A full-automatic installation and replacement device and method for a shield machine grease bucket

Abstract

An automated installation and replacement device and method for grease drums on tunnel boring machines (TBMs) is disclosed. The device includes: a receiving platform comprising a base and a linear drive mechanism; the base top plate consists of two fixed plates on the left and right sides and a movable support plate in the middle for supporting the grease drum; the linear drive mechanism drives the movable support plate to move horizontally; a rotating mechanism including a traveling beam and a rotating drive assembly; one end of the traveling beam is rotatably connected to a fixed column of a trolley via the rotating drive assembly, while the other end is suspended; a traveling mechanism and a lifting and hoisting mechanism that move along the traveling beam and are interconnected; the traveling beam is equipped with a near-end proximity switch and a far-end proximity switch; the lifting and hoisting mechanism is equipped with a proximity switch trigger rod; and a grease drum clamping mechanism for clamping the grease drum and removing the lid. The replacement method using this device enables automated hoisting and replacement of the grease drum, effectively improving construction efficiency and safety.

Description

Technical Field

[0001] This invention belongs to the field of tunnel boring machine construction, specifically relating to a fully automatic installation and replacement device and method for the grease tank of a tunnel boring machine. Background Technology

[0002] The shield tail sealing system utilizes multiple shield tail wire brushes to form a sealing cavity with the shield shell and segments. Shield tail sealing grease with water-blocking capabilities is injected into the sealing cavity to isolate and lubricate the shield tail segments from external slurry.

[0003] The tail grease is pumped from a grease tank to the tail grease sealing cavity using a pneumatic grease pump. Pneumatic ball valves, manual ball valves, and pressure sensors are installed along the intermediate pipeline. The main function of the tail grease is to fill the gap between the tail sealing cavity and the inside of the wire brush, preventing external cement and mortar from entering the tunnel.

[0004] When using a pneumatic grease pump to deliver grease, it is necessary to replace the old grease tank with a new one. Currently, there are the following shortcomings and defects:

[0005] (1) The grease pump requires manual operation throughout the entire process. Two people are needed to operate the grease drum during hoisting, lowering and installation. The grease drum is heavy, and the process consumes a lot of manpower and resources and takes a long time.

[0006] (2) Due to the large weight of the grease drum, there is a certain risk in the process of hoisting it manually (installing the hook, pulling the chain hoist, lowering, pushing and moving the grease drum, etc.), especially during the movement, which can easily lead to injury;

[0007] (3) As the equipment on the tunnel boring machine gradually becomes automated, the process of changing the grease tank is complicated, consumes manpower and resources, affects the construction progress, and reduces the equipment's production capacity. Summary of the Invention

[0008] The purpose of this invention is to provide a fully automatic installation and replacement device and method for the grease tank of a tunnel boring machine, so as to improve the automation level of grease tank replacement and grease pumping.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is: a fully automatic installation and replacement device for the grease tank of a tunnel boring machine, installed on a trolley inside the tunnel, comprising:

[0010] The receiving platform includes a base and a linear drive mechanism. The top plate of the base consists of two fixed plates on the left and right and a movable support plate in the middle for supporting the grease container. The movable support plate is slidably connected to the fixed plates. The linear drive mechanism is located inside the base, and the linear motion part of the linear drive mechanism is connected to the movable support plate. A pneumatic grease pump is also installed on the base, and the bracket of the pneumatic grease pump is fixed on the two fixed plates.

[0011] The rotating mechanism includes a traveling beam and a rotating drive assembly. One end of the traveling beam is rotatably connected to the upper part of the trolley fixed column through the rotating drive assembly, and the axis of rotation is perpendicular to the horizontal plane. The other end of the traveling beam is suspended in the air. The rotating drive assembly has a rotary motor that drives the traveling beam to rotate.

[0012] The traveling mechanism includes a traveling mechanism frame and a traveling drive motor. The traveling mechanism frame is equipped with traveling mechanism wheels, which move along the horizontal track of the traveling beam. The traveling drive motor is used to drive the traveling mechanism frame to move along the traveling beam.

[0013] A lifting and hoisting mechanism includes a hoisting mechanism frame and a lifting motor. The hoisting mechanism frame is equipped with hoisting mechanism traveling wheels that move along a traveling beam track. The hoisting mechanism frame and the traveling mechanism frame are fixedly connected by a connecting component. The lifting motor is hung on the lower part of the hoisting mechanism frame. The traveling beam is equipped with a near-end proximity switch and a far-end proximity switch. The far-end proximity switch is closer to the free end of the traveling beam than the near-end proximity switch. The hoisting mechanism frame is equipped with a proximity switch trigger rod for use with the near-end proximity switch and the far-end proximity switch. The traveling mechanism drives the lifting and hoisting mechanism to reciprocate within the range of the near-end proximity switch and the far-end proximity switch.

[0014] The grease container clamping mechanism includes a lifting lug, a chain, a stabilizing support frame, and a robotic arm. The upper end of the chain is connected to the lifting lug, and the lower end is connected to the robotic arm. The stabilizing support frame is connected to the chain and spreads out multiple chains. The robotic arm hangs down naturally. The lifting lug is connected to the motor hook of the lifting motor of the lifting and hoisting mechanism. An electromagnet for picking up the lid of the grease container is also suspended on the lifting lug.

[0015] The movable support plate is provided with correction baffles on both sides. The correction baffles are fixed on the fixed plate and are arranged in a trumpet shape with their small openings facing the direction in which the movable support plate retracts.

[0016] The linear drive mechanism is a hydraulic cylinder, a gear and rack mechanism driven by a motor, or an electric cylinder.

