CN115217491A - Full-automatic intelligent tunnel wet spraying vehicle with machine vision and slurry spraying method - Google Patents
Full-automatic intelligent tunnel wet spraying vehicle with machine vision and slurry spraying method Download PDFInfo
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- CN115217491A CN115217491A CN202210657536.5A CN202210657536A CN115217491A CN 115217491 A CN115217491 A CN 115217491A CN 202210657536 A CN202210657536 A CN 202210657536A CN 115217491 A CN115217491 A CN 115217491A
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- 238000005507 spraying Methods 0.000 title claims abstract description 159
- 239000002002 slurry Substances 0.000 title claims description 14
- 239000007921 spray Substances 0.000 claims abstract description 91
- 238000000034 method Methods 0.000 claims abstract description 42
- 230000008569 process Effects 0.000 claims abstract description 26
- 238000011897 real-time detection Methods 0.000 claims abstract description 15
- 238000012545 processing Methods 0.000 claims description 30
- 229910000831 Steel Inorganic materials 0.000 claims description 26
- 239000010959 steel Substances 0.000 claims description 26
- 230000009471 action Effects 0.000 claims description 6
- 238000005422 blasting Methods 0.000 claims description 4
- 230000003287 optical effect Effects 0.000 claims description 4
- 239000003638 chemical reducing agent Substances 0.000 claims description 3
- 239000002893 slag Substances 0.000 claims description 2
- 238000011109 contamination Methods 0.000 claims 1
- 238000010276 construction Methods 0.000 abstract description 6
- 238000001514 detection method Methods 0.000 abstract description 4
- 238000005086 pumping Methods 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D11/00—Lining tunnels, galleries or other underground cavities, e.g. large underground chambers; Linings therefor; Making such linings in situ, e.g. by assembling
- E21D11/04—Lining with building materials
- E21D11/10—Lining with building materials with concrete cast in situ; Shuttering also lost shutterings, e.g. made of blocks, of metal plates or other equipment adapted therefor
- E21D11/105—Transport or application of concrete specially adapted for the lining of tunnels or galleries ; Backfilling the space between main building element and the surrounding rock, e.g. with concrete
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21F—SAFETY DEVICES, TRANSPORT, FILLING-UP, RESCUE, VENTILATION, OR DRAINING IN OR OF MINES OR TUNNELS
- E21F17/00—Methods or devices for use in mines or tunnels, not covered elsewhere
- E21F17/18—Special adaptations of signalling or alarm devices
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01C—MEASURING DISTANCES, LEVELS OR BEARINGS; SURVEYING; NAVIGATION; GYROSCOPIC INSTRUMENTS; PHOTOGRAMMETRY OR VIDEOGRAMMETRY
- G01C21/00—Navigation; Navigational instruments not provided for in groups G01C1/00 - G01C19/00
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Abstract
The invention provides a full-automatic intelligent tunnel wet spraying vehicle with machine vision and a guniting method, wherein the full-automatic intelligent tunnel wet spraying vehicle with machine vision comprises the following steps: a machine vision system for detecting the thickness of the guniting in real time, a real-time planning system for a nozzle path and a wet-spraying execution component; the real-time guniting thickness detection machine vision system detects the concrete thickness value of the guniting area in real time; the spray head path real-time planning system controls the wet spraying execution component to carry out S-shaped path spraying, simultaneously receives the thickness value of the concrete in the current spraying area in real time, and optimizes the spraying path of the wet spraying execution component in the next circulating spraying process according to the thickness value signal. And the wet spraying execution component is connected with the spray head path real-time planning system and is used for executing the spray path optimized by the spray head path real-time planning system. The invention can realize automatic unmanned guniting, can realize real-time detection of guniting thickness without three-dimensional reconstruction of the surface profile of the tunnel, has high construction speed and high efficiency, and greatly reduces the labor intensity of workers while ensuring the personal safety of the workers.
Description
Technical Field
The invention relates to the technical field of automation of wet spraying vehicles in tunnel engineering, in particular to a full-automatic intelligent tunnel wet spraying vehicle with machine vision and a guniting method.
Background
With the continuous expansion of the development scale of underground spaces and the continuous improvement of the tunneling speed of coal mine tunnels in China, the support speed of the underground spaces such as tunnel tunnels is required to be continuously improved, so the requirements of concrete spraying support technology and equipment development are more and more urgent, but the tunnel construction has the characteristics of high danger coefficient, severe working environment and the like, and the adoption of automatic construction equipment and a construction method is a great trend. In tunnel construction, a large-scale mechanical arm wet spraying machine is generally adopted for spraying concrete, workers are required to hold a remote controller to operate a mechanical arm in a spraying process, and the spraying thickness and quality are required to be observed nearby a spraying area in a close range, so that the workload of the workers is undoubtedly greatly increased, the working environment is severe, the visibility is low, and the technical requirement on a guniting hand is high; and especially the personal safety of workers cannot be practically guaranteed.
At present, in the research of tunnel wet spraying automation, besides the wet spraying vehicle with the large mechanical arm controlled by the manual handheld remote controller, an intelligent wet spraying vehicle based on a three-dimensional laser radar is provided. Although the method can realize the unmanned intervention of the whole guniting process, the reconstruction process is complicated in steps and needs to perform precise calibration preparation on equipment such as a sensor in advance. In addition, the processing period of the point cloud data is long and the real-time performance is not achieved.
