隧道工程用的計算機控制的鉆孔車.doc

隧道工程用的計算機控制的鉆孔車Computerised Drilling Rig for Tunnelling 圖1Robot Boomer MK不需移位，就能在165平方米的截面積上鉆孔。采用液壓方式調(diào)節(jié)高度的工作室可以確保操作人員不受妨礙地觀察鉆孔過程H. H. Cohrs幾十年來，打眼+爆破掘進的施工程序基本保持不變：在開挖面鉆炮眼，爆破，清除廢石，加固巖石，再鉆炮眼。在這一過程中，隧道鉆孔車起著關(guān)鍵的作用。如果沒有鉆孔車就無法掘進，后續(xù)的施工機械和操作人員將處于昂貴的非生產(chǎn)性等候狀態(tài)。如果鉆孔車長時間發(fā)生故障或鉆孔時間過長，則掘進速度明顯受到限制。另一方面，縮短打標記和鉆孔時間能提高掘進速度。由于隧道鉆孔車采用自動化，加上不再需要打標記而大大節(jié)省時間，因此能夠?qū)涌炀蜻M做出顯著貢獻。比起許多地上和地下的施工及掘進，在掘進面鉆孔更適合采用自動化：鉆頭在隧道斷面和巖石上的各孔點進行重復(fù)的鉆孔動作，鉆桿導(dǎo)架在鉆孔時也進行重復(fù)的動作，這對操作人員來說也是單調(diào)的。鉆孔自動化可以減輕操作人員的工作負擔，尤其是令人疲勞的重復(fù)工作，并且使鉆孔更精確、更快。 自動化帶來的多方面益處由于采用自動控制，使得鉆孔準確，這樣，在控制超挖和欠挖方面具有明顯的優(yōu)點。自動鉆孔車能夠相當好地控制斷面。每一立方厘米的超挖或欠挖都會大大增加以后的費用，還要增加其它設(shè)備，以及為填充超挖的空穴使用大量的混凝土。支持自動化的觀點是，采用手動控制鉆孔時，每次實際爆破深度僅為鉆孔深度的90-95%。因此，爆破后的開挖面一般留有約20-30厘米深的孔眼。采用自動化鉆孔系統(tǒng)，由于鉆孔深度均勻，所以能夠優(yōu)化每次爆破深度。采用自動化的一個重要理由是,人工將鉆桿導(dǎo)架從一個孔移至另一個孔平均需要30-60秒。因為6厘米/秒高的鉆孔速度，使得鉆孔時間往往低于30秒，所以這么長的鉆桿導(dǎo)架移位時間不再為人們所接受。鉆桿導(dǎo)架在兩孔之間的移動和定位時間不應(yīng)超過實際鉆孔時間。這就是鉆孔車的主要任務(wù)?？傊?，自動化縮短了設(shè)備工時，提高了設(shè)備的利用率。操作人員只需檢查核實鉆孔位置和鉆孔方式，設(shè)備就可以獨立自動地鉆孔，一直鉆到程序設(shè)定的鉆孔深度。鉆桿導(dǎo)架的移位由計算機控制，即自動控制。另外，也應(yīng)當考慮采用自動鉆孔車優(yōu)化實際的鉆孔計劃和爆破圖形的可能性。一般來說，預(yù)先準確確定爆破圖形不是依據(jù)科學(xué)計算，而是基于經(jīng)驗值。因此，通常的作業(yè)方法是，打一定數(shù)量的附加孔，以確保預(yù)定的爆破。由于計算機控制的鉆孔車鉆孔精確度高，所以不需要打附加孔。實際上在許多情況下，對斷面和爆破體積進行精確觀測可以將鉆孔孔數(shù)降到最低。盡管采用了所有的現(xiàn)代電子技術(shù)，計算機控制的自動鉆孔車仍應(yīng)安裝防撞裝置，依靠這個裝置可以盡可能避免設(shè)備自我毀壞。Atlas Copco 新開發(fā)的Robot Boomer MK有防撞安全裝置，以確保自動系統(tǒng)不受任何損害。 顯示屏顯示的三維爆破圖形用激光對鉆桿導(dǎo)架定位，并將鉆桿導(dǎo)架的準確位置輸入計算機后，預(yù)先編程的數(shù)據(jù)，包括激光和隧道坐標以及隧道斷面，以三維爆破圖形顯示在鉆孔車的顯示屏上。在以后的鉆孔過程中，操作人員可以在顯示屏上檢查鉆孔深度、鉆孔速度及鉆好的孔。定位相應(yīng)簡單：操作人員將鉆桿導(dǎo)架移到鉆孔合適的作用點上。這時，操作人員能在顯示屏上跟蹤鉆桿導(dǎo)架的瞬間位置。當鉆桿導(dǎo)架的位置與顯示屏上顯示的孔眼吻合時，操作人員便開始鉆孔。開始鉆孔時，自動系統(tǒng)可以避免極高的接觸壓力，這有利于保護鉆頭，并可避免鉆孔偏離方向。收集的數(shù)據(jù)提出了有趣的觀點。由于自動鉆孔車配備了計算機，如Boomer353或Atlas Copco MK，所以收集的數(shù)據(jù)或多或少只起些次要作用。實際鉆孔結(jié)果的記錄和文件指出每一個錯誤，由此分析鉆孔過程，對此進行評價，并改正可能出現(xiàn)的錯誤。鉆孔車甚至能夠提供圍巖的信息。為此需要一個預(yù)鉆模型，Atlas Copco提供這種模型。這樣，擴大鉆孔種類時，也就是鉆勘探孔和噴射孔時，能夠紀錄和收集全部鉆孔數(shù)據(jù)。Atlas Copo新開發(fā)的自動鉆孔車配備了專門為鉆孔車設(shè)計的爆破圖形和評價炮眼記錄的CAD軟件，該軟件可在眾所周知和用戶熟悉的WINDOWS程序上運行?，F(xiàn)有的PC機程序含有鉆孔圖形的所有重要參數(shù)，如孔眼位置、方向和深度。對其它的參數(shù)，如孔眼順序以及爆破負荷圖形，也予以最優(yōu)化。將完全在PC機上繪制的鉆孔圖形存儲在一張標準的3.5寸盤上，然后存儲于鉆孔車的計算機內(nèi)。 圖2讀取存儲有鉆孔圖形的軟盤后，用激光點對鉆桿臂進行定位，將鉆桿臂推進到準確位置，然后開始自動鉆孔鉆孔車不必準確定位在隧道軸線上硬件包括計算機和鉆頭由于鉆孔過程自動化計算復(fù)雜，所以鉆孔車上配備的計算機的處理能力十分重要。高性能的計算機除了大大地縮短計算時間外，還改善了操作人員和鉆孔車之間的聯(lián)系。盡管在自動化方面取得了許多進步，但鉆孔車的硬件仍是重要的。例如，Atlas Copco的Robot Boomer MK型鉆桿導(dǎo)架裝備了一種新的傳感器，這種傳感器能顯著提高定位精確度。根據(jù)制造廠家的意見，安裝在汽缸內(nèi)的傳感器的測量精度在長度上不超過0.5 毫米。一種新式的采用液壓方式調(diào)節(jié)高度的工作室，可以確保操作人員能夠在最適宜的位置不受妨礙地觀察鉆孔。采用取得專利的運動學(xué)和特殊的鉆桿導(dǎo)架移動系統(tǒng)，兩個外側(cè)鉆桿導(dǎo)架支撐在Y形臂上?，F(xiàn)代化的計算機控制的鉆孔車，如Robot Boomer，作用范圍可達16.5米。因此，鉆孔車不需移位，就能迅速地在165平方米的截面積上鉆孔。 圖3采用用戶熟悉的Windows 軟件，將PC機上繪制的鉆孔圖形用一張3.5寸盤存儲在鉆孔車的計算機內(nèi)，并為自動鉆孔提供數(shù)據(jù)自動化可選擇使用由于種種原因，操作人員可隨時停止鉆孔車的自動運行.Atlas Copco公司最近開發(fā)的第二代Robot Boomer 系列產(chǎn)品，允許操作人員在需要時調(diào)整操作順序，必要時還可采用手動控制。在鉆桿導(dǎo)架移位和鉆孔期間，從自動化作業(yè)過渡到完全手動操作，可以任意配合使用。例如，鉆桿導(dǎo)架移位采用自動化，鉆孔采用手動，也可以反過來。但也可以采用手動方式借助計算機進行鉆孔和定位。另外，也可隨時在各操作方式中進行選擇。這就駁斥了太多的自動化設(shè)備常會引起操作故障的論點。當鉆孔車以自動化方式運行，由操作人員對鉆孔車進行監(jiān)控時，防撞自動系統(tǒng)能杜絕鉆桿導(dǎo)架的損壞。當鉆桿導(dǎo)架移位時，關(guān)閉防撞功能能夠節(jié)省時間。