Emergency replacement method for long-distance single-hole tunnel TBM main bearing

Abstract

The invention provides a long-distance single-hole tunnel TBM main bearing emergency replacement method, and belongs to the technical field of tunnel construction.The method comprises the steps that excavation of a storage cavern is conducted at the rear matched tail, meanwhile, a cutter head is fixed, and the excavation direction of a tunnel is defined as the front end; the new main bearing is transported into the storage cavern; the main machine is disconnected from the equipment bridge, the main machine is matched to the front end of the equipment bridge to cross the storage cavern after integrally retreating, and hoisting equipment used for hoisting a new main bearing is built above the storage pit before the rear matching device retreats; according to the emergency replacement method, another tunnel is not needed, the storage cavern and the storage pit are arranged, the new main bearing and the old main bearing are temporarily stored, avoidance is provided for back matching and main engine retreating, bearing replacement is facilitated, the storage cavern does not need to be too long, and the construction difficulty and the construction cost are reduced.

Description

Technical Field

[0001] The invention relates to the technical field of tunnel construction, and in particular to an emergency replacement method for a main bearing of a TBM in a long-distance single-hole tunnel. Background Art

[0002] In long-distance tunnel construction, due to the long tunnel distance, the service life and life of the TBM main bearing are exceeded, or due to the complex geological conditions, the main bearing of the TBM may need emergency repair or replacement due to wear and damage during the excavation process. The difficulty of repair and replacement lies in the following: first, the main bearing of the TBM is large in size and indivisible, which makes it difficult to transport; second, the main bearing installation location and installation method are special and difficult to remove; third, the tunnel space is small, and the replacement and maintenance work requires a large space. The existing inclined shaft or vertical shaft maintenance and replacement methods have problems such as high cost, low efficiency, high difficulty, and poor adaptability, which affect the construction progress and safety.

[0003] The invention patent with publication number CN114109416B discloses a method for replacing the main bearing of a TBM in a tunnel. The method includes the following steps:

[0004] (1) After the main bearing of the horizontal guide / main tunnel TBM is confirmed to be damaged and needs to be replaced, the initial support structure behind the shield is removed;

[0005] (2) After the TBM moves back a certain distance, the cutterhead is fixed by driving anchor rods and welding steel supports;

[0006] (3) Separate the cutter head from the main machine, and move the main machine back again to reserve a maintenance space between the cutter head and the main machine, and install a steel mesh and steel arch support in the maintenance space;

[0007] (4) Synchronously open a main bearing transportation transverse channel from the positive / horizontal guide tunnel to the horizontal guide / positive tunnel;

[0008] (5) Set up a gantry and lifting beam between the cutter head and the shield, and then remove and replace the main bearing.

[0009] The present invention opens a transverse passage through a parallel tunnel to serve as a TBM main bearing replacement transportation passage, the passage length is short, the civil engineering workload is small, and the difficulty of main bearing replacement is reduced.

[0010] However, this solution also has certain limitations. In a certain tunnel construction project, the length of the TBM is considered to be 245 meters. If the main bearing of the TBM is damaged and needs to be replaced, the parallel guide tunnel excavation method is used to transport the main bearing. The parallel guide tunnel excavation distance is long, and the stratum with better surrounding rock conditions needs to be selected for shutdown excavation. According to the construction progress, it is estimated that it will take at least 3 months of shutdown to wait, which will affect the construction progress. Summary of the invention

[0011] The invention provides an emergency replacement method for a main bearing of a TBM in a long-distance single-hole tunnel, so as to solve the technical problems in the prior art.

[0012] In order to solve the above problems, the present invention provides a method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel, which adopts the following technical solution, including the following steps:

[0013] The storage cavern is excavated at the rear of the rear supporting equipment, and the cutterhead is fixed at the same time, and the excavation direction of the tunnel is defined as the front end;

[0014] Transport the new main bearing to the storage cave;

[0015] The main engine is disconnected from the equipment bridge, and the whole is retreated to the front end of the equipment bridge and passes over the storage cavern. Before the rear supporting equipment retreats, a hoisting device for hoisting the new main bearing is built above the storage pit;

[0016] Two storage pits are excavated at the bottom of the tunnel at the front end of the equipment bridge, and the two storage pits are arranged in the front-to-back direction;

[0017] Transport and store the new main bearings in the storage cavern to one of the storage pits;

[0018] Separate the cutter head, disassemble the inner and outer seals of the main drive, and disassemble the slag collecting bucket in sequence;

[0019] Build the portal frame, remove the drive plate and old main bearing;

[0020] The main engine moves backwards between the storage pit and the equipment bridge to provide clearance for bearing replacement, and a bearing replacement platform is built at the rear end of the portal frame;

[0021] The old main bearing is hoisted to the bearing replacement platform by the lifting equipment on the top of the tunnel and flipped from vertical to horizontal. The flipped old main bearing is then transported to another storage pit for storage.

