A TBM test device and method integrating rolling, stamping and wear test

Abstract

This invention discloses a TBM testing device and method integrating rolling, stamping, and wear testing. It includes a frame, a main drive mechanism, a reciprocating motion guide mechanism, a rotary support mechanism, a synchronous propulsion transmission box, an impact system, a cutter head system, and a rock box system. The main drive mechanism, synchronous propulsion transmission box, rotary support mechanism, cutter head system, and rock box system are arranged sequentially from top to bottom within the frame. The reciprocating motion guide mechanism is located between the synchronous propulsion transmission box and the frame. The overall structure of the device is relatively simple, and its components are flexible, with reasonable assembly and significant room for improvement. Furthermore, this invention integrates multiple technologies such as impact technology, hydraulic transmission, and electric technology, enabling it to achieve functions such as rolling rock breaking, pressure-impact coupled rock breaking, and cutter wear testing. It is highly practical, highly adjustable, and has broad application prospects.

Description

Technical Field

[0001] This invention belongs to the field of rock-breaking tunneling test technology, specifically relating to a TBM test device and method that integrates rolling, stamping, and wear testing. Background Technology

[0002] Currently available TBM cutterhead rock-breaking tools are extremely inefficient at breaking hard rock, and suffer from slow tunneling speeds and significant cutter wear. There is an urgent need to develop a new and advanced TBM tunneling method. Impact rock breaking is a dynamic rock-breaking method with significant advantages in terms of high efficiency and feasibility. However, existing rock-breaking tunneling test equipment lacks vibration and impact capabilities and cannot assess TBM cutter wear and rock abrasiveness, resulting in a limited design functionality for rock-breaking tunneling test platforms. Summary of the Invention

[0003] To address the problems in existing technologies, this invention provides a TBM testing device integrating rolling, stamping, and wear testing. The device includes a frame, a main drive mechanism, a reciprocating motion guide mechanism, a rotary support mechanism, a synchronous propulsion transmission box, an impact system, a cutter head system, and a rock box system. Within the frame, the main drive mechanism, synchronous propulsion transmission box, rotary support mechanism, cutter head system, and rock box system are arranged sequentially from top to bottom. The upper end of the main drive mechanism is connected to the upper end of the frame, and the lower end of the main drive mechanism is connected to the synchronous propulsion transmission box. The lower end of the synchronous propulsion transmission box is connected to the impact system. The upper end of the rotary support mechanism is connected to the upper end of the cutter head system, the lower end of the cutter head system is located above the rock box system, the lower end of the rock box system is fixed to the lower end of the frame, the lower end of the impact system is fixedly connected to the cutter head system, the reciprocating motion guide mechanism is located between the synchronous propulsion transmission box and the frame, the upper end of the reciprocating motion guide mechanism is connected to the upper end of the frame, the lower end of the reciprocating motion guide mechanism is connected to the lower end of the frame, and the reciprocating motion guide mechanism is also fixedly connected to the synchronous propulsion transmission box.

[0004] Furthermore, the frame includes uprights, an upper crossbeam, and a base. Four uprights are provided, with the upper end of each upright fixed to the upper crossbeam and the lower end of each upright fixed to the base.

[0005] Furthermore, the synchronous propulsion transmission box includes an end plate, reinforcing support columns, and a base plate, wherein the end plate and the base plate are connected and fixed by four reinforcing support columns.

[0006] Furthermore, the main drive mechanism includes a rotary drive mechanism and a propulsion drive mechanism. The rotary drive mechanism consists of a stepper motor, a reducer, a cloverleaf coupling, and a connecting spindle. The stepper motor is connected to the reducer. The output shaft of the reducer passes through the end plate and is connected to the connecting spindle via the cloverleaf coupling. The lower end of the connecting spindle is connected to the base plate. The propulsion drive mechanism includes hydraulic cylinders and cylinder body connecting lugs. There are four hydraulic cylinders and eight cylinder body connecting lugs. The upper and lower ends of the hydraulic cylinders are connected to the upper crossbeam and the end plate respectively via the cylinder body connecting lugs.

[0007] Furthermore, the reciprocating motion guide mechanism includes a guide rail and a slider. The guide rail is fixedly mounted on the column, and a slider that slides along the guide rail is provided on the guide rail. The upper end of the slider is fixedly connected to the end plate, and the lower end of the slider is fixedly connected to the base plate.

[0008] Furthermore, the slewing support mechanism consists of a slewing bearing and a slewing force transmission flange. One end of the slewing bearing is connected to the end plate, and the other end is connected to the slewing force transmission flange. A conductive system is provided on the connecting main shaft. The conductive system includes an electric slip ring, and the output wire of the electric slip ring is connected to the impact system through a through hole on the slewing force transmission flange.

[0009] Furthermore, the cutterhead system consists of a roller cutterhead and roller cutter brackets. Multiple roller cutter brackets are provided, which can be added or removed adaptively according to the shape of the roller cutterhead. The lower end of each roller cutter bracket is fixed to the roller cutterhead, and the upper end is fixedly connected to the rotary force transmission flange. The impact system consists of an impact breaker and a vertical plate. The impact breaker is fixedly connected to the vertical plate, and the vertical plate is fixed to the roller cutterhead. The impact breaker includes an impact breaker body, impact rollers, and an impact drill rod. The impact breaker body is fixedly connected to the vertical plate and can extend from a hole in the roller cutterhead. The impact breaker body and the impact rollers are connected via the impact drill rod. During rock breaking and excavation, the impact breaker body drives the impact rollers to reciprocate up and down in the vertical direction.

[0010] Furthermore, the rock box is composed of box panels, which are mounted on the base. The base has an opening slot, the size of which is adapted to the size of the rock box. There are four box panels, which together form the interior of the rock box and are embedded in the base. The outer surface of each box panel is fixedly connected to a lead screw. Four supports are fixedly mounted on the base, each support having a through hole. The lead screw passes through the through hole and is connected to the support. A lead screw handle is also connected to the end of the lead screw.