在可預(yù)見的未來一段時間內(nèi)，鉆孔車的自動化還不能使操作人員成為多余。盡管鉆桿導(dǎo)架自動運行，但仍需要操作人員在操作室內(nèi)觀察鉆桿導(dǎo)架運行。操作人員必須有足夠能力隨時按下正確的按鈕。必須考慮操作人員的工作動力。鉆孔車上的計算機能夠引起操作人員的興趣，事實上，可以明顯提高操作人員的興趣。首先，操作人員的日常工作變得更加清楚。操作人員能夠以類似于玩游戲機的方式，直接在計算機上跟蹤鉆孔運行過程，并知道自己的作用超過自動化的作用。如果操作人員負責(zé)繪制鉆孔圖形，這也有助于提高工作動力。在進行培訓(xùn)和與操作人員進行討論時，總是強調(diào)計算機是有用的工具，不過，從某種意義上說，計算機類似于尺子和圓規(guī)，只不過是電腦。人是必不可少的。圖4鉆孔操作的紀錄對分析和優(yōu)化爆破圖形提供了有趣的依據(jù)，有些可使用鉆孔車的計算機進行。這是一張記錄鉆孔過程的圖形（照片和繪圖由Atlas Copco公司提供） H. H. Cohrs特許工程師建筑機械專業(yè)記者，德國GrubeBACK HOME For decades now, the working cycle for drill+blast operations has basically rem-ained unchanged: the boring of blast-holes at the face, blasting the round and cle-aring away the muck, securing the rock and fresh boring. In this connection, tunneldrilling rigs play a key role - without them, the drive would not progress a single metre and follow-up machines toge-ther with their operators would find them-selves in expensive, unproductive holding positions.Should a drilling rig be out-of-action over a lengthy period or if drilling times are excessively long, the rate of advance is restricted to a considerable degree. On the other hand, brief marking and bor-ing times can lead to the drive being spe-eded up. The automation of tunnel drilling rigs - including considerable savings in time, as marking is no longer necessary - can afford a considerable contributiontowards speeding up the drive.Drilling the face is extremely suited forautomation more than many other constru-ction and excavation activities either on or beneath the surface: ever recurring application points for the drills corre-sponding to the tunnel profile and the rock; this applies as well to the const-antly recurring drilling for the applied booms, something which is monotonous for the operator as well. In this connection, automation can relieve the operator, espe-cially from fatiguing repetitive work and in addition, cater for more precise andfaster drilling. Automation provides many AdvantagesPrecise drilling thanks to automatic stee-ring can furthermore result in consider-able advantages regarding over and under-break. Automatic drilling rigs facilitate considerably better profile controls. Every cm3 of over or under-break causesconsiderable follow-up costs and the app-lication of additional machines as well as substantial volumes of concrete in order to fill the cavities.A further point in favour of automation is the experience that in the case of manually controlled drilling, the actual advance per round arrived at is only 90 to 95% of the drilled length. As a result, there is usually a residual borehole length of some 20 to 30 cm left in the face.Thanks to the automatic drilling system, the advance per round can be optimised owing to the homogeneous drilling depths.An important argument for automation is the fact that today it takes on average 30 to 60 s to relocate the drilling boom from hole to hole by hand. Such lengthy relocation times are no longer acceptable given the high drilling speeds of up to6 cm/s and the resultant short drilling times, which are frequently less than 30 s - the moving and positioning of the dri-lling boom from hole to hole should not take more time than the actual drilling itself, which after all, is the main taskof a drilling rig.Furthermore, automation improves working times and utilisation factors of machines.For once the boom operator has checked the borehole position and the drilling pattern, the machine drills independentlyand fully automatically until the progr-ammed borehole depth is reached. Subseq-uently, the relocating of the boom is carried out via computer, in other words, automatically.In addition, the possibility of optimising the actual drilling plan and the blasting pattern by means of an automated drilling rig should also be considered. A blasting pattern is generally no exactly predete-rmined scientific work but, first and foremost, is based on experimental values.Thus it is customary in practice to assurecompletion of the desired round by crea-ting a certain number of additional holes. Thanks to the high drilling accuracy of a computer-controlled drilling rig, this is no longer required. In many cases, in fact, the number of boreholes can be mini-mised through exact observation of the profileand round volumes.In spite of all modern electronics, allcomputer-controlled drilling rigs should have an anti-collision device at their disposal, through which self-destruction is excluded as far as possible. The new Robot Boomer MK II from Atlas Copco poss-esses a safety device of this nature,which makes sure that the automatic system cannot cause any harm. 3-D Blasting Pattern on the Display After positioning the drilling boom per laser and feeding in the exact location into the computer,the pre-programmed data-including laser and tunnel co-ordinates as well as the tunnel profile - are pre-sented on the drilling rigs screen as a3-dimensional blasting pattern. Later during drilling, the operator can also check on the screen, the drilled hole length, the drilling speed as well as the holes that have already been bored.Positioning is correspondingly simple: theoperator moves the boom to the appropriateapplication point for the borehole. He is able to follow the momentary position on the screen. When the boom position corre-sponds with the borehole display on the screen, the operator starts the drilling phase. When starting to drill, au automatic system prevents excessively high contactpressure from being applied, something which is kind to the drill steel and pre-vents any deviation from the correct bor-ehole direction. Interesting perspectives are provided by data collection, which is possible more or less as a side effect in automated drilling rigs such as the Boomer, 353 or MK II from Atlas Copco thanks to the board computer. The registering and documenta-tion of the actual drilling result showsevery error and thus provides the chance to analyse the drilling process, evaluate it and correct possible mistakes.The drilling rig is even capable of docu-Menting data relating to the surrounding rock. A so-called pre-bore module, which is available from Atlas Copco, is requi-red for this purpose. In this way, all drilling data can be recorded and colle-cted during extension bores, in other