专利摘要:
Process for removing cavities underground, in particular cavities with excavation cross-sections of at least 5 square meters, with producing at least one layer (16-19; 21-24) planned to be deformable in the expanded state under the occurrence of rock pressure on an inside (11) of an underground one Cavity, the deformable layer being produced by means of 3D printing.
公开号:CH715137A2
申请号:CH6742019
申请日:2019-05-24
公开日:2019-11-29
发明作者:Steiner Patrick
申请人:Solexperts Ag;
IPC主号:
专利说明:

Description Field of the Invention The invention relates to a method and a device for expanding cavities underground, in particular cavities with excavation cross sections of at least 5 square meters (hereinafter: m 2 ).
PRIOR ART In underground construction, there are various methods of building structures in pressurized or swellable mountains.
A structure can be created according to the resistance principle if the occurring mountain pressures can be mastered with the rigid expansion systems known today. A rigid expansion system withstands the rock pressure without significant deformation.
The expansion strength and thus also the application of the resistance principle, however, are particularly limited in larger building diameters in combination with a large coverage. The space requirement increases significantly for a high expansion resistance, so that large excavation diameters are necessary. In pressurey or swellable rock with high rock pressures and large diameters, structures based on the resistance principle are technically very difficult and can only be realized with great effort or not at all and are therefore generally not economical.
Are the mountain pressures and the associated deformations with a rigid expansion no longer manageable or economical, different variants of a deformable expansion are used. In the case of deformable expansion, deformation of the rock is permitted and the resulting stress on the expansion is reduced.
There are various deformable expansion systems in combination with shotcrete for conventional, sequential propulsion. Upset elements, which are installed parallel to the tunnel axis on the tunnel wall and are filled with shotcrete, absorb the deformation. The load and deformation in the compression elements are tangential to the tunnel profile.
The systems mentioned above are not suitable for mechanical, continuous propulsion, since they are not compatible with segment segments. Furthermore, the systems described above with the possibility of tangential deformation do not have a deformable layer between the rock and the inner shell with the possibility of radial deformation. Such systems with the possibility of radial deformation are also called areal systems. Various areal systems are known and used:
- Compressible annular gap mortar, e.g. Compex: the annular gap between the rock and the tubbing is grouted with compressible mortar.
- Flat sandwich segment elements, e.g. Solexperts hiDCon-F, Andra Bure: a deformable layer of fired clay tubes is added to the segment.
- Compressible shotcrete: a deformable mortar or concrete is pneumatically sprayed onto the excavation area.
[0008] These two-dimensional systems are indeed suitable for mechanically driving tunnel tubes. However, these systems are only suitable to a limited extent in the area of intersection structures or cross-passages. Intersection structures require more complex geometries for the expansion than constant tunnel cross-sections.
For grouting compressible mortar, an annular gap is necessary. That is why it is only suitable for TBM tunneling where there is an annular gap between rock and tubbing. In branch or crossing structures, complex formwork constructions are required for the compression of compressible mortar.
Because of the complex geometry, the production of segment segments with an additional, deformable layer for intersection and branch structures is extremely complex.
State of the art is to finish the inner shell in one direction and to create the intersection or the cross pass conventionally at a later time. The inner shell is then often created using special formwork carriages.
[0012] The layer thickness and its deformation properties are important parameters for the function of a deformable, two-dimensional system. When using deformable shotcrete, both parameters are subject to comparatively great uncertainties in practice. The deformation properties and the thickness of the applied layer are very difficult to guarantee within a narrow tolerance range and depend heavily on the machine operator and the application method.
[0013] EP 0 557 269 A1 discloses a system for tunneling in segmental construction which achieves a planned compliance with rock pressure through the use of springs.
A 3D printing method for concrete is explained in EP 3147 269 A1, in which BCT cement is used.
DISCLOSURE OF THE INVENTION The object of the invention is, compared to the prior art, improved devices and methods for expanding cavities underground, in particular cavities with excavation cross sections of at least 5 m 2 .
The object is achieved with a method according to claim 1 and a further method and a device according to the independent claims.
