The efficient construction capability of the wet spraying trolley stems from its technological innovation and systematic design. The following is an in-depth analysis of its core secrets:
I. Intelligent control system optimizes operating efficiency
1. Dual power system ensures continuous operation
The dual power switching mode of diesel engine and electric motor is adopted to adapt to unstable power supply or emergency conditions in the tunnel and reduce downtime.
2. Intelligent proportioning technology of quick-setting agent
Equipped with dual 1000L quick-setting agent barrels and a large-capacity storage system, the flow sensor is used to match the concrete injection volume in real time with an accuracy of ±2%, reducing the frequency of manual intervention.
3. Automatic nozzle control
The nozzle automatic control system developed by CCCC Second Engineering Bureau dynamically adjusts the injection angle and distance through the distance sensor, so that the flatness error is controlled within 5mm, reducing the workload of secondary repair.
II. Design of efficient pumping and injection system
1. Low pulsation pumping technology
The multi-cylinder alternating pumping structure is adopted to effectively reduce pressure fluctuations, and the pipe blocking rate is reduced by 80% compared with traditional equipment. For example, after the pumping stability of Zhengxun ZXP4017 is improved, the continuous injection time is extended to more than 4 hours.
2. Super wear-resistant conveying pipeline
The service life of steel fiber concrete special pipeline is twice that of conventional pipelines. With automatic anti-blocking technology, it can adapt to the continuous injection of fiber-containing and high-grade concrete.
3. 40m³/h high-speed injection capacity
The large-displacement hydraulic pump and optimized boom work together to achieve a 300% increase in the coverage area of single-cycle injection. For example, in a railway tunnel project in Yunnan, the daily injection volume exceeded 800m³.
III. Innovation of mechanical structure and construction process
1. 9-DOF robotic arm technology
The Z-type telescopic arm combined with the sliding turntable realizes 360° blind-zone-free spraying, covering a height of 26 meters, and a single positioning spraying distance of 12 meters, reducing the number of equipment movements.
2. Hydrostatic four-wheel drive chassis
Four-wheel independent steering and torque adaptive control can complete on-site U-turns in a 3.5-meter-wide tunnel, increasing the transfer efficiency by 50%.
3. Integration of standardized operation processes
Through "one-button leg leveling" and pre-programmed spraying paths, the equipment positioning time is shortened from 30 minutes to 8 minutes, and the mixer truck cooperates with the operation to form a continuous production chain.
IV. Environmental adaptability and maintenance guarantee
1. Dynamic control of dust concentration
The multi-stage cyclone dust removal system makes the dust concentration in the operation area less than 10mg/m³, and cooperates with remote control operation to reduce the impact of the environment on the construction rhythm.
2. Modular quick maintenance design
Key components such as eyeglass plates and cutting rings adopt quick-release structures, and the replacement time is compressed from 2 hours to 30 minutes. The hydraulic system is equipped with online monitoring of oil contamination, and the fault warning accuracy rate exceeds 95%.
V. Comparison of efficiency of typical cases
In a railway tunnel in Northwest China, the average daily spraying volume of the traditional manual spraying team (8 people) is about 60m³, while the average daily spraying volume of the wet spraying trolley (3 people operating) is 320m³, and the rebound rate is reduced from 25% to 8%, and the overall efficiency is increased by more than 5 times.