[0022] Take out the new main bearing and transport it to the bearing replacement platform. Flip the new main bearing from horizontal to vertical. Remove the bearing replacement platform and push the main engine forward to the side of the portal frame.

[0023] Install the new main bearing and drive disc to the main engine in sequence, remove the portal frame, and then install the slag bucket and the inner and outer seals of the main drive;

[0024] Debug the main drive during idling, and connect the cutter disc after checking that there is no abnormality.

[0025] As a further improvement, the angle between the storage cavern and the main cavern satisfies rail transportation, and the turning radius of the line is not less than 25m.

[0026] As a further improvement, the cutter head fixing includes the following steps:

[0027] Before fixing the cutterhead, move it back once to clean the slag at the bottom of the tunnel between the tunnel face and the cutterhead, then push the cutterhead 5-15cm away from the tunnel face, rotate the cutterhead to the set position, and then push the cutterhead against the tunnel face;

[0028] The cutter disc is laterally fixed, bottom supported and axially fixed respectively to limit the spatial freedom of the cutter disc to prevent the cutter disc from shifting.

[0029] As a further improvement, before the new main bearing is stored in the storage pit, a protective layer is wrapped on the outer surface of the new main bearing, and after the new main bearing is placed in the storage pit, the gap between the new main bearing and the storage pit is filled with fine sand.

[0030] As a further improvement, the portal frame is fixedly installed with a slide rail arranged along the front-rear direction, and a sliding trolley for driving the new main bearing or the driving disc to move is provided on the slide rail.

[0031] As a further improvement, when removing the drive disc, the sliding trolley moves to the top of the inner side of the drive disc to support the drive disc. After the drive disc is removed and separated from the main machine, the sliding trolley drives the drive disc to move to the front end of the slide rail in a vertical posture, and a temporary support for the drive disc is set at the bottom of the drive disc, so that the sliding trolley is fixed to the door frame;

[0032] When removing the old main bearing, set another sliding trolley on the slide rail and move it to the top of the old main bearing to support the old main bearing. After the old main bearing is separated from the main engine, the sliding trolley drives the old main bearing to move forward to the set position in a vertical posture, and set a temporary support for the old main bearing at the bottom of the old main bearing.

[0033] As a further improvement, top turning ears and bottom turning ears are installed on the top and bottom of the old main bearing respectively, and the old main bearing is lifted by a lifting device and moved to the bearing replacement platform. The bottom turning ears are rotatably connected to the ear seats of the bearing replacement platform, and the old main bearing is flipped from vertical to horizontal by the lifting device, and then the old main bearing is transported to the other storage pit for burial.

[0034] As a further improvement, the hoisting equipment lifts the new main bearing, and a transfer equipment is arranged on a temporary track at the bottom of the tunnel to transfer the new main bearing to the bearing replacement platform.

[0035] As a further improvement, before the main engine is propelled, the temporary track is removed and debris in front of the main engine that affects the propulsion is cleared.

[0036] The beneficial effects of the above technical solution of the present invention are as follows:

[0037] 1. The present invention sets up storage caverns and storage pits to temporarily store new and old main bearings, providing a way for the subsequent matching and main engine retreat to facilitate bearing replacement. The length of the storage cavern does not need to be too long, which reduces the construction difficulty and construction cost. When the construction progress difference between the left and right tunnels is large, there is no need to wait for another tunnel to avoid affecting the construction progress. At the same time, the construction cost is relatively lower and the limitations are relatively smaller.

[0038] In addition, since the emergency replacement method of the present invention does not require the use of another tunnel, the construction progress of another tunnel will not be affected by the use of another tunnel to transport the new main bearing.

[0039] 2. The present invention utilizes the structure of the cutter disc, adopts the overall method of seven-point locking and four-position support at the bottom, ensures the stability of the cutter disc after being fixed, and is conducive to the precise docking of the cutter disc with the host. That is, anchor rods are installed at the top 5 scraper bins and the bottom 2 scraper bins at 55° on the left and right, a pad is set at the bottom of the cutter disc to support the cutter disc, and anchor rods are set at the corresponding knife holes to prevent the cutter disc from axial deviation, thereby ensuring the stability of the cutter disc. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] By reading the following detailed description with reference to the accompanying drawings, the above and other objects, features and advantages of the exemplary embodiments of the present invention will become readily understood. In the accompanying drawings, several embodiments of the present invention are shown in an exemplary and non-limiting manner, and the same or corresponding reference numerals represent the same or corresponding parts, wherein:

[0041] Figure 1 It is a replacement flow chart of the emergency replacement method of the main bearing of a TBM in a long-distance single-hole tunnel of the present invention;

[0042] Figure 2 A schematic diagram of a new main bearing truck transportation method for emergency replacement of a main bearing of a long-distance single-hole tunnel TBM according to the present invention;