A first aspect of the invention relates to a method for expanding cavities underground, in particular cavities with cut-out cross-sections of at least 5 square meters, with producing at least one planned in the expanded state under the occurrence of rock pressure deformable or planned compliant layer on an inside an underground cavity, the deformable layer being produced by means of 3D printing. Typically, one or each of the at least one deformable layers may have multiple printing layers, i.e. several printing layers are printed for one deformable layer.
The smallest diameter of the cavity is typically 2 m, in embodiments at least 3 m or at least 4 m. The smallest diameter is the smallest opposite distance between two cut-out areas of a cross-section. Typical minimum sizes of cavities have a cross section of more than 5 m 2 or typically more than 10 m 2 or typically less than 300 m 2 . Typical embodiments include a planned deformable layer. Such planned deformable or resilient layers are known per se from the prior art in order to absorb deformation of the surrounding mountains and in this way to relieve stress.
The deformability can typically be defined as a minimum plastic deformation, typically in the range of a plastic deformation of at least 10% or at least 20% or at least 30% in the removed state. Typically, the deformability of the at least one deformable layer is at least 40% or at most 80% or at most 90%. The deformability typically indicates the reduction in volume which can be achieved with plastic deformation before the resistance of the layer has increased to twice the compression limit, that is to say the transition from elastic to plastic deformation.
The at least one deformable layer can also be defined in that the at least one deformable layer has a modulus of elasticity that is comparatively low for concrete. The at least one deformable layer typically has a strength of at most 20 MPa or at most 10 MPa or at most 5 MPa. The at least one deformable layer typically has a strength of at least 0.1 MPa or at least 0.2 MPa.
[0021] In typical embodiments of methods of the invention, a rigid layer is additionally produced radially within the at least one deformable layer. The rigid layer is typically also produced by 3D printing. In this way, one device can be used for both types of layers, rigid and deformable. In further embodiments, prefabricated elements or in-situ concrete with formwork elements are used for the rigid layer.
The deformable layer is typically produced with micropores. Typical micropores have a size of at most 16 mm or at most 8 mm or at most 4 mm. Typically, the micropores in the deformable layer are created by adding pore-containing granules, foaming agents or foam to a printed material which is used in 3D printing to produce the deformable layer. The addition to the printed matter is typically carried out before the printing process and thus enables efficient working with the method according to the invention. In typical methods, the deformable layer is made with macropores. A controller can be used to create the macro pores according to a specification. The macropores can also be shaped in such a way that, in particular, deformations in the circumferential direction of the deformable layer are made possible in order to make it easier for the layer to yield.
The macropores are typically produced in the deformable layer by providing cutouts in selected printing layers during 3D printing. In this way, the macro pores can be created easily and efficiently.
Typically, the print material used for 3D printing comprises cement or plastic. Depending on the requirements of the layer, the strength of the printed material can be chosen between 0.2 and 5 MPa or up to 20 MPa for the deformable layer or up to 55 MPa or up to 35 MPa for the non-deformable layer. The printed material itself can be deformable or rigid, and deformable layers can also be produced from a rigid printed material by means of micropores or macropores. The word "stiff" refers to a state after the print material has hardened. The base material of the printed material can be cement or plastic. Properties such as deformability and strength of the printed material can be varied with additives. Possible supplements are limes, open- and closed-pore granules e.g. Glass foam, polystyrene, expanded clay, metal and plastic foams, gas pores either as a result of pore formers or by adding foam, sand and plastic, steel, carbon and glass fibers. Typically, the printed matter has a binder, typical binders are cement-based or plastic-based.
Typically, in the method of the invention, before or during the application of a further deformable layer, the inside of the cavity or the inside of a previously applied deformable layer is measured by means of a laser scanner. In this way, the layer to be applied can be adapted exactly to the existing conditions.
In typical processes, the thickness of the further deformable layer is adjusted depending on the measured inside of the previously applied deformable layer or the inside of the cavity. In typical processes, the layer thickness of this layer which is already being printed is measured during the application or printing of a layer. In this way, the thickness of the layer can be created as accurately as possible. Typically, in the method of the invention, a pattern of the pressure to create cavities, the width of a print jet or the mixture of the printed matter is adjusted depending on the measurement.
