Long-distance single-hole tunnel TBM main bearing emergency replacement method

Abstract

The application provides a long-distance single-hole tunnel TBM main bearing emergency replacement method, and belongs to the technical field of tunnel construction, which comprises the following steps: excavating a storage cavern at the rear matching tail part while fixing a cutter head, and defining the excavation direction of the tunnel as the front end; transporting a new main bearing into the storage cavern; disconnecting a main machine and a device bridge, and retreating the whole rear matching to the front end of the device bridge to pass over the storage cavern, wherein the rear matching retreats before a storage pit; and building a hoisting device for hoisting the new main bearing above the storage pit; the emergency replacement method does not need to rely on another tunnel, temporarily stores the new main bearing and the old main bearing by setting the storage cavern and the storage pit, provides an avoidance for the rear matching and the main machine retreat, so that the bearing replacement is carried out, the length of 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 application relates to the technical field of tunnel construction, in particular to an emergency replacement method for a long-distance single-hole tunnel TBM main bearing. BACKGROUND

[0002] In long-distance tunnel construction, due to the long distance of the tunnel, the TBM main bearing exceeds the service life and service life, or due to the complex geological conditions, the main bearing of the TBM may need emergency repair or replacement due to wear, damage, etc. The difficulty of repair and replacement is that first, the TBM main bearing is large in size and cannot be transported in sections, which is difficult to transport; second, the main bearing installation part and installation method are special, which is difficult to remove; third, the tunnel space is narrow, and the space required for replacement and repair operation is large, and the existing inclined shaft or vertical shaft replacement method has problems of high cost, low efficiency, great difficulty, poor adaptability and the like, which affects the construction progress and safety.

[0003] The patent with the publication number CN114109416B discloses a tunnel TBM main bearing replacement method, which comprises the following steps:

[0004] (1) After determining that the TBM main bearing of the flat guide / normal hole needs to be replaced due to damage, the initial support structure behind the shield is removed;

[0005] (2) After the TBM whole machine retreats a certain distance, the anchor rod is set and the steel support is welded to fix the cutter head;

[0006] (3) The cutter head is separated from the main machine, the main machine retreats again in the reserved maintenance space between the cutter head and the main machine, and the steel mesh and the steel arch support are installed in the maintenance space;

[0007] (4) A main bearing transportation horizontal channel is opened from the normal / flat guide hole to the flat guide / normal hole;

[0008] (5) The gantry and the hoisting beam are erected between the cutter head and the shield, and then the main bearing is removed and replaced.

[0009] The application opens a horizontal channel in the parallel tunnel to replace the TBM main bearing, the channel length is short, the amount of civil engineering is small, and the difficulty of replacing the main bearing is reduced.

[0010] However, the scheme also has certain limitations. In a certain tunnel construction project, the length of the TBM whole machine is considered to be 245 meters, if the TBM main bearing needs to be replaced due to damage, the parallel guide hole is excavated to transport the main bearing, the parallel guide hole distance is long, and the stratum with good surrounding rock conditions needs to be selected for excavation during shutdown, and according to the construction progress, it is estimated that at least 3 months of shutdown waiting is needed, which affects the construction progress. SUMMARY

[0011] The application provides a long-distance single-hole tunnel TBM main bearing emergency replacement method to solve the technical problems in the prior art.

[0012] To solve the above problems, the long-distance single-hole tunnel TBM main bearing emergency replacement method provided by the application adopts the following technical scheme, including the following steps:

[0013] Excavate the storage cavern in the rear matching tail part, fix the cutter head, and define the excavation direction of the tunnel as the front end;

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

[0015] Disconnect the main machine and the equipment bridge, and retreat the whole rear matching to the front end of the equipment bridge to pass over the storage cavern, wherein the rear matching retreats before the hoisting equipment for hoisting the new main bearing is built above the storage pit;

[0016] Excavate two storage pits at the bottom of the tunnel at the front end of the equipment bridge, and the two storage pits are arranged along the front-rear direction;

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

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

[0019] Build a door-shaped frame, and remove the driving disc and the old main bearing;