[0043] Figure 3 It is a structural schematic diagram of a storage cavern of the method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel of the present invention;

[0044] Figure 4 It is a cutterhead fixing flow chart of the method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel of the present invention;

[0045] Figure 5 A schematic diagram of the cutterhead fixing method of the TBM main bearing emergency replacement method for a long-distance single-hole tunnel according to the present invention;

[0046] Figure 6 It is a schematic diagram of the arrangement of axial anchor rods in the method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel of the present invention;

[0047] Figure 7It is a schematic diagram of the main machine disconnection point of the method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel of the present invention;

[0048] Figure 8 A schematic diagram of a portal frame of the method for emergency replacement of a main bearing of a TBM in a long-distance single-hole tunnel according to the present invention;

[0049] Fig. 9 A schematic diagram of fixing the drive plate of the emergency replacement method of the main bearing of a TBM in a long-distance single-hole tunnel according to the present invention;

[0050] Fig.10 A schematic diagram of the main bearing disassembly and assembly points of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the present invention;

[0051] Fig.11 It is a structural schematic diagram of a bearing replacement platform of a method for emergency replacement of a main bearing of a TBM in a long-distance single-hole tunnel according to the present invention;

[0052] Fig.12 A schematic diagram of turning over a new main bearing or an old main bearing of the method for emergency replacement of a main bearing of a long-distance single-hole tunnel TBM according to the present invention;

[0053] Fig.13 It is a schematic diagram of the main engine idle thrust position of the method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel according to the present invention;

[0054] Fig.14 A reference diagram of maintenance assessment standards for Example 2 of a method for emergency replacement of a main bearing of a TBM in a long-distance single-hole tunnel according to the present invention;

[0055] Fig.15 A maintenance operation flow chart of Example 2 of the emergency replacement method for the main bearing of a TBM in a long-distance single-hole tunnel of the present invention;

[0056] Fig.16 This is a schematic diagram of the main bearing decomposition of Example 2 of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the present invention.

[0057] Description of reference numerals:

[0058] 1. New main bearing; 2. Flatbed truck; 3. Storage cavern; 4. Cutter head; 5. Main machine; 6. Equipment bridge; 7. Slide rail; 8. Gantry; 9. Main drive; 10. Sliding trolley; 11. Temporary support; 12. Bearing replacement platform; 13. Old main bearing; 14. Bearing disassembly gantry. DETAILED DESCRIPTION

[0059] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Those skilled in the art should know that the embodiments described below are part of the embodiments of the present disclosure, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0060] In long-distance tunnel construction, due to the long tunnel distance, the service life and life of the TBM main bearing are exceeded, and emergency replacement is required. The difficulty of replacement lies in the following reasons: first, the TBM main bearing is large in size and indivisible for transportation, second, the main bearing installation location and installation method are special and difficult to remove, and third, the tunnel space is small, and the replacement and maintenance work requires a large space. The existing inclined shaft, vertical shaft or circuitous guide tunnel maintenance and replacement methods have problems such as high cost, low efficiency, high difficulty, and poor adaptability, which affect the construction progress and safety.

[0061] If the construction progress of the left and right lines differs greatly, the only options are to use the roundabout guide tunnel method (digging a roundabout guide tunnel from the tail of the TBM to the front of the cutterhead and expanding the tunnel in front of the cutterhead to repair or replace the TBM main bearing) or wait for another tunnel. Of these two methods, the former has a higher construction cost, and the latter requires a longer waiting time, which may affect the construction progress.

[0062] In response to the above problem, the present invention opens a storage cavern connected to the tunnel at a position about 20 meters from the tail of the TBM. The prepared new main bearing is first transferred to the storage cavern. When the rear supporting equipment retreats to the rear side of the storage cavern, a storage pit is excavated and the new main bearing is buried in the storage pit. In this way, while storing the new main bearing, the cutter disc can be detached, the internal and external seals can be removed, and the replacement cycle can be shortened. On the other hand, the difficulty and cost of excavating the storage cavern and the storage pit are relatively lower, and the operability and safety are higher.

[0063] After introducing the basic principle of the present invention, various non-limiting embodiments of the present invention are described in detail below. The number of any element in the drawings is for illustration and not for limitation, and any naming is only for distinction and does not have any limiting meaning.

[0064] The principle and spirit of the present invention are explained in detail below with reference to several representative embodiments of the present invention.

