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Energy Consumption Analysis and Optimized Management of Wet Spraying Trolley Systems
Release time:
2026-07-30
Source:
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Summary:
As a core piece of equipment for support operations in tunneling and underground engineering, wet‑spraying rigs exhibit a complex energy‑consumption profile with substantial overall demand. Scientific analysis and effective management of their energy use are crucial for reducing construction costs and enhancing project economic performance. Energy‑consumption management for wet‑spraying rigs must be approached from multiple perspectives, including system architecture, operating‑condition analysis, and operational strategies.
Analysis of System Energy Consumption Composition
The energy consumption of wet-spraying trolleys primarily stems from several core systems, each with distinct consumption characteristics:
1. Concrete pumping system
This is the equipment’s primary energy‑consuming component, with its power consumption positively correlated to the concrete delivery rate, pumping pressure, and pipeline resistance. When spraying low‑slump concrete or performing long‑distance, high‑lift pumping, the hydraulic system must generate higher pressures to overcome pipeline friction, resulting in a substantial increase in energy consumption. Moreover, the flow resistance of the hydraulic fluid within the system and the mechanical efficiency of the components themselves directly influence the overall energy consumption.
2. Accelerator Addition and Metering System
Although this system has low power consumption at a single point, its precision metering pump and control valve assembly require a continuous power supply to maintain accurate dosing ratios. Its energy consumption is closely tied to the total duration of the injection process and constitutes a fundamental yet indispensable component of overall energy use.
3. Robotic Manipulator Control System
The energy consumption profile of the robotic manipulator exhibits intermittent peak characteristics. During frequent, large‑range, high‑precision positioning and pose adjustments, the power demand of the solenoid valve banks and servo mechanisms driving multiple hydraulic cylinders rises in distinct phases. The operator’s skill and fluidity of motion directly influence the system’s energy‑consumption curve.
4. Chassis Mobility and Assistive Systems
During equipment relocation, the undercarriage locomotion system is the component with extremely high transient energy consumption. The auxiliary systems—including lighting, control computers, and cooling fans—while each individual unit has limited power draw, collectively account for a significant total energy consumption over extended periods.
Energy Consumption Calculation and Assessment Methods
The energy consumption assessment of wet-spraying rigs requires a systems‑based approach, comprehensively accounting for both direct and indirect factors:
1. Theoretical Estimation Based on Equipment Power and Operating Time
The most basic approach involves summing the rated power of each major subsystem—such as the main oil pump motor and the air compressor—and multiplying it by the system’s effective operating time during a typical duty cycle, thereby providing a preliminary estimate of electricity or fuel consumption. Although this method is rather rough, it offers a foundational framework and direction for energy‑consumption management.
2. Monitoring and Analysis of Key Operating Parameters
Modern wet-spraying rigs are typically equipped with data acquisition systems that can monitor the main pump pressure and engine performance in real time. / Key parameters such as motor load factor and pumping displacement. By analyzing historical data for these parameters, it is possible to identify high‑energy‑consumption operating conditions—such as energy performance under specific spray angles or particular concrete mix proportions—providing a basis for optimizing operations.
3. The Introduction of a Comprehensive Efficiency Indicator
Going beyond the mere total energy consumption, introducing “ Comprehensive energy consumption per unit injection volume ” This efficiency metric is more scientifically sound. It quantifies the total energy—whether electrical or fuel consumption—required to produce each cubic meter of shotcrete, enabling cross‑comparison of energy‑efficiency levels across different equipment, shifts, and process parameters. As such, it serves as a core performance indicator for energy‑efficiency management.
Energy Consumption Optimization: Pathways and Practices
Based on the foregoing analysis, reducing energy consumption requires a coordinated approach that integrates both technological and managerial measures:
1. Equipment Selection and Technical Configuration
Prioritize equipment equipped with an intelligent power‑adaptive system, which dynamically adjusts output in response to real‑time load conditions, thereby preventing unnecessary energy waste. At the same time, optimize the layout of the delivery piping to minimize unnecessary bends and pipe length, thus reducing flow resistance.
2. Detailed Construction Organization and Operational Standards
By optimizing the concrete mix design and appropriately enhancing workability while maintaining pumpability, pumping pressure can be reduced. Additionally, strengthening operator training to ensure smooth, consistent operating techniques—thereby minimizing unnecessary movements and abrupt stops and starts of the pumping equipment—can effectively mitigate peak energy consumption.
3. Maintenance and Equipment Condition Preservation
Regularly replace hydraulic oil and filter elements to maintain the cleanliness and efficiency of the hydraulic system; promptly adjust worn components to ensure the precision of mechanical transmission. Keeping equipment in good working condition is a fundamental prerequisite for achieving its designed energy efficiency.
Summary
Energy consumption management for wet-spraying rigs is an ongoing effort that spans the entire lifecycle, from equipment selection to daily operation and routine maintenance. Managers should establish a system that… “ Unit volume energy consumption ” A core‑driven performance evaluation system guides teams to shift their focus from total energy consumption to improving energy efficiency. By integrating technological solutions with management optimization, it is entirely possible to achieve substantial energy savings and reduced resource use while maintaining construction quality and schedule, thereby delivering enhanced economic and environmental benefits for the project.
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