[0020] Retreat the main machine to between the storage pit and the equipment bridge to provide a refuge for bearing replacement, and build a bearing replacement platform at the rear end of the door-shaped frame;

[0021] Through the hoisting equipment at the top of the tunnel, hoist the old main bearing to the bearing replacement platform and vertically flip it to be horizontal, and then transport the horizontally flipped old main bearing to the other storage pit for storage;

[0022] Transport the new main bearing to the bearing replacement platform, flip the new main bearing from horizontal to vertical, remove the bearing replacement platform, and advance the main machine to the side of the door-shaped frame;

[0023] Install the new main bearing, the driving disc to the main machine in sequence, remove the door-shaped frame, and then install the slag collecting bucket and the main drive inner and outer seals;

[0024] Perform the main drive idling debugging, and butt the cutter head after checking that there is no abnormality.

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

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

[0027] Before fixing the cutter head, retreat a cycle, clean the stone residue between the tunnel bottom and the cutter head, then push the cutter head to be 5-15cm away from the tunnel bottom, rotate the cutter head to the set position, and then push the cutter head to be close to the tunnel bottom.

[0028] The cutter head is fixed laterally, supported at the bottom and fixed axially to limit the spatial freedom of the cutter head and prevent the cutter head from deviating.

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

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

[0031] As a further improvement, when the driving disc is disassembled, the sliding trolley moves to the inside of the driving disc to support the driving disc, and after the driving disc is disassembled and separated from the main machine, the sliding trolley drives the driving disc to move to the front end of the sliding rail in a vertical posture, and a temporary support for the driving disc is arranged at the bottom of the driving disc to fix the sliding trolley on the door-shaped frame.

[0032] When disassembling the old main bearing, another sliding trolley is arranged on the sliding rail and moved to the inside of the old main bearing to support the old main bearing, and after the old main bearing is separated from the main machine, the sliding trolley drives the old main bearing to move to the set position in a vertical posture, and a temporary support for the old main bearing is arranged at the bottom of the old main bearing.

[0033] As a further improvement, a top turnover lifting lug and a bottom turnover lifting lug are respectively installed at the top and the bottom of the old main bearing, the old main bearing is lifted by the hoisting equipment and moved to the bearing replacement platform, the bottom turnover lifting lug is rotationally connected with the lug seat of the bearing replacement platform, the old main bearing is turned from vertical to horizontal by the hoisting equipment, and then the old main bearing is transferred to the other storage pit for storage.

[0034] As a further improvement, the lifting equipment lifts the new main bearing, and a transfer device is arranged on the 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 machine is pushed forward, the temporary track is removed, and the debris in front of the main machine affecting the pushing is cleaned.

[0036] The beneficial effects of the above technical solutions of the present application are as follows:

[0037] 1. The application provides temporary storage for new main bearings and old main bearings by setting storage cavities and storage pits, provides avoidance for the later matching and main machine retreat, so as to replace the bearings, the length of the storage cavity does not need to be too long, and the construction difficulty and construction cost are reduced.

[0038] In addition, since the emergency replacement method of the application does not need to rely on another tunnel, the construction progress of another tunnel will not be affected by transporting new main bearings by relying on another tunnel.

[0039] 2. The application uses the structure of the cutter head, adopts the overall method of seven-point locking and four-position support at the bottom, ensures the stability of the cutter head after being fixed, and is beneficial to the accurate butt joint of the cutter head and the main machine. BRIEF DESCRIPTION OF DRAWINGS

[0040] The above and other objects, features and advantages of the exemplary embodiments of the application will be more apparent from the following detailed description read in conjunction with the accompanying drawings, in which several embodiments of the application are shown by way of example, and in which the same or corresponding elements are denoted by the same or corresponding reference numerals, wherein:

[0041] Figure 1 The replacement flowchart of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0042] Figure 2 The new main bearing plate car transportation schematic diagram of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0043] Figure 3 The structure schematic diagram of the storage cavity of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0044] Figure 4 The cutter head fixing flowchart of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0045] Figure 5 The cutter head fixing schematic diagram of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0046] Figure 6 The arrangement schematic diagram of the axial anchor rod of the long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0047] Figure 7Schematic diagram of main machine disconnection for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0048] Figure 8 Schematic diagram of door type frame for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0049] Figure 9 Schematic diagram of driving disc fixation for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0050] Figure 10 Schematic diagram of main bearing disassembly point for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0051] Figure 11 Structural schematic diagram of bearing replacement platform for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0052] Figure 12 Schematic diagram of new main bearing or old main bearing overturning for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0053] Figure 13 Schematic diagram of main machine empty pushing position for long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0054] Figure 14 Maintenance evaluation standard reference diagram for embodiment 2 of long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0055] Figure 15 Maintenance operation flowchart for embodiment 2 of long-distance single-hole tunnel TBM main bearing emergency replacement method of the application;

[0056] Figure 16 Schematic diagram of main bearing disassembly for embodiment 2 of long-distance single-hole tunnel TBM main bearing emergency replacement method of the application.

[0057] Explanation of reference numerals:

[0058] 1, new main bearing; 2, flat car; 3, storage cave; 4, cutter head; 5, main machine; 6, equipment bridge; 7, slide rail; 8, door type frame; 9, main drive; 10, sliding trolley; 11, temporary support; 12, bearing replacement platform; 13, old main bearing; 14, bearing disassembly door frame. DETAILED DESCRIPTION

[0059] With reference to the accompanying drawings, the technical solutions in the embodiments of the present application will be clearly and completely described below, and those skilled in the art shall know that the embodiments described below are only part of the embodiments of the present disclosure, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work shall fall within the scope of protection of the present application.

[0060] In long-distance tunnel construction, due to the long distance of the tunnel, the main bearing of the TBM needs to be replaced in emergency as it exceeds the service life and the life span. The difficulty of replacement lies in that the main bearing is large in size and cannot be transported in pieces, the installation part and the installation method of the main bearing are special, and the space in the tunnel is narrow. The existing methods of maintenance and replacement by means of inclined shaft, vertical shaft or detour guide hole have problems of high cost, low efficiency, great difficulty and poor adaptability, which affect the construction progress and safety.

[0061] If the construction progress of the left and right lines is quite different, only the detour guide hole method (a method of excavating a detour guide hole to the front of the cutter head from the position of the tail of the TBM and expanding the tunnel in front of the cutter head to form a chamber) or waiting for the other tunnel can be used. The former has a high construction cost, and the latter needs to wait for a long time, which may affect the construction progress.

[0062] To solve the above problems, a storage chamber in communication with the tunnel is opened at a position about 20 meters from the tail of the TBM, the new main bearing is transferred to the storage chamber in advance, and when the rear support is matched and retreated to the rear side of the storage chamber, a storage pit is excavated and the new main bearing is buried in the storage pit. In this way, on the one hand, the new main bearing is stored while the cutter head is separated, the inner and outer seals are removed and other steps are performed synchronously, thereby shortening the replacement period. On the other hand, the difficulty and cost of excavating the storage chamber and the storage pit are relatively low, and the operability and safety are higher.

[0063] After introducing the basic principles of the present application, various non-limiting embodiments of the present application will be specifically introduced below. Any number of elements in the drawings is used for illustration and not limitation, and any naming is only used for distinction and does not have any limiting meaning.

[0064] The principles and spirits of the present application will be explained in detail below with reference to several representative embodiments of the present application.

[0065] Embodiment 1 of the long-distance single-hole tunnel TBM main bearing emergency replacement method provided by the present application, as shown in Figures 1-13 includes the following steps:

[0066] S1, excavating the storage chamber 3 at the rear support tail, and fixing the cutter head 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 engine 5 is disconnected from the equipment bridge 6, and the whole body retreats to the front end of the equipment bridge 6 and passes over the storage cavern 3. Before the rear supporting equipment retreats, a lifting device for lifting the new main bearing 1 is set up above the storage pit;

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

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

[0071] S6, sequentially disengage the cutter head 4, dismantle the inner and outer seals of the main drive 9, and dismantle the slag collecting hopper;

[0072] S7, build the 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 a clearance for bearing replacement, and a bearing replacement platform 12 is built at the rear end of the portal frame 8;