[0017] A support frame is fixedly installed on the upper part of the trolley fixing column, and a rotating pin is fixedly connected to the end of the traveling beam. The rotating pin passes through the support frame and is rotatably connected to the support frame. The rotating drive assembly is set inside the support frame and includes a rotating motor and a gear set. The rotating motor drives the rotating pin to rotate through the gear set, so as to drive the traveling beam to rotate around the rotating pin as an axis.

[0018] The walking mechanism frame is provided with a transmission gear, which is driven to rotate by the walking drive motor through the walking reducer; the lower surface of the walking beam is provided with a rack extending along its length, and the transmission gear meshes with the rack.

[0019] A near-end limit switch is provided on the traveling beam at one end near the fixed column of the trolley, and a near-end limit trigger rod is provided on the hoisting mechanism frame for use with the near-end limit switch; a far-end limit switch is provided on the free end of the traveling beam, and a far-end limit trigger rod is provided on the traveling mechanism frame for use with the far-end limit switch; the near-end limit switch and the far-end limit switch are connected to the industrial control computer in the control room via control lines.

[0020] The robotic arm can be a hydraulic robotic arm, a pneumatic robotic arm, or an electric robotic arm.

[0021] A control box for local control is installed on the trolley's fixed column. The control box is connected to the rotary motor, the travel drive motor, the lifting motor, and the electromagnet via control lines.

[0022] A fully automated method for installing and replacing grease tanks in tunnel boring machines (TBMs) utilizes a fully automated grease tank installation and replacement device. First, a new grease tank is transported by a segment transport vehicle inside the tunnel to a designated location near the receiving platform on the trolley. Then, the automatic replacement start button in the control room is pressed, and the automatic replacement proceeds according to the following steps:

[0023] S1, the pressure plate of the pneumatic grease pump is lifted and detached from the grease tank;

[0024] S2, The linear telescopic mechanism of the receiving platform base pushes the movable support plate out of the base, sending out the empty grease drum to be replaced, waiting to be hoisted away;

[0025] S3, the walking drive motor drives the walking mechanism and the lifting and hoisting mechanism to move towards the near end of the walking beam until the near end proximity switch on the walking beam senses the proximity switch trigger rod on the hoisting mechanism frame, and the walking drive motor stops moving. At this time, the lifting and hoisting mechanism is located directly above the empty grease drum waiting to be sent out on the receiving platform.

[0026] S4, the lifting motor of the hoisting mechanism lowers the grease drum clamping mechanism, and the empty grease drum is clamped by the grease drum clamping mechanism;

[0027] S5, after the lifting motor drives the grease drum clamping mechanism to rise to the predetermined position, the rotating motor of the rotating mechanism starts, driving the traveling beam to rotate until the empty grease drum held by the grease drum clamping mechanism is directly above the designated position of the segment transport vehicle, and then stops rotating.

[0028] S6, the lifting motor lowers the grease drum clamping mechanism until the empty grease drum is placed in the designated position of the segment transport vehicle. After the grease drum clamping mechanism releases the grease drum, it is lifted by the lifting motor to the predetermined position.

[0029] S7, the travel drive motor drives the travel mechanism and the lifting and hoisting mechanism to move towards the far end of the travel beam until the proximity switch at the far end of the travel beam senses the proximity switch trigger rod on the hoisting mechanism frame, and the travel drive motor stops. At this time, the lifting and hoisting mechanism is above the new grease bucket to be clamped; the lifting motor drives the grease bucket clamping mechanism to lower to clamp the new grease bucket, and then the lifting motor raises the clamped new grease bucket.

[0030] S8, the walking drive motor drives the walking mechanism and the lifting and hoisting mechanism to move towards the near end of the walking beam until the near end proximity switch on the walking beam senses the proximity switch trigger rod on the hoisting mechanism frame, and the walking drive motor stops moving; then the rotary motor drives the walking beam to rotate, rotating the new grease bucket that has been picked up to above the movable support plate that extends from the receiving platform.

[0031] S9, the lifting motor lowers the new grease bucket to the movable support plate extended from the receiving platform, and the grease bucket clamping mechanism releases the new grease bucket;

[0032] S10, after the lid of the new grease container is lifted by the magnetic force of the electromagnet, the lifting motor raises the grease container clamping mechanism to the predetermined position, and the lid is placed on the recycled empty grease container according to steps S5 and S6.

[0033] S11, the linear telescopic mechanism of the receiving platform retracts the movable support plate containing the new grease drum, and the pneumatic grease pump pumps the grease.

[0034] In step S11, the correction baffle set on the receiving platform corrects the position of the new grease bucket that has shifted.

[0035] The beneficial effects of this invention are: it can improve the automation level of grease drum replacement and installation, save manpower, and improve construction efficiency; grease drums are relatively heavy, and with this invention, the hoisting of grease drums is an automated process, which has a higher safety factor and reduces the risk of worker injury. Attached Figure Description

[0036] Figure 1 Front view of the layout of the fully automatic grease tank installation and replacement device for the tunnel boring machine inside the tunnel;

[0037] Figure 2 A side view of the arrangement of the fully automatic grease tank installation and replacement device for the tunnel boring machine inside the tunnel.

[0038] Figure 3 The front view of the receiving platform in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine;

[0039] Figure 4 A side view of the receiving platform in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine;

[0040] Figure 5A schematic diagram of the traveling beam of the rotating mechanism in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine when it is perpendicular to the tunnel.

[0041] Figure 6 A schematic diagram of the traveling beam of the rotating mechanism in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine when it is parallel to the tunnel.

[0042] Figure 7 A schematic diagram of the traveling mechanism in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine.

[0043] Figure 8 A schematic diagram of the lifting and hoisting mechanism in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine;

[0044] Figure 9 A schematic diagram of the grease tank clamping mechanism in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine.

