A dual-machine collaborative disassembly method for a segmented cutterhead under TBM conditions without an expanded cavern

Abstract

The present invention discloses a dual-machine collaborative disassembly method for a block-type cutterhead under the condition of a TBM without an expanded cavern, wherein the side blocks on the cutterheads of TBM-a and TBM-b are rotated to the bottom to be defined as the bottom cutterhead side blocks, and the bottom cutterhead side blocks of TBM-a and TBM-b are welded to each other through support beams; the bottom cutterhead side blocks of the two TBMs form an integral connection structure bridged by support beams; TBM-a retreats, the bottom cutterhead side block of TBM-a is disassembled, the next side block of TBM-a to be disassembled is rotated to the bottom, the next side block of TBM-a to be disassembled is welded and connected with the bottom cutterhead side block of the last disassembled TBM-a through support beams, TBM-b retreats, and the bottom cutterhead side block of TBM-b is disassembled; the cutterhead side blocks of TBM-a and TBM-b are disassembled one by one by relying on the integral connection structure bridged by support beams. This method abandons the traditional construction process of expanding the cavern, utilizes the action and reaction forces of two TBMs relying on each other for disassembly support, and makes full use of the tunnel construction space for collaborative disassembly.

Description

Technical Field

[0001] The invention relates to the field of tunnel construction, to a full-section method, and in particular to a double-machine collaborative disassembly method for a cutterhead of a block-type TBM (full-section tunnel boring machine) under the condition of no expanded cavern. Background Art

[0002] With the acceleration of infrastructure construction, full-section tunnel boring machines (TBMs) play a vital role in the construction of tunnel projects in industries such as water conservancy, highways, railways, and urban rail transit. The scale of tunnel projects continues to expand, and long and large tunnel projects use clustered construction of multiple TBMs.

[0003] In tunnel construction technology, after the tunnel is penetrated, the disassembly of the TBM is usually carried out in the tunnel; among them, the segmented cutterhead of the TBM often needs to be organized as a separate construction process due to its weight and size, which becomes an important process in the clustered construction of TBM. The disassembly of the segmented cutterhead of the TBM usually needs to be completed in the expanded cavern with the cooperation of large-scale lifting equipment with corresponding lifting capacity. The construction period of the expanded cavern of the TBM is long and the cost is high. The key components of the TBM are heavy (especially the segmented cutterhead), and there are certain safety hazards in the disassembly and lifting; especially when facing the disassembly of two TBMs in the same tunnel, the two TBMs are often independent of each other, the overall disassembly progress is slow, and the coordination performance is poor.

[0004] In recent years, with the development of long and large tunnels, the use of two TBMs to excavate the same tunnel in opposite directions has become more and more common. After the TBM completes the tunnel excavation, it is dismantled at the tunnel penetration point. In the tunnel, the TBM cutterhead is close to the tunnel wall. It is large in size and heavy in weight. It is necessary to expand the tunnel to construct a disassembly chamber. After there is sufficient space and hoisting conditions, the cutterhead can be hoisted and disassembled in the disassembly chamber. Due to the differences in geological conditions in different tunnel sections and the construction levels of different units, the tunnel penetration point often deviates from expectations, and the disassembly chamber cannot be constructed in advance. The civil construction period for expanding and disassembling the chamber is long, and the cost of hoisting equipment is high, which has a great impact on the overall construction period and cost of the project. Summary of the invention

[0005] Based on the above analysis, the present invention proposes a dual-machine collaborative disassembly construction method for segmented cutter discs under the condition of TBM without an expanded cavern, through which unnecessary cavern expansion and hoisting can be reduced; the present method uses the main structures of two TBMs to apply support reaction force, and the two TBMs cooperate with each other to carry out step-by-step disassembly, gradually completing the disassembly of the segmented cutter disc, and at the same time, there is no need to expand the disassembly cavern, which can fully ensure construction safety, reduce costs and construction period, and improve the disassembly efficiency of the segmented cutter disc.

