complex tunnel environment
Solution Approach 2:
The control system acts as an intermediary that processes sensor data and translates it into precise control commands. The intermediary software algorithms calculate optimal placement positions and generate trajectories, bridging the gap between raw sensor measurements and accurate segment positioning
4Manufacturing precision
If multiple sensors are used to improve measurement accuracy, then positioning precision is enhanced, but the device complexity increases
Solution Approach 1:
The patent merges multiple sensor types into a unified sensing system with centralized control. By integrating laser scanners, cameras, and distance sensors under a single control architecture, the system achieves high measurement precision while managing complexity through consolidation rather than proliferation of independent systems
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
Enables accurate and efficient placement of tunnel lining segments with improved safety by providing precise alignment and positioning, reducing human error and environmental interference, and allowing for automated operation of the tunneling machine components.
Implementation Method 1
at least one sensor, in particular a sensor of the time-of-flight camera, is provided on the tool
Data Source
AI summary
The invention relates to a device for the automated installation of at least one tunnel lining segment of a tunnel lining ring, said device being couplable to a tunnelling machine, • having a manipulator with at least one tool for receiving, holding and placing the at least one tunnel lining segment, and with at least one actuator for moving the at least one tool, the at least one tool being movable • by means of the at least one actuator in the radial, tangential and/or axial direction in relation to the machine axis of the tunnelling machine in the space of the tunnel section created by the tunnelling machine, • having at least one tool position sensor, which is provided on the manipulator and/or tool, for sensing the respective actual position and actual location of the tool in the space of the tunnel section, having at least one tunnel lining segment sensor, which is provided on the manipulator and/or tool, with which an actual position and/or actual location of at least one section of at least one already arranged tunnel lining segment can be sensed, and/or with which an actual position and/or actual location of the tunnel lining segment to be placed can be sensed, • having a controller, which accesses installation data of the tunnel lining segments and which accesses the measurement data of the at least one tool position sensor and the at least one tunnel lining segment sensor, and with which the at least one actuator and the at least one tool can be controlled on the basis of the installation data and measurement data in order to move the tool from the receiving position to the target placing position of the respective tunnel lining segment and to orient same in the actual placing position and to arrange same against the at least one already placed tunnel lining segment of the tunnel lining ring, wherein at least two tunnel lining segment sensors are provided, and wherein the tunnel lining segment sensor is a time-of-flight camera.