The device mainly comprises a circular guide rail concentric with a tunnel, and a spray head can carry out guniting work along the circular guide rail through a guniting hand-held remote controller and can keep stable spraying distance and angle. Compared with the traditional wet spraying vehicle of a manual remote control large-scale multi-degree-of-freedom mechanical arm, the equipment greatly reduces the technical requirements on a guniting hand. But the defects still need manual participation in the whole process, and the requirement of the current project on the automation of the wet spraying vehicle cannot be met.
Disclosure of Invention
According to the technical problem, the full-automatic intelligent tunnel wet spraying vehicle with the machine vision and the guniting method are provided. The invention can realize automatic unmanned guniting, can realize real-time detection of guniting thickness without three-dimensional reconstruction of the surface profile of the tunnel, has high construction speed and high efficiency, and greatly reduces the labor intensity of workers while ensuring the personal safety of the workers.
The technical means adopted by the invention are as follows:
a full-automatic intelligent tunnel wet spraying vehicle with machine vision comprises: the system comprises a guniting thickness real-time detection system, a spray head path real-time planning system and a wet spraying execution component; wherein:
the guniting thickness real-time detection machine vision system is used for detecting the thickness value of concrete in a guniting area in real time;
the spray head path real-time planning system is connected with the guniting thickness real-time detection machine vision system and used for controlling the wet-spraying execution component to carry out S-shaped path guniting, receiving the concrete thickness value of the current guniting area transmitted by the guniting thickness real-time detection machine vision system in real time, and optimizing the guniting path of the wet-spraying execution component in the next circulating guniting process according to the thickness value signal.
And the wet spraying execution component is connected with the spray head path real-time planning system and is used for executing the spray path optimized by the spray head path real-time planning system.
Further, the machine vision system for detecting the guniting thickness in real time comprises an industrial camera, a laser, an image acquisition system and an image processing system; the industrial camera and the laser are both arranged on the wet spraying mobile device; the image acquisition system is used for controlling the industrial camera to acquire the laser bar information and transmitting the laser bar information to the image processing system in real time; the image processing system is used for receiving the laser bar information transmitted by the image acquisition system in real time, processing the laser bar information and analyzing whether the concrete thickness value of the guniting area reaches the standard or not in real time.
Furthermore, the wet spraying execution component comprises an industrial trolley, an arch type guide rail arranged on the industrial trolley, a traveling guide rail, a wet spraying moving device, a spray head assembly and an arch pushing device; wherein:
the arch frame type guide rail is hinged on the advancing guide rail, and the advancing guide rail is horizontally arranged at two sides of the industrial trolley and is welded and fixed with the trolley body;
the wet spraying mobile device is provided with a wet spraying telescopic arm support, a wet spraying rotary support, a camera protection device, a camera support and a laser support from top to bottom respectively, wherein the upper part of the wet spraying rotary support bears the wet spraying telescopic arm support, a lead screw at the lower part penetrates through the wet spraying telescopic arm support, and a first motor and a second motor are further arranged at two ends of the wet spraying mobile device and are firmly connected with the lead screw through a coupler to provide power for the wet spraying rotary support and the transverse movement of a spray head within the length range of the lead screw; the camera protection device is arranged on the industrial camera and used for preventing rebounded concrete slag from polluting the camera in the guniting process.
The spray head assembly comprises a spray head fixing support and a spray head arranged on the spray head fixing support, the spray head fixing support is arranged at the front end of the wet spraying telescopic arm support, and the spray head fixing support can move close to or far away from the wall surface of the tunnel through the telescopic motion of the telescopic arm; the spray head is positioned on the spray head fixing support, and the spray angle of the spray head can be adjusted by adjusting a knob on the support;
the arch frame propelling device comprises a third motor, a fourth motor, a hydraulic pump station, a jacking oil cylinder and an oil pipe, wherein the hydraulic pump station provides power for a hydraulic system, the jacking oil cylinder is connected with the arch frame type guide rail, the arch frame type guide rail is propelled to move along the advancing guide rail under the telescopic action of the jacking oil cylinder, and the arch frame type guide rail is pushed into the position below the surface to be sprayed.
Furthermore, the industrial camera and the laser are respectively arranged on the camera support and the laser support, the laser support and the camera support are respectively provided with a knob, so that the included angle between the light plane projected by the laser and the optical axis of the camera can be adjusted, and the laser strip emitted by the laser is projected on the two steel arches and the middle guniting area of the two steel arches at the same time.
Furthermore, the advancing guide rail is two straight steel structure guide rails, rail grooves are formed in the two straight steel structure guide rails, and the two straight steel structure guide rails are connected with the arch frame type guide rail through sliding hinged supports.
Furthermore, the arch-type guide rail is three arch-shaped steel structure guide rails, namely a first arch-type guide rail, a second arch-type guide rail and a third arch-type guide rail; three arched steel structure guide rails are respectively hinged on the advancing guide rail through 6 groups of sliding hinge supports; wherein:
and a third motor and a fourth motor are arranged at the sliding hinge support connected to the second arched guide rail, and the third motor and the fourth motor directly drive a pulley on the sliding hinge support when working, so that the second arched guide rail moves between the first arched guide rail and the third arched guide rail.
Further, the wet spraying moving device is connected to the arch type guide rail through a gear device, and under the action of a fifth motor and a sixth motor, the wet spraying moving device moves longitudinally along the guide rail through gears in the gear device; and the fifth motor and the sixth motor are connected at two ends of the wet spraying moving device through bolts, and speed reducers are arranged at output shafts of the fifth motor and the sixth motor and are used as power protection devices.