[0074] S9, using the hoisting equipment on the top of the tunnel, lift the old main bearing 13 to the bearing replacement platform 12 and flip it from vertical to horizontal. The flipped-horizontal old main bearing 13 is then transported 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 move the main engine 5 forward to the side of the portal frame 8;

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

[0077] S12, the main drive 9 is debugged in idle operation, 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 supporting structure (the nearest connecting passage between the left and right lines is initially used as the storage cavern; if the connecting passage is insufficient, a new storage cavern is excavated). Its dimensions are designed to accommodate a dedicated flatbed truck 2 for transporting the main bearing. In this embodiment, the storage cavern measures 10 × 7.5 × 4.3 meters in length × width × height. The angle between the storage cavern and the main tunnel allows for rail transport, with a turning radius of no less than 25 meters. After the replacement is complete, the over-excavation, excluding the storage cavern, is backfilled with concrete of the same grade. The storage cavern is much smaller than the circuitous passages used in existing technologies, resulting in a relatively lower construction cost.

[0079] As Figures 4-6 shown, the cutter head 4 is fixed including the following steps:

[0080] Before the cutter head 4 is fixed, it is retreated for a cycle, which is 1.8 meters in this embodiment, to clean the stone residue at the bottom of the tunnel between the tunnel face and the cutter head 4, then the cutter head 4 is pushed to be 10 cm away from the tunnel face, the 40# cutter position of the cutter head 4 is turned to the bottom of the tunnel in manual mode, and then the cutter head 4 is pushed to be in close contact with the tunnel face.

[0081] The cutter head 4 is fixed laterally, supported at the bottom and fixed axially respectively to limit the spatial freedom of the cutter head 4 to prevent the cutter head 4 from deviating.

[0082] Lateral fixation: 10 anchor rods are installed in each of the 10 residue scraping bins at the top, 6 anchor rods are installed in each of the 2 residue scraping bins at the bottom left and right at an angle of 55°, a total of 72 anchor rods are installed at 7 fixed positions; the anchor rods are made of φ25 threaded steel, the cutting length is 3 m, and the anchoring length is 2.5 m.

[0083] Bottom support: support the cutter head 4 at the positions of the three residue scraping bins at the bottom, and set four support points. First, appropriate steel plates are inserted between the outer ring plate of the cutter head 4 and the tunnel wall; then, support plates are inserted between the back conical plate of the cutter head 4 and the tunnel wall, the distribution angle of the support plates overlaps with the angle of the inserted plates, and the support plates are welded with the cutter head 4.

[0084] Axial fixation: at the positions of the 27#, 28#, 29# and 30# cutter holes, 3 anchor rod holes are made at each cutter hole, a steel plate with a size of 600*250*20 mm is cut to pass through the anchor rod and is locked, and the axial anchor rod is made of a 3 m long φ25 glass fiber anchor rod.

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

[0086] As Figure 7 shown, before the main machine 5 is disconnected from the rear matching part, temporary wheel sets are installed at the bottom of the connecting bridge to facilitate the rearward movement, the pipelines connected between the rear matching part and the main machine 5 are removed, and identification and protection measures are taken.

[0087] In step S4, after the rear matching part is retreated to create space, the construction of the storage pit can be carried out; the storage pit has a diameter of 7 m and a depth of 1.5 m, the laid precast blocks are first removed, and then the hole bottom is laid out; when laying out, the point positions are referred to the requirements of the blast hole layout to construct the blast hole. The depth of the storage pit should be ensured to store the new main bearing 1 or the old main bearing 13 without exploring the rock surface.

[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, steel sleepers are laid in front of the inverted arch block, and a temporary track is erected, with the length being sufficient for the bearing plate car to be above the storage pit; after the bearing plate car drives to the upper part of the storage pit, the new main bearing 1 is hoisted by the hoisting equipment at the top of the storage pit, the plate car retreats, and the temporary track and the steel sleepers are removed; the new main bearing 1 is stored in the pit, the storage pit needs to be wrapped with non-woven fabric, and after the bearing is stably placed in the pit, fine sand is used to fill the gap between the bearing and the storage pit, the hydraulic and control pipelines of the main machine 5 are connected (extended), and the main machine 5 retreats after step.