In typical processes, the at least one deformable layer or the at least one rigid layer is applied as a function of reference points. In this way, a certain inner profile of the deformable layer can be reliably achieved. Reference points can, for example, be arranged on a cross section that has already been completed, or can be points that continuously check for displacements with respect to a fixed point, which can also be located outside the cavity or tunnel cross section.
[0029] The at least one deformable layer typically has a thickness of at least 5 mm, at least 10 mm or at least 20 mm or at most 500 mm or at most 800 mm. In typical processes, the micropores or the macropores are provided as a function of a predetermined deformability. In this way, a desired macroscopic deformation behavior can be set by adjusting the micropores or the macropores.
One aspect of the invention relates to a method for removing cavities underground, in particular cavities with cut-out cross-sections of at least 5 m 2 , with producing at least one layer which is planned to be deformable in the expanded state with the occurrence of rock pressure, the deformable layer using 3D printing is produced and the deformable layer is produced in a geometric shape depending on an inside of an underground cavity or an inside of a previously applied deformable layer.
Typically, before the production of a layer, in particular a deformable layer or a plurality of deformable layers printed one above the other, the inside of the cavity or the inside of the previously applied deformable layer is measured by means of a laser scanner and the result of this measurement during production the following deformable layer. In this way, an optimal adjustment of the thickness to existing conditions is possible.
The breakout surface can be sealed or left unsealed before printing the first deformable layer of the at least one deformable layer. Sealing, also called initial sealing, can serve to protect health and safety. By increasing the cohesion due to the sealing, the surface can be stabilized in embodiments and the risk of breakages reduced. In typical embodiments, a network is injected, which can offer advantages as head protection.
In typical embodiments, rigid and compressible layers are combined, for example arranged alternately. Typically, a number of deformable layers are first arranged or printed on the excavation surface and then a rigid layer is applied on the inside.
A 3D printing unit is typically used for printing, which comprises a pump system for pumping the printed matter and a robot, on the arm of which there is a print head with which the printed matter is applied.
For any excavation geometry, typical methods of the invention can be used to apply both deformable layers having a predetermined extent and defined deformation properties and relatively rigid layers or combinations of deformable and rigid layers to the excavation surface, which can be sealed or unsealed. The first layer, typically a deformable layer, can be applied to both sealed breakout surfaces, e.g. a shotcrete layer, or directly on the unsealed rock. The layers can consist of one or more layers or printing layers. A layer typically denotes a print layer. Typical embodiments can be used in conventional, sequential or mechanical, continuous tunneling, for example with tunnel boring machines.
Typical methods of the invention can be operated with mobile or stationary printing units. In typical embodiments, the printing unit consists, among other things, of a pump system and a robot or industrial robot, with typical robots used having at least 4, at least 5 or at least 6 axes. The robot comprises an arm with a plurality of degrees of freedom, for example at least 5 or 6, on the last element of which a print head is arranged, by means of which the printed matter is applied to the breakout surface. The printing unit is typically mounted on a platform. In typical mobile printing units of embodiments, the platform is moved with caterpillar carriages, bogies or rail-bound.
In typical processes, the mechanical properties such as strength and plastic deformability of a printed layer are not only dependent on the properties of the printed matter. In typical processes, the mechanical properties are also determined by the choice of the pattern of the printing layers of a layer.
The porosity of a print layer with patterns typically consists, on the one hand, of the micropores in the printed matter itself, and of the macropores of the pattern of the print layer. By varying this double porosity, layers can be produced in a very wide range of deformability (for example from 0% to 85%) and strength (for example 0.2 to 60 MPa).
With typical methods, both the width and the thickness of individual printing layers can be varied over a wide range. This enables the production of smooth or even surfaces for the inner shell regardless of whether it is made with in-situ concrete or is made from segment segments. This is particularly advantageous in the case of branch or intersection structures of typically complex surface geometries, but can also offer great advantages on straight lines.
Typical processes can produce prefabricated deformable sheet-like or linear elements with the properties described herein for deformable layers. Such prefabricated elements can be attached directly to the excavation area or used in combination with segment segments or steel arches. The prefabrication can also take place outside the underground cavity, for example a tunnel.