Furthermore, the industrial trolley is divided into two areas, wherein a guniting working area is arranged in front of a trolley head, and a main equipment area is arranged behind the trolley head; during guniting work, the arch type guide rail and the equipment structure on the arch type guide rail are located in a guniting work area in front of the car body, and other main equipment is located in a main equipment area behind the car body, so that the rebound concrete is prevented from falling on the main equipment.
The invention provides a full-automatic intelligent tunnel wet spraying vehicle based on line structured light, which has the following working principle:
when the spray head carries out reciprocating guniting work along a set S-shaped route, the laser projects line-structured light on a guniting area just finished by the spray head and tunnel steel arches on two sides of the spray head, the industrial camera collects laser bar information of the area irradiated by the structured light, the image processing system carries out real-time processing on the laser bar information, extracts the central points of all laser bars, fits the laser bars into a straight line, and reflects the deflection degree of the laser bars by the fitting root mean square error, namely the thickness information of the guniting area at the moment. Further, the thickness information is fed back to the spray head path planning system in real time to guide the mechanical arm to complete the next guniting work until the guniting is completely finished.
The invention also provides a guniting method based on the full-automatic intelligent tunnel wet spraying vehicle, which comprises the following steps:
s1, after the guniting path real-time planning system sends a guniting instruction, the first motor and the second motor start to work, and the nozzle can transversely move along the direction of a screw rod to guniting; at the moment, the laser line projected by the laser is positioned below the transverse moving guniting area which is just completed;
s2, after the transverse guniting is finished based on the step S1, the fifth motor and the sixth motor start to work, so that the whole wet spraying moving device longitudinally moves along the direction of the arch-type guide rail, and because the industrial camera and the laser are both positioned on the wet spraying moving device, a laser line projected by the laser is positioned in a transverse guniting area which is just finished;
s3, after the overall longitudinal movement of the guniting moving device is completed based on the step S2, the guniting path real-time planning system sends a stop instruction to the motors, at the moment, the first motor, the second motor, the fifth motor and the sixth motor are all in a stop state, and the stop state lasts for 1 second; during the stop state, the image acquisition system controls the industrial camera to take pictures of the guniting area with the laser bar, namely the transverse guniting area just completed in the step S1;
s4, the image acquisition system transmits the image of the guniting area with the laser bar information to the image processing system, and the image information is processed and analyzed; extracting the central point of the stripe from the laser strip by a Steger algorithm, fitting the central point with a straight line by using a least square method, and taking the fitted Root Mean Square Error (RMSE) as a representative value of the guniting thickness;
s5, the image processing system feeds back the processing result to the guniting path real-time planning system in real time, at the moment, the guniting path real-time planning system sets a root mean square error threshold value a, and when the fitting root mean square error R transmitted by the image processing system is i When the spraying thickness in the area is less than or equal to a, judging that the spraying thickness in the area meets the requirement;
s6, after the step S3 is completed, namely the photographing in the stop state is finished, and the steps S1-S5 are continuously repeated, wherein in the repeated process, the spray head sprays slurry from one side of the tunnel arch surface to the other side of the tunnel arch surface according to an S-shaped path to complete one-time slurry spraying of the whole arch surface; the repeated process is to manually teach the guniting, and when the nozzle finishes the guniting on the other side of the arch surface, a worker manually stops the guniting;
s7, after the spray head finishes spraying the tunnel arch surface for one time, the spray head path real-time planning system records the total times c of the transverse moving spraying of the spray head in the repeated process, namely indirectly divides the whole tunnel working wall surface into c equal parts by taking a transverse moving spraying area as a unit;
s8, repeating the steps S1-S5 for a plurality of times, and obtaining a fitting error root mean square value R of a transverse guniting area when the guniting thickness value of the transverse guniting area reaches the standard i When a is less than or equal to a, the guniting path is solidRecording the position of the completed area by the time planning system, marking as 'horizontal i' and recording the number of the completed horizontal moving guniting areas, wherein the number is b; when the steps S1-S5 are repeated next time, after the transverse moving guniting area of the previous transverse moving guniting area of the transverse moving guniting area finishes the transverse moving guniting, the spray head does not execute the transverse moving guniting of the area and directly moves longitudinally along the arch frame type guide rail to the next R behind the transverse moving guniting area i A transverse slurry spraying area is larger than a;
s9, along with repeated circulation of the guniting process, the value b is increased, namely the number of the lateral moving guniting areas with the guniting thickness reaching the standard is increased, but the number of the lateral moving guniting areas with the guniting thickness reaching the standard is not more than c; and when b/c is greater than d, d is the set guniting completion progress value, namely the guniting of the whole tunnel is considered to be completed, and the guniting path real-time planning system sends a stopping instruction to the four motors and the spray heads.
Compared with the prior art, the invention has the following advantages:
1. the full-automatic intelligent tunnel wet spraying vehicle with the machine vision directly adopts the image processing technology to realize the real-time detection of the tunnel wet spraying thickness, and does not need to carry out three-dimensional scanning reconstruction on the tunnel contour in the detection process, so that the data processing period is greatly simplified, the efficiency is high, and the stability is extremely high.
2. The full-automatic intelligent tunnel wet spraying vehicle with the machine vision creatively adopts an S-shaped spraying path real-time planning system, and is well combined with the spraying thickness detection machine vision system, so that intelligent unmanned spraying of the tunnel is realized, the labor amount of workers is greatly reduced, and the personal safety of the workers is guaranteed.