[0011] Furthermore, four machine tool leveling plates are provided at the bottom of the base, and the machine tool leveling plates are fixed to the base by bolts. Multiple bolt through holes are regularly opened on the base to facilitate connection and cooperation with other connecting parts.

[0012] Furthermore, multiple hob cutter boxes are provided at the lower end of the hob cutter disc. Each hob cutter box includes an upper base, a lower base, a bearing end cover, a hob cutter shaft, a hob cutter, and a ball bearing. The bearing end cover is connected to the sides of the upper base and the lower base. The hob cutter shaft is placed between the upper base and the lower base. A washer, a hob cutter, a set nut, and a ball bearing are sequentially connected to the hob cutter shaft. The hob cutter is fixed by the washer, the set nut, and the ball bearing.

[0013] The present invention also provides a method for a rolling test, the method comprising the following steps:

[0014] S1. Place the test rock sample in the rock box and check the working status of the rotary drive mechanism and the propulsion drive mechanism to ensure they are in normal working condition.

[0015] S2. Configure the test hob and install the configured hob into the hob box. Fix the hob box onto the hob disc.

[0016] S3. Start the hydraulic pump station, adjust the hydraulic cylinder to a suitable extension speed via the speed control valve, and simultaneously adjust the pulse controller to regulate the rotation speed of the hobbing cutter head.

[0017] S4. Start the rolling rock breaking test. When the roller cutter head reaches the maximum displacement, the limit switch is triggered to stop the control system.

[0018] Furthermore, by adding a limiting device to the control system, i.e., the hydraulic cylinder itself has a limit elongation, the control system adaptively reduces the elongation as the maximum displacement based on the limit elongation of the hydraulic cylinder, thus ensuring the safety of the test and the stability of the heat generation during the operation of the device.

[0019] The present invention also provides a method for stamping tests, the method comprising the following steps:

[0020] S1. Place the test rock sample in the rock box and check the working status of the rotary drive mechanism and the propulsion drive mechanism to ensure they are in normal working condition.

[0021] S2. Configure the test hob and install the configured hob into the hob box. Fix the hob box onto the hob disc.

[0022] S4. According to the set impact frequency required for the test, start the impact system, the rotary drive mechanism, and the propulsion drive mechanism. The impact of the impact cutter and the rolling pressure of the cutter are coupled together to participate in the rock sample crushing, that is, to realize the pressure-impact coupled rock breaking function.

[0023] S5. After the cutterhead completes the entire tunneling operation under the set parameters, the hydraulic system is controlled, and the cutterhead returns to its original position under the drive of the hydraulic cylinders. This allows the test personnel to clean and collect the rock debris to inspect its quality and then carry out subsequent analysis work.

[0024] S6. Replace the impact hob and conduct different stamping tests.

[0025] The present invention also provides a method for wear testing, the method comprising the following steps:

[0026] S1. Place the test rock sample in the rock box and check the working status of the rotary drive mechanism and the propulsion drive mechanism to ensure they are in normal working condition.

[0027] S2. Configure the test hob and install the configured hob into the hob box. Fix the hob box onto the hob disc.

[0028] S4. Conduct a wear test on the cutter. During the test, keep the cutter moving in a circular motion on the rock sample while simultaneously making a penetrating motion in the vertical direction. Use compressed air to remove dust and debris from the track to ensure that the cutter only contacts the rock sample during the test.

[0029] S5. After the test, the wear of the cutter is judged by the depth of the indentation on the rock sample.

[0030] Compared with existing technologies, the TBM testing device of this invention, which integrates rolling, stamping, and wear testing, has a simple overall structure, suitable size, and does not occupy too much installation space, thus greatly saving manufacturing costs and reducing manufacturing difficulty. Moreover, the various components of the device are flexible, rationally assembled, and have significant room for improvement. While ensuring the strength of the machine body, it is user-friendly, convenient for experimental personnel to operate and maintain. Furthermore, this invention integrates multiple technologies such as impact technology, hydraulic transmission, and electric technology, enabling it to achieve functions such as rolling rock breaking, pressure-impact coupled rock breaking, and tool wear testing. It is highly practical, highly adjustable, and has broad application prospects. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall structure of the TBM rock-breaking test device of the present invention;

[0032] Figure 2 This is a schematic diagram of the slewing bearing structure of the TBM rock-breaking test device of the present invention;

[0033] Figure 3 This is a schematic diagram of the cutterhead system of the TBM rock-breaking test device of the present invention;

[0034] Figure 4 This is a schematic diagram of the overall structure of the roller cutter box of the TBM rock-breaking test device of the present invention;

[0035] Figure 5 This is a schematic diagram of the impact system of the TBM rock-breaking test device of the present invention;

[0036] Figure 6 This is a schematic diagram of the rock box system structure of the TBM rock breaking test device of the present invention;

[0037] Figure 7 This is a logic diagram of the control system of the TBM rock-breaking test device of the present invention;

[0038] Figure 8 This is a schematic diagram of the hydraulic system of an embodiment of the TBM rock-breaking test device of the present invention;

[0039] Figure 9 This is a schematic diagram of the hydraulic pump station of an embodiment of the TBM rock-breaking test device of the present invention.

[0040] Among them, 1-Column; 2-Upper crossbeam; 3-Right-angle steel connector; 4-Bolt; 5-Cylinder body connecting lug; 6-Hydraulic cylinder; 7-Guide rail; 8-Slider; 9-Reinforced support column; 10-Synchronous propulsion transmission box; 1001-Rear end face of synchronous propulsion transmission box; 11-Slewing bearing; 12-Upright plate; 13-Impact breaker; 1301-Impact breaker body; 1302-Vibration damping pad; 1303-Impact cutter head; 1304-Impact drill rod; 14-Base; 15-Machine bed pad; 16-Rock box; 17-Screw handle; 18-Screw support; 19-Curl cutter head; 20-Curl cutter bracket. ; 21-Holl cutter box; 2101-Upper base of cutter box; 2102-Shim; 2103-Bearing end cover; 2104-Lower base of cutter box; 2105-Holl cutter; 2106-Holl cutter shaft; 2107-Ball bearing; 2108-Set nut; 22-Lead screw; 23-Steel fastener; 24-Rotary transmission flange; 25-Electric slip ring; 26-Connecting spindle; 27-Plum blossom type coupling; 28-Reducer; 29-Stepper motor; 30-Rock sample; 36-Hydraulic pump drive motor; 37-Hydraulic pump; 38-Hydraulic combination control valve; 39-Hydraulic oil tank; 40-Inlet synchronous motor; 41-Return synchronous motor. Detailed Implementation

[0041] The present invention will be further explained and described below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0042] According to the appendix Figure 1 As shown, this invention provides a TBM testing device integrating rolling, stamping, and wear testing, including a frame, a main drive mechanism, a reciprocating motion guide mechanism, a rotary support mechanism, a synchronous propulsion transmission box, an impact system, a cutter head system, and a rock box system. The main drive mechanism, synchronous propulsion transmission box, rotary support mechanism, cutter head system, and rock box system are arranged sequentially from top to bottom within the frame. The upper end of the main drive mechanism is connected to the upper end of the frame, and the lower end of the main drive mechanism is connected to the synchronous propulsion transmission box. The lower end of the synchronous propulsion transmission box is connected to the rotary support mechanism. The upper end of the structure is connected, the lower end of the rotary support mechanism is connected to the upper end of the cutter head system, the lower end of the cutter head system is located above the rock box system, the lower end of the rock box system is fixed to the lower end of the frame, the lower end of the impact system is fixedly connected to the cutter head system, the reciprocating motion guide mechanism is located between the synchronous propulsion transmission box and the frame, the upper end of the reciprocating motion guide mechanism is connected to the upper end of the frame, the lower end of the reciprocating motion guide mechanism is connected to the lower end of the frame, and the reciprocating motion guide mechanism is also fixedly connected to the synchronous propulsion transmission box.

[0043] According to an embodiment of the present invention, the frame includes columns 1, upper crossbeams 2, and a base 14. Four columns 1 are provided, with the upper ends of the columns 1 fixed to the upper crossbeams 2 via right-angle steel connectors 3, and the lower ends of the columns 1 fixed to the base 14. The upper crossbeams 2 mainly participate in the assembly of the hydraulic cylinder, the synchronous propulsion transmission box 10, and the cutter head system. Two upper crossbeams 2 are connected to four columns 1, ensuring the stability of the entire device, preventing interference with the operation of other components, maintaining the consistency of the cutter head system's installation orientation with the machine tool coordinate system and the test coordinate system, and ensuring the directional installation of parts on the device, enabling other components to maintain a certain coordinate relationship with the overall device. Four columns 1 are mounted on the base 14 via steel fasteners 23, and a rock box 16 is configured on the base 14. The features of the entire frame are as follows: ① Ensures the strength and working stability of the entire device, with high strength requirements; ② Allows for the reasonable assembly of other structural components, including the rotary drive mechanism, the propulsion drive mechanism, and the cutter head system; ③ Clamps the rock sample 30, facilitating rock breaking tests; ④ Has a simple structure, low manufacturing cost, and is easy for test personnel to operate.

[0044] According to an embodiment of the present invention, the synchronous propulsion transmission box 10 includes an end plate, a reinforcing support column 9 and a bottom plate, wherein the end plate and the bottom plate are connected and fixed by four reinforcing support columns 9.

[0045] According to an embodiment of the present invention, the main drive mechanism includes a rotary drive mechanism and a propulsion drive mechanism. The rotary drive mechanism consists of a stepper motor 29, a reducer 28, a plum blossom coupling 27, and a connecting main shaft 26. The stepper motor 29 is connected to the reducer 28. The output shaft of the reducer 28 passes through the end plate and is connected to the connecting main shaft 26 through the plum blossom coupling 27. The lower end of the connecting main shaft 26 is connected to the base plate. The propulsion drive mechanism includes hydraulic cylinders 6 and cylinder body connecting lugs 5. Four hydraulic cylinders 6 are provided, and eight cylinder body connecting lugs 5 are provided. The upper and lower ends of the hydraulic cylinders 6 are respectively connected to the upper crossbeam 2 and the end plate through the cylinder body connecting lugs 5. The rotary drive mechanism of the device uses a 130BYG350D stepper motor as the power output device to drive the rotation of the cutter head system. The stepper motor 29 is controlled by a DMA860H driver. The speed of the stepper motor 29 is controlled by an RCmf-1 pulse generator, thereby realizing the adjustment of the speed of the cutter head system.

[0046] According to an embodiment of the present invention, the reciprocating motion guide mechanism includes a guide rail 7 and a slider 8. The guide rail 7 is fixedly mounted on the column 1, and the slider 8 is mounted on the guide rail 7 and slides in cooperation with the guide rail 7. The upper end of the slider 8 is fixedly connected to the end plate, and the lower end of the slider 8 is fixedly connected to the base plate.

[0047] According to embodiments of the present invention and accompanying drawings Figure 2 As shown, the rotary support mechanism consists of a rotary bearing 11 and a rotary force transmission flange 24. One end of the rotary bearing 11 is connected to the end plate, and the other end is connected to the rotary force transmission flange 24. A conductive system is provided on the connecting spindle 26. The conductive system includes an electric slip ring 25, and the output wire of the electric slip ring 25 is connected to the impact system through a through hole in the rotary force transmission flange 24. The core component of the rotary support structure is the rotary bearing 11, which not only provides a large thrust for the cutter head system but also transmits torque, driving the entire cutter head system to complete the rotary motion.

[0048] According to embodiments of the present invention and accompanying drawings Figure 3As shown, the cutter head system consists of a roller cutter head 19 and roller cutter brackets 20. There are four roller cutter brackets 20. The lower end of each roller cutter bracket 20 is fixed to the roller cutter head 19, and the upper end of each roller cutter bracket 20 is fixedly connected to the rotary force transmission flange 24. The impact system consists of an impact breaker 13 and a vertical plate 12. The impact breaker 13 is fixedly connected to the vertical plate 12, and the vertical plate 12 is fixed to the roller cutter head 19. The hob cutter head 19 is connected to the rotary force transmission flange 24 via the hob bracket 20. To simplify the machining of the hob cutter head 19, reduce machining costs, and ensure smooth pressure-impact coupled rock breaking tests, a "cross" shaped hob cutter head 19 was designed based on the size of the rock box. Two positive hobs 2105 are mounted on the existing hob cutter head 19. The diameter of the two hobs 2105 on the hob cutter head 19 is adjustable, which allows for adjustment of the distance between the hobs 2105 and the impact hobs 1303 in the pressure-impact coupled rock breaking test, thereby studying the influence of the tool spacing on cutting efficiency. The hobs 2105 and impact hobs 1303 used are easy to replace, and rock breaking tests can be carried out on hobs 2105 and impact hobs 1303 with different diameters and cutting edges to study the influence of different hobs 2105 and impact hobs 1303 on rock breaking efficiency, ensuring the strength and working stability of the cutter head system.

[0049] According to embodiments of the present invention and accompanying drawings Figure 4 As shown, a hob cutter box 21 is also provided at the lower end of the hob cutter disc 19. The hob cutter box 21 includes an upper base 2101, a lower base 2104, a bearing end cover 2103, a hob cutter shaft 2106, a hob cutter 2105, and a ball bearing 2107. The bearing end cover 2103 is connected to the sides of the upper base 2101 and the lower base 2104. The hob cutter shaft 2106 is placed between the upper base 2101 and the lower base 2104. A washer 2102, a hob cutter 2105, a set nut 2108, and a ball bearing 2107 are connected sequentially on the hob cutter shaft 2106. The hob cutter 2105 is fixed by the washer 2102, the set nut 2108, and the ball bearing 2107.

[0050] According to embodiments of the present invention and accompanying drawings Figure 5As shown, the impact breaker 13 includes an impact breaker body 1301, an impact cutter head 1303, and an impact chisel 1304. The impact breaker body 1301 is fixedly connected to the vertical plate 12. The impact breaker body 1301 can extend from a hole in the cutter head 19. The impact breaker body 1301 and the impact cutter head 1303 are connected by the impact chisel 1304. The impact cutter head 1303 is fixed in the cutter head box 21 below the cutter head 19. The impact cutter head 1303 actually manufactured meets the design requirements. Different shapes of impact cutter head 1303, including blunt, wedge, and circular, can be replaced to explore the influence of different blade types and masses of impact cutter head 1303 on the impact rock breaking efficiency. For the impact system, the impact frequency can be adjusted by adjusting the speed of the motor in the impact breaker body 1301.

[0051] According to embodiments of the present invention and accompanying drawings Figure 6 As shown, the rock box 16 is composed of box panels, which are mounted on the base 14. The base 14 has an opening slot, the size of which is adapted to the size of the box panel, but slightly larger than the dimensions of the rock box 16 to facilitate the placement of the rock sample 30. There are four box panels, which together form the rock box 16 and are embedded in the base 14. The outer surface of each box panel is fixedly connected to a lead screw 22. Four lead screw supports 18 are fixedly mounted on the base 14. Each lead screw support 18 has a through hole through which the lead screw 22 passes and connects to the lead screw support 18. A lead screw handle 17 is also connected to the end of the lead screw 22. After the rock sample 30 is placed in the rock box 16, the screw rod 22 is tightened by the screw handle 17 to clamp the rock sample 30. The screw rod 22 has a self-locking function, so it will not rotate without external force, ensuring that the rock box 16 can securely clamp the rock sample 30. The rock sample 30 is then placed inside the rock box 30. The base 14 is the load-bearing part of the entire machine, equipped with four columns 1 and four adjustable leveling pads 15. The leveling pads 15 allow the height of the entire device to be adjusted between 1 and 10 mm, preventing the sample from tilting due to uneven ground, which could cause the device to lose its horizontal and vertical accuracy, leading to wear on other components during operation, and in severe cases, damage to some parts, resulting in a test accident. Furthermore, the structure of the base 14 determines the stability of the entire device, and the size of the base 14 also determines the overall size of the rock box 16. The working principle of the base and rock box 16 is based on the clamping principle of flat-jaw pliers. The box plate in the horizontal x and y directions can be adjusted to achieve the clamping and loosening function of rock sample 30. In addition, it facilitates the placement and removal of rock sample 30 during the test.

[0052] According to embodiments of the present invention and accompanying drawings Figure 7 As shown, the main circuit components of the control system include: stepper motor 29 drive module, hydraulic pump drive motor 36 module, proximity switch, emergency stop switch, electromagnetic relay, button, indicator light, DC power supply, pulse encoder, safety switch, encoder, etc. First, the wires at the input end of the stepper motor 29 are connected to the stepper motor 29 drive module in the control box. To avoid problems such as tangled and messy wires, the wires are arranged along the upper crossbeam. After the wires that provide power to the impact system are connected to the slip ring 25, the wires are connected to the power switch in the control box through the internal space of the synchronous propulsion transmission box 10. The function of limiting the maximum displacement of the cutter head 19 is achieved by a proximity switch. The power line of the proximity switch is connected from the control box to the limit switch on the column 1. The limit switch is magnetically attached to the column for easy position adjustment. The power output line of the hydraulic pump drive motor 36 module in the control box is connected to the motor and the solenoid valve of the hydraulic pump station, so as to realize the electrical signal control of the hydraulic pump station. The wires leading out from the control box are arranged reasonably so as not to interfere with the operation of the entire device. The control system can realize independent control of the hydraulic system and the motor system. The working states of the two do not interfere with each other, and can realize synchronous control of the prototype's propulsion and rotation, thereby completing the complete tunneling action. The control system is required to adjust various variable factors, including the rotation speed of the hobbing cutter head 19, the cutter penetration speed and depth, and the impact speed of the impact hobbing cutter 1303. The control system mainly consists of a hydraulic adjustment control system and a motor control system. These control systems control the lifting and lowering motion of the hobbing cutter head 19 and its rotation via the hydraulic cylinder 6 and stepper motor 29, respectively, ensuring the normal operation of the hobbing cutter head 19. The control system should have emergency stop, limit, and basic functions. The emergency stop function has the highest priority, followed by the limit function, with the basic functions having the lowest priority. The start / stop and reversing functions of the basic functions are at the same level. The working principle of the control system is as follows: under normal operating conditions, the emergency stop function is off. The start, stop, and reversing functions of the prototype are independent and can be switched between each other. The start / stop function and speed regulation function are at the same level and do not interfere with each other. At this time, the limit function is off. When the displacement of the hobbing cutter head 19 reaches its limit, the limit function activates, causing the hobbing cutter head 19 to switch to a stop state. At this time, the limit state can be released by changing the advance direction of the hobbing cutter head 19. However, when the prototype is in an abnormal operating condition, pressing the emergency stop switch will put the hobbing cutter head 19 into an emergency stop state, stopping all operations.

[0053] According to embodiments of the present invention and accompanying drawings Figure 8As shown, in order to achieve simultaneous rotation and advancement of the cutterhead 19 at the set rotational speed and advance speed, i.e., stable tunneling motion during rock breaking, the hydraulic system needs to have the following functions: First, it needs to use four hydraulic cylinders matched with the four guide rails 7, a synchronous propulsion transmission box 10, and the cutterhead 19 to ensure smooth advancement, prevent uneven load from causing the guide rails 7 to jam, and ensure the synchronization of the four hydraulic cylinders; Second, during the tunneling process, the external load changes greatly, which will cause large changes in the cylinder inlet pressure, thus affecting the stability of the flow rate and consequently the stability of the tunneling speed. It is necessary to set up a speed regulating valve or an overflow throttle valve to ensure the stability and uniformity of the flow rate of each hydraulic cylinder.

[0054] The hydraulic pump drive motor 36 drives the hydraulic pump 37 to work. The oil port of the hydraulic pump 37 is connected to the oil port of the combined hydraulic control valve to realize the opening and closing of different oil circuits, thereby realizing the control function of the hydraulic cylinder 6. To ensure the synchronous operation of the four hydraulic cylinders 6 and to ensure that the hydraulic oil flow and pressure of each cylinder are the same, a one-inlet and four-outlet hydraulic synchronization valve is configured. The oil outlet of the hydraulic oil pump station is connected to the oil inlet of the synchronization valve through an oil pipe. The four oil outlets of the synchronization valve are connected to the oil inlets of the four hydraulic cylinders 6 respectively through hydraulic pipes. The oil inlet of the hydraulic pump 37 is connected to the oil inlet of another synchronization valve through a hydraulic oil pipe. The four oil outlets of the other synchronization valve are connected to the oil outlets of the four hydraulic cylinders 6 respectively through hydraulic pipes. In order to filter out various impurities in the hydraulic system and ensure the cleanliness of the hydraulic oil, a filter is configured and connected to the hydraulic system. The pump has a return oil port 37; a cooler is installed so that during operation, the high-temperature oil in the hydraulic system flows through the hydraulic cooler to reduce the oil temperature and ensure continuous and normal operation of the main unit; the most critical part of the prototype's operation is ensuring that the tunneling runs stably at the preset speed. An electro-hydraulic proportional valve is used, mainly to proportionally control the pressure and flow in the hydraulic system to ensure operational stability; however, to ensure precise flow control in the system, a pressure compensation valve is needed to control the pressure difference before and after throttling, ensuring that the actuator works at the set speed under the condition that the flow in the system is sufficient; to increase the smoothness of the entire moving parts, an overflow valve is installed on the return oil line to generate back pressure and maintain the pressure stability of the entire hydraulic system; in addition, to ensure the safety of the main unit during operation, manual shut-off valves are installed at the inlet and outlet oil ports of the hydraulic cylinder 6.

[0055] According to embodiments of the present invention and accompanying drawings Figure 9 As shown, an inlet synchronous motor 40 and an outlet synchronous motor 41 are respectively configured in the inlet and outlet oil circuits of the hydraulic system, thereby achieving the purpose of equal flow distribution of hydraulic oil in the hydraulic oil tanks 39 of the two oil circuits, ensuring that the four hydraulic cylinders 6 of the propulsion system operate synchronously and improving the stability of the mechanism operation; the main working parameters of the customized hydraulic pump station are 220V-2.2KW-8L, horizontal hydraulic pump 37, and the oil circuit is controlled by a series of hydraulic combination control valves 38.

[0056] The specific operating steps of the rolling test of the present invention are further described below:

[0057] The first step is to clamp the rock sample. Before conducting the test, the rock sample 30 should be placed in the rock box 16, as shown in the attached diagram. Figure 6 As shown, rotating the screw handle 17 drives the screw 22 to rotate, dragging the box plate to its maximum displacement. At this point, the rock box 16 is in a relaxed state, and the rock sample is placed inside the box under the operation of the tester. The screw 22 is then rotated in the opposite direction to push the box plate to move and clamp the rock sample 30.

[0058] The second step is to check whether the working status of the rotary drive system is normal, that is, to check whether the stepper motor 29 can run normally. After powering on the equipment, start the motor driver. The stepper motor 29 is controlled to run by the DMA860H type driver and the rotation speed is controlled by the RCmf-1 pulse generator. After adjusting the controller to the set speed, the operation test is carried out.

[0059] The third step is to check whether the propulsion drive system is functioning properly, specifically by checking the hydraulic pump station, including hydraulic cylinder 6, to ensure it is operating normally. (See attached document.) Figure 9 As shown, start the stepper motor 29 to drive the hydraulic pump 37 to run, adjust the flow rate of the relief valve, observe whether the hydraulic cylinder 6 extends and retracts normally, and check its operating status.

[0060] Fourth, after testing the drive system's operating status, configure the 2105 hobbing cutter used in the test, referring to the attached document. Figure 4 The type of hob 2105 can be changed according to different experimental needs, and it can be fully assembled with the hob box 21.

[0061] The fifth step is to properly assemble the hob cutter box 21 with the hob cutter 2105 assembled onto the hob cutter disc 19. In this test, two hobs 2105 are installed. According to the test parameters, the installation position is properly adjusted, the cutter spacing is determined, and the hobs are fixed onto the hob cutter disc 19 with bolts.

[0062] The sixth step is to conduct a pure cutterhead rolling test. Start the hydraulic pump station and adjust the hydraulic cylinder 6 to a suitable extension speed via the speed control valve, thereby adjusting the tunneling penetration. Simultaneously, adjust the pulse controller to adjust the appropriate rotation speed of the cutterhead 19. After all parameters are fully adjusted, begin the rolling rock breaking test, combining the control system logic with reference to… Figure 7 The schematic diagram shows that this system has added a limit device. When the entire hobbing cutter head 19 reaches the maximum displacement, the limit switch can be triggered, and the entire propulsion system will be powered off and stop working. This function ensures the safety of the test and the stability of the device operation.

[0063] According to an embodiment of the present invention, a pure roller cutter rock breaking test was conducted. The roller cutter 2105 used was of constant cross-section, with a diameter of 48.3 mm and a cutting width of 2 mm. In the first group of tests, the distance between the two roller cutters 2105 was adjusted to 30 mm, the penetration depth was set to 2 mm, and the total penetration depth was 5 mm, forming two concentric circular cuts. The rock under the cutters was ground into powder, and it was found that the rock between the cuts was peeled off in the form of flaky rock fragments, which is similar to the actual rock breaking form of a TBM roller cutter. This indirectly verified the rationality of using a small roller cutter for rock breaking in principle.

[0064] According to an embodiment of the present invention, the purpose of conducting a pure roller cutter rock-breaking test is to verify the similarity between the rock-breaking mode of the entire device and the actual TBM under a reasonable rock-breaking cutter spacing, and to verify the rationality of using small roller cutters for rock breaking in principle; and to verify the high efficiency of impact rock breaking by comparing with the effect achieved by impact.

[0065] The specific operating steps of the stamping test of the present invention are further described below:

[0066] The first step is to clamp the rock sample. Before conducting the test, the rock sample 30 should be placed in the rock box 16, as shown in the attached diagram. Figure 6 As shown, rotating the screw handle 17 drives the screw 22 to rotate, dragging the box plate to its maximum displacement. At this point, the rock box 16 is in a relaxed state, and the rock sample is placed inside the box under the operation of the tester. The screw 22 is then rotated in the opposite direction to push the box plate to move and clamp the rock sample 30.

[0067] The second step is to check whether the working status of the rotary drive system is normal, that is, to check whether the stepper motor 29 can run normally. After powering on the equipment, start the motor driver. The stepper motor 29 is controlled to run by the DMA860H type driver and the rotation speed is controlled by the RCmf-1 pulse generator. After adjusting the controller to the set speed, the operation test is carried out.

[0068] The third step is to check whether the propulsion drive system is functioning properly, specifically by checking the hydraulic pump station, including hydraulic cylinder 6, to ensure it is operating normally. (See attached document.) Figure 9 As shown, start the stepper motor 29 to drive the hydraulic pump 37 to run, adjust the flow rate of the relief valve, observe whether the hydraulic cylinder 6 extends and retracts normally, and check its operating status.

[0069] Fourth, after testing the drive system's operating status, configure the 2105 hobbing cutter used in the test, referring to the attached document. Figure 4 The type of hob 2105 can be changed according to different experimental needs, and it can be fully assembled with the hob box 21.

[0070] The fifth step is to properly assemble the hob cutter box 21 with the hob cutter 2105 assembled onto the hob cutter disc. In this test, two hobs 2105 are installed. According to the test parameters, the installation position is properly adjusted, the hob cutter 2105 spacing is determined, and the hobs are fixed to the hob cutter disc 19 with bolts.

[0071] Step 6: Check if the electrical conductivity of slip ring 25 is normal. Refer to the attached document. Figure 5 As shown, power is supplied to the impact breaker body 1301 in the impact system, and the test run is performed according to the set vibration frequency to check the operating status.

[0072] Step 7: Install the impact system on the cutter head 19. Adjust the installation position according to the test requirements. After determining the appropriate distance between the cutter head 2105 and the impact cutter head 1303, fix it. During installation, pay attention to the proper installation of the buffer pad 1302 so as to better buffer and dampen the shock and reduce the negative impact of the impact on the entire device.

[0073] The eighth step is to set the required impact frequency for the test, start the impact system, the rotary drive mechanism and the propulsion drive mechanism, and begin the impact rock breaking test. At this time, the impact of the impact cutter and the rolling of the cutter are coupled together to participate in rock breaking, that is, to realize the pressure-impact coupled rock breaking function. After the cutter head 19 completes the entire tunneling action under the set parameters, the hydraulic system is controlled and the cutter head 19 returns to its original position under the drive of the hydraulic cylinder 6, so that the test personnel can clean and collect the rock debris to check its quality and then carry out subsequent analysis work.

[0074] Furthermore, replace the impact hob 1303 and conduct different stamping tests, refer to the attached document. Figure 5 The impact drill rod 1304 and the impact cutter 1303 can be disassembled and replaced. Then, steps seven and eight are repeated to properly assemble the impact cutter 1303 and carry out subsequent tests.

[0075] According to an embodiment of the present invention, a series of rock-breaking tests were conducted using an impact cutter. The wedge angle of the impact cutter 1303 was 60°, the impact frequency was 85Hz, the mass of the impact cutter 1303-impact drill rod 1304 assembly was 311g, and the penetration depth was adjusted to 2mm. The tests showed that the impact cutter 1303, after contacting the rock surface, fully broke the rock between the two cuts in the cutter test, mainly in the form of flaky rock fragments. The area below the cuts was relatively smooth, without any uneven impact pits. The impact test indicates that the impact of the impact cutter 1303 can effectively promote the connection of cracks between adjacent cutter marks into fragments.

[0076] According to an embodiment of the present invention, a rock-breaking test was conducted using a single roller cutter 2105 to verify that the impact of the roller cutter 1303 can effectively promote the penetration of cracks between adjacent roller cutter marks, indicating that the rock-breaking effect of impact is good. Subsequently, a pressure-impact coupled rock-breaking test was conducted to verify the high efficiency of the pressure-impact coupled rock-breaking method, which is more effective than the single roller cutter 2105 rolling and impact roller cutter 1303 impact.

[0077] The following is a description of the function of conducting wear tests on hobbing cutters 2105, but it should be noted that:

[0078] First, when conducting the wear test of the roller cutter 2105, during the test, the roller cutter 2105 maintains a circular rotation on the rock sample 30 and simultaneously makes a penetrating motion in the vertical direction. To ensure that the roller cutter 2105 is always in contact with the intact surface of the rock sample 30, the suction of compressed air can be used to remove dust and debris from the rock-breaking track, so as to ensure that the roller cutter 2105 only contacts the rock sample 30 during the rock-breaking process, making the results closer to the actual values.

[0079] Second, this test method has a strong ability to assess the abrasive wear of the hob to predict the life of the hob 2105, and is also applicable to the prediction of the abrasive range of various rocks.

[0080] Third, the life assessment is mainly carried out by testing the weight loss of the roller 2105 before and after the test, and at least three tests are conducted to obtain a representative average value. In addition to the weight loss, the penetration force of the roller 2105 into the intact rock can also be measured after the test, and the depth of the indentation on the rock sample 30 after the test is used to determine the life.

[0081] Fourth, for different rock samples, the experimental results will vary due to the differences in the rock sample 30 itself. Generally speaking, the wear of the roller 2105 is inversely proportional to the depth of the indentation, that is, the wear resistance is inversely proportional to the indentation. At the same time, the higher the hardness of the rock sample, the higher the wear of the roller 2105 and the shallower the indentation. This relationship indicates that the wear of the roller 2105 depends on the hardness of the rock surface or the resistance of the roller disc 19 to the indentation.

[0082] The specific operating steps for the wear test of this invention are as follows:

[0083] First, select a rock sample with appropriate length and width as required, and place the rock sample in the rock box 16, referring to step one above.

[0084] Secondly, the structure of the rock box plate was changed, the screw 22 and its manufacturing parts were removed, and several small hydraulic cylinders were added to apply confining pressure to the rock sample 30. The confining pressure can be changed by changing the hydraulic cylinders, and its value can be adjusted between 0-70MPa.

[0085] Then, referring to steps four and five of the above-mentioned function of conducting the hob 2105 wear test, set a reasonable tool spacing. When assembling the hob 2105, the distance between the tips of the two hobs 2105 should be 60mm.

[0086] Next, adjust the rotation speed of the cutter head 19 and the normal thrust required for the test. The rolling speed of the cutter 2105 should be set to 40 revolutions per minute, and the normal thrust of the cutter on the rock sample should be about 1250N.

[0087] Finally, combining the above steps, wear tests are conducted. At the same time, it is necessary to pay attention to the power consumption of the entire device, reasonably control the working time, and operate intermittently to ensure the stability of the device and the safety of the test. After the test, observe the rolling marks on the rock. The rolling contact indentation can more intuitively show the relationship between the wear resistance of the 2105 cutter and the hardness of the rock sample, so that subsequent tunneling in different geological environments can reduce economic losses and improve tunneling efficiency.

[0088] To ensure a close approximation of actual TBM conditions in hard rock tunneling, the weight loss of the cutterhead before and after the test was used to assess its lifespan, and a representative average value was obtained through at least three tests.

[0089] In summary, compared with existing rock breaking test platforms and technologies, the present invention innovatively integrates multiple technologies such as impact technology, hydraulic transmission, and electric technology. It can realize functions such as rolling rock breaking, pressure-impact coupled rock breaking, and tool wear testing. It is highly practical, highly adjustable, and has a wide range of application prospects.

[0090] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A TBM testing device integrating rolling, stamping, and wear testing, characterized in that, This includes the frame, main drive mechanism, reciprocating motion guide mechanism, rotary support mechanism, synchronous propulsion transmission box, impact system, cutterhead system, and rock box system. The main drive mechanism, synchronous propulsion transmission box, rotary support mechanism, cutterhead system, and rock box system are arranged sequentially from top to bottom within the frame. The upper end of the main drive mechanism is connected to the upper end of the frame, and the lower end of the main drive mechanism is connected to the synchronous propulsion transmission box. The lower end of the synchronous propulsion transmission box is connected to the upper end of the rotary support mechanism, and the lower end of the rotary support mechanism is connected to the upper end of the cutterhead system. The lower end of the cutterhead system is positioned above the rock box system, and the lower end of the rock box system is fixed to the lower end of the frame. The lower end of the impact system is fixedly connected to the cutterhead system. The reciprocating motion guide mechanism is disposed between the synchronous propulsion transmission box and the frame. The upper end of the reciprocating motion guide mechanism is connected to the upper end of the frame, and the lower end of the reciprocating motion guide mechanism is connected to the lower end of the frame. The reciprocating motion guide mechanism is also fixedly connected to the synchronous propulsion transmission box. The frame includes uprights, an upper crossbeam, and a base. Four uprights are provided. The upper end of each upright is fixed to the upper crossbeam, and the lower end of each upright is fixed to the base. The synchronous propulsion transmission box includes an end plate, reinforced support columns, and a base plate. The end plate and the base plate are connected and fixed by four reinforced support columns. The main drive mechanism includes a rotary drive mechanism and a propulsion drive mechanism. The rotary drive mechanism consists of a stepper motor, a reducer, a perforated coupling, and a connecting spindle. The stepper motor is connected to the reducer, and the output shaft of the reducer passes through the end plate and is connected to the connecting spindle via the perforated coupling. The lower end of the connecting spindle is connected to the base plate. The propulsion drive mechanism includes hydraulic cylinders and cylinder body connecting lugs. There are four hydraulic cylinders and eight cylinder body connecting lugs. The upper and lower ends of the hydraulic cylinders are connected to the upper crossbeam and the end plate respectively through the cylinder body connecting lugs.

2. The TBM testing device integrating rolling, stamping, and wear testing as described in claim 1, characterized in that, The reciprocating motion guide mechanism includes a guide rail and a slider. The guide rail is fixedly mounted on the column, and a slider that slides along the guide rail is provided on the guide rail. The upper end of the slider is fixedly connected to the end plate, and the lower end of the slider is fixedly connected to the base plate.

3. The TBM testing device integrating rolling, stamping, and wear testing according to claim 1, characterized in that, The slewing support mechanism consists of a slewing bearing and a slewing force transmission flange. One end of the slewing bearing is connected to the end plate, and the other end is connected to the slewing force transmission flange. A conductive system is provided on the connecting spindle, the conductive system including an electric slip ring, and the output wire of the electric slip ring is connected to the impact system through a through hole on the rotary force transmission flange.

4. The TBM testing device integrating rolling, stamping, and wear testing according to claim 3, characterized in that, The cutter head system consists of a hobbing cutter head and a hobbing cutter bracket. The lower end of the hobbing cutter bracket is fixed to the hobbing cutter head, and the upper end of the hobbing cutter bracket is fixedly connected to the rotary force transmission flange. The impact system consists of an impact breaker hammer and a vertical plate. The impact breaker hammer is fixedly connected to the vertical plate, and the vertical plate is fixed to the roller cutter head. The impact breaker includes an impact breaker body, an impact cutter head, and an impact chisel. The impact breaker body is fixedly connected to the vertical plate and can extend from a hole in the cutter head panel. The impact breaker body and the impact cutter head are connected via the impact chisel. Multiple hobbing cutter boxes are also provided at the lower end of the hobbing cutter head.

5. A rolling test method based on the TBM testing apparatus according to any one of claims 1 to 4, the method comprising the following steps: S1. Place the test rock sample in the rock box and check the working status of the rotary drive mechanism and the propulsion drive mechanism to ensure they are in normal working condition. S2. Configure the test hob and install the configured hob into the hob box. Fix the hob box onto the hob disc. S3. Start the hydraulic pump station, adjust the hydraulic cylinder to a suitable extension speed via the speed control valve, and simultaneously adjust the pulse controller to regulate the rotation speed of the hobbing cutter head. S4. Start the rolling rock breaking test. When the roller cutter head reaches the maximum displacement, the limit switch is triggered to stop the control system.

6. A stamping test method based on the TBM testing apparatus according to any one of claims 1 to 4, the method comprising the following steps: S1. Place the test rock sample in the rock box and check the working status of the rotary drive mechanism and the propulsion drive mechanism to ensure they are in normal working condition. S2. Configure the test hob and install the configured hob into the hob box. Fix the hob box onto the hob disc. S3. Check if the slip rings are conducting electricity normally. Then, after energizing the impact breaker, test run it at the set vibration frequency. After confirming that its operation is normal, install the impact system on the cutter head. S4. According to the set impact frequency required for the test, start the impact system, the rotary drive mechanism, and the propulsion drive mechanism. The impact of the impact cutter and the rolling pressure of the cutter are coupled together to participate in the rock sample crushing, that is, to realize the pressure-impact coupled rock breaking function. S5. After the cutterhead completes the entire tunneling operation under the set parameters, the hydraulic system is controlled, and the cutterhead returns to its original position under the drive of the hydraulic cylinders. This allows the test personnel to clean and collect the rock debris to inspect its quality and then carry out subsequent analysis work. S6. Replace the impact hob and conduct different stamping tests.

7. A wear test method based on the TBM testing apparatus according to any one of claims 1 to 4, the method comprising the following steps: S1. Place the test rock sample in the rock box and check the working status of the rotary drive mechanism and the propulsion drive mechanism to ensure they are in normal working condition. S2. Configure the test hob and install the configured hob into the hob box. Fix the hob box onto the hob disc. S3. Conduct a wear test on the cutter. During the test, keep the cutter moving in a circular motion on the rock sample while simultaneously making a penetrating motion in the vertical direction. Use compressed air to remove dust and debris from the track to ensure that the cutter only contacts the rock sample during the test. S4. After the test, the wear of the roller is judged by the depth of the indentation on the rock sample.

Images