Tunnel Ring End-Surface Levelness Measurement With Laser Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manual measurement of tunnel ring levelness is arbitrary, inefficient, and difficult in spatially constrained environments, leading to poor levelness and potential fracture of concrete segments during tunnel construction.
Innovation Solution
An automated system using laser sensors, PLC, automatic guiding system, and industrial computer for real-time levelness measurement, calculating a calibration plane based on laser displacement data and spatial vectors to compensate for deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual measurement method using three points is used, then the measurement process is simple, but the arbitrariness is high and measurement precision is poor
Solution Approach 1:
The measurement process is segmented into multiple independent measurement points (at least three, preferably more) distributed across the end surface, with each point measured independently by laser sensors. This allows systematic data collection and processing to eliminate arbitrariness while maintaining operational simplicity through automated coordinate input and calculation.
Solution Approach 2:
The manual mechanical measurement system (total station, manual coordinate input) is replaced with an automated optical measurement system using laser displacement sensors that automatically measure distances and calculate coordinates. This substitution eliminates manual operation arbitrariness while maintaining ease of use, achieving both simplicity and precision.
2Productivity
If manual measurement with total station is used, then measurement can be performed, but the operation is not convenient and measuring efficiency is poor
Solution Approach 1:
Multiple functions are merged into an integrated measurement system: laser displacement sensors for distance measurement, automatic coordinate calculation based on spatial vectors, real-time data processing, and levelness evaluation are combined in one automated system. This eliminates the need for separate manual operations with total station while improving both efficiency and convenience.
Solution Approach 2:
The measurement system performs self-calibration and automatic calculation of measuring point coordinates based on spatial vectors of the tunneling shield. The system automatically processes measurement data, calculates levelness deviations, and provides evaluation results without requiring manual intervention, thereby dramatically improving efficiency and operational convenience.
3Loss of time
If measurement is delayed until after excavation, then the measurement process can be completed, but timeliness is poor affecting construction schedule
Solution Approach 1:
The levelness measurement is performed preliminarily during the excavation process itself rather than after completion. By measuring at multiple points during excavation and calculating levelness in real-time, the system enables timely detection and compensation before the next excavation cycle, ensuring both timeliness and reliability of levelness control.
Solution Approach 2:
The system implements real-time feedback by continuously measuring distances at multiple points, calculating current levelness status, and providing immediate evaluation results. This feedback mechanism allows for timely compensation adjustments during the excavation process, maintaining both timeliness and reliability of levelness control throughout construction.
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
Achieves precise, automated levelness measurement and compensation, reducing manual labor and ensuring high precision in tunnel ring assembly.
Implementation Method 1
at least one laser displacement sensor... emitting laser light parallel to an axial line of the thrust cylinders
Data Source
AI summary
A system for the measurement of the levelness of a tunnel ring of a boring machine, which comprises laser displacement sensors, a PLC, an automated guidance system, an industrial computer, and a display; wherein the laser displacement sensors measure in real time the distance from base points to measurement points of a tunnel ring end surface when in an excavation state; the PLC obtains the distances measured by the laser displacement sensors and performs correction; the industrial computer comprises a system configuration module, a data communication module, a levelness calculation module, a data storage module, and a data visualization module; the levelness calculation module calculates spatial coordinates of each measurement point according to the distance between the base points and the measurement points, a spatial vector of an axis of a rear shield body, and base point coordinates, subsequently obtains a calibrated plane equation by means of fitting and correction, and then further calculates distance deviations between each measurement point and the calibrated plane, and provides deviation data to the data storage module and the data visualization module; and a compensatory operation is performed according to the deviation data.