Based on the reason, the method can be widely popularized in the fields of tunnel engineering wet spraying vehicle intellectualization and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a schematic structural diagram of a wet spraying vehicle system according to the present invention;
FIG. 2 is a top view of the wet spraying vehicle system of the present invention;
FIG. 3 is a schematic structural diagram of a wet-spraying moving device for a tunnel according to the present invention;
FIG. 4 is a flow chart of the system for real-time planning of a guniting path according to the present invention;
FIG. 5 is a schematic diagram of the guniting thickness detection method of the invention.
In the figure: 1. an arch type guide rail; 1a, a first arch guide rail, 1b and a second arch guide rail; 1c, a third arch guide rail; 2. a travel guide rail; 3. a wet-jet moving device; 4. a hydraulic jacking device; 5. a propulsion motor; 5a, a third motor; 5b, a fourth motor; 6. a belt wheel; 7. a traversing motor; 7a, a first motor; 7b, a second motor; 8. a longitudinal movement motor; 8a, a fifth motor; 8b, a sixth motor; 9. a lead screw; 10. wet-spraying the rotating support; 11. a camera mount; 12. a laser mount; 13. a laser; 14. an industrial camera; 15. wet spraying telescopic arm support; 16. a nozzle fixing support; 17. a spray head; 18. an accelerator addition system; 19. a hopper; 20. an air compressor system; 21. a pumping system; 22. an illumination device; 23. a headstock; 24. a camera protection device; 25. a sliding hinge support; 26. a gear arrangement.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. Any specific values in all examples shown and discussed herein are to be construed as exemplary only and not as limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present invention, it is to be understood that the directions or positional relationships indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the directions or positional relationships shown in the drawings for the convenience of description and simplicity of description, and that these directional terms, unless otherwise specified, do not indicate and imply that the device or element so referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore should not be considered as limiting the scope of the invention: the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
For ease of description, spatially relative terms such as "over … …", "over … …", "over … …", "over", etc. may be used herein to describe the spatial positional relationship of one device or feature to another device or feature as shown in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" may include both orientations of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of the present invention should not be construed as being limited.
As shown in fig. 1 and 2, the present invention provides a fully automatic intelligent tunnel wet spraying vehicle with machine vision, comprising: a machine vision system for detecting the thickness of the guniting in real time, a real-time planning system for a nozzle path and a wet-spraying execution component; wherein:
the guniting thickness real-time detection machine vision system is used for detecting the concrete thickness value of a guniting area in real time;
the spray head path real-time planning system is connected with the guniting thickness real-time detection machine vision system and used for controlling the wet-spraying execution component to carry out S-shaped path guniting, receiving the concrete thickness value of the current guniting area transmitted by the guniting thickness real-time detection machine vision system in real time, and optimizing the guniting path of the wet-spraying execution component in the next circulating guniting process according to the thickness value signal. The real-time guniting path planning system mainly comprises electric equipment such as motors, controllers and signal lamps, and mainly has the functions of power supply, start-stop control of each motor, path planning, signal display and the like. And the wet spraying execution component is connected with the spray head path real-time planning system and is used for executing the optimized spraying path of the spray head path real-time planning system.
In specific implementation, as a preferred embodiment of the present invention, the machine vision system for real-time detection of slurry spraying thickness includes an industrial camera 14, a laser 13, an image acquisition system, and an image processing system; the industrial camera 14 and the laser 13 are both arranged on the wet-spraying mobile device 3; the image acquisition system is used for controlling the industrial camera 14 to acquire laser bar information and transmitting the laser bar information to the image processing system in real time; the image processing system is used for receiving the laser bar information transmitted by the image acquisition system in real time, processing the laser bar information and analyzing whether the concrete thickness value of the guniting area reaches the standard or not in real time. In the present embodiment, the industrial camera 14 is a CMOS camera. The image processing system analyzes whether the thickness of the concrete in the guniting area reaches the standard or not, and the concrete steps are as follows:
the method comprises the steps of extracting stripe center points from laser stripes at a steel arch and laser stripes in a guniting area through a Steger algorithm, fitting the center points into a straight line by using a least square method, taking fitted Root Mean Square Error (RMSE) as a representative value of guniting thickness, and further comparing the representative value with a set RMSE threshold value to judge whether the guniting thickness reaches the standard or not.
In specific implementation, as a preferred embodiment of the present invention, the wet spraying execution component includes an industrial trolley, an arch type guide rail 1 arranged on the industrial trolley, a traveling guide rail 2, a wet spraying moving device 3, a spray head assembly, and an arch pushing device; wherein:
the arch type guide rail 1 is hinged on the advancing guide rail 2, and the advancing guide rail 2 is horizontally arranged at two sides of the industrial trolley and is welded and fixed with the trolley body; the advancing guide rail 2 is two straight steel structure guide rails, rail grooves are formed in the two straight steel structure guide rails, and the two straight steel structure guide rails are connected with the arch type guide rail 1 through a sliding hinged support 25. The arch guide rail 1 is three arch steel guide rails, namely a first arch guide rail 1a, a second arch guide rail 1b and a third arch guide rail 1c; three arched steel structure guide rails are respectively hinged on the advancing guide rail 2 through 6 groups of sliding hinge supports 25; wherein: a third motor 5a and a fourth motor 5b are arranged at a sliding hinge support 25 connected on the second arch guide rail 1b, and the third motor 5a and the fourth motor 5b directly drive pulleys on the sliding hinge support 25 when working, thereby realizing the movement of the second arch guide rail 1b between the first arch guide rail 1a and the third arch guide rail 1 c.