[0065] Embodiment 1 of the method for emergency replacement of the main bearing of a TBM in a long-distance single-hole tunnel provided by the present invention is as follows: Figure 1-Figure 13 As shown, the following steps are included:

[0066] S1, excavating the storage cavern 3 at the rear end of the rear supporting device, fixing the cutterhead 4 at the same time, and defining the excavation direction of the tunnel as the front end;

[0067] S2, transporting the new main bearing 1 to the storage cave 3;

[0068] S3, the main machine 5 is disconnected from the equipment bridge 6, and the whole is retreated to the front end of the equipment bridge 6 to pass the storage cavern 3. Before the rear supporting equipment retreats, a hoisting device for hoisting the new main bearing 1 is built above the storage pit;

[0069] S4, excavating two storage pits at the bottom of the tunnel at the front end of the equipment bridge 6, and the two storage pits are arranged in the front-to-back direction;

[0070] S5, transporting and storing the new main bearing 1 in the storage cavern 3 to one of the storage pits;

[0071] S6, sequentially disengaging the cutter head 4, disassembling the inner and outer seals of the main drive 9, and disassembling the slag collecting bucket;

[0072] S7, build a portal frame 8, remove the drive plate and the old main bearing 13;

[0073] S8, the main engine 5 retreats to between the storage pit and the equipment bridge 6 to provide avoidance for bearing replacement, and a bearing replacement platform 12 is built at the rear end of the portal frame 8;

[0074] S9, using the lifting equipment on the top of the tunnel, hoist the old main bearing 13 to the bearing replacement platform 12 and flip it from vertical to horizontal, and then transport the flipped old main bearing 13 to another storage pit for storage;

[0075] S10, take out the new main bearing 1 and transport it to the bearing replacement platform 12, flip the new main bearing 1 from horizontal to vertical, remove the bearing replacement platform 12, and push the main machine 5 forward to the side of the portal frame 8;

[0076] S11, install the new main bearing 1 and the drive disc to the main engine 5 in sequence, remove the portal frame 8, and then install the inner and outer seals of the slag collecting bucket and the main drive 9;

[0077] S12, the main drive 9 is debugged in idling mode, and after checking that there is no abnormality, the cutter head 4 is connected.

[0078] In step S1, Figure 3 As shown, a storage cavern for temporarily storing the new main bearing 1 is constructed 20 meters from the rear of the rear supporting part (first use the nearest connecting channel of the left and right lines as the storage cavern, if the connecting channel cannot meet the requirements, a new storage cavern is excavated), and its size is based on the need to accommodate the main bearing special transport flatbed truck 2. In this embodiment, the length × width × height of the storage cavern = 10 × 7.5 × 4.3m; the angle between the storage cavern and the main tunnel meets the requirements of rail transportation, and the line turning radius is not less than 25m; after the replacement task is completed, the over-excavated part except the storage cavern part is backfilled with concrete of the same grade. The size of the storage cavern is much smaller than the detour channel in the prior art, and the construction cost is relatively lower.

[0079] like Figure 4-Figure 6 As shown, the fixing of the cutter disc 4 includes the following steps:

[0080] Before the cutterhead 4 is fixed, it is first retracted for one cycle. In this embodiment, one cycle is 1.8 meters. The slag at the bottom of the tunnel between the tunnel face and the cutterhead 4 is cleaned. Then the cutterhead 4 is pushed 10 cm away from the tunnel face. In manual mode, the scraping bin where the cutterhead 440# is located is moved to the bottom of the tunnel. Then the cutterhead 4 is pushed to press against the tunnel face.

[0081] The cutter disc 4 is laterally fixed, bottom supported and axially fixed respectively, and the spatial freedom of the cutter disc 4 is limited to prevent the cutter disc 4 from shifting.

[0082] Lateral fixation: 10 anchor rods are installed in each of the 5 scraper bins on the top, and 6 anchor rods are installed in each of the 2 scraper bins at 55° on the bottom. There are seven fixed points in total, with a total of 72 anchor rods. The anchor rods are made of φ25 threaded steel, with a cutting length of 3m and an anchoring length of 2.5m.

[0083] Bottom support: The cutter disc 4 is supported at the three bottom scraper bins, and four support points are set. First, a suitable steel plate is inserted between the outer ring plate of the cutter disc 4 and the hole wall; then the support plate is placed between the cone plate on the back of the cutter disc 4 and the hole wall. The distribution angle of the support plate overlaps with the angle of the pad plate, and is welded to the cutter disc 4.

[0084] Axial fixation: At the four knife hole positions of 27#, 28#, 29#, and 30#, three anchor holes are made in each knife hole. A 600*250*20mm steel plate is used to cut holes through the anchors and lock them. The axial anchor uses a 3m long, φ25 fiberglass anchor.

[0085] In step S3, the hoisting equipment has four hoisting points, and the designed hoisting capacity of each hoisting point is 25T.

[0086] like Figure 7 As shown, before the main engine 5 is disconnected from the rear supporting equipment, a temporary wheel set is installed at the bottom of the connecting bridge for retreating, and the pipelines connected to the rear supporting equipment and the main engine 5 are removed and marked and protected.

[0087] In step S4, after the rear supporting equipment is retreated to make room, the construction of the storage pit can be carried out; the diameter of the storage pit is 7m and the depth is 1.5m. First, the prefabricated blocks laid for overhead supply are removed, and then the bottom of the hole is laid out. When laying out, the point positions refer to the hole layout requirements during blasting to construct the blasting holes. The depth of the storage pit should ensure that the new main bearing 1 or the old main bearing 13 does not protrude from the rock surface after being stored.

[0088] In step S5, after the construction of the two storage pits is completed, the new main bearing 1 is stored in the rear storage pit, a steel sleeper is laid in front of the invert block, and a temporary track is erected. The laying length is sufficient for the bearing trolley to be located above the storage pit; after the bearing trolley travels to the upper part of the storage pit, the new main bearing 1 is lifted by the lifting equipment on the top of the storage pit, the trolley retreats, and the temporary track and steel sleeper are removed; the new main bearing 1 is stored in the pit, and the bearing needs to be tightly wrapped with non-woven fabric before storage. After the bearing is firmly placed in the pit, the gap between the bearing and the storage pit is filled with fine sand, and the hydraulic and control pipelines of the main engine 5 are connected (extended), and the main engine 5 steps backward.

[0089] In step S6, the cutter head 4 is disengaged, including the following steps:

[0090] Before disengagement, check the fixing status of the cutterhead 4 to confirm that it is firmly fixed and can be disengaged only when the disengagement conditions are met. Record the data of the guide system before disengagement and the original position of the TBM in detail for use when docking the cutterhead 4. The original position of the TBM includes the position of the gripper shoe, the extension length of the top gripper shoe cylinder, the extension length of the torque cylinder and the position of the rear edge of the side shield, the connection position mark between the drive disc and the cutterhead 4 (no less than 4 places), etc. Make the mark before disengaging the cutterhead 4;

[0091] Remove all the protective caps of the stud bolts connecting the cutter disc 4;

[0092] Reduce the bolt pulling pressure gradually three times in sequence. Completely loosen the bolts for the last time, remove the nuts, then remove the stud bolts, clean them with kerosene, apply hydraulic oil, and store them properly.

[0093] The order of loosening and removing bolts: 4 to 5 bolts in a batch, one by one;

[0094] After the bolts are removed, check the connection between the cutter disc 4 and the main drive 9 again. After confirming that all are disconnected, the cutter disc 4 can be disengaged. Place four 100-ton thin jacks between the cutter disc 4 and the main drive 9. First, use the jacks and thrust cylinders to smoothly separate the cutter disc 4 from the main drive 9. The separation distance should be more than 50 mm.

[0095] Disassemble the inner and outer seals of the main drive 9:

[0096] After the cutter disc 4 is successfully separated, the main machine 5 retreats 1.2 meters, and a seal disassembly platform is built between the cutter disc 4 and the main drive 9. A slideway is welded at a suitable position between the main drive 9 and the cutter disc 4 for moving the ring after removal. A lifting lug is welded on the top of the outer sealing pressure ring, and the hoist is hung and tightened.

[0097] Weld 2-3 hanging rods on the back of the cutter head 4 to temporarily store the sealing rings and spacer rings;

[0098] Weld a lifting lug (lifting weight 3 tons) above the top shield for installing a hand chain hoist. Weld a pull plate assembly on the cutter head 4, a total of 6 locations, for removing and installing the outer seal clamping ring, the outer seal outer spacer ring and the outer seal inner spacer ring. The pull plate assembly hole is aligned with the threaded hole of the outer seal clamping ring;

[0099] Remove the bolts according to the diagonal principle and mark the positions;

[0100] Remove the hexagon socket screws, outer seal protection plate, outer seal pressure ring, outer seal lip seal, and outer seal spacer ring of the outer seal ring in sequence, place them in the hanging position on the back of the cutter head 4 (a steel rod can be inserted into the bolt hole of the cutter head 4 for storage), and measure the wear of the outer seal wear track and lip seal;

[0101] Insert bolts into the bolt holes on the top of the drive disc, tighten the hoisting plate (can hoist 3T weight) and install the hand chain hoist; weld the pull plate assembly on the inner panel of the cutter disc 4, a total of 6 places, for taking out and installing the inner seal clamping ring, inner seal outer spacer ring and inner seal inner spacer ring, and align the pull plate assembly hole with the threaded hole of the outer seal clamping ring; remove the inner seal ring parts hexagon screws, inner seal labyrinth ring 1, inner seal labyrinth ring 2, inner seal, pressure ring, inner seal lip seal, inner seal spacer ring in turn in the same way as the outer seal disassembly method, and place them on the back of the cutter disc 4. Measure the wear of the inner seal wear track and lip seal.

[0102] Dismantle the slag bucket:

[0103] After the seal and ring parts are removed and stored, the working platform is removed and the main machine 5 is continued to move back to reserve space (≥2 meters) for the removal of the slag bucket.

[0104] Build a disassembly platform; weld lifting lugs on the top shield, and use the lifting lugs on the slag bucket to hang the hoist and tighten the hoist.

[0105] Remove the pin between the slag bucket and the drive box.

[0106] Lift the slag bucket and move it to a position close to the cutter head 4.

[0107] like Figure 8 As shown, in step S7, building the door frame 8 includes the following steps:

[0108] The main machine 5 moves back to the installation position of the gantry frame 8 and stops when the top shield is exposed for 3 meters;

[0109] Build the portal frame 8, and the main frame is built from bottom to top. The bottom is fixed in time after it is built, and the main frame is fixed to the cave wall by anchor rods;

[0110] After the portal frame 8 is erected, the bottom steel sleeper and the slide rail 7 are installed;

[0111] After the bottom steel sleepers are laid, the slide rails 7 are welded to the main beam through the portal frame 8, and the diagonal supports are installed.

[0112] like Fig. 9 As shown, removing the drive disk includes the following steps:

[0113] Remove the three (11 to 13) drive plate gear ring connection bolts on the left and right sides of the top, and use M48×700 studs and washers to install the sliding trolley 10 bracket and the bottom slide rail 7 support rubber pad;

[0114] After the installation of the sliding trolley 10 is completed, remove the studs between the drive plate and the main bearing three times according to the diagonal principle, place them in a suitable area, check whether the studs are damaged, and mark the installation holes of the bolts;

[0115] Draw a line at the position of the motor torque limiter to mark the position and use a thin line to mark the rotation direction (the length of the line ensures that the torque limiter can rotate 5 times);

[0116] Use M30 screws to push the base outward at 8 points at the same time. Pay attention to keeping the screw sizes of each screw consistent to ensure that the drive disc slides out of the installation cavity evenly in the circumferential direction. Synchronously move the sliding trolley 10 to ensure that the drive disc is vertical. Four M48×1300 guide rods can be installed in advance in the bottom bolt holes. At the same time, arrange someone on the motor side to record the direction and displacement of each motor when it is disengaged to provide a reference for the drive disc when docking.

[0117] After the drive disc is completely separated from the installation cavity, it is moved to the door frame 8 and fixed, and the bottom is supported and fixed by two supporting points; use kerosene to thoroughly clean the surface of the drive disc and the driving large gear ring, and check whether the large gear ring is damaged (at the same time mark the position of the small gear to prevent the position from being changed during subsequent work).

[0118] like Fig.10 As shown, disassembling the old main bearing 13 includes the following steps:

[0119] Set another sliding trolley 10 on the slide rail 7 and move it to the top of the old main bearing 13 to support the old main bearing 13. Install M56 lifting rings at the three lifting points of the main bearing. Use three 2T hoists at the corresponding positions of the portal frame 8 to pull the old main bearing 13 outward at the same time. Pay attention to keeping the hoist sizes consistent (or use 4RLT-41 flat jacks between the bearing and the drive box, and four jacks are evenly stressed at the same time) to ensure that the old main bearing 13 slides out of the installation cavity evenly in the circumferential direction.

[0120] After the old main bearing 13 is separated from the main engine 5, the sliding trolley 10 drives the old main bearing 13 to move forward to a set position in a vertical posture, and a temporary support 11 for the old main bearing 13 is set at the bottom of the old main bearing 13;

[0121] like Figure 11-13 As shown, in step S9, a top turning ear and a bottom turning ear are respectively installed on the top and the bottom of the old main bearing 13, the lifting equipment lifts the old main bearing 13 and moves it to the bearing replacement platform 12, the bottom turning ear is rotatably connected with the ear seat of the bearing replacement platform 12, the old main bearing 13 is flipped from vertical to horizontal by the lifting equipment, and then the old main bearing 13 is transferred to the other storage pit for burial. The burying step of the old main bearing 13 can refer to the burying step of the new main bearing 1, which mainly includes: wrapping the old main bearing 13 with non-woven fabric, the wheel group supports the transfer of the old main bearing 13 to the top of another storage pit, the lifting equipment lifts the old main bearing 13, the temporary track is removed, the old main bearing 13 is buried and filled with fine sand.

[0122] The lifting equipment lifts the new main bearing 1 (the temporary track is temporarily removed before lifting, and the temporary track is re-fixed after the new main bearing 1 is lifted), and a transfer equipment is set on the temporary track at the bottom of the tunnel to transfer the new main bearing 1 to the bearing replacement platform 12.

[0123] Before the main engine 5 is advanced, the temporary track is removed and debris in front of the main engine 5 that affects the advancement is cleared.

[0124] The subsequent installation and debugging steps will not be repeated here.

[0125] Example 2

[0126] This embodiment discloses an emergency maintenance method for the main bearing of a long-distance single-hole tunnel TBM, and the starting condition is: if the surrounding rock conditions are good, and a large fluctuation of 800KN.M-1500KN.M occurs during the dry push, the machine is immediately shut down for investigation. If it is determined that the condition of the old main bearing 13 has a tendency to deteriorate or has deteriorated sharply (in this embodiment, the old main bearing 13 refers to the main bearing currently in use), after evaluation (evaluation criteria such as Fig.14 As shown, for example, shallow damage with a depth of less than 3 mm is considered to be relatively light damage, otherwise it is considered to be relatively heavy damage). If the damage to the raceway of the old main bearing 13 is relatively light, only repair is required to meet the excavation needs of the remaining sections of the entire project. In this case, the machine is shut down and the maintenance plan for the old main bearing 13 is started; otherwise, the replacement plan for the old main bearing 13 is started.

[0127] like Fig.15 As shown in the figure, the emergency maintenance method of the main bearing of the long-distance single-hole tunnel TBM includes the following steps:

[0128] S1. Preliminary preparation work: If the short-distance excavation can be met, continue to advance 18 meters, and the newly installed invert block will not be cast at the bottom. The initial support will be in the form of anchor rod + mesh + initial spraying. If excavation is not possible, the arch frame and invert block will be gradually removed during the process of retreating the main engine 5, and the arch part will be sprayed simultaneously; at the same time, prepare the old main bearing 13 retainer, rollers and other parts.

[0129] S2, the cutter disc 4 is fixed.

[0130] S3, the cutter disc 4 is disengaged.

[0131] S4. Disassemble the inner and outer seals of the main drive 9.

[0132] S5. Disassemble the slag collecting bucket.

[0133] S6. Build the door frame 8.

[0134] S7. Remove the drive disk.

[0135] S8. Disassemble the old main bearing 13.

[0136] S9. Check and clean the drive box.

[0137] Steps S2 to S9 are the same as those in Example 1 and will not be described in detail in this example.

[0138] S10, build a maintenance platform, install the bearing turning lugs, and build the bearing disassembly gantry 14 and lifting equipment (or other lifting and hoisting equipment).

[0139] S11, repairing the old main bearing 13; first, using a lifting device to flip the old main bearing 13 from vertical to horizontal;

[0140] Secondly, disassemble the old main bearing 13, such as Fig.16 As shown, disassembling the old main bearing 13 includes the following steps:

[0141] (1) Hang a 10T hoist according to the position of the bearing lifting point and install it at the lifting point of the inner ring of the bearing with three M56 lifting eye screws;

[0142] (2) Make alignment marks on the inner diameters of the two inner rings, then remove the screws connecting the two inner rings, the hexagon socket screws and plastic rods that protect the inner ring positioning pins, and finally lift the inner rings;

[0143] (3) Lift the inner ring to a certain height and fix it, remove the push roller and cage, and check the raceway surface of the push roller; then remove the radial roller and cage, and then take the roller out of the cage;

[0144] (4) Lift the outer ring of the bearing through the lifting points on the wall of the tunnel and four 10T hoists, and remove the reverse row rollers and cages;

[0145] After that, repair the old main bearing 13, replace all rollers, cages, seals, and spring units under the thrust raceway; for the raceway, follow the steps below: Fig.14 to process;

[0146] Finally, reassemble the old main bearing 13; after all raceway surfaces are repaired, install the summer push rollers and cages; at the same time, place 3 sets of radial rollers evenly on the radial raceways; remove the temporary support 11 of the outer ring, and slowly insert the outer ring into the inner ring; install the radial rollers and cages; install the main push rollers and cages; remove the fixed support on the inner ring, and slowly lower the inner ring. After the inner ring is installed, install the locking screws and tighten them in place.

[0147] S12, reinstall the old main bearing 13, drive plate, slag collecting bucket and other parts to the main machine 5.

[0148] S13, no-load test of main drive 9; after the installation of internal and external seals is completed, remove the installation platform and cut off the auxiliary lifting lugs, and fill the drive box with gear oil; after checking whether the drive has interference, drive the equipment to idle; during equipment commissioning, check in detail whether there is any abnormality in the drive box; check whether there is gear oil in the detection cavity of the internal and external seal system of main drive 9.

[0149] S14, installing the cutter head 4.

[0150] In this embodiment, if it involves replacing the old main bearing inner ring or the old main bearing outer ring, the old main bearing inner ring or the old main bearing outer ring can be transported in the way of transporting the new main bearing 1 in embodiment 1.

[0151] Although this specification has shown and described a plurality of embodiments of the present invention, it is obvious to those skilled in the art that such embodiments are provided by way of example only. Those skilled in the art will think of many changes, modifications and alternatives without departing from the thought and spirit of the present invention. It should be understood that in the process of practicing the present invention, various alternatives to the embodiments of the present invention described herein may be adopted. The attached claims are intended to define the scope of protection of the present invention, and therefore cover the modular composition, equivalent or alternatives within the scope of protection of these claims.

