大直径盾构隧道弧形件预制拼装技术与智能化安装机应用

Assembly Technology of Prefabricated Arc Parts and Application of Intelligent Assembling Machine for Large-Diameter Shield Tunnels

为解决传统盾构隧道弧形件(口子件)在拼装施工中存在的拼装工艺不先进、拼装精度差、装备智能化程度低、施工进度慢等技术难题,通过引进装备设计和智能化控制理念,采用弧形构件内部穿行式设计思路,结合毫米级负载敏感液压系统和亚毫米级位姿测量系统,研制出一台可实现弧形件一键智能化拼装的穿行式弧形件智能安装机。该装备具有精调数据测量系统、自动检测与感知、自动运算与分析处理、自动决策与动作执行、人机交互与信息储存等智能化控制技术,在上海轨道交通市域线机场联络线JCXSG-11标工程首次应用,取得了良好的拼装效果。结果表明:1)安装机液压系统控制精度达到0.5 mm,弧形件拼装精度达到±5 mm,实现了高精度拼装;2)安装机通过智能化控制技术,实现了一键式操作,每循环工作耗时32 min,施工效率提高30%以上,节省人工50%以上;3)穿行式弧形件智能安装机工作性能稳定可靠,可实现运行状态、控制方式、传感器数据、液压油缸行程数据、通信状态等参数的记录与储存,实现人机交互。

In order to solve the technical problems existing during assembly of the traditional arc parts(box-shaped piece)for shield tunnels,such as unadvanced assembly technology,poor assembly accuracy,low degree of equipment intelligentization,slow construction progress,etc.,an intelligent walk-through assembling machine for arc parts is developed,by introducing the concept of equipment design and intelligent control,adopting the design idea of walk-through arc-shaped components,and combining the millimeter-level load-sensitive hydraulic system and sub-millimeter level attitude monitoring system.It can realize intelligent assembly of arc parts with one-button operation.The assembling machine is equipped with intelligent control technology such as fine-adjustment measurement system,automatic detection and perception,automatic calculation and analytical processing,automatic decision making and action execution,human-computer interaction and information storage,etc.It has been applied for the first time in Contract JCXSG-11 of Shanghai rail transit airport link line,and has achieved good performance in assembly.The results show that:(1)The control accuracy of the hydraulic system of assembling machine is up to 0.5 mm,and the assembly accuracy of arc parts is up to±5mm,and thus high-precision assembly is achieved.(2)Through the intelligent control technology,one-button operation is realized for the assembling machine.It takes 32 min for each cycle,improving the construction efficiency by more than 30%,and saving labor by more than 50%.(3)The intelligent walk-through assembling machine for arc parts has stable and reliable performance,which can record and store the parameters such as operation state,control mode,sensor data,hydraulic cylinder stroke data and communication state,and realize human-computer interaction.