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

[0090] Before detachment, the fixed state of the cutter head 4 is checked to confirm that it is firmly fixed and meets the detachment conditions. The data of the guide system before detachment and the original position of the TBM are recorded in detail for use when the cutter head 4 is connected. The original position of the TBM includes the position of the support shoe, the extension length of the top support shoe oil cylinder, the extension length of the torque oil cylinder, and the position of the rear edge of the side shield, the connection position mark (not less than 4) of the drive disc and the cutter head 4, etc. The cutter head 4 is marked before detachment;

[0091] Remove all cutter head 4 connection double-headed bolt protection caps;

[0092] Gradually reduce the bolt pulling pressure in 3 times in sequence, and completely loosen the bolt in the last time, remove the nut, then remove the double-headed bolt, clean it with kerosene, apply hydraulic oil, and properly store it;

[0093] Bolt loosening and removal sequence: 4-5 in sequence according to up, down, left and right;

[0094] After the bolt removal is completed, the connection between the cutter head 4 and the main drive 9 is checked again, and after confirming that all are disconnected, the cutter head 4 detachment work can be carried out. Four 100-ton thin jacks are placed between the cutter head 4 and the main drive 9, and the cutter head 4 is stably separated from the main drive 9 by cooperating with the jacks and the advancing oil cylinder, and the separation distance is more than 50 mm.

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

[0096] After the cutter head 4 is successfully detached, the main machine 5 retreats 1.2 meters, a sealing and disassembly platform is built between the cutter head 4 and the main drive 9, a slide is welded at a suitable position between the main drive 9 and the cutter head 4 for moving after the ring is removed, and a lifting lug is welded on the top of the outer seal compression ring to suspend a hoist and tighten it;

[0097] Two to three suspension rods are welded on the back of the cutter head 4 for temporarily storing each seal compression ring and spacer ring;

[0098] Welding lifting lugs (3 tons of lifting weight) on the top shield for installing the hand chain block. Welding 6 sets of pull plate assemblies on the cutter head 4 for taking out and installing the outer sealing compression ring, outer sealing outer spacer ring and outer sealing inner spacer ring. The pull plate assembly holes are aligned with the outer sealing compression ring threaded holes;

[0099] Remove the bolts according to the diagonal principle and make position marks;

[0100] Remove the outer sealing ring piece hexagonal screws, outer sealing protection plate, outer sealing compression ring, outer sealing lip seal and outer sealing spacer ring in sequence and place them at the hanging place at the back of the cutter head 4 (steel rods can be stored by being inserted into the bolt holes of the cutter head 4). Measure the wear of the outer sealing wear track and the lip seal.

[0101] Insert bolts into the bolt holes at the top of the driving disc, press the lifting plate (3T weight can be lifted) and install the hand chain block. Weld 6 sets of pull plate assemblies on the inner panel of the cutter head 4 for taking out and installing the inner sealing compression ring, inner sealing outer spacer ring and inner sealing inner spacer ring. The pull plate assembly holes are aligned with the outer sealing compression ring threaded holes. Remove the inner sealing ring piece hexagonal screws, inner sealing labyrinth ring 1, inner sealing labyrinth ring 2, inner sealing compression ring, inner sealing lip seal and inner sealing spacer ring in sequence according to the outer sealing removal method and place them at the hanging place at the back of the cutter head 4. Measure the wear of the inner sealing wear track and the lip seal.

[0102] Remove the slag collecting hopper:

[0103] After the removal of the sealing and ring pieces is completed, remove the working platform and continue to retreat the main machine 5 to reserve space (≥2 meters) for the removal of the slag collecting hopper.

[0104] Build the removal platform, weld lifting lugs on the top shield, suspend the chain block by the lugs of the slag hopper and pull the chain block tight.

[0105] Remove the pin shaft between the slag collecting hopper and the driving box.

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

[0107] As shown in Figure 8 Fig. 7, step S7 of building the portal frame 8 includes the following steps:

[0108] Retreat the main machine 5 to stop when the top shield is exposed for 3 meters at the portal frame 8 installation position;

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

[0110] After the portal frame 8 is built, install the bottom steel sleeper and the slide rail 7;

[0111] After the bottom sleeper is laid, the door frame 8 is welded with the main beam sliding rail 7, and the inclined support is fixed.