[0045] Figure 10 A schematic diagram of the annular stabilizing frame structure of the grease tank clamping mechanism in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine;

[0046] Figure 11 A schematic diagram showing the clamping state of the grease tank in the fully automatic installation and replacement device for the grease tank of a tunnel boring machine;

[0047] Figure 12 This is a schematic diagram of the structure of the grease drum fixing platform on the segment transport vehicle in this invention;

[0048] Marked in the diagram: 1. Trolley, 101. Trolley fixing column, 102. Control cable reel, 103. Control box;

[0049] 2. Segment transport vehicle; 201. Wheels of the segment transport vehicle; 202. Grease drum fixing seat;

[0050] 3. Receiving platform, 301. Base, 302. Movable support plate, 303. Hydraulic cylinder, 304. Fixing plate, 305. Hydraulic cylinder fixing block, 306. Correction baffle, 307. Hydraulic cylinder telescopic rod;

[0051] 4. Rotating mechanism; 401. Traveling beam; 402. Support frame; 403. Rotating pin; 404. Bearing; 405. Rotating drive assembly; 406. Rotating motor; 407. Pinion; 408. Large gear.

[0052] 5. Walking mechanism; 501. Walking mechanism frame; 502. Walking mechanism walking wheel; 503. Remote limit trigger rod; 504. Remote limit switch; 505. Walking drive motor; 506. Walking reducer; 507. Reducer gear; 508. Transmission gear; 509. Rack; 510. First connecting rod.

[0053] 6. Lifting and hoisting mechanism; 601. Hoisting mechanism frame; 602. Hoisting mechanism traveling wheel; 603. Second connecting rod; 604. Connecting block; 605. Motor hoisting rod; 606. Lifting motor; 607. Motor hook; 608. Motor chain bag; 609. Proximity limit trigger rod; 610. Proximity limit switch; 611. Proximity proximity switch; 612. Distance proximity switch; 613. Proximity switch trigger rod.

[0054] 7. Grease drum clamping mechanism, 701. Lifting lug, 702. Chain, 703. Stable support frame, 704. Hydraulic manipulator, 705. Electromagnet, 706. Wire, 707. Inner circle, 708. Outer circle, 709. Radial support bar;

[0055] 8. Grease container; 801. Container lid;

[0056] 9. Pneumatic grease pump. Detailed Implementation

[0057] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments, but this should not be construed as limiting the invention in any way.

[0058] Example 1: As Figure 1 , 2 As shown, a fully automatic installation and replacement device for grease tanks of a tunnel boring machine is fixed on a trolley 1 inside the tunnel. It includes a receiving platform 3, a rotating mechanism 4, a traveling mechanism 5, a lifting and hoisting mechanism 6, a grease tank clamping mechanism 7, and a pneumatic grease pump 9.

[0059] The structure of the receiving platform 3 is as follows: Figure 3 , 4 As shown, the system includes a base 301 and a hydraulic cylinder 303. The base 301 is a hollow rectangular structure, welded or bolted to the trolley 1. A horizontally arranged hydraulic cylinder 303 is installed inside the base 301. The bottom of the cylinder body is welded to the inner wall of the base 301, and the cylinder body is supported by a cylinder body fixing block 305 to maintain its horizontal position. The top plate of the base 301 includes left and right fixed plates 304 and a movable support plate 302 located between the two fixed plates 304. The left and right sides of the movable support plate 302 are slidably supported in the grooves of the two fixed plates 304. The movable support plate 302 is fixedly connected to the side plates of the base 301. The end of the hydraulic cylinder extension rod 307 of the hydraulic cylinder 303 is fixedly connected to the side plate. As the hydraulic cylinder extension rod 307 extends and retracts, the movable support plate 302 slides inward or outward along the fixed plate 304, realizing the horizontal transport of the grease drum it carries. The movable support plate 302 has two working positions: a pumping position and a changing position. When the movable support plate 302 slides inward to the pumping position, the pneumatic grease pump can draw grease. When the movable support plate 302 slides outward to the changing position, the grease container can be changed.

[0060] The bracket of the pneumatic grease pump 9 is fixed on the fixed plate 304. When an empty grease can needs to be sent out, the cylinder extension rod 307 extends, and the movable support plate 302 drives the empty grease can to be horizontally sent out from under the pressure plate of the pneumatic grease pump 9 until the movable support plate 302 reaches the replacement position. At this time, all the empty grease cans have left the pneumatic grease pump 9, and the grease cans can be hoisted. When a new grease can needs to be sent to the position of the pneumatic grease pump 9, the cylinder extension rod 307 retracts, and the movable support plate 302 drives the new grease can to move under the pressure plate of the pneumatic grease pump 9. At this time, the movable support plate 302 is in the pumping position, and the pneumatic grease pump 9 can pump out the grease from the new grease can.

[0061] Specifically, such as Figure 3 As shown, the cylinder block fixing block 305 is an annular component formed by the mating and connection of semi-circular support members. Multiple cylinder block fixing blocks 305 are spaced apart along the length of the cylinder block; for example, three cylinder block fixing blocks can be provided, distributed at both ends and the middle of the cylinder block. The bottom end of the cylinder block fixing block 305 is supported on the base plate of the base 301, and the top end of the cylinder block fixing block 305 is supported on the lower surface of the movable support plate 302.

[0062] Preferably, the hydraulic cylinder 303 can be one or more. When one hydraulic cylinder is used, it is centrally located within the base to ensure reliable support for the movable support plate and the grease container on it. When multiple hydraulic cylinders are used, they are spaced apart within the base.

[0063] Furthermore, when multiple hydraulic cylinders are used, such as Figure 3 As shown, the upper and lower semicircular support components of the two cylinder fixing blocks of adjacent cylinders share a single bolt connection.

[0064] As a replacement for the hydraulic cylinder, other linear drive mechanisms such as gear and rack mechanisms and electric cylinders can also be used, which can also drive the movable support plate 302 to extend and retract.

