隧道工程用的计算机控制的钻孔车.doc

隧道工程用的计算机控制的钻孔车

Computerised Drilling Rig for Tunnelling

图1
Robot Boomer MKⅡ不需移位，就能在165平方米的截面积上钻孔。采用

液压方式调节高度的工作室可以确保操作人员不受妨碍地观察钻孔过程

H. H. Cohrs

    几十年来，打眼+爆破掘进的施
工程序基本保持不变：在开挖面钻炮
眼，爆破，清除废石，加固岩石，再
钻炮眼。在这一过程中，隧道钻孔车
起着关键的作用。如果没有钻孔车就
无法掘进，后续的施工机械和操作人
员将处于昂贵的非生产性等候状态。
    如果钻孔车长时间发生故障或钻
孔时间过长，则掘进速度明显受到限
制。另一方面，缩短打标记和钻孔时
间能提高掘进速度。由于隧道钻孔车
采用自动化，加上不再需要打标记而
大大节省时间，因此能够对加快掘进
做出显著贡献。
    比起许多地上和地下的施工及掘
进，在掘进面钻孔更适合采用自动化：
钻头在隧道断面和岩石上的各孔点进
行重复的钻孔动作，钻杆导架在钻孔
时也进行重复的动作，这对操作人员
来说也是单调的。钻孔自动化可以减
轻操作人员的工作负担，尤其是令人
疲劳的重复工作，并且使钻孔更精
确、更快。

自动化带来的多方面益处
    由于采用自动控制，使得钻孔准
确，这样，在控制超挖和欠挖方面具
有明显的优点。自动钻孔车能够相当
好地控制断面。每一立方厘米的超挖
或欠挖都会大大增加以后的费用，还
要增加其它设备，以及为填充超挖的
空穴使用大量的混凝土。
    支持自动化的观点是，采用手动
控制钻孔时，每次实际爆破深度仅为
钻孔深度的90-95%。因此，爆破后的
开挖面一般留有约20-30厘米深的孔
眼。采用自动化钻孔系统，由于钻孔
深度均匀，所以能够优化每次爆破深
度。
    采用自动化的一个重要理由是,
人工将钻杆导架从一个孔移至另一个
孔平均需要30-60秒。因为6厘米/秒
高的钻孔速度，使得钻孔时间往往低
于30秒，所以这么长的钻杆导架移位
时间不再为人们所接受。钻杆导架在
两孔之间的移动和定位时间不应超过
实际钻孔时间。这就是钻孔车的主要
任务。
    总之，自动化缩短了设备工时，
提高了设备的利用率。操作人员只需
检查核实钻孔位置和钻孔方式，设备
就可以独立自动地钻孔，一直钻到程
序设定的钻孔深度。钻杆导架的移位
由计算机控制，即自动控制。
    另外，也应当考虑采用自动钻孔
车优化实际的钻孔计划和爆破图形的
可能性。一般来说，预先准确确定爆
破图形不是依据科学计算，而是基于
经验值。
    因此，通常的作业方法是，打一
定数量的附加孔，以确保预定的爆破。
由于计算机控制的钻孔车钻孔精确度
高，所以不需要打附加孔。实际上在
许多情况下，对断面和爆破体积进行
精确观测可以将钻孔孔数降到最低。
    尽管采用了所有的现代电子技术，
计算机控制的自动钻孔车仍应安装防
撞装置，依靠这个装置可以尽可能避
免设备自我毁坏。Atlas Copco 新开
发的Robot Boomer MKⅡ有防撞安全
装置，以确保自动系统不受任何损害。
显示屏显示的三维爆破图形
    用激光对钻杆导架定位，并将钻
杆导架的准确位置输入计算机后，预
先编程的数据，包括激光和隧道坐标
以及隧道断面，以三维爆破图形显示
在钻孔车的显示屏上。在以后的钻孔
过程中，操作人员可以在显示屏上检
查钻孔深度、钻孔速度及钻好的孔。
    定位相应简单：
    操作人员将钻杆导架移到钻孔合
适的作用点上。这时，操作人员能在
显示屏上跟踪钻杆导架的瞬间位置。
当钻杆导架的位置与显示屏上显示的
孔眼吻合时，操作人员便开始钻孔。
开始钻孔时，自动系统可以避免极高
的接触压力，这有利于保护钻头，并
可避免钻孔偏离方向。
    收集的数据提出了有趣的观点。
由于自动钻孔车配备了计算机，如
Boomer353或Atlas Copco MKⅡ，所
以收集的数据或多或少只起些次要作
用。实际钻孔结果的记录和文件指出
每一个错误，由此分析钻孔过程，对
此进行评价，并改正可能出现的错误。
    钻孔车甚至能够提供围岩的信息。
为此需要一个预钻模型，Atlas Copco
提供这种模型。这样，扩大钻孔种类
时，也就是钻勘探孔和喷射孔时，能
够纪录和收集全部钻孔数据。
    Atlas Copo新开发的自动钻孔车
配备了专门为钻孔车设计的爆破图形
和评价炮眼记录的CAD软件，该软件
可在众所周知和用户熟悉的WINDOWS
程序上运行。
    现有的PC机程序含有钻孔图形的
所有重要参数，如孔眼位置、方向和
深度。对其它的参数，如孔眼顺序以
及爆破负荷图形，也予以最优化。将
完全在PC机上绘制的钻孔图形存储在
一张标准的3.5寸盘上，然后存储于
钻孔车的计算机内。