[0112] As shown in Figure 9 the disassembly of the driving disc includes the following steps:

[0113] The driving disc tooth ring connecting bolts on the left and right sides of the top are removed, and the M48x700 double-headed studs are installed with a gasket to support the sliding trolley 10 support, and the bottom sliding rail 7 is supported with a rubber pad;

[0114] After the sliding trolley 10 is installed, the double-headed studs between the driving disc and the main bearing are removed three times according to the diagonal principle, placed in the appropriate area, and checked whether the double-headed studs are damaged, and the bolt hole position is marked;

[0115] Mark the position with a line at the position of the motor torque limiter, and mark the rotation direction with a fine line (the length of the line ensures that the torque limiter can rotate 5 times);

[0116] Use M30 top wire to simultaneously outwardly top the base at 8 points, pay attention to keep the top wire rotation size consistent at all places, so as to ensure that the driving disc slides out of the installation cavity uniformly in the circumferential direction. Synchronously move the sliding trolley 10 to ensure that the driving disc attitude is vertical, 4 M48x1300 guide rods can be installed in advance in the bottom bolt hole; at the same time, people arranged on the motor side record the rotation direction and displacement of each motor when it is separated, to provide reference for the docking of the driving disc;

[0117] After the driving disc completely separates from the installation cavity, it is fixed on the door frame 8, supported and fixed through 2 support points at the bottom; kerosene is used to completely clean the surface of the driving disc and the driving gear ring, and the damage of the gear ring is checked (at the same time, the position of the pinion is marked to prevent position change caused by collision in subsequent work).

[0118] As shown in Figure 10 the disassembly of the old main bearing 13 includes the following steps:

[0119] Another sliding trolley 10 is arranged on the sliding rail 7 and moved to the inside of the old main bearing 13 to support the old main bearing 13, M56 lifting rings are installed at the three lifting points of the main bearing, 3 2T hoists are used to simultaneously outwardly pull the old main bearing 13 at the corresponding position of the door frame 8, pay attention to keep the hoist stroke size consistent at all places (or use 4 RLT-41 flat jacks between the bearing and the driving box, and four jacks are simultaneously and uniformly stressed), to ensure that the old main bearing 13 slides out of the installation cavity uniformly in the circumferential direction

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

[0121] AsFigures 11-13 As shown in the figure, in step S9, the top and bottom turnover ears are respectively installed on the top and bottom of the old main bearing 13, the hoisting equipment hoists the old main bearing 13 and moves it to the bearing replacement platform 12, the bottom turnover ear is rotationally connected with the ear seat of the bearing replacement platform 12, the old main bearing 13 is turned from vertical to horizontal by the hoisting equipment, and then the old main bearing 13 is transported to the other storage pit for storage. The storage step of the old main bearing 13 can refer to the storage step of the new main bearing 1, mainly including: wrapping the old main bearing 13 with non-woven fabric, supporting the old main bearing 13 by the wheel set, hoisting the old main bearing 13 by the hoisting equipment, removing the temporary track, and storing the old main bearing 13 and filling the fine sand.

[0122] The hoisting equipment hoists the new main bearing 1 (the temporary track is temporarily removed before hoisting, and then the temporary track is fixed again after the new main bearing 1 is hoisted), and the transportation equipment is arranged on the temporary track at the bottom of the tunnel to transport the new main bearing 1 to the bearing replacement platform 12.

[0123] Before the main machine 5 is pushed forward, the temporary track is removed, and the sundries in front of the main machine 5 affecting the pushing are cleaned.

[0124] The subsequent installation and debugging steps are not described here.