[0065] Preferably, each of the fixed plates 304 is further provided with a correction baffle 306. The correction baffle 306 is located between the two stations of the movable support plate 302. The two correction baffles 306 are arranged in a trumpet shape, with the small end facing the pumping station and the large end facing the replacement station. When the position of the new grease bucket is offset, the grease bucket moves with the movable support plate 302 and comes into contact with the correction baffle 306, and is corrected to the correct position by the correction baffle 306, ensuring that the pressure plate of the pneumatic grease pump 9 can smoothly enter the grease bucket.

[0066] The structural reference of the rotating mechanism Figure 5 , 6As shown, the rotating mechanism is located on the upper part of the trolley fixing column 101, including a traveling beam 401 for mounting the traveling mechanism 5 and the lifting and hoisting mechanism 6, and a rotating drive assembly 405. A support frame 402 is fixedly installed on the upper part of the trolley fixing column 101. One end of the traveling beam 401 is fixedly connected to a vertically arranged rotating pin 403. The rotating pin 403 passes through the support frame 402 and is connected to two bearings 404 at the top and bottom of the support frame 402, so that the traveling beam 401 is suspended on the upper part of the trolley fixing column 101. The rotating drive assembly 405 includes a rotary motor 406 and a pair of meshing right-angle transmission gears. The small gear 407 is installed on the output shaft of the drive motor 406, and the large gear 408 is installed on the rotating pin 403. The large gear 408 drives the rotating pin 403 to rotate through a spline, thereby causing the traveling beam 401 to swing in the horizontal direction.

[0067] The two ends of the rotating pin 403 are respectively connected to the rotating pin cover plate by bolts to prevent external dust and water from entering the support frame along the rotating pin.

[0068] The traveling mechanism 5 and the lifting and hoisting mechanism 6 are both suspended on the traveling beam 401 of the rotating mechanism, and their structures are as follows: Figure 7 , 8 As shown.

[0069] The structure of the walking mechanism 5 is as follows: Figure 7 As shown, the system includes a walking mechanism frame 501, walking mechanism wheels 502, a gear and rack mechanism, and a walking drive motor 505. The walking mechanism wheels 502 are mounted on the upper part of the walking mechanism frame 501. The walking mechanism wheels 502 roll along a track on the walking beam 401, driving the walking mechanism frame 501 to move along the walking beam 401. The gear and rack mechanism includes a rack 509 disposed on the lower surface of the walking beam 401 and a transmission gear 508 disposed on the walking mechanism frame 501. The transmission gear 508 meshes with the rack 509, and as the transmission gear 508 moves on the rack 509, it drives the walking mechanism wheels 502 to move along the track of the walking beam 401. The walking drive motor 505 is connected to the walking reducer 506 to provide power to the transmission gear 508. The walking drive motor 505 and the walking reducer 506 are fixed to the lower part of the walking mechanism frame 501. The output shaft of the walking reducer 506 is equipped with a reducer gear 507 that meshes with the transmission gear 508. The diameter of the transmission gear 508 is larger than that of the reducer gear 507, which can reduce the speed again on the basis of the reducer, so as to ensure the smooth operation of the walking mechanism 5 on the walking beam 401.

[0070] The walking mechanism frame 501 is composed of two parallel metal plates connected by multiple support rods perpendicular to the metal plates located between the two metal plates. The walking mechanism wheels 502 are installed on the inner side of the metal plates, and the gear and rack mechanism and the walking mechanism reducer are both installed in the space between the two metal plates.

[0071] The traveling mechanism 5 is connected to the lifting and hoisting mechanism 6 via a connecting component. The reciprocating motion of the traveling mechanism 5 on the traveling beam 401 can drive the lifting and hoisting mechanism 6 to reciprocate synchronously along the traveling beam 401 via the connecting component.

[0072] In this embodiment, the driving method for moving the walking mechanism frame 501 is a walking drive motor 505 and a walking reducer 506 driving a gear and rack mechanism. In actual use, other methods can also be used to realize the movement of the walking mechanism frame according to the actual situation. For example, the walking wheel 502 of the walking mechanism can be set as an active walking wheel and connected to the drive motor and reducer. Multiple walking wheels of the walking mechanism can be set as active walking wheels, or one of them can be set as an active walking wheel and the others as passive walking wheels.

[0073] The structure of the lifting and hoisting mechanism 6 is as follows: Figure 8 As shown, it includes a hoisting mechanism frame 601, hoisting mechanism traveling wheels 602, motor hoisting rod 605, lifting motor 606, motor hook 607, near-end limit trigger rod 609, and proximity switch trigger rod 613.

[0074] The hoisting mechanism frame 601 consists of two metal plates connected face-to-face and multiple support rods positioned between the two metal plates. Multiple hoisting mechanism traveling wheels 602 are mounted on the upper part of the hoisting mechanism frame 601, moving along the traveling beam track. A motor hoisting rod 605 is mounted on the lower part of the hoisting mechanism frame 601, and a hook at the upper end of a lifting motor 606 is attached to this motor hoisting rod 605. The lifting motor 606 is an electric hoist. The connecting assembly between the hoisting mechanism frame 601 and the traveling mechanism frame 501 includes a first connecting rod 510 mounted on the traveling mechanism frame 501, a second connecting rod 603 mounted on the hoisting mechanism frame 601, and a connecting block 604 connecting the first connecting rod 510 and the second connecting rod 603. Through the connecting assembly, the hoisting mechanism 6 can reciprocate synchronously with the traveling mechanism 5 along the traveling beam.

