A tunnel segment replacement device and a tunnel segment replacement method

Abstract

This invention discloses a tunnel segment replacement device and a tunnel segment replacement method. The tunnel segment replacement device includes a support frame and several rotating gear rings mounted on the support frame. Each rotating gear ring is equipped with a rotating mechanism that travels along the rotating gear ring. At least one rotating mechanism is equipped with a radially telescopic protective mechanism, a vibrator, and an assembly mechanism. The vibrator is used to vibrate and break up the damaged tunnel segments. The protective mechanism is used to support the tunnel segments adjacent to the damaged segments. The assembly mechanism is used to assemble new tunnel segments. The tunnel segment replacement method uses the aforementioned tunnel segment replacement device. This invention not only solves the problem of repairing and replacing severely damaged or misaligned tunnel segments, but also allows the tunnel boring machine to operate without stopping during the operation of the tunnel segment replacement device. There is no waiting time from segment vibration to assembly, resulting in high efficiency. Timely repair and replacement of tunnel segments ensures construction safety and the safe use of the tunnel afterwards.

Description

Technical Field

[0001] This invention relates to the technical field of tunnel segment repair and replacement, and in particular to a tunnel segment replacement device and a tunnel segment replacement method. Background Technology

[0002] When tunnels are constructed using tunnel boring machines (TBMs) or other excavation equipment, the precast segments assembled inside serve as the load-bearing and waterproofing structure. These segments are assembled sequentially, ring by ring, from the beginning to the end of the tunnel. Due to various accidental factors such as the quality of segment manufacturing, impacts during transportation or assembly, and ground vibrations, the assembled segments may be damaged or broken. Sometimes, due to assembly errors, there may be significant misalignments or gaps between different rings of segments. All of these abnormal segment conditions can lead to tunnel leakage, reduce the load-bearing capacity of the tunnel structure, and compromise the tunnel's subsequent usability. Therefore, it is necessary to repair segments in abnormal condition.

[0003] For example, the invention patent application CN111997656A, published on November 27, 2020, discloses a method for preparing a repair structure for damaged segments of a shield tunnel. The specific steps are: 1. Chiseling away fragments; 2. Cleaning the fractured surface; 3. Drilling and anchoring expansion bolts; 4. Applying an interface agent; 5. Binding wire mesh; 6. Layering and filling with repair mortar; 7. Filling the surface with tinted mortar and polishing. This technical solution repairs damaged segments through a series of steps including chipping away fragments, cleaning, drilling and anchoring expansion bolts, applying an interface agent, binding wire mesh, layering and filling with repair mortar, filling with tinted mortar, and polishing. However, this repair method can only repair areas with minor damage. For severely fractured segments, without an underlying support structure, it is impossible to drill and anchor expansion bolts, and the bolts lack stable and secure anchoring points.

[0004] For example, patent application CN118065928 A, published on May 24, 2024, discloses a device and method for repairing cracks in tunnel lining segments of a tunnel boring machine (TBM). This device repairs cracks in TBM segments during TBM construction. The device includes side frames, a passive connecting frame, an active connecting frame, and a repair platform. The top of the side frames is arc-shaped, and the active connecting frame is slidably connected to the arc-shaped portions of the two side frames. This allows the active connecting frame to extend and retract, changing the distance between the two side frames, and to slide and change its position on the side frames. The passive connecting frame is connected to the middle of the two side frames and acts as a guide. The repair platform in the middle of the active connecting frame is equipped with a multi-directional drilling mechanism that can drill along the longitudinal direction of the crack within the segment. In essence, it designs a platform with a detection and drilling device installed. When a crack is detected inside the segment, a hole is drilled at the crack, and then grouting is performed. This method can repair cracks and gaps on the back of the segments, providing waterproofing and reinforcement, but it cannot repair surface damage or misalignment between different ring segments.

[0005] In summary, while some progress has been made in the research of tunnel segment repair methods, it still cannot meet the needs of comprehensive segment repair, especially for severely damaged segments and segments with misalignment. Therefore, it is necessary to design a device capable of repairing and replacing damaged and unusable tunnel segments.

[0006] It should be noted that the above technical information is intended only to enhance the understanding of the overall background technology of the present invention, and should not be regarded as an admission or in any way implying that the above technical information constitutes prior art known to those skilled in the art. Summary of the Invention

[0007] To address the shortcomings in the aforementioned background technology, this invention proposes a tunnel segment replacement device and a tunnel segment replacement method. The technical problem to be solved is: how to repair and replace tunnel segments that are unusable due to severe damage or misalignment.

[0008] The technical solution of this invention is as follows:

[0009] A tunnel segment replacement device includes a support frame and a plurality of rotary gear rings disposed on the support frame. Each rotary gear ring is provided with a rotary mechanism that travels along the rotary gear ring. At least one rotary mechanism is provided with a radially telescopic protective mechanism. At least one rotary mechanism is provided with a vibrator. At least one rotary mechanism is provided with an assembly mechanism. The vibrator is used to vibrate and break the damaged tunnel segment. The protective mechanism is used to support the tunnel segment adjacent to the damaged tunnel segment. The assembly mechanism is used to assemble a new tunnel segment.

[0010] In this technical solