Method for controlling the gap of the segmented flange connection surface of a TBM cutter head

Abstract

The present application relates to a kind of methods for controlling the gap between TBM cutterhead block flange connecting surface, comprising the following steps: step 1, determine the reserved machining allowance of each cutterhead block flange connecting surface, and the change of edge cutter box radius;Step 2, pre-process each cutterhead block, including the pre-processing of flange connecting surface, quick cutter positioning tool pin hole and scraper seat positioning process block;Step 3, using quick cutter positioning tool, scraper seat positioning process block is positioned respectively and welded, using rotary cutter positioning tool and cutter positioning template to position edge cutter box and weld, then machine each cutterhead block flange connecting surface to drawing requirement size;Step 4, after the secondary processing of each cutterhead block flange, carry out group pair.The present application carries out first processing to block flange connecting surface before welding, which reserves machining allowance, carries out secondary processing to block flange connecting surface after welding, directly processes to drawing requirement size, which can solve the problem of large gap between block flange connecting surface.

Description

Technical Field

[0001] This invention relates to the field of shield tunneling cutterhead installation technology, and in particular to a method for controlling the gap between the segment flange connection surfaces of the TBM cutterhead. Background Technology

[0002] Considering factors such as cutterhead manufacturing, transportation, and installation, the cutterhead of a hard rock tunnel boring machine is often designed and manufactured in a modular form, which includes a central cutterhead block and side cutterhead blocks. Each block is manufactured and processed separately, and then assembled into a whole cutterhead by bolting.

[0003] Current TBM cutter head manufacturing typically involves machining each section separately to the required dimensions. Then, a fixed-tool fixture positions the toolbox and scraper holder, which are subsequently welded onto the individual cutter heads. The scraper holder is used to mount the scrapers located at the edge of the cutter head.

[0004] Because tool boxes and scraper seats are arranged near the connection positions of adjacent segments, and the amount of welding on tool boxes and scraper seats is large, deformation of the segment flange connection surface is easily caused after welding. This deformation will affect the original machining dimensional accuracy, resulting in large and uneven gaps on the connection surfaces of each segment assembly.

[0005] If significant deformation occurs at the connection surface, it is necessary to re-process each segment flange connection surface and use additional plugs to fill the gaps. This process requires substantial manpower and resources, increasing manufacturing costs and impacting delivery time. It may also cause the cutter head radius to exceed tolerances and the connecting bolts to be sheared, affecting the cutter head's excavation diameter, service life, and overall tunneling efficiency. Summary of the Invention

[0006] To address the problem of large gaps at the joint surfaces of segmented flanges due to excessive welding, this invention provides a method for controlling the gaps at the joint surfaces of TBM cutterheads. This method not only solves the problem of large gaps at the joint surfaces but also ensures the design strength of the cutterhead and the trajectory radius of the cutter, while reducing manufacturing costs and improving production efficiency.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A method for controlling the clearance between the segmented flange connection surfaces of a TBM cutterhead includes the following steps:

[0009] Step 1: Determine the allowable machining margin for the flange connection surface of each cutter head segment and the variation in the radius of the side cutter box. Each cutter head segment includes the cutter head center block and the cutter head side block.

[0010] Step 2: Pre-machine each cutter head block, including the flange connection surface, quick-set tooling pin hole, and scraper seat positioning process block; make tool positioning template according to the radius change of the side tool box;

[0011] Step 3: Use a quick-set tooling and a scraper seat positioning process block to position and weld the main tool box and the scraper seat respectively. Use a rotating tooling and a tool positioning template to position and weld the side tool box. After the main tool box, scraper seat and side tool box are welded to the cutter head in sections, machine the flange connection surfaces of each cutter head section to the dimensions required by the drawing.

[0012] Step 4: After secondary machining of each cutter head segment flange, they are assembled. After assembly, the tool trajectory radius and height, as well as the scraper radius and height, are checked. The tool height and trajectory radius meet the design drawing requirements, and the gap between the segment flange connection surfaces also meets the drawing and process requirements.

[0013] Furthermore, in step 1, the flange connection surfaces of each cutterhead segment include the flange connection surfaces between the center blocks of the cutterhead, between the edge blocks and the center blocks, and between the edge blocks; the machining allowance is determined based on the TBM cutterhead diameter and the deformation of the cutterhead segment flange connection plates after welding. A machining allowance is pre-set during the initial machining of each cutterhead segment flange connection surface to accommodate the deformation of the cutter box and scraper seat after welding.

[0014] Furthermore, step 3 includes the following steps: Step 3.1: Using a quick-set tooling fixture in conjunction with pre-machined quick-set tooling pin holes, the spur tool box is positioned on the cutter head block and welded to ensure the accuracy of the spur tool box installation position;

[0015] Step 3.2: Based on the scraper seat positioning process block, position and weld the scraper seat on the cutter head side block to ensure the accuracy of the scraper seat installation position;

[0016] Step 3.3: After positioning and welding the positive tool box on the cutter head section, machine the flange connection surface of the cutter head center block and the cutter head flange to the dimensions required by the drawing;

[0017] Step 3.4: Assemble the center block of the cutter head with each side block of the cutter head. Using the rotating fixed tool fixture and the tool positioning template, position and weld the side tool boxes on the cutter head blocks to ensure the accuracy of the side tool box installation position.

[0018] Step 3.5: After positioning and welding the side tool boxes on the cutter head blocks, machine the flange connection surfaces of the cutter head side blocks to the dimensions required by the drawing.

[0019] Furthermore, in step 3, the tool box and scraper seat near the flange connection surface of each cutter head are subjected to CO2 gas shielded welding or 80%Ar+20%CO2 mixed gas shielded welding.

[0020] Furthermore, the following welding parameters are used for welding: Vertical welding: root pass welding current 140-160A, voltage 16-18V, welding speed 120-180mm / min; fill and cover pass welding current 160-180A, voltage 18-20V, welding speed 120-180mm / min; Flat and horizontal welding: root pass welding current 220-240A, voltage 24-26V, welding speed 300-350mm / min; fill and cover pass welding current 240-260A, voltage 26-28V, welding speed 300-350mm / min.

[0021] The beneficial effects of the present invention through the above technical solution are:

[0022] This invention addresses the problem of large gaps at the joint surfaces of the cutter head's segmented flanges, which are inevitably caused by large welding volume. By pre-machining a machining allowance during the initial machining of each segmented flange joint surface, this allowance is used to accommodate post-weld deformation. The dimensions of the segmented flange joint surface at this initial machining stage are not the final installation dimensions. A quick-set tooling fixture with pin holes is used on each cutter head segmented flange to position and weld the main tool box; a scraper seat positioning block is used to position and weld the scraper seat; and a rotating tooling fixture with a tool positioning template is used to position and weld the side tool box. While ensuring accurate installation of the tool box and scraper seat, a secondary machining process is performed on each cutter head segmented flange joint surface to address welding deformation, directly machining it to the dimensions required by the drawings. This avoids the problem of large gaps at the joint surfaces caused by post-weld deformation, eliminating the need for filler plates to fill the gaps. It ensures that the tool / scraper trajectory radius and height meet the design requirements, guarantees the design strength of the cutter head and the tool trajectory radius, reduces manufacturing costs, improves production efficiency, and achieves good economic benefits. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of step 3.1 of the method for controlling the gap between the segmented flange connection surfaces of a TBM cutterhead according to the present invention, in which the positor is positioned on the center block of the cutterhead using a quick-set tooling fixture.

[0024] Figure 2 This invention relates to a method for controlling the gap between the segmented flange connection surfaces of a TBM cutterhead. Figure 1 The diagram shows the process of positioning the spur tool box on the center block of the cutter head using a quick-set tooling fixture in step 3.2 of direction A, and positioning the scraper seat using a scraper seat positioning process block.

[0025] Figure 3 This is a schematic diagram of the tool positioning template in step 3.4 of the method for controlling the gap of the segmented flange connection surface of a TBM cutter head according to the present invention.

[0026] The attached diagram is labeled as follows: 1. Tool box, 2. Scraper seat positioning process block, 3. Tool head center block, 4. Tool head side block, 5. Quick tool setting fixture, 6. Tool positioning template. Detailed Implementation

[0027] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings:

[0028] like Figures 1-3 As shown, a method for controlling the clearance of the segmented flange connection surface of a TBM cutterhead includes the following steps:

[0029] Step 1: Determine the reserved machining allowance for the flange connection surface of each cutter head segment and the change in the radius of the side cutter box. Each cutter head segment includes the cutter head center block 3 and the cutter head side block 4, and both the cutter head center block 3 and the cutter head side block 4 are multiple pieces.

[0030] The flange connection surfaces of each cutterhead segment include those between the cutterhead center blocks 3, between the cutterhead side blocks 4 and the center blocks, and between the side blocks. The machining allowance is determined based on the TBM cutterhead diameter and the post-weld deformation of the cutterhead segment flange connection plates.

[0031] In short, it involves determining the allowance for machining and the change in the radius of the side tool box based on the diameter of the cutter head and the deformation of the cutter head segment flange connection plate after welding.

[0032] Step 2: Pre-machine each cutter head block, including the flange connection surface, the quick-set tooling pin hole, and the pre-machine of the scraper seat positioning process block 2. The machining method is machining. Make the tool positioning template 6 according to the change of the side tool box radius. That is, calculate the change of the side hob trajectory according to the machining allowance reserved on the flange connection surface of the cutter head block, and then make the tool positioning template 6.

[0033] Step 3: Use the quick-set tool fixture 5 and the scraper seat positioning process block 2 to position the main tool box 1 and the scraper seat respectively. The main tool box 1 is the main hob tool box, and the scraper seat is the seat used to install the scraper. Use the rotating tool fixture and the tool positioning template 6 to position the side tool box, which is the side hob tool box.

[0034] After the main cutter box 1, scraper seat and side cutter box are welded to the cutter head in sections, the flange connection surfaces of each cutter head section are machined to the dimensions required by the drawings.

[0035] Specifically, step 3 includes the following steps: Step 3.1, using the quick-set tool fixture 5 in conjunction with the pre-machined quick-set tool fixture pin holes, positioning and welding the positive tool box 1 on the tool disc segment, as follows. Figure 1 As shown. Here, the rapid tooling fixture 5 uses the toolbox rapid positioning device of the segmented hard rock TBM cutter head applied for by our unit, with authorization announcement number CN214741330U.

[0036] Step 3.2: Based on the scraper seat positioning process block 2, position the scraper seat on the cutter head side block 4 and weld it, as shown. Figure 2 As shown.

[0037] Step 3.3: After positioning and welding the positive tool box 1 on the cutter head segment, machine the flange connection surface of the cutter head center block 3 and the cutter head flange to the dimensions required by the drawing. Here, the cutter head flange is the connecting component between the cutter head and the main drive. One end is connected to the cutter head, and the other end is connected to the main drive bearing. When the main drive rotates, it transmits power to the cutter head. The cutter head segment flanges are the connecting components for each segment of the cutter head. Each cutter head segment flange is bolted to the cutter head flange, so that the cutter head is assembled as a whole.

[0038] Step 3.4: Assemble the center block 3 of the cutter head with each side block 4 of the cutter head. Using the rotating fixed tool fixture and the tool positioning template 6, position and weld the side tool boxes on the cutter head blocks. Figure 3 As shown. The rotating fixed cutter fixture and the cutter positioning template 6 adopt the shield machine cutterhead positioning rotating fixture applied for by our unit, with authorization announcement number CN207245711U.

[0039] Step 3.5: After positioning and welding the edge tool boxes on the cutter head blocks, machine the flange connection surface of cutter head edge block 4 to the dimensions required by the drawing. At this point, both the center block 3 and the flange connection surfaces of the cutter head edge block 4 have undergone secondary machining.

[0040] In step 3, when welding the tool box and scraper seat near the flange connection surface of each tool disc segment, CO2 gas shielded welding or 80%Ar+20%CO2 mixed gas shielded welding is used.

[0041] The following welding parameters are used simultaneously: Vertical welding: root pass welding current 140-160A, voltage 16-18V, welding speed 120-180mm / min; fill and cover pass welding current 160-180A, voltage 18-20V, welding speed 120-180mm / min; Flat and horizontal welding: root pass welding current 220-240A, voltage 24-26V, welding speed 300-350mm / min; fill and cover pass welding current 240-260A, voltage 26-28V, welding speed 300-350mm / min. Using these parameters can control welding deformation caused by large welding heat input, avoiding the risk of over-processing due to excessive deformation of the segmented flange connection surface, and ensuring the structural strength requirements of the cutter head design.

[0042] Step 4: After secondary machining of each cutter head segment flange, they are assembled. After assembly, the radius and height of the tool / scraper trajectory are checked and found to meet the design drawing requirements. The gap of the segment flange connection surface also meets the drawing and process requirements.

[0043] In this invention, when machining the cutter head segments once, a machining allowance is reserved in advance on the flange connection surface of the cutter head segments. This machining allowance can effectively cope with the deformation after welding, and the deformation after welding will not affect the design requirements of the flange connection surface dimensions of the cutter head segments.

[0044] After the tool box and scraper seat are positioned and welded, the tool disc is then machined in sections. The flange connection surfaces of the tool disc sections can be directly machined to the drawing requirements. During machining, the deformation after welding is removed together, eliminating the need to use a plug plate to fill the gap. This not only solves the problem of large gaps but also ensures the design strength of the tool disc and the trajectory radius of the tool, reduces manufacturing costs, improves production efficiency, and achieves good economic benefits.

[0045] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention should be included within the scope of the present invention.

Claims

1. A method of controlling the TBM cutterhead segment flange joint face gap, characterized in that, Includes the following steps: Step 1: Determine the reserved machining allowance of the flange connection surface of each cutter head segment and the change in the radius of the side cutter box. Each cutter head segment includes the cutter head center block (3) and the cutter head side block (4). Step 2: Pre-process each cutter head block, including the flange connection surface, quick-set tooling pin hole and scraper seat positioning process block (2); make tool positioning template (6) according to the change of the side tool box radius. Step 3: Use the quick-set tool fixture (5) to position the main tool box (1), and use the scraper seat positioning process block (2) to position the scraper seat. Use the rotating tool fixture and the tool positioning template (6) to position the side tool box. After the main tool box (1), scraper seat and side tool box are welded to the cutter disc in sections, the flange connection surfaces of each cutter disc section are machined to the dimensions required by the drawing. Step 3 includes the following steps: Step 3.1, using a quick-set tool fixture (5) in conjunction with pre-machined quick-set tool fixture pin holes, positioning the positive tool box (1) on the tool disc segment and welding it; Step 3.2: Position the scraper seat on the cutter head side block (4) and weld it according to the scraper seat positioning process block (2); Step 3.3: After positioning and welding the positive tool box (1) on the cutter head block, machine the flange connection surface of the cutter head center block (3) and the cutter head flange to the dimensions required by the drawing; Step 3.4: Assemble the center block (3) of the cutter head with each cutter head side block (4), and use the rotating fixed tool fixture and the tool positioning template (6) to position and weld the side tool boxes on the cutter head blocks; Step 3.5: After positioning and welding the side tool boxes on the cutter head blocks, machine the flange connection surface of the cutter head side blocks (4) to the dimensions required by the drawing; Step 4: After secondary machining of each cutter head segment flange, they are assembled. After assembly, the tool trajectory radius, height and scraper radius are checked. The tool height and trajectory radius meet the design drawing requirements, and the gap of the segment flange connection surface also meets the drawing and process requirements.

2. The method for controlling the gap between the segmented flange connection surfaces of a TBM cutterhead according to claim 1, characterized in that, In step 1, the flange connection surfaces of each cutterhead segment include the flange connection surfaces between the cutterhead center blocks (3), between the cutterhead side blocks (4) and the center blocks, and between the side blocks; The machining allowance is determined based on the diameter of the TBM cutter head and the deformation of the cutter head segment flange connection plate after welding.

3. The method for controlling the gap between the segmented flange connection surfaces of a TBM cutterhead according to claim 1, characterized in that, In step 3, the tool box and scraper seat near the flange connection surface of each cutter head are protected by CO2 gas shielded welding or 80%Ar+20%CO2 mixed gas shielded welding.

4. The method for controlling the gap between the segmented flange connection surfaces of a TBM cutterhead according to claim 3, characterized in that, Welding should be performed using the following parameters: Vertical welding: Root pass welding current 140-160A, voltage 16-18V, welding speed 120-180mm / min; Fill and cover pass welding current 160-180A, voltage 18-20V, welding speed 120-180mm / min; Flat and horizontal welding: For the root pass welding, the welding current is 220-240A, the voltage is 24-26V, and the welding speed is 300-350mm / min. For the fill and cover passes welding, the welding current is 240-260A, the voltage is 26-28V, and the welding speed is 300-350mm / min.

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