As shown in fig. 3, the wet spraying mobile device 3 is provided with a wet spraying telescopic boom 15, a wet spraying rotary support 10, a camera protection device 24, a camera support 11 and a laser support 12 from top to bottom, respectively, wherein the wet spraying telescopic boom 15 is supported on the upper portion of the wet spraying rotary support 10, a lower lead screw 9 penetrates through the wet spraying telescopic boom, and a first motor 7a and a second motor 7b are further provided at two ends of the wet spraying mobile device 3 and are firmly connected with the lead screw 9 through a coupler to provide power for the wet spraying rotary support 10 and the transverse movement of the spray head within the length range of the lead screw 9; a camera guard 24 is provided on the industrial camera 14 for preventing rebounding concrete debris from contaminating the camera during the guniting process. The wet spraying moving device 3 is connected to the arch type guide rail 1 through a gear device 26, and moves longitudinally along the guide rail through gears in the gear device 26 under the action of a fifth motor 8a and a sixth motor 8 b; the fifth motor 8a and the sixth motor 8b are connected to two ends of the wet spraying moving device 3 through bolts, and speed reducers are arranged at output shafts of the fifth motor 8a and the sixth motor 8b and used as power protection devices.
The spray head assembly comprises a spray head fixing support 16 and a spray head 17 arranged on the spray head fixing support 16, the spray head fixing support 16 is arranged at the front end of the wet spraying telescopic arm frame 15, and the spray head fixing support can move close to or far away from the wall surface of the tunnel through the telescopic motion of the telescopic arm; the spray head 17 is positioned on the spray head fixing bracket 16, and the spray angle of the spray head 17 can be adjusted by adjusting a knob on the bracket;
the arch pushing device comprises a third motor 5a, a fourth motor 5b, a hydraulic pump station, a jacking oil cylinder 4 and an oil pipe, wherein the hydraulic pump station provides power for a hydraulic system, the jacking oil cylinder 4 is connected with an arch guide rail 1, the pushing movement of the arch guide rail 1 along a traveling guide rail 2 is realized under the telescopic action of the jacking oil cylinder 4, the arch guide rail 1 is pushed into a slurry spraying working area of an industrial trolley, namely, below the wall surface of a tunnel to be sprayed, and the main body part of the industrial trolley is in a safe position outside the surface to be sprayed.
In specific implementation, as a preferred embodiment of the present invention, the industrial camera 14 and the laser 13 are respectively disposed on the camera support 11 and the laser support 12, and the laser support 12 and the camera support 11 are both provided with a knob, so that an included angle between a light plane projected by the laser 13 and an optical axis of the camera 14 can be adjusted, a guniting area is located between the two steel arches, and a laser bar emitted by the laser 13 is simultaneously projected on the two steel arches and a guniting area between the two steel arches.
In specific implementation, as a preferred embodiment of the present invention, the industrial trolley is divided into two areas, a guniting work area is located before the trolley head 23, and a main equipment area is located behind the trolley head 23; during guniting work, the arch type guide rail 1 and the equipment structure on the arch type guide rail are located in a guniting work area in front of the vehicle body, and other main equipment are located in a main equipment area behind the vehicle body, so that rebound concrete is prevented from falling on the main equipment. The industrial trolley mainly comprises a trolley cab 23, a traveling device 6 (the traveling device in the invention is a crawler type and can also be a tire type), an air compressor system 20, a pumping system 21 and an accelerator adding system 18. The air compressor system 20 is composed of an air compressor, a cooler, a pipeline, a switch valve and the like, and mainly provides continuous jet air flow, and concrete mixture with a certain mixing ratio is pressed and fed through the spray head 17 to be sprayed to the sprayed surface at a high speed by utilizing compressed air. The pumping system consists of a pumping main oil cylinder, a central pump, a hopper, a swing oil cylinder and the like, and is used for continuously conveying concrete to the spray head 17 along a conveying pipeline. The accelerator adding system 18 is mainly responsible for conveying the accelerators and other additives, completes concrete spraying together with a pumping system, and mainly comprises a hydraulic motor, a hose pump, a valve and other parts. The industrial trolley, the pumping system 21, the air compression system 20, the accelerator addition system 18, and the like included in the industrial trolley are all prior art and commercially available, so the specific structural details thereof are not described in detail.
Examples
As shown in fig. 4 and 5, in the specific implementation process, the method of the invention includes the following implementation steps:
1. positioning a wet spraying vehicle: after the tunnel is supported by the steel arch frame, the intelligent wet blasting vehicle for the tunnel is driven into the position to be blasted of the tunnel, the whole vehicle body and the tunnel are kept on the same central axis line as much as possible, and the working area of the wet blasting vehicle is positioned below the surface to be blasted of the tunnel.
2. Positioning an arch frame type guide rail: and a driver in the cab operates the arch propulsion system, and controls the hydraulic equipment 4 to push the arch guide rail 1 into a vehicle body guniting working area along the traveling guide rail 2, namely the arch guide rail 1 is positioned below the surface to be gunned of the tunnel. And then the arch pushing system drives a third motor 5a and a fourth motor 5b, and adjusts the distance between the first arch guide rail 1a and the second arch guide rail 1b according to the width of the area to be sprayed.