words, for investigation and injection bores.In the case of Atlas Copcos new automateddrilling rig, the CAD software for prep-aring the blast patterns and also for eva-luating the round reports has been exte-nded by a version specially devised for the drilling rig, which operates through the well-known and user-friendly Windowsprogramme.The actual PC programme contains all sign-Ificant parameters for the drilling patt-ern such as e.g. borehole position, dire-ction and depth. Further parameters such as borehole sequence and explosive loading pattern are also optimised. The drillingpattern, which is completely compiled on the PC, is stored on a standard 3.5 disc and subsequently memorised in the board computer of the drilling rig. Hardware includes Computer and Steel On account of the complex calculations forautomating the drilling process, the perf-ormance of the board computer installed on the drilling rig is certainly of impor-tance. A powerful computer improves the communication possibilities between the drilling rig and its operator, quite apart-from considerably cutting down on compu-ting times.In spite of all the progress made in auto-mation, the drilling rigs hardware is still important. The drilling booms of Atlas Copcos Robot Boomer MK II for inst-ance were provided with a new sensor techn-ique, which has considerably improved positioning. According to the manufacturer, the sensors now installed in the cylinders operate with a measuring accuracy of less than 0.5 mm lengthways. A hydraulically height-adjustable cabin, which ensures that the operator always has an unimpeded, optimal view of the borehole, is also new. Thanks to patented kinematics and a special drilling boom shifting system, in the caseof which the 2 outer drilling booms are supported on Y-shaped arms, modern, computer-controlled drilling rigs such as the Robot Boomer have a reach of 15.6 m. As a conse-quence, cross-sections of up to 165 m2 can rapidly be drilled from one position with-out the need to relocate the basic rig. Optional AutomationFor various reasons, it appears advisable that the automation of the drilling rig can be switched of by the operator at any time. In the case of the 2nd generation of the Robot Boomer series, recently pres-ented by Atlas Copco, the board computer also permits the operator to intervenewhenever needed in the operating sequence and to steer manually as far as is required.In this connection, during the relocating of the booms and during drilling, all comb-inations from automatic by way of arbitr-arily mixed as right up to pure manual operation are possible, in other words, e.g. relocating automatically and drillingmanually or vice versa, but it is also possible to drill and position by computer-supported means in the manual mode. In addition, it is also possible to choose between the individual operating modes at any time. This makes the argument baseless that too much automatic equipment too often causes operating breakdowns.When the drilling rig is supervised by theoperator in automatic mode and the antic-ollision automatic system precludes dam-age to the drilling booms, ti