[0075] The lifting and hoisting mechanism 6 is mainly used to hoist new grease drums from the segment transport vehicle to the receiving platform and place them at the replacement station on the receiving platform, as well as to hoist empty grease drums from the replacement station onto the segment transport vehicle. To achieve automatic stopping and positioning of the lifting and hoisting mechanism 6 on the traveling beam, two proximity switches are also installed on the traveling beam: a remote proximity switch 612 and a near-end proximity switch 611. The remote proximity switch 612 is closer to the free end of the traveling beam than the near-end proximity switch 611. A proximity switch trigger rod 613 is installed on the hoisting mechanism frame 601. When the traveling mechanism drives the lifting and hoisting mechanism to move along the traveling beam, when the remote proximity switch 612 senses the proximity switch trigger rod 613 approaching, it sends a power-off signal, and the traveling drive motor 505 is de-energized and stops moving forward; when the near-end proximity switch 611 senses the proximity switch trigger rod 613 approaching, it sends a power-off signal, and the traveling drive motor 505 is de-energized and stops moving forward.

[0076] The "far end" on the traveling beam 401 refers to the free end of the traveling beam 401, and the "proximal end" on the traveling beam 401 refers to the end of the traveling beam 401 that is connected to the trolley fixing column 101.

[0077] To prevent the traveling mechanism and lifting mechanism from colliding with the trolley's fixed column or rushing out of the traveling beam due to malfunction of the near-end proximity switch and the far-end proximity switch, near-end limit switches and far-end limit switches are also installed on the traveling beam.

[0078] The near-end limit switch 610 is installed on the traveling beam 401 at one end near the trolley fixed column 101. The near-end limit trigger rod 609 is installed on the hoisting mechanism frame 601. With the cooperation of the near-end limit trigger rod 609 and the near-end limit switch 610, the near-end limit switch 610 sends a signal in time to control the travel drive motor 505 to cut off the power, so as to avoid the hoisting mechanism 6 from moving excessively and hitting the trolley fixed column due to the failure of the near-end proximity switch.

[0079] The remote limit switch 504 is located at the free end of the traveling beam 401, that is, at the end away from the trolley fixing column 101. A remote limit trigger rod 503 is provided on the traveling mechanism frame 501 facing the remote limit switch 504. With the cooperation of the remote limit trigger rod 503 and the remote limit switch 504, when the remote proximity switch fails, the remote limit switch 504 promptly sends a signal to control the traveling drive motor 505 to cut off power and brake, so as to prevent the traveling mechanism 5 from falling off the traveling beam 401.

[0080] The structure of the grease drum clamping mechanism 7 is as follows: Figure 9As shown, the system includes a lifting lug 701, chains 702, a stabilizing support frame 703, and a hydraulic manipulator 704. Multiple chains 702 of uniform length are connected, with their upper ends connected to the lifting lug 701 and their lower ends connected to the hydraulic manipulator 704. The stabilizing support frame 703 is circular and fixedly connected to the chains 702, used to spread the multiple chains apart. The lifting lug 701 is located directly above the center of the stabilizing support frame 703, allowing the multiple chains 702 to be evenly distributed radially. The hydraulic manipulator 704 hangs naturally due to its own weight. The lifting lug 701 is hooked onto the motor hook 607 of the lifting and hoisting mechanism 6.

[0081] To facilitate the removal of the lid from the new grease container, an electromagnet 705 is suspended from the lifting lug 701. The height of the electromagnet 705 can be adjusted according to the actual situation. When it is necessary to remove the lid, the lifting lug 701 is lowered appropriately, and the magnetic attraction of the electromagnet 705 is used to remove the lid.

[0082] The structure of the stable support frame 703 is as follows: Figure 10 As shown, the stable support frame 703 includes a concentric outer circle 708 and an inner circle 707, and multiple radial support bars 709 are evenly distributed between the outer circle 708 and the inner circle 707 to enhance the stability of the support frame. The chain 702 is fixedly connected to the outer circle 708. The suspension rope for suspending the electromagnet 705 and the wire 706 of the electromagnet 705 pass through the inner circle 707.

[0083] like Figure 11 As shown, after the grease drum clamping mechanism 7 uses the hydraulic manipulator 704 to clamp the edge of the grease drum 8, the lifting motor of the lifting and hoisting mechanism 6 can transfer the grease drum 8 to complete the replacement of the grease drum 8.

[0084] In this embodiment, a hydraulic manipulator is used to hold the grease container. In actual implementation, a pneumatic manipulator or an electric manipulator can also be used to hold the grease container.

[0085] In this invention, the rotary motor 406 of the rotating mechanism 4, the walking drive motor 505 of the walking mechanism 5, the lifting motor 606 of the lifting and hoisting mechanism 6, and the electromagnet 705 of the grease drum clamping mechanism 7 are all connected to the control circuit in the control box set on the trolley via control lines. The remote limit switch 504 of the walking mechanism 5, the near-end proximity switch 611, the remote proximity switch 612, and the near-end limit switch 610 of the lifting and hoisting mechanism 6 are all connected to the industrial control computer in the control room via control lines to realize signal input. After receiving the signal, the industrial control computer processes the signal according to the program settings and sends the feedback signal to the control circuit in the control box, thereby controlling the electrical components such as the rotary motor 406 of the rotating mechanism 4, the walking drive motor 505 of the walking mechanism 5, the lifting motor 606 of the lifting and hoisting mechanism 6, and the electromagnet 705 of the near-grease drum clamping mechanism 7, realizing the automatic control of this invention by the industrial control computer. The hydraulic cylinder 303 of the receiving platform 3 and the hydraulic manipulator 704 of the grease drum clamping mechanism 7 are connected to the hydraulic pump station on the trolley. The hydraulic pump station is also connected to the industrial control computer in the control room to realize automatic control of the hydraulic pump station.