3. Positioning of the wet-spraying mobile device: at this time, the system for planning the guniting path in real time drives the fifth motor 8a and the sixth motor 8b to move the wet-spraying moving device 3 to the guniting area at the lowest part of the tunnel wall, and ensures that the spray head 17 is directly opposite to the guniting area at this time. After the completion, the wet spraying rotary support 10 and the wet spraying telescopic arm frame are adjusted, so that the spray head 17 and the wall surface of the tunnel achieve a good spray included angle and a good spray distance.
4. Positioning of the industrial camera 14 and the laser 13: after the above steps are completed, the knobs of the camera support 11 and the laser support are adjusted, so that the optical axis of the industrial camera 14 and the line structure light projected by the laser 13 are located at about 10cm under the guniting area opposite to the nozzle 17, and the laser bar can simultaneously cover the guniting area between the tunnel steel arch and the steel arch, and the distance is related to the aperture of the nozzle 17 and the injection rate, namely the width of the effective area of the tunnel wall surface which is sprayed by each time the nozzle 17 moves transversely for guniting.
5. Manually demonstrating guniting: the aim of manually teaching the guniting is to enable the guniting path real-time planning system to record the total number of times of longitudinal movement executed by the wet-spraying moving device 3 from the lowest guniting area on one side of the tunnel to the lowest guniting area on the other side of the tunnel during S-shaped one-time circulating guniting, and the telescopic distance and angle information of the wet-spraying telescopic boom 15 and the spray head 17 during each small guniting area. In the process of spraying the wet spraying telescopic boom 15 from one side of the tunnel to the other side of the tunnel, workers need to manually adjust the telescopic distance of the boom 15 and the rotating angle of the spray head 17 in each small spraying area, at the moment, the path and planning system can record the distance and angle information of each small spraying area, and in the next spraying, the wet spraying telescopic boom 15 and the spray head 17 still keep the position posture. After the manual teaching of the guniting is completed, the guniting path real-time planning system calculates the value c, wherein c = the number of times of longitudinal movement +1 executed by the wet-spraying moving device 3, namely the total number of the transverse guniting areas included in the whole tunnel guniting work, and indirectly divides the whole tunnel work wall into c equal parts by taking the transverse guniting areas as units.
6. Automatic guniting of a wet spraying vehicle: after the completion of one manual teaching guniting, the wet-blasting moving device 3 has moved to the other side with respect to the initial positioning side. Starting automatic guniting by a wet spraying vehicle: the method comprises the following steps:
s1, after the guniting path real-time planning system sends a guniting instruction, the first motor 7a and the second motor 7b start to work to realize the transverse movement of the spray head 17 along the direction of the screw rod 9 for guniting; at this time, the laser line projected by the laser 13 is positioned below the just completed traverse guniting area;
s2, after the transverse guniting is finished based on the step S1, the fifth motor 8a and the sixth motor 8b start to work, so that the whole wet spraying moving device 3 longitudinally moves along the direction of the arch-type guide rail 1, and since the industrial camera 14 and the laser 13 are both positioned on the wet spraying moving device 3, the laser line projected by the laser 13 is positioned in a transverse guniting area which is just finished;
s3, after the overall longitudinal movement of the guniting moving device 3 is completed based on the step S2, the guniting path real-time planning system sends a stop instruction to the motors, and at the moment, the first motor 7a, the second motor 7b, the fifth motor 8a and the sixth motor 8b are all in a stop state, wherein the stop state lasts for 1 second; during this stop state, the image acquisition system controls the industrial camera 14 to take a picture of the guniting area with the laser stripe, namely the transverse guniting area just completed in step S1;
s4, the image acquisition system transmits the image of the guniting area with the laser bar information to the image processing system, and the image information is processed and analyzed; extracting the central point of the stripe from the laser strip by a Steger algorithm, fitting the central point with a straight line by using a least square method, and taking the fitted Root Mean Square Error (RMSE) as a representative value of the guniting thickness;
s5, the image processing system feeds back the processing result to the guniting path real-time planning system in real time, at the moment, the guniting path real-time planning system sets a threshold value a of the root mean square error, and when the image processing system transmits a fitting root mean square error R i When a is less than or equal to a, judging that the spraying thickness of the area meets the requirement;
s6, after the step S3 is completed, namely the photographing in the stop state is finished, and the steps S1-S5 are continuously repeated, wherein in the repeated process, the spray head sprays slurry from one side of the tunnel arch surface to the other side of the tunnel arch surface according to an S-shaped path to complete one-time slurry spraying of the whole arch surface; the repeated process is to manually teach the guniting, and when the nozzle 17 finishes the guniting on the other side of the arch surface, the worker manually stops the guniting;
s7, after the spray head 17 finishes spraying the tunnel arch surface for one time, the spray head path real-time planning system records the total times c of the transverse moving spraying of the spray head 17 in the repeated process, namely indirectly divides the whole tunnel working wall surface into c equal parts by taking a transverse moving spraying area as a unit;
s8, repeating the steps S1-S5 for a plurality of times by the spray head 17, and obtaining a fitting error root mean square value R of a transverse moving guniting area when the guniting thickness value of the transverse moving guniting area reaches the standard i When a is less than or equal to a, the slurry is sprayedRecording the position of the completed area by the real-time path planning system, recording as a horizontal i, and recording the number of the completed horizontal movement guniting areas, wherein the number is b; when the steps S1-S5 are repeated next time, after the transverse moving guniting area of the previous transverse moving guniting area of the transverse moving guniting area finishes the transverse moving guniting, the spray head 17 does not execute the transverse moving guniting of the area, and directly moves longitudinally along the arch-shaped guide rail 1 to the next R behind the transverse moving guniting area i A transverse slurry spraying area is larger than a;
s9, along with repeated circulation of the guniting process, the value b is increased, namely the number of the lateral movement guniting areas with the guniting thickness reaching the standard is increased, but the number of the lateral movement guniting areas with the guniting thickness reaching the standard is not larger than c; and when b/c is greater than d, d is the set guniting completion progress value, namely the guniting of the whole tunnel is considered to be completed, and the guniting path real-time planning system sends a stopping instruction to the four motors and the spray heads.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and these modifications or substitutions do not depart from the spirit of the corresponding technical solutions of the embodiments of the present invention.