BRIEF DESCRIPTION OF THE FIGURES [0041] In the following, embodiments of the invention are explained with reference to the attached figures, which show:
Fig. 1 shows schematically an apparatus with which typical methods of the invention can be carried out;
Fig. 2 schematically shows a detail of the device of Fig. 1 in more detail when performing a typical method;
Fig. 3 schematically shows a detail of the device of Fig. 1 in more detail when carrying out another typical method;
4 to 8 schematically show patterns which can be produced using typical methods of the invention;
9 shows in a schematic flow diagram the simplified sequence of a typical method; and
10 schematically shows different crossing situations of tunnel cross sections.
DESCRIPTION OF PREFERRED EXEMPLARY EMBODIMENTS Typical exemplary embodiments are described below, the same reference numerals being used in part for the same or similar parts, and in some cases also for several different embodiments. Basically, the application is not limited to the different embodiments, the scope is rather determined by the claims. In some cases, individual parts are only explained in connection with a figure; if these parts are shown in further figures, they are not necessarily described again.
Fig. 1 shows schematically an apparatus with which typical methods of the invention can be carried out. A 3D printing unit 12, as is shown schematically in FIG. 1, is typically used for printing.
The printing unit 12 has a pump system 9 for pumping the printed material and a robot 5, on the arm of which there is a print head 7 with which the printed material is applied. The printed matter is conveyed from a mixer or reservoir to the pump system via a line (not shown).
Furthermore, the printing unit 12 has a scanner 8, which is designed as a real-time scanner system with a laser scanner. Furthermore, the printing unit comprises a base platform 6, which is built on a chassis 4 and which carries the robot 5 and a control computer 10 with a GUI and a wireless interface for transmitting data.
With the print head 7, the print material is applied to an excavation surface 11 of a main tunnel 1, which represents an inside of an underground cavity. In embodiments, the printed matter can be applied directly to a surface of a rock 3 on the excavated surface 11.
In Fig. 1 is also a cross section 2 of the main tunnel 1 is shown, wherein producing an inner formwork with the printing unit 12 in the intersection of the main tunnel 1 with the cross section 2 can offer particular advantages, since a flexible adaptation to different geometries is possible is.
FIG. 2 shows how printing layers 16, 17 and 18 of variable thickness are produced with the printing unit 12 of the exemplary embodiment in FIG. 1. The breakout surface 11 has an irregular contour.
For example, in order to be able to produce a uniform inner shell for a uniform tunnel cross section, irregularities in the excavation surface can be automatically compensated for using methods according to the invention or typical 3D printing units. Typical embodiments of the invention, for example typical 3D printing units, comprise a print head with a thickness control. The thickness control comprises, for example, a flap or an aperture on the print head of the 3D printing unit. The thickness control is set up to influence a thickness of the printed layer. Typical embodiments of 3D printing units include a delivery rate control or a speed control. The flow control, the thickness control or the speed control are used individually or together in typical methods of the invention to adjust the amount of printing material applied or the thickness of a printing layer.
The pressure layers 16, 17 and 18 of FIG. 2 are layers of a deformable layer with a strength in this example of 1.5 MPa and a deformability of 50%. By adapting the thickness of the printing layers 16, 17 and 18, the layer thus created almost completely compensates for the irregularities of the excavation area. A further homogenization can be achieved by applying a further layer with variable thicknesses of the individual printing layers of the further layer.
3 shows a further exemplary embodiment of a multi-layer tunnel installation, which can be produced using typical methods and devices of the invention. In this example, in contrast to the example in FIG. 2, a plurality of non-deformable layers 16-19 provided for compensation were first applied to a breakout surface 11. The layers 16-19 have a strength of 30 MPa and at least essentially no deformability and serve to compensate for irregularities in the excavation area 11.
The layers 16-19 of the embodiment of FIG. 3 are each at least substantially similarly thick, however, as shown schematically in FIG. 3, not all layers are applied at every point in order to achieve a height compensation. In this way it is possible, but not mandatory, to work with a printhead which has no mechanical thickness control on the printhead.
On the last layer 19, four highly deformable layers 21-24 have already been applied, which have a strength of only 1.5 MPa and a deformability of 70%. The high deformability is achieved by macro and micro pores in the highly deformable layers 21-24.