图2
读取存储有钻孔图形的软盘后，

用激光点对钻杆臂进行定位，

将钻杆臂推进到准确位置，然

后开始自动钻孔—钻孔车不必

准确定位在隧道轴线上
硬件包括计算机和钻头
    由于钻孔过程自动化计算复杂，
所以钻孔车上配备的计算机的处理能
力十分重要。高性能的计算机除了大
大地缩短计算时间外，还改善了操作
人员和钻孔车之间的联系。
    尽管在自动化方面取得了许多进
步，但钻孔车的硬件仍是重要的。
例如，Atlas Copco的
Robot Boomer MKⅡ型钻杆导架装备了
一种新的传感器，这种传感器能显著
提高定位精确度。根据制造厂家的意
见，安装在汽缸内的传感器的测量精
度在长度上不超过0.5 毫米。
    一种新式的采用液压方式调节高
度的工作室，可以确保操作人员能够
在最适宜的位置不受妨碍地观察钻孔。
采用取得专利的运动学和特殊的钻杆
导架移动系统，两个外侧钻杆导架支
撑在Y形臂上。现代化的计算机控制
的钻孔车，如Robot Boomer，作用范
围可达16.5米。因此，钻孔车不需移
位，就能迅速地在165平方米的截面
积上钻孔。

图3
采用用户熟悉的Windows 软件，

将PC机上绘制的钻孔图形用一张

3.5寸盘存储在钻孔车的计算机

内，并为自动钻孔提供数据
自动化可选择使用
    由于种种原因，操作人员可随时
停止钻孔车的自动运行.Atlas Copco
公司最近开发的第二代Robot Boomer
系列产品，允许操作人员在需要时调
整操作顺序，必要时还可采用手动控
制。
    在钻杆导架移位和钻孔期间，从
自动化作业过渡到完全手动操作，可
以任意配合使用。例如，钻杆导架移
位采用自动化，钻孔采用手动，也可
以反过来。但也可以采用手动方式借
助计算机进行钻孔和定位。另外，也
可随时在各操作方式中进行选择。这
就驳斥了太多的自动化设备常会引起
操作故障的论点。当钻孔车以自动化
方式运行，由操作人员对钻孔车进行
监控时，防撞自动系统能杜绝钻杆导
架的损坏。当钻杆导架移位时，关闭
防撞功能能够节省时间。
    在可预见的未来一段时间内，钻
孔车的自动化还不能使操作人员成为
多余。尽管钻杆导架自动运行，但仍
需要操作人员在操作室内观察钻杆导
架运行。操作人员必须有足够能力随
时按下正确的按钮。
    必须考虑操作人员的工作动力。
钻孔车上的计算机能够引起操作人员
的兴趣，事实上，可以明显提高操作
人员的兴趣。首先，操作人员的日常
工作变得更加清楚。操作人员能够以
类似于玩游戏机的方式，直接在计算
机上跟踪钻孔运行过程，并知道自己
的作用超过自动化的作用。
    如果操作人员负责绘制钻孔图形，
这也有助于提高工作动力。在进行培
训和与操作人员进行讨论时，总是强
调计算机是有用的工具，不过，从某
种意义上说，计算机类似于尺子和圆
规，只不过是电脑。人是必不可少的。

图4
钻孔操作的纪录对分析和优化

爆破图形提供了有趣的依据，有些

可使用钻孔车的计算机进行。这是

一张记录钻孔过程的图形（照片和

绘图由Atlas Copco公司提供）

H. H. Cohrs特许工程师
建筑机械专业记者，德国Grube
BACK 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, tunnel
drilling 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 contribution
towards speeding up the drive.
Drilling the face is extremely suited for
automation 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 and
faster drilling.
Automation provides many Advantages
Precise 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 causes
considerable 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 to
6 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 task
of 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 independently
and 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 assure
completion 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, all
computer-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 rig's screen as a
3-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: the
operator moves the boom to the appropriate
application 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 contact
pressure 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 shows
every 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 Copco's new automated
drilling 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 Windows
programme.
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 drilling
pattern, 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 for
automating 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 rig's hardware is
still important. The drilling booms of
Atlas Copco's 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 case
of 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 Automation
For 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 intervene
whenever 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 drilling
manually 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 the
operator in automatic mode and the antic-
ollision automatic system precludes dam-
age to the drilling booms, time can cert-
ainly be saved when the booms are reloc-
ated with anti-collision function switched
off.
In the foreseeable future, automation in
the drilling rig will not be able to make
the operator unnecessary. In fact, it will
be essential to have someone in the cabin
to watch over the operations in spite of
the fact that the drilling booms work on
their own. This person has to be competent
enough to be in a position to press the
correct button at any time.
Aspects of job motivation have to be taken
into consideration here. The operator's
interest can be held by the board computer
on the drilling rig, in fact, it can be
considerably increased. First of all, his
everyday work becomes more transparent for
him. In similar fashion to a video game,
the operator can follow the course of the
drilling operations directly on the comp-
uter and is aware that his actions have
greater priority than the automation.
Furthermore, if the operator is also made
responsible for working out the drilling
pattern, this can also help to enhance
motivation. It must always be stressed,
particularly during training and discu-
ssing matters with the operator that the
function of the computer is that of a
helpful tool, in a certain way comparable
with rule and compass, not, however, that
of an automatic brain, which appears to
make man superfluous.