Claims (9)
1. The utility model provides a full-automatic intelligent tunnel wet blasting car with machine vision which characterized in that includes: a machine vision system for detecting the thickness of the guniting in real time, a real-time planning system for a nozzle path and a wet-spraying execution component; wherein:
the guniting thickness real-time detection machine vision system is used for detecting the concrete thickness value of a guniting area in real time;
the spray head path real-time planning system is connected with the guniting thickness real-time detection machine vision system and used for controlling the wet-spraying execution component to carry out S-shaped path guniting, receiving the concrete thickness value of the current guniting area transmitted by the guniting thickness real-time detection machine vision system in real time, and optimizing the guniting path of the wet-spraying execution component in the next circulating guniting process according to the thickness value signal.
And the wet spraying execution component is connected with the spray head path real-time planning system and is used for executing the spray path optimized by the spray head path real-time planning system.
2. The full-automatic intelligent tunnel wet spraying vehicle with machine vision according to claim 1, wherein the guniting thickness real-time detection machine vision system comprises an industrial camera (14), a laser (13), an image acquisition system and an image processing system; the industrial camera (14) and the laser (13) are both arranged on the wet spraying moving device (3); the image acquisition system is used for controlling the industrial camera (14) to acquire laser bar information and transmitting the laser bar information to the image processing system in real time; the image processing system is used for receiving the laser bar information transmitted by the image acquisition system in real time, processing the laser bar information and analyzing whether the concrete thickness value of the guniting area reaches the standard or not in real time.
3. The full-automatic intelligent tunnel wet spraying vehicle with machine vision according to claim 1, wherein the wet spraying execution component comprises an industrial trolley, an arch type guide rail (1) arranged on the industrial trolley, a traveling guide rail (2), a wet spraying moving device (3), a spray head assembly and an arch pushing device; wherein:
the arch type guide rail (1) is hinged on the advancing guide rail (2), and the advancing guide rail (2) is horizontally arranged at two sides of the industrial trolley and is welded and fixed with the trolley body;
the wet spraying moving device (3) is provided with a wet spraying telescopic arm support (15), a wet spraying rotary support (10), a camera protection device (24), a camera support (11) and a laser support (12) from top to bottom, wherein the wet spraying telescopic arm support (15) is borne on the upper part of the wet spraying rotary support (10), a lower lead screw (9) penetrates through the wet spraying telescopic arm support, a first motor (7 a) and a second motor (7 b) are further arranged at two ends of the wet spraying moving device (3) and are firmly connected with the lead screw (9) through a coupler, and power is provided for the wet spraying rotary support (10) and the transverse movement of a spray head in the length range of the lead screw (9); a camera protection device (24) is provided on the industrial camera (14) for preventing contamination of the camera by concrete slag rebounding during the guniting process.
The spray head assembly comprises a spray head fixing support (16) and a spray head (17) arranged on the spray head fixing support (16), the spray head fixing support (16) is arranged at the front end of the wet spraying telescopic arm support (15), and the spray head fixing support can move close to or away from the wall surface of the tunnel through the telescopic movement of the telescopic arm; the spray head (17) is positioned on the spray head fixing support (16), and the spray angle of the spray head (17) can be adjusted by adjusting a knob on the support;
the arch pushing device comprises a third motor (5 a), a fourth motor (5 b), a hydraulic pump station, a jacking oil cylinder (4) and an oil pipe, wherein the hydraulic pump station provides power for a hydraulic system, the jacking oil cylinder (4) is connected with the arch guide rail (1), the arch guide rail (1) is pushed to move along the advancing guide rail (2) under the telescopic action of the jacking oil cylinder (4), and the arch guide rail (1) is pushed to the position below a surface to be sprayed.
4. The full-automatic intelligent tunnel wet spraying vehicle with machine vision according to claim 3, wherein the industrial camera (14) and the laser (13) are respectively arranged on a camera support (11) and a laser support (12), the laser support (12) and the camera support (11) are respectively provided with a knob, so that an included angle between a light plane projected by the laser (13) and an optical axis of the camera (14) can be adjusted, and a laser strip emitted by the laser (13) is projected on two steel arches and a middle spraying area of the two steel arches simultaneously.
5. The full-automatic intelligent tunnel wet spraying vehicle with machine vision is characterized in that the traveling guide rails (2) are two straight steel guide rails provided with rail grooves, and the two straight steel guide rails are connected with the arch-type guide rails (1) through sliding hinged supports (25).