[0006] In view of the mass and size of the TBM segmented cutterhead, the disassembly of the traditional TBM segmented cutterhead requires the expansion of the disassembly chamber and the use of lifting equipment for disassembly, and the entire process is cumbersome; the present invention proposes to achieve the disassembly of the cutterhead side blocks without the need to expand the disassembly chamber and without or with less lifting through the collaborative operation of the two segmented cutterheads of the TBM.

[0007] The construction technology principle of the present invention is as follows: two identical TBMs, namely TBM-a and TBM-b, are arranged symmetrically (the cutter heads of TBM-a and TBM-b are arranged relatively), the edge blocks on the cutter heads of TBM-a and TBM-b are rotated to the bottom to be defined as the bottom cutter head edge blocks (i.e., the edge blocks to be removed), the bottom cutter head edge blocks of TBM-a and the bottom cutter head edge blocks of TBM-b at the symmetrical position are welded to each other through the support beam; the bottom cutter head edge blocks of TBM-a and the bottom cutter head edge blocks of TBM-b form a support beam. The overall connection structure is bridged by beams; TBM-a retreats, the bottom cutter head side block of TBM-a is disassembled, the next side block of TBM-a to be disassembled is rotated to the bottom (that is, the side block to be disassembled), the next side block of TBM-a to be disassembled is welded and connected to the bottom cutter head side block of the last disassembled TBM-a through support beams, TBM-b retreats, and the bottom cutter head side block of TBM-b is disassembled; the cutter head side blocks of TBM-a and TBM-b are disassembled one by one by relying on the overall connection structure bridged by support beams.

[0008] The method of the present invention abandons the traditional construction process of expanding the cavern, and utilizes the overall connection structure of the support beam bridge, as well as the mutual action and reaction force of the two TBMs for disassembly support, with the help of the support beam for auxiliary transportation, making full use of the tunnel construction space for coordinated disassembly, eliminating the need for expanding the tunnel.

[0009] Specifically, the technical solution adopted by the present invention is a dual-machine collaborative disassembly method for a segmented cutterhead under the condition of a TBM without an expanded cavern, and the dual-machine collaborative disassembly method comprises the following steps:

[0010] S1. After the tunnel is constructed by a full-section tunnel boring machine, the full-section tunnel boring machine is a TBM, and the cutterhead of the TBM is a block structure, and two TBMs are separated by a distance; the weld seams of the cutterheads of the two TBMs are removed, and the cutterheads of the two TBMs are divided into multiple edge blocks.

[0011] S2. After the weld removal in step S1 is completed, the space occupied and the distance between the two TBMs are the collaborative disassembly space; the two TBMs are named TBM-a and TBM-b respectively.

[0012] S3. In the collaborative disassembly space, the cutterhead positions of the two TBMs are adjusted, and one side block on the cutterheads of the two TBMs is simultaneously rotated to the bottom horizontal position to form a bottom cutterhead side block (i.e., the side block to be dismantled).

[0013] S4. Use support beams to weld and connect the bottom cutter head side blocks of the two TBMs to form an integral connection structure bridged by support beams. First, remove the connecting bolts of the bottom cutter head side blocks on TBM-a.

[0014] S5. Start TBM-a to retreat. In the initial state, the bottom cutter head edge block of TBM-a is still connected to TBM-a. Steel supports are installed at the bottom of the bottom cutter head edge block of TBM-a to fix it horizontally (to prevent overturning and deviation). Continue to retreat TBM-a and complete the removal of the first bottom cutter head edge block of TBM-a. At this time, TBM-b is the reaction support structure of TBM-a.

[0015] S6. The cutter disc of TBM-a rotates, and the second side block to be removed is rotated to the bottom horizontal position, that is, the second bottom cutter disc side block to be removed by TBM-a. The second bottom cutter disc side block to be removed by TBM-a is connected and fixed with the first bottom cutter disc side block of TBM-a that has been removed by welding with a support beam.

[0016] S7. Remove the connecting bolts on the cutter head side block at the bottom of TBM-b, start TBM-b to retreat, and the cutter head side block at the bottom of TBM-b is still connected to TBM-b in the initial state. Steel supports are installed at the bottom of the cutter head side block of TBM-b to fix it horizontally (to prevent overturning and deviation), and the removal of the first cutter head side block at the bottom of TBM-b is completed. At this time, TBM-a is the reaction support structure of TBM-b.

[0017] S8, repeating steps S3-S7, alternately removing the upper edge blocks of the cutter heads of the two TBMs; thus, the removal of the edge blocks of the cutter heads of the two TBMs is completed. The edge blocks of the cutter heads of the two TBMs are connected in series through the support beams.

[0018] Furthermore, the last side block on the TBM cutter head is removed, and the removed welded side blocks are used as a reaction support structure; that is, the last bottom cutter head side block of the TBM cutter head is reacted by the self-weight of the removed bottom cutter head side blocks, support beams and steel supports.

[0019] Furthermore, if the TBM segmented cutterhead in S1 includes a center block in addition to a plurality of side blocks, after the disassembly of the two TBM cutterhead side blocks in S8 is completed; a sky anchor lifting point is constructed at the top of the tunnel above the two TBM cutterheads, a lifting device is installed to pre-lift the center block, the connecting bolts of the center block are removed, the center block is lifted away from the TBM by the lifting device and placed at the bottom of the tunnel, and the disassembly of the center block is completed; the lifting device is a lifting hoist.

[0020] Furthermore, the support beam is an I-beam, an H-beam or an angle steel, etc. In order to maintain the force balance of the bottom cutter head edge block during the TBM retreat process, at least two support beams should be set in parallel.

[0021] Furthermore, the bottom cutter head side blocks to be removed need to be rotated to the bottom of the TBM cutter head and placed horizontally.

[0022] Furthermore, in steps S5 and S7, during the removal of the side blocks of the two TBM cutter heads, the retreat distance is the same, which is the thickness of the TBM cutter head plus 0.5 m, so as to reserve space for subsequent operations.

[0023] The positive technical effects of the present invention are as follows:

[0024] The present invention proposes a dual-machine collaborative disassembly method for the cutterhead under the condition of no expanded TBM cavern, which is suitable for the disassembly of the cutterheads of two TBMs working in opposite directions in the same tunnel after the tunnel is penetrated, and changes the traditional disassembly method which mainly relies on hoisting to dismantle the cutterheads. The disassembly of the two cutterheads is completed by the cooperation of the dual machines, and there is no need to construct an expanded disassembly cavern, and the disassembly can be completed without or with little hoisting, which ensures the safety of the cutterhead disassembly construction, saves construction cost and construction period, and greatly improves the disassembly efficiency of the cutterhead. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the positions of the two TBMs before disassembly.

[0026] Figure 2 Schematic diagram of a five-piece TBM cutterhead.

[0027] Figure 3 Schematic diagram of the initial state of disassembly of the bottom edge block of the first cutter head of TBM-a.

[0028] Figure 4 This is a schematic diagram of the state where the bottom edge block of the first cutter head of TBM-a has been disassembled.

[0029] Figure 5 Schematic diagram of the initial state of disassembly of the bottom edge block of the first cutter head of TBM-b.

[0030] Figure 6 This is a schematic diagram of the state where the bottom edge block of the first cutter head of TBM-b has been disassembled.

[0031] Figure 7 Schematic diagram of the disassembly of two TBM cutter head side blocks.

[0032] In the figure: 1. TBM-a, 2. TBM-b, 3. Support beam, 4. Steel support, 11. The first bottom cutter head side block of TBM-a, 21. The first bottom cutter head side block of TBM-b. DETAILED DESCRIPTION

[0033] The present invention is described in detail below with reference to the accompanying drawings and embodiments.

[0034] like Figure 1As shown, the present invention proposes a dual-machine collaborative disassembly method for a segmented cutterhead under the condition of no expanded cavern of a TBM. This method can realize the disassembly of the segmented TBM cutterhead without hoisting, or the disassembly of the segmented TBM cutterhead with less hoisting (only the center block of the cutterhead needs to be hoisted); ensure the safety of the segmented TBM cutterhead disassembly process, reduce the disassembly cost, and shorten the disassembly period. The two TBMs retreat a distance of 2m apart, so as to facilitate the planing of the cutterhead weld and the welding of the support beam in front of the cutterhead, and provide working space for them.

[0035] To facilitate the transportation and assembly of TBM cutter heads, cutter heads are generally divided into integral and block types according to the size of the cross-section. The block type is generally divided into two or five pieces. This method is not applicable to integral cutter heads, but only to block cutter heads of large-section TBMs.

[0036] Example 1

[0037] like Figure 2 As shown in the figure, the cutter head of the TBM is divided into five structures, namely four sub-blocks and one central block V. Figure 2 , side blocks I, IV, II, and III are arranged counterclockwise around the center block V from the bottom.

[0038] S1. After the tunnel is penetrated, the two TBMs retreat a certain distance (2 to 3 m) respectively, and the welds of the two TBM cutter heads are planed off, so that the TBM cutter heads are divided into multiple blocks as when assembled (one central block V; four side blocks are: side block I, side block II, side block III, side block IV, side block III and side block IV are placed horizontally, and side block I and side block II are placed vertically).

[0039] S2. After completing the weld removal in step S1, the space occupied and the distance between the two TBMs are the collaborative disassembly space; the two TBMs are named TBM-a1 and TBM-b2 respectively.

[0040] S3. In the collaborative disassembly space, adjust the cutterhead positions of the two TBMs, and rotate one edge block on the cutterheads of the two TBMs to the bottom horizontal position at the same time to form the bottom cutterhead edge block. The two TBMs step forward to a distance of about 2m to facilitate construction in front of the cutterhead. Adjust the cutterheads of the two TBMs so that the edge blocks I of the cutterheads of the two TBMs rotate to the bottom.

[0041] S4. Use the support beam 3 to weld the bottom cutter head edge blocks of the two TBMs (i.e., the edge blocks I of the two TBM cutter heads) to form an overall connection structure bridged by the support beam. First, remove the connecting bolts of the bottom cutter head edge block on TBM-a. Figure 3 shown.

[0042] S5, start TBM-a1 to retreat. In the initial state, the bottom cutter head edge block of TBM-a1 is still connected to TBM-a1. A steel support 4 is applied to the bottom of the bottom cutter head edge block of TBM-a1 to fix it horizontally (to prevent overturning and deviation). Continue to retreat TBM-a1 and complete the removal of the first bottom cutter head edge block 11 of TBM-a. At this time, TBM-b2 is the reaction force support structure of TBM-a1. TBM-a1 retreats a distance equal to the cutter head thickness + about 0.5m. Figure 4 shown.

[0043] S6, the cutter head of TBM-a1 rotates, and the second side block II to be removed is rotated to the bottom horizontal position, that is, the second bottom cutter head side block of TBM-a1 to be removed, and the second bottom cutter head side block of TBM-a1 to be removed (i.e., side block II) is welded and fixed to the first bottom cutter head side block 11 of TBM-a1 that has been removed by the support beam 3, as shown in FIG. Figure 5 shown.

[0044] S7, remove the connecting bolts on the cutter head edge block at the bottom of TBM-b2, start TBM-b2 to retreat, the cutter head edge block at the bottom of TBM-b2 in the initial state is still connected to TBM-b2, and a steel support 4 is applied to the lower part of the cutter head edge block at the bottom of TBM-b2 for horizontal fixation (to prevent overturning and deviation), and the first cutter head edge block 21 at the bottom of TBM-b2 is removed; at this time, TBM-a1 is the reaction force support structure of TBM-b2; the retreat distance of TBM-b2 is the cutter head thickness + about 0.5m, such as Figure 6 shown.

[0045] S8, repeat steps S3-S7, and dismantle the upper edge blocks of the cutter heads of the two TBMs alternately; the removal of the edge blocks of the cutter heads of the two TBMs is now completed, and the edge blocks are connected in series through the support beam 3, such as Figure 7 shown.

[0046] S9. After all the side blocks of the two cutter heads are dismantled, the TBM is withdrawn for a distance (cutter head thickness + about 0.5m), and sky anchor points are constructed at the top of the tunnel above the two TBM cutter heads to dismantle the center blocks of the two TBM cutter heads (i.e., center block V).

[0047] S10, disassembly of two TBM cutter heads completed;

[0048] Furthermore, the disassembly order of the two TBM cutter heads being divided into five blocks is: side block I, side block II, side block III, side block IV, and center block V.

[0049] Furthermore, the support beam 3 can be made of materials such as I-beams, H-beams, angle steels, etc. In order to maintain the force balance of the cutter head edge blocks during the TBM retreat process, there are at least two support beams.

[0050] Furthermore, the cutter head side blocks to be removed need to be rotated to the bottom and placed horizontally.

[0051] Furthermore, after removing the edge block I, the corresponding TBM cutter head rotates 180°, removes the edge block II, rotates the cutter head 90°, removes the edge block III, rotates the cutter head 180°, and then removes the edge block IV.

[0052] Furthermore, if the TBM cutterhead is composed of two pieces (divided into an upper piece and a lower piece, without a center piece), there is no need to construct the sky anchor suspension point described in S9.

[0053] Example 2

[0054] In the existing TBM block structure of tunnels, the block cutterhead is divided into two or five pieces.

[0055] Taking a water diversion project as an example, two open-type TBMs with an excavation section of 8.02m were used for opposite excavation construction. The structural form and equipment parameters of the two TBMs were almost the same. The TBM cutterhead was divided into five parts. The size and weight of the cutterhead of a single TBM are as follows:

[0056] The number of center blocks of the cutter disc is 1; the total weight is 65t; the dimensions (length × height × width) / m: 4.5 × 4.5 × 2.25.

[0057] The number of cutter disc edge blocks is 4; the total weight is 23t; the dimensions (length × height × width) / m: 5.8×2.25×2.15.

[0058] After the tunnel was penetrated, the two TBMs retreated a distance of 2m apart to facilitate the removal of the cutterhead welds and welding of support beams in front of the cutterhead, providing them with working space.

[0059] The specific disassembly steps are as follows:

[0060] ① Remove the welds of the two TBM cutter heads so that the cutter heads are divided into five pieces as during assembly. Adjust the two TBM cutter heads so that the side block I of the two cutter heads rotates to the bottom, the side blocks III and IV are placed horizontally, and the side blocks I and II are placed vertically.

[0061] ② Use support beams to weld the bottom edge blocks (edge ​​block I) of the two TBM cutter heads into a whole to provide conditions for their dismantling.

[0062] ③ Remove the side block I of the TBM-a cutter disc. Remove the connecting bolts of the side block I of the TBM-a cutter disc to prepare for the separation of the side block I of the TBM-a cutter disc and TBM-a. TBM-a retreats a certain distance. At this time, the other parts of the TBM-a cutter disc are still connected to TBM-a, while the side block I of the TBM-a cutter disc and TBM-b remain in place. Steel supports 4 are applied to fix the side block I of the TBM-a cutter disc. The side block I of the TBM-a cutter disc is completely removed.

[0063] ④ Cutterhead rotation and side block welding. After the side block I of TBM-a is removed, the TBM-a cutterhead is rotated 180° until the side block II is horizontally located at the bottom, and the TBM-a side block II is welded to the removed side block II of TBM-a as a whole.

[0064] ⑤ Remove the side block I of the TBM-b cutter disc. Remove the connecting bolts of the side block I of the TBM-b cutter disc, and move TBM-b back a certain distance. At this time, the side block I of the TBM-b cutter disc, the side block I of the TBM-a cutter disc, and the TBM-a cutter disc remain in place as a whole. The side block of the TBM-b cutter disc is fixed by steel support, and the side block of the TBM-b cutter disc is completely removed.

[0065] ⑥ Repeat steps ③, ④ and ⑤ to alternately complete the disassembly of the two TBM cutter head side blocks.

[0066] ⑦ Center block removal. After the two TBM cutterhead side blocks are removed, there is a certain amount of space between the cutterhead and the top of the tunnel. A sky anchor lifting point is constructed in the area above the cutterhead at the top of the tunnel, and a simple lifting device (hoisting hoist) is installed to pre-lift the cutterhead center block. The connecting bolts of the center block are removed, and the cutterhead center block separated from the TBM is placed at the bottom of the tunnel by the lifting device to complete the removal of the cutterhead center block.

Claims

1. A dual-machine collaborative disassembly method for a block-type cutterhead under the condition of a TBM without an expanded cavern, characterized in that: The dual-machine collaborative disassembly method comprises the following steps: S1. After the tunnel construction of the full-section tunnel boring machine is completed, the full-section tunnel boring machine is a TBM, the cutterhead of the TBM is a block structure, and two TBMs are separated by a distance; the cutterhead welds of the two TBMs are removed, and the cutterheads of the two TBMs are divided into multiple edge blocks; S2. After the weld removal in step S1 is completed, the space occupied and the distance between the two TBMs are the collaborative disassembly space; the two TBMs are named TBM-a and TBM-b respectively; S3. In the collaborative disassembly space, the cutterhead positions of the two TBMs are adjusted, and a side block on the cutterheads of the two TBMs is simultaneously rotated to a bottom horizontal position to form a bottom cutterhead side block; S4. Use support beams to weld and connect the bottom cutterhead side blocks of the two TBMs to form an integral connection structure bridged by the support beams. First, remove the connection bolts of the bottom cutterhead side blocks on TBM-a. S5, start TBM-a to retreat, initially the bottom cutterhead edge block of TBM-a is still connected to TBM-a, a steel support is applied to the bottom of the bottom cutterhead edge block of TBM-a for horizontal fixation, and TBM-a continues to retreat, completing the removal of the first bottom cutterhead edge block of TBM-a; at this time, TBM-b is the reaction force support structure of TBM-a; S6, the cutter head of TBM-a rotates, and the second side block to be removed is rotated to the bottom horizontal position, that is, the second bottom cutter head side block to be removed by TBM-a, and the second bottom cutter head side block to be removed by TBM-a is welded and fixed to the first bottom cutter head side block of TBM-a that has been removed by using a support beam; S7, remove the connecting bolts on the cutter head side block at the bottom of TBM-b, start TBM-b to retreat, the cutter head side block at the bottom of TBM-b in the initial state is still connected to TBM-b, a steel support is applied to the lower part of the cutter head side block at the bottom of TBM-b for horizontal fixation, and the first cutter head side block at the bottom of TBM-b is removed; at this time, TBM-a is the reaction force support structure of TBM-b; S8, repeat steps S3-S7 to dismantle the upper side blocks of the cutter heads of the two TBMs alternately; the dismantling of the side blocks of the cutter heads of the two TBMs is now completed; the side blocks of the cutter heads of the two TBMs are connected in series through the support beams.

2. The method for collaboratively disassembling a block-type cutterhead without expanding a TBM chamber according to claim 1 is characterized in that: The last side block on the TBM cutter head is removed, and the removed welded side blocks are used as the reaction support structure; that is, the last bottom cutter head side block of the TBM cutter head is supported by the deadweight of the removed bottom cutter head side blocks, support beams and steel supports.

3. The method for collaborative disassembly of a block-type cutterhead by two machines under the condition of TBM without expanding the cavern according to claim 1 is characterized in that: If the TBM segmented cutterhead in S1 includes a center block in addition to multiple side blocks, after the side blocks of the two TBM cutterheads in S8 are dismantled, a sky anchor lifting point is constructed at the top of the tunnel above the two TBM cutterheads, and the lifting equipment is installed to pre-lift the center block. The connecting bolts of the center block are removed, and the center block is lifted away from the TBM by the lifting equipment and placed at the bottom of the tunnel to complete the dismantling of the center block.

4. The method for collaboratively disassembling a block-type cutterhead without expanding a TBM chamber according to claim 1 is characterized in that: The support beam is an I-beam, an H-beam or an angle steel; in order to maintain the force balance of the bottom cutter head edge block during the TBM retreat process, at least two support beams are arranged in parallel.

5. The method for collaboratively disassembling a block-type cutterhead without expanding a TBM chamber according to claim 1 is characterized in that: The bottom cutter head side blocks to be removed must be rotated to the bottom of the TBM cutter head and placed horizontally.

6. The method for collaboratively disassembling a block-type cutterhead without expanding a TBM chamber according to claim 1 is characterized in that: In the steps S5 and S7, the retreat distance of the two TBM cutter heads during the removal of the side blocks is the same, which is the thickness of the TBM cutter head plus 0.5m, so as to reserve space for subsequent operations.

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