[0086] Alternatively, in this invention, the rotary motor 406 of the rotating mechanism 4, the travel drive motor 505 of the traveling mechanism 5, the lifting motor 606 of the lifting and hoisting mechanism 6, and the electromagnet 705 of the grease drum clamping mechanism 7 are all connected to the control circuit in the control box 103 on the trolley fixed column 101 via control lines; the hydraulic cylinder 303 of the receiving platform 3 and the hydraulic manipulator 704 of the grease drum clamping mechanism 7 are connected to the hydraulic pump station on the trolley, and the hydraulic pump station is connected to the control box 103. When necessary, the operator can achieve local control of this device through the control box 103. The power supply to the circuit is controlled by the operator turning off the control button on the control box 103. The push-button switches have forward and reverse buttons for controlling the rotary motor 406 of the rotating mechanism 4, the travel drive motor 505 of the traveling mechanism 5, and the lifting motor 606 of the lifting and hoisting mechanism 6, respectively. The push-button switches also have extension and retraction buttons for controlling the hydraulic cylinder 303 of the receiving platform 3 and the hydraulic manipulator 704 of the grease drum clamping mechanism 7, respectively. The operation of each component is continuously controlled by pressing and holding the push-button switch. The control box 103 is connected to the industrial computer in the control room via a control line. Signal input is achieved by opening and closing the push-button switches. After receiving the signals, the industrial computer processes the signals from the push-button switches, the remote limit switch 504 of the traveling mechanism 5, the end proximity switch 611, the remote proximity switch 612 and the near limit switch 610 of the lifting and hoisting mechanism 6 according to the program settings, and sends feedback signals to the control circuit in the control box 103 to control each component.

[0087] Furthermore, the control box 103 is also equipped with an operation permission selection knob, which can be used to authorize remote automatic control or local control in the control room.

[0088] Example 2: The fully automatic installation and replacement method for grease drums in tunnel boring machines proposed in this example utilizes the fully automatic installation and replacement device from Example 1. In this example, the material platform for placing grease drums on the segment transport vehicle is located at one end of the vehicle. The grease drums are placed in two rows on the material platform, with empty grease drums (i.e., empty oil drums) on the left side closer to the receiving platform, and new grease drums on the right side. Therefore, the fully automatic installation and replacement method specifically includes the following steps:

[0089] Step 1: Material feeding

[0090] The starting wellhead gantry crane lifts the new grease drum and places it onto segment transport vehicle 2 in the underground battery-powered vehicle group. Segment transport vehicle 2 is equipped with a dedicated material platform.

[0091] Step 2: Entering the tunnel

[0092] The electric vehicles are driven into the tunnel and into the work area. The electric vehicle driver stops the vehicle at a designated location near the receiving platform 3 on the trolley 1.

[0093] Step 3: Start

[0094] The automatic replacement process begins when the operator presses the automatic replacement start button in the control room.

[0095] Step 4: Lifting the pressure plate

[0096] When the pressure plate of the pneumatic grease pump 9 is lifted upwards to a certain position, the proximity switch on the pneumatic grease pump 9 senses the lifting rod, the pneumatic valve is de-energized and reset, the air intake pipe stops intake, and the lifting stops. At this time, the pressure plate is detached from the grease tank.

[0097] Step 5: The receiving platform extends

[0098] The cylinder 303 of the receiving platform 3 at the bottom of the pneumatic grease pump 9 extends the movable support plate 302 to send out the empty grease tank. The empty grease tank completely leaves the pneumatic grease pump 9 and waits to be hoisted away.

[0099] Step 6: Walking

[0100] When the control circuit (forward rotation) contactor coil of the walking drive motor 505 is energized, the contactor engages and the circuit is connected, the walking drive motor 505 moves forward, driving the walking mechanism 5 and the lifting and hoisting mechanism 6 to move towards the near end of the walking beam 401, until the near end proximity switch 611 on the walking beam 401 senses the proximity switch trigger rod 613 on the hoisting mechanism frame 601 and gives a power-off signal, the control circuit (forward rotation) contactor coil of the walking drive motor 505 is de-energized, the contactor opens, the walking mechanism 5 stops moving forward, and at this time, the lifting and hoisting mechanism 6 is located directly above the empty grease drum waiting to be delivered on the receiving platform 3;

[0101] Step 7: Lower the hook

[0102] When the contactor coil of the control circuit (reverse) of the lifting motor 606 is energized, the contactor is engaged and the circuit is connected. The motor hook 607 hangs the grease drum clamping mechanism 7 and slowly lowers it to a certain position. The hydraulic manipulator 704 of the grease drum clamping mechanism 7 clamps and holds the top edge of the grease drum.

[0103] Step 8: Increase rotation

[0104] After the robotic arm clamps the empty grease can, the lifting motor 606 rotates forward, driving the grease can clamping mechanism 7 to slowly rise. After rising to a certain height, the rotary motor 406 is energized and starts, driving the traveling beam 401 to rotate through the right-angle transmission gear. After rotating to a certain angle (generally 90°), the contactor of the control circuit of the rotary motor 406 is de-energized. At this time, the empty grease can clamped by the grease can clamping mechanism 7 is located directly above the position where the empty grease can is placed on the segment transport vehicle 2.

[0105] Step 9: Lower the empty grease container

[0106] The lifting motor 606 drives the grease drum clamping mechanism 7 to slowly lower until the grease drum is placed in the designated position of the segment transport vehicle 2. The hydraulic manipulator is released, and the lifting motor 606 drives the grease drum clamping mechanism 7 to slowly rise. After rising to a suitable height, the lifting motor is de-energized and stops moving.

[0107] Step 10: Pick up the new grease container

[0108] When the travel drive motor 505 is energized, it drives the travel mechanism 5 and the lifting and hoisting mechanism 6 to move towards the far end of the travel beam 401 until they contact the far end proximity switch 612. The contactor of the control circuit of the travel drive motor 505 is de-energized, and the travel drive motor 505 stops moving. At this time, the lifting and hoisting mechanism 6 is located above the new grease drum to be picked up. The lifting motor 606 drives the grease drum clamping mechanism 7 to slowly lower down. When it is lowered to a certain position, the hydraulic manipulator 704 of the grease drum clamping mechanism 7 clamps against the top edge of the new grease drum and clamps it. Then the lifting mechanism 606 slowly rises up. The lifting height should be such that the new grease drum being lifted is higher than the grease drum on the segment transport vehicle 2.

[0109] Step 11: Rotate

[0110] When the walking drive motor 505 is energized, it drives the walking mechanism 5 and the lifting and hoisting mechanism 6 to move towards the near end of the walking beam 401 until they contact the near end proximity switch 611. The contactor of the control circuit of the walking drive motor 505 is de-energized, and the walking drive motor 505 stops moving. Then, the rotary motor 406 is energized and starts, driving the walking beam 401 to rotate a certain angle towards the receiving platform 3, generally 90°. The rotary motor 406 is de-energized and stops moving. At this time, the lifting and hoisting mechanism 6 and the new grease bucket it has picked up are located above the movable support plate 303 extending from the receiving platform 3.

[0111] Step 12: Place the new grease container down.

[0112] When the control circuit (reverse) of the lifting motor 606 is energized, the contactor coil is energized and the contactor is engaged, the motor hook 607 hangs on the grease drum clamping mechanism 7 and slowly lowers it, placing the new grease drum onto the movable support plate 302 extending from the receiving platform 3. The hydraulic manipulator 704 slowly opens and releases the new grease drum.

[0113] Step 13: Remove the lid

[0114] When the electromagnet 705 circuit is energized, it uses magnetism to lift the lid of the new grease container. The lifting motor 606 slowly lifts it up to a certain height (the lifting height can be set by setting the working time) and then stops. The lifted lid is placed on the empty grease container of the segment transport vehicle in the same way as the empty grease container is clamped (i.e., steps 8 and 9).

[0115] Step 14: Platform Reclaims

[0116] The hydraulic cylinder 303 of the receiving platform 3 slowly retracts the movable support plate 302. When the position of the new grease can is offset, the new grease can will hit the correction baffles 306 with a certain angle on both sides and slowly return to the correct position along the correction baffles 306. After the new grease can reaches the correct position, the hydraulic cylinder stops and the platform completes the retraction.

[0117] Step 15: Press down the pressure plate

[0118] When the pneumatic grease pump 9 pressure plate is pressed down, the pneumatic ball valve bypassing the grease pipeline opens, and closes after releasing a certain amount of gas.

[0119] Step 16: Normal grease pumping

[0120] The pressure plate is pressed down normally, and the grease pump pumps grease normally, thus completing the replacement of the new grease tank and the empty grease tank.

[0121] After pumping for a certain period of time, the proximity switch on the grease pump head contacts the grease platform frame at the warning height. The controller receives the signal and sends a yellow alarm signal to indicate that the grease tank is empty.

[0122] During normal operation, the traveling mechanism 5 and the lifting and hoisting mechanism 6 operate between two proximity switches. The far-end limit switch 612 and the near-end limit switch 611 on the traveling beam 401 can protect the traveling mechanism 5 and the lifting and hoisting mechanism 6 from rushing out of the traveling beam 401 or hitting the trolley fixing column 101 when the proximity switches fail.

[0123] In this embodiment, the empty grease container is placed on the left side of the segment transport vehicle, and the new grease container is placed on the right side. During replacement, the remote proximity switch 612 corresponds to the position of the new grease container, and the near proximity switch 611 corresponds to the position of the empty grease container. In actual use, the positions of the two types of grease containers can also be interchanged. After the interchange, the remote proximity switch 612 corresponds to the position of the empty grease container, and the near proximity switch 611 corresponds to the position of the new grease container.

[0124] The "grease bucket" mentioned in this invention refers not only to the grease bucket at the tail of the shield, but also to a grease bucket or other grease buckets used in shield tunneling.

[0125] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Those skilled in the art should understand that modifications or equivalent substitutions can be made to the specific implementation of the present invention with reference to the above embodiments. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention are within the protection scope of the pending claims.

Claims

1. A fully automatic installation and replacement device for the grease tank of a tunnel boring machine, installed on a trolley inside the tunnel, characterized in that, include: The receiving platform includes a base and a linear drive mechanism. The top plate of the base consists of two fixed plates on the left and right and a movable support plate in the middle for supporting the grease container. The movable support plate is slidably connected to the fixed plates. The linear drive mechanism is located inside the base, and the linear motion part of the linear drive mechanism is connected to the movable support plate. A pneumatic grease pump is also installed on the base, and the bracket of the pneumatic grease pump is fixed on the two fixed plates. The rotating mechanism includes a traveling beam and a rotating drive assembly. One end of the traveling beam is rotatably connected to the upper part of the trolley fixed column through the rotating drive assembly, and the axis of rotation is perpendicular to the horizontal plane. The other end of the traveling beam is suspended in the air. The rotary drive assembly includes a rotary motor that drives the traveling beam to rotate; The traveling mechanism includes a traveling mechanism frame and a traveling drive motor. The traveling mechanism frame is equipped with traveling mechanism wheels, which move along the horizontal track of the traveling beam. The traveling drive motor is used to drive the traveling mechanism frame to move along the traveling beam. A lifting and hoisting mechanism includes a hoisting mechanism frame and a lifting motor. The hoisting mechanism frame is equipped with hoisting mechanism traveling wheels that move along a traveling beam track. The hoisting mechanism frame and the traveling mechanism frame are fixedly connected by a connecting component. The lifting motor is hung on the lower part of the hoisting mechanism frame. The traveling beam is equipped with a near-end proximity switch and a far-end proximity switch. The far-end proximity switch is closer to the free end of the traveling beam than the near-end proximity switch. The hoisting mechanism frame is equipped with a proximity switch trigger rod for use with the near-end proximity switch and the far-end proximity switch. The traveling mechanism drives the lifting and hoisting mechanism to reciprocate within the range of the near-end proximity switch and the far-end proximity switch. The grease container clamping mechanism includes a lifting lug, a chain, a stabilizing support frame, and a robotic arm. The upper end of the chain is connected to the lifting lug, and the lower end is connected to the robotic arm. The stabilizing support frame is connected to the chain and spreads out multiple chains. The robotic arm hangs down naturally. The lifting lug is connected to the motor hook of the lifting motor of the lifting and hoisting mechanism. An electromagnet for picking up the lid of the grease container is also suspended on the lifting lug.

2. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: The movable support plate is provided with correction baffles on both sides. The correction baffles are fixed on the fixed plate and are arranged in a trumpet shape with their small openings facing the direction in which the movable support plate retracts.

3. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: The linear drive mechanism is a hydraulic cylinder, a gear and rack mechanism driven by a motor, or an electric cylinder.

4. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: A support frame is fixedly installed on the upper part of the trolley fixing column, and a rotating pin is fixedly connected to the end of the traveling beam. The rotating pin passes through the support frame and is rotatably connected to the support frame. The rotating drive assembly is set inside the support frame and includes a rotating motor and a gear set. The rotating motor drives the rotating pin to rotate through the gear set, so as to drive the traveling beam to rotate around the rotating pin as an axis.

5. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: The walking mechanism frame is provided with a transmission gear, which is driven to rotate by the walking drive motor through the walking reducer; the lower surface of the walking beam is provided with a rack extending along its length, and the transmission gear meshes with the rack.

6. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: A near-end limit switch is provided on the traveling beam at one end near the fixed column of the trolley, and a near-end limit trigger rod is provided on the hoisting mechanism frame for use with the near-end limit switch; a far-end limit switch is provided on the free end of the traveling beam, and a far-end limit trigger rod is provided on the traveling mechanism frame for use with the far-end limit switch; the near-end limit switch and the far-end limit switch are connected to the industrial control computer in the control room via control lines.

7. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: The robotic arm can be a hydraulic robotic arm, a pneumatic robotic arm, or an electric robotic arm.

8. The fully automatic installation and replacement device for the grease tank of a tunnel boring machine according to claim 1, characterized in that: A control box for local control is installed on the trolley's fixed column. The control box is connected to the rotary motor, the travel drive motor, the lifting motor, and the electromagnet via control lines.

9. A fully automatic installation and replacement method for the grease tank of a tunnel boring machine, characterized in that, This method utilizes the fully automatic installation and replacement device for the grease tank of a tunnel boring machine as described in any one of claims 1-7. First, the new grease tank is transported by a segment transport vehicle inside the tunnel to a designated position near the receiving platform on the trolley; then, the automatic replacement start button in the control room is pressed, and the automatic replacement proceeds according to the following steps: S1, the pressure plate of the pneumatic grease pump is lifted and detached from the grease tank; S2, The linear drive mechanism of the receiving platform base pushes the movable support plate out of the base, sending out the empty grease can to be replaced, waiting to be hoisted away; S3, the walking drive motor drives the walking mechanism and the lifting and hoisting mechanism to move towards the near end of the walking beam until the near end proximity switch on the walking beam senses the proximity switch trigger rod on the hoisting mechanism frame, and the walking drive motor stops moving. At this time, the lifting and hoisting mechanism is located directly above the empty grease drum waiting to be sent out on the receiving platform. S4, the lifting motor of the hoisting mechanism lowers the grease drum clamping mechanism, and the empty grease drum is clamped by the grease drum clamping mechanism; S5, after the lifting motor drives the grease drum clamping mechanism to rise to the predetermined position, the rotating motor of the rotating mechanism starts, driving the traveling beam to rotate until the empty grease drum held by the grease drum clamping mechanism is directly above the designated position of the segment transport vehicle, and then stops rotating. S6, the lifting motor lowers the grease drum clamping mechanism until the empty grease drum is placed in the designated position of the segment transport vehicle. After the grease drum clamping mechanism releases the grease drum, it is lifted by the lifting motor to the predetermined position. S7, the travel drive motor drives the travel mechanism and the lifting and hoisting mechanism to move towards the far end of the travel beam until the proximity switch at the far end of the travel beam senses the proximity switch trigger rod on the hoisting mechanism frame, and the travel drive motor stops. At this time, the lifting and hoisting mechanism is above the new grease bucket to be clamped; the lifting motor drives the grease bucket clamping mechanism to lower to clamp the new grease bucket, and then the lifting motor raises the clamped new grease bucket. S8, the walking drive motor drives the walking mechanism and the lifting and hoisting mechanism to move towards the near end of the walking beam until the near end proximity switch on the walking beam senses the proximity switch trigger rod on the hoisting mechanism frame, and the walking drive motor stops moving; then the rotary motor drives the walking beam to rotate, rotating the new grease bucket that has been picked up to above the movable support plate that extends from the receiving platform. S9, the lifting motor lowers the new grease bucket to the movable support plate extended from the receiving platform, and the grease bucket clamping mechanism releases the new grease bucket; S10, after the lid of the new grease container is lifted by the magnetic force of the electromagnet, the lifting motor raises the grease container clamping mechanism to the predetermined position, and the lid is placed on the recycled empty grease container according to steps S5 and S6. S11, the linear drive mechanism of the receiving platform retracts the movable support plate containing the new grease container, and the pneumatic grease pump pumps the grease.

10. A fully automatic installation and replacement method for the grease tank of a tunnel boring machine according to claim 9, characterized in that, In step S11, the correction baffle set on the receiving platform corrects the position of the new grease bucket that has shifted.

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