Claims

1. A method for emergency replacement of TBM main bearings in a long-distance single-hole tunnel, characterized in that: The following steps are involved: The storage cavern is excavated at the rear of the rear supporting equipment, and the cutterhead is fixed at the same time, and the excavation direction of the tunnel is defined as the front end; Transport the new main bearing to the storage cave; The main engine is disconnected from the equipment bridge, and the whole is retreated to the front end of the equipment bridge and passes over the storage cavern. Before the rear supporting equipment retreats, a hoisting device for hoisting the new main bearing is built above the storage pit; Two storage pits are excavated at the bottom of the tunnel at the front end of the equipment bridge, and the two storage pits are arranged in the front-to-back direction; Transport and store the new main bearings in the storage cavern to one of the storage pits; Separate the cutter head, disassemble the inner and outer seals of the main drive, and disassemble the slag collecting bucket in sequence; Build the portal frame, remove the drive plate and old main bearing; The main engine moves backwards between the storage pit and the equipment bridge to provide clearance for bearing replacement, and a bearing replacement platform is built at the rear end of the portal frame; The old main bearing is hoisted to the bearing replacement platform by the lifting equipment on the top of the tunnel and flipped from vertical to horizontal. The flipped old main bearing is then transported to another storage pit for storage. Take out the new main bearing and transport it to the bearing replacement platform. Flip the new main bearing from horizontal to vertical. Remove the bearing replacement platform and push the main engine forward to the side of the portal frame. Install the new main bearing and drive disc to the main engine in sequence, remove the portal frame, and then install the slag bucket and the inner and outer seals of the main drive; Debug the main drive during idling, and connect the cutter disc after checking that there is no abnormality.

2. The method for emergency replacement of main bearings of a long-distance single-hole tunnel TBM according to claim 1 is characterized in that: The angle between the storage cavern and the main cavern satisfies rail transportation, and the turning radius of the line is not less than 25m.

3. The method for emergency replacement of main bearings of TBM in long-distance single-hole tunnel according to claim 1 is characterized in that: The cutter head fixing includes the following steps: Before fixing the cutterhead, move it back once to clean the slag at the bottom of the tunnel between the tunnel face and the cutterhead, then push the cutterhead 5-15cm away from the tunnel face, rotate the cutterhead to the set position, and then push the cutterhead against the tunnel face; The cutter disc is laterally fixed, bottom supported and axially fixed respectively to limit the spatial freedom of the cutter disc to prevent the cutter disc from shifting.

4. The method for emergency replacement of main bearings of a long-distance single-hole tunnel TBM according to claim 1 is characterized in that: Before the new main bearing is stored in the storage pit, a protective layer is wrapped on the outer surface of the new main bearing. After the new main bearing is placed in the storage pit, the gap between the new main bearing and the storage pit is filled with fine sand.

5. The method for emergency replacement of main bearings of TBM in long-distance single-hole tunnel according to claim 1 is characterized in that: The portal frame is fixedly provided with a slide rail arranged along the front-rear direction, and a sliding trolley for driving a new main bearing or a driving disc to move is arranged on the slide rail.

6. The method for emergency replacement of main bearings of a long-distance single-hole tunnel TBM according to claim 5 is characterized in that: When removing the drive disc, the sliding trolley moves to the top of the inner side of the drive disc to support the drive disc. After the drive disc is removed and separated from the main machine, the sliding trolley drives the drive disc to move to the front end of the slide rail in a vertical posture, and a temporary support for the drive disc is set at the bottom of the drive disc to fix the sliding trolley on the door frame; When removing the old main bearing, set another sliding trolley on the slide rail and move it to the top of the old main bearing to support the old main bearing. After the old main bearing is separated from the main engine, the sliding trolley drives the old main bearing to move forward to the set position in a vertical posture, and set a temporary support for the old main bearing at the bottom of the old main bearing.

7. The method for emergency replacement of main bearings of a long-distance single-hole tunnel TBM according to claim 6 is characterized in that: A top turning ear and a bottom turning ear are respectively installed on the top and bottom of the old main bearing. The old main bearing is lifted by a lifting device and moved to the bearing replacement platform. The bottom turning ear is rotatably connected to the ear seat of the bearing replacement platform. The old main bearing is flipped from vertical to horizontal by the lifting device, and then the old main bearing is transported to the other storage pit for burial.

8. The method for emergency replacement of main bearings of a long-distance single-hole tunnel TBM according to claim 7 is characterized in that: The hoisting equipment lifts the new main bearing, and a transfer equipment is set on the temporary track at the bottom of the tunnel to transfer the new main bearing to the bearing replacement platform.

9. The method for emergency replacement of main bearings of a long-distance single-hole tunnel TBM according to claim 8 is characterized in that: Before the main engine is propelled, the temporary track is removed and debris in front of the main engine that affects the propulsion is cleared.

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