[0125] Embodiment 2

[0126] The embodiment discloses an emergency maintenance method for a long-distance single-hole tunnel TBM main bearing, and the starting condition is: if large torque fluctuation of 800KN.M-1500KN.M occurs in the empty pushing process under good surrounding rock conditions, the machine is immediately stopped for troubleshooting, and if it is determined that the old main bearing 13 has a deterioration trend or severe deterioration (in this embodiment, the old main bearing 13 refers to the main bearing currently in use), the old main bearing 13 is started after evaluation (evaluation standards are as follows: for example, a shallow damage with a depth of less than 3mm is light damage, and vice versa is heavy damage), the old main bearing 13 has light damage, and only repair can meet the tunneling of the remaining section of the whole project, the machine is stopped and the old main bearing 13 maintenance scheme is started; otherwise, the old main bearing 13 replacement scheme is started. Figure 14 As shown in the figure, the emergency maintenance method for the long-distance single-hole tunnel TBM main bearing includes the following steps:

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

[0128] S1, preliminary preparation; if short-distance tunneling can be met, continue to push forward 18 meters, do not perform bottom pouring for the newly installed inverted arch block, and use the form of anchor rod + mesh + primary spraying for the initial support; if tunneling cannot be performed, gradually remove the arch frame and inverted arch block during the process of retreating the main machine 5, and simultaneously perform arch spraying; at the same time, prepare the old main bearing 13 retainer, roller and other parts. ​

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

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

[0131] S4, the inner and outer seals of the main drive 9 are disassembled.

[0132] S5, the slag collecting bucket is disassembled.

[0133] S6, the door frame 8 is built.

[0134] S7, the drive disc is disassembled.

[0135] S8, the old main bearing 13 is disassembled.

[0136] S9, the drive box is inspected and cleaned.

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

[0138] S10, the maintenance platform is built, the bearing overturning lifting lug is installed, and the bearing disassembly gantry 14 and hoisting equipment (or other lifting and hoisting equipment) are built.

[0139] S11, the old main bearing 13 is repaired; first, the old main bearing 13 is overturned from vertical to horizontal by the hoisting equipment;

[0140] Secondly, disassemble the old main bearing 13, as shown, disassembling the old main bearing 13 includes the following steps: Figure 16

[0141] (1) According to the bearing lifting point position, hang a 10T hoist, and install it on the lifting point of the inner ring of the bearing with three M56 lifting ring screws;

[0142] (2) Mark the position at the inner diameter of the two inner rings, then remove the screws connecting the two inner rings, the inner hexagonal screws protecting the inner ring positioning pins, and the plastic rods, and finally lift the inner ring;

[0143] (3) After lifting the inner ring to a certain height, fix it, remove the main thrust roller and the retainer, and check the raceway surface of the main thrust roller; then remove the radial roller and the retainer, and then take out the roller from the retainer;

[0144] (4) Lift the outer ring of the bearing through the hole wall lifting point and four 10T hoists, and remove the counter-thrust roller and the retainer;

[0145] Then repair the old main bearing 13, replace all the rollers, retainers, seals, and spring units under the counter-thrust raceway; and treat the raceway as shown in Figure 14 ;

[0146] ​Finally, the old main bearing 13 is reassembled; after all the raceway surfaces are repaired, the thrust rollers and the cage are installed; at the same time, 3 groups of radial rollers are placed evenly in the radial raceway; the temporary support 11 of the outer ring is removed, and the outer ring is slowly sleeved into the inner ring; the radial rollers and the cage are installed; the main thrust rollers and the cage are installed; the fixed support on the inner ring is removed, and the inner ring is slowly lowered; after the installation of the inner ring is completed, the locking screw is installed and fastened in place.

[0147] S12, the old main bearing 13, the driving disc, the slag collecting bucket and other parts are reinstalled to the main machine 5.

[0148] S13, the main drive 9 is tested under no load; after the installation of the inner and outer seals is completed, the installation platform and the auxiliary lifting lug are removed, the drive box is filled with gear oil; after checking whether the drive is interfered, the drive device is idling; during the debugging of the device, it is checked whether the drive box has any abnormal conditions; it is checked whether the gear oil exists in the detection cavity of the inner and outer seal systems of the main drive 9.

[0149] S14, the cutter head 4 is installed.

[0150] In this embodiment, if the old main bearing inner ring or the old main bearing outer ring is replaced, the old main bearing inner ring or the old main bearing outer ring can be transported in the manner of transporting the new main bearing 1 in embodiment 1.