6. The full-automatic intelligent tunnel wet spraying vehicle with machine vision according to claim 3, wherein the arch-type guide rails (1) are three arch-shaped steel structure guide rails, namely a first arch-type guide rail (1 a), a second arch-type guide rail (1 b) and a third arch-type guide rail (1 c); three arched steel structure guide rails are respectively hinged on the advancing guide rail (2) through 6 groups of sliding hinge supports (25); wherein:
a third motor (5 a) and a fourth motor (5 b) are arranged at a sliding hinge support (25) connected to the second arched guide rail (1 b), and the third motor (5 a) and the fourth motor (5 b) directly drive a pulley on the sliding hinge support (25) when working, so that the second arched guide rail (1 b) moves between the first arched guide rail (1 a) and the third arched guide rail (1 c).
7. The full-automatic intelligent tunnel wet spraying vehicle with machine vision according to claim 3, characterized in that the wet spraying moving device (3) is connected to the arch-type guide rail (1) through a gear device (26), and under the action of a fifth motor (8 a) and a sixth motor (8 b), the wet spraying moving device moves longitudinally along the guide rail through gears in the gear device (26); the fifth motor (8 a) and the sixth motor (8 b) are connected to two ends of the wet spraying moving device (3) through bolts, and speed reducers are arranged at output shafts of the fifth motor (8 a) and the sixth motor (8 b) and used as power protection devices.
8. The full-automatic intelligent tunnel wet spraying vehicle with the machine vision is characterized in that the industrial trolley is divided into two areas, wherein a guniting work area is arranged in front of a vehicle head (23), and a main equipment area is arranged behind the vehicle head (23); during guniting work, the arch type guide rail (1) and the equipment structure on the arch type guide rail are located in a guniting work area in front of the vehicle body, and other main equipment is located in a main equipment area behind the vehicle body, so that rebound concrete is prevented from falling on the main equipment.
9. The guniting method of the full-automatic intelligent tunnel wet spraying vehicle based on the claims 1-8 is characterized by comprising the following steps:
s1, after the guniting path real-time planning system sends a guniting instruction, the first motor (7 a) and the second motor (7 b) start to work, and the nozzle (17) moves transversely along the direction of a lead screw (9) to guniting; at the moment, the laser line projected by the laser (13) is positioned below the transverse moving guniting area which is just completed;
s2, after the transverse guniting is finished based on the step S1, the fifth motor (8 a) and the sixth motor (8 b) start to work, the whole wet spraying moving device (3) moves longitudinally along the direction of the arch type guide rail (1), and since the industrial camera (14) and the laser (13) are both positioned on the wet spraying moving device (3), the laser line projected by the laser (13) is positioned in a transverse guniting area which is just finished;
s3, after the overall longitudinal movement of the guniting moving device (3) is completed based on the step S2, the guniting path real-time planning system sends a stop instruction to the motors, and at the moment, the first motor (7 a), the second motor (7 b), the fifth motor (8 a) and the sixth motor (8 b) are all in a stop state, wherein the stop state lasts for 1 second; during the stop state, the image acquisition system controls the industrial camera (14) to take pictures of the guniting area with the laser strip, namely the transverse guniting area which is just completed in the step S1;
s4, the image acquisition system transmits the image of the guniting area with the laser bar information to the image processing system, and the image information is processed and analyzed; extracting the central point of the stripe from the laser strip by a Steger algorithm, fitting the central point with a straight line by using a least square method, and taking the fitting Root Mean Square Error (RMSE) as a representative value of the guniting thickness;
s5, the image processing system feeds back the processing result to the guniting path real-time planning system in real time, at the moment, the guniting path real-time planning system sets a threshold value a of the root mean square error, and when the image processing system transmits a fitting root mean square error R i When the spraying thickness in the area is less than or equal to a, judging that the spraying thickness in the area meets the requirement;
s6, after the step S3 is completed, namely the photographing in the stop state is finished, and the steps S1-S5 are continuously repeated, wherein in the repeated process, the spray head sprays slurry from one side of the tunnel arch surface to the other side of the tunnel arch surface according to an S-shaped path to complete one-time slurry spraying of the whole arch surface; the repeated process is to manually teach the guniting, and when the nozzle (17) finishes the guniting on the other side of the arch surface, a worker manually stops the guniting;
s7, after the spray head (17) finishes spraying the tunnel arch surface for one time, the spray head path real-time planning system records the total number c of the transverse moving spraying of the spray head (17) in the repeated process, namely indirectly divides the whole tunnel working wall surface into c equal parts by taking a transverse moving spraying area as a unit;
s8, repeating the steps S1-S5 for a plurality of times by the spray head (17), and when the spraying thickness value of a certain transverse moving spraying area reaches the standard, obtaining the fitting error root mean square value R of the transverse moving spraying area i When the number is less than or equal to a, the guniting path real-time planning system records the position of the completed area as a horizontal i and records the number of the completed transverse guniting areas, wherein the number is b; when the steps S1-S5 are repeated next time, after the transverse moving guniting area of the previous transverse moving guniting area finishes the transverse moving guniting, the spray head (17) does not execute the transverse moving guniting of the area, and directly moves longitudinally along the arch-frame type guide rail (1) to the next R behind the transverse moving guniting area i A transverse slurry spraying area is larger than a;
s9, along with repeated circulation of the guniting process, the value b is increased, namely the number of the lateral moving guniting areas with the guniting thickness reaching the standard is increased, but the number of the lateral moving guniting areas with the guniting thickness reaching the standard is not more than c; and when b/c is greater than d, d is the set guniting completion progress value, namely the guniting of the whole tunnel is considered to be completed, and the guniting path real-time planning system sends a stopping instruction to the four motors and the spray heads.
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