Typical exemplary embodiments include combinations of deformable layers with different material properties. For example, compensation layers located on the outside may have a lower or higher deformability than layers lying further on the inside.
As a final layer, a rigid layer 25 is applied to the innermost, highly deformable layer 24. The rigid layer 25 has a strength of 30 MPa and a deformability of less than 5% or is essentially non-deformable.
4 shows what the print pattern of part of an applied print layer can look like in typical processes. 4 is created with a comparatively simple parallel printing pattern of several printing lines 32. The printing lines 32 are printed in parallel in one go with a typical printing unit, a turn 33 being made at the end of a straight line. There are hardly or no macropores in the layer which comprises a plurality of printing layers according to FIG. 4, in particular macropores can be avoided by displacing the individual webs arranged one above the other by half a web width. The pattern of FIG. 4 is particularly suitable for rigid but also for deformable layers with only low deformability.
5 shows a further print pattern which can be produced using typical methods. The print pattern of FIG. 5 comprises individual print lines 32, which meander slightly, so that small gaps 36 are formed, which form macropores in the finished layer with a plurality of print layers in accordance with the print pattern of FIG. 5.
6 shows a print pattern with more meandering print lines 32, so that large gaps 37 are created. In addition, printing layers lying one above the other are printed with an unaltered and identical pattern (simple stacking), so the printing queue 38 of the subsequent printing layer lies exactly above the printing queue 32 of the first printing layer. As in all of FIGS. 4 to 8, both print layers are only shown schematically in sections.
7 shows a print pattern which uses similar or identical print queues 32 and 38 as the print pattern of FIG. 6, but the print layers 32 and 38 are arranged offset (offset stacking). There are very large gaps which ensure great deformability.
8 shows a print pattern which uses similar or identical print queues 32 and 38 as the print patterns of FIGS. 6 and 7, but the print layers 32 and 38 are arranged rotated by 90 ° (staggered and crossed stacking). , There are large gaps which ensure great deformability, but a comparatively high strength can still be achieved.
A typical method of the invention is shown schematically in FIG. 9. The method can be used to create a plurality of layers, in particular a plurality of deformable layers and possibly at least one rigid layer. Other typical features described herein may be used in the method.
In addition to the print patterns of FIGS. 4-8 that can be produced with 3D printing, numerous other print patterns can be used. In particular, the printed samples can be produced with printed matter which has micropores. For example, the print pattern of FIG. 8 can be combined well with micropores in order to further increase the deformability with an acceptable strength.
First, the printing unit is positioned in a block 110 by means of conventional measurement or by position detection on the basis of previously installed reference points. In block 120, a real-time scanner system detects the geometry of the excavation surface or of deformable or rigid layers previously applied by printing. The real-time scanner system can be implemented with a central laser scanner or with a system made up of different scan modules.
In a block 130, the actual state is recorded and the subsequent expansion, typically the subsequent deformable or rigid layer to be applied, is planned, a three-dimensional virtual model of the excavation geometry being created using the scanner data. The desired tunnel expansion, i.e. integrates the next deformable layer and rigid layer to be created. The arrangement, the dimension and the properties of the individual print layers for the next layer to be created are also defined.
After verification of the planned expansion by a user in block 140, the print program is created in accordance with the specifications from block 130 and the print material is prepared. In a block 150, the different layers are applied to the excavation surface. The print head applies either a cement-based or a plastic-based mortar in layers to the surface. With quick-setting mortar, it can also be applied overhead.
The three-dimensional model is updated in a block 160 with acquired scanner data and compared with the target model of the expansion in block 170.
If it is determined in a block 170 that the respective layer is already finished, the method jumps to block 180, in which it is checked whether there is still a layer to be printed. If this is the case, the method jumps to block 130, in which the next layer, a deformable or a rigid layer, is then planned.
If, on the other hand, it is determined in block 170 that the layer currently being produced has not yet been completed, the method jumps back to block 150 so that further printing takes place with the updated model. In typical embodiments, a print layer currently printed in block 150 is immediately detected in step 160 and represented in the model and thus influences the printing of the next print layer of the deformable or rigid layer currently being printed.
If it is determined in block 180 that all layers have been printed, the method is ended in block 190.