[0151] Although the present specification has shown and described several embodiments of the present application, it will be apparent to those skilled in the art that many modifications, changes and substitutions can be made to the embodiments without departing from the spirit and scope of the present application. It should be understood that various alternatives to the embodiments of the present application described herein can be employed in practicing the present application. The appended claims are intended to cover all such alternatives as falling within the scope of the present application.

Claims

1. A long-distance single-hole tunnel TBM main bearing emergency replacement method, characterized in that, The method comprises the following steps: Excavating a storage chamber in the rear matching tail section while fixing the cutter head, and defining the excavation direction of the tunnel as the front end; Transporting the new main bearing to the storage chamber; Disconnecting the main machine and the equipment bridge, and retreating the whole to the front end of the equipment bridge to pass over the storage chamber, wherein the rear matching retreats forward before the storage pit, and a hoisting device for lifting the new main bearing is built above the storage pit; Excavating two storage pits at the bottom of the tunnel at the front end of the equipment bridge, and arranging the two storage pits along the front-rear direction; Transporting the new main bearing in the storage chamber to one of the storage pits; In sequence, the cutter head is detached, the main drive inner and outer seals are disassembled, and the slag collecting bucket is disassembled; Building a door-shaped frame, and disassembling the driving disc and the old main bearing; Retreating the main machine between the storage pit and the equipment bridge to provide a shelter for bearing replacement, and building a bearing replacement platform at the rear end of the door-shaped frame; Through the hoisting device at the top of the tunnel, the old main bearing is hoisted to the bearing replacement platform and is flipped vertically to horizontally, and then the horizontally flipped old main bearing is transported to the other storage pit for storage; The new main bearing is transported to the bearing replacement platform, and the new main bearing is flipped from horizontal to vertical, the bearing replacement platform is disassembled, and the main machine is pushed forward to the side of the door-shaped frame; In sequence, the new main bearing, the driving disc are installed to the main machine, the door-shaped frame is disassembled, and then the slag collecting bucket and the main drive inner and outer seals are installed. The main drive is idled and debugged, and the cutter head is connected after checking that there is no abnormality.

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

3. The long-distance single-hole tunnel TBM main bearing emergency replacement method according to claim 1, characterized in that: The cutter head fixing comprises the following steps: Before fixing the cutter head, retreat a cycle, clean the stone residue at the bottom of the tunnel between the cutter head and the working face, then push the cutter head to be 5-15 cm away from the working face, rotate the cutter head to the set position, and then push the cutter head to abut against the working face; The cutter head is fixed laterally, supported at the bottom, and fixed axially to limit the spatial degrees of freedom of the cutter head to prevent the cutter head from deviating.

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

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

6. The long-distance single-hole tunnel TBM main bearing emergency replacement method according to claim 5, characterized in that: When disassembling the driving disc, the sliding trolley is moved to the inside of the driving disc to support the driving disc, and after the driving disc is disassembled and separated from the main machine, the sliding trolley drives the driving disc to move to the front end of the sliding rail in a vertical posture, and a temporary support for the driving disc is arranged at the bottom of the driving disc to fix the sliding trolley to the door-shaped frame. When disassembling the old main bearing, another sliding trolley is arranged on the sliding rail and is moved to the inside of the old main bearing to support the old main bearing, and after the old main bearing is separated from the main machine, the sliding trolley drives the old main bearing to move to the set position in a vertical posture, and a temporary support for the old main bearing is arranged at the bottom of the old main bearing.

7. The long-distance single-hole tunnel TBM main bearing emergency replacement method according to claim 6, characterized in that: A top turnover lug and a bottom turnover lug are respectively installed at the top and the bottom of the old main bearing, the old main bearing is moved to the bearing replacement platform by the hoisting device, the bottom turnover lug is rotationally connected with an ear seat of the bearing replacement platform, the old main bearing is flipped from vertical to horizontal by the hoisting device, and then the old main bearing is transferred to the other storage pit for storage.

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

9. The long-distance single-hole tunnel TBM main bearing emergency replacement method according to claim 8, characterized in that: Before the main machine is propelled, the temporary track is removed, and the sundries affecting the propulsion in front of the main machine are cleaned.

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