自动布料带压浇筑隧道智能衬砌台车研制及应用

为解决隧道衬砌背后空洞及不密实、施工缝压溃、掉块、止水带偏位等技术难题，创新研制了自动布料带压浇筑隧道智能衬砌台车，构建了隧道衬砌混凝土自动布料、带压浇筑、施工缝零搭接和防空洞监测等新工艺体系，可减少或消除衬砌质量缺陷。试验表明： 1）采用自动布料封闭管路带压浇筑系统，能实现分层逐仓浇筑，减少混凝土离析和污染，实现单次换管2～3 min，提高效率35％以上，节省人工50%以上； 2）拱部采用自动振捣器，混凝土不密实减少85%以上； 3）运用双模式控制系统，提升定位精度和安全性，比普通台车定位时间缩短30 min以上； 4）采用“V”形槽零搭接装置，可避免施工缝顶裂和压溃，且利用可视化堵头板，方便施工； 5）应用智能集成控制系统，可实现自动布料、自动振捣、自动监测和自动生成数据报表，实现人机交互。

Development and Application of Intelligent Tunnel Lining Trolley with Automatic Concrete Distribution and Pressure Casting

The tunnel lining might has many problems such as hollow behind lining, insufficient compactness, construction joint collapse and fall block, and waterstop tie deviation, etc. As a result, an intelligent tunnel lining trolley with automatic distribution and pressure casting is developed. A new technical system including automatic concrete distribution, casting with pressure, construction joint zero overlapping and cavity monitoring, etc. is established, which can avoid or reduce lining quality defects. The test results show that: (1) By adopting automatic concrete distribution system with closed pipeline and pressure casting, layer by layer and chamber by chamber casting can be realized, the concrete segregation and pollution can be reduced, the one time pipe replacing within 2~3 min can be realized, the construction efficiency can be improved by more than 35%, and the labor consumption can be reduced by more than 50%. (2) By adopting automatic vibrator in the arch, the uncompactness of concrete can be reduced by more than 85%. (3) With the help of double mode control system, the positioning accuracy and safety can be improved, and the positioning time is shortened by more than 30 min compared with the conventional trolley. (4) The crack and collapse of construction joint can be avoided by adopting V shaped groove zero lap device, and the construction becomes more convenient with visual bulkhead. (5) The application of intelligent integrated control system helps to realize automatic distribution, automatic vibration, automatic monitoring and automatic generation of data reports, and thus achieves human computer interaction.