10 shows, for explanation, intersection situations of a main tunnel 1 each with a cross pass 2 in a schematic sectional view from above. The figure on the left shows a branch structure with which the cross section 2 branches off from the main section 1. The right illustration of FIG. 10 shows a niche with an approach 50 for future extensions. Particularly in the case of non-circular tunnel cross sections, complex geometries occur in such intersection areas, which must be taken into account when expanding the tunnel. With the methods and devices according to the invention, adapted segments for such geometries can be created flexibly.
The invention is not limited to the exemplary embodiments described above. Rather, the scope of the invention is defined by the claims.
权利要求:
Claims (16)
[1]
claims
1. Method for expanding cavities (1,2) underground, in particular cavities (1, 2) with excavation cross-sections of at least 5 square meters, with
Producing at least one layer (16-19; 21-24) which is planned to be deformable in the expanded state when mountain pressure occurs, on an inside (11) of an underground cavity (1, 2),
- The deformable layer is produced by means of 3D printing.
[2]
2. The method of claim 1, wherein in addition a rigid layer (25) is produced radially within the at least one deformable (16-19; 21-24) layer.
[3]
3. The method according to any one of the preceding claims, wherein the deformable layer (16-19; 21-24) is produced with micropores.
[4]
4. The method according to claim 3, wherein the micropores in the deformable layer (16-19; 21-24) by adding pore-containing granules, foaming agent and / or foam in a print material which is used in 3D printing to produce the deformable layer ( 16-19; 21-24) is used to be generated.
[5]
5. The method according to any one of the preceding claims, wherein the deformable layer (16-19; 21-24) is made with macropores.
[6]
6. The method according to claim 5, wherein the macropores are produced in the deformable layer by providing recesses (36) in selected printing layers during 3D printing.
[7]
7. The method according to any one of the preceding claims, wherein the printed material used for SD printing comprises cement and / or plastic.
[8]
8. The method according to any one of the preceding claims, wherein before and / or during the application of a further deformable layer (17-19, 21-24) the inside of a previously applied deformable layer (16-19, 21-23) by means of a laser scanner (8) is measured.
[9]
9. The method according to claim 8, wherein the thickness of the further deformable layer (17-19, 21-24) is adjusted depending on the measured inside of the previously applied deformable layer (16-19, 21-23).
[10]
10. The method according to any one of the preceding claims, wherein the at least one deformable layer (16-19, 21-24) has a thickness of at least 5 mm and / or at most 800 mm.
[11]
11. The method according to any one of the preceding claims, wherein the at least one deformable layer has a strength of at least 0.1 MPa and / or at most 60 MPa.
[12]
12. The method according to any one of the preceding claims, wherein the at least one deformable layer (16-19, 21-24) has a deformability of at least 20% and / or at most 80%.
[13]
13. The method according to any one of the preceding claims, wherein the at least one deformable layer (16-19, 21-24) and / or the at least one rigid layer (25) is produced as a function of reference points.
[14]
14. A method for expanding cavities (1,2) underground, in particular cavities (1, 2) with excavation cross-sections of at least 5 square meters, with
- producing at least one layer (16-19, 21-24) planned to be deformable in the expanded state under the occurrence of rock pressure,
- The deformable layer (16-19, 21-24) is produced by means of 3D printing, and
-wherein the deformable layer (16-19, 21-24) has a geometric shape depending on an inside (11) of an underground cavity (1, 2) or an inside of a previously applied deformable layer (16-19, 21-23 ) will be produced.
[15]
15. The method according to claim 14, wherein prior to producing the deformable (16-19, 21-24) layer, the inside (11) of the cavity (1,2) or the inside of the previously applied deformable layer (16-19,21 -23) is measured by means of a laser scanner and the result of this measurement is used in the production of the deformable layer (17-19, 21-24).
[16]
16. The device, in particular a 3D printing unit (12), is set up to carry out at least one of the methods of claims 1 to 15.












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法律状态:
优先权:
申请号 | 申请日 | 专利标题
DE102018112613.1A|DE102018112613A1|2018-05-25|2018-05-25|Method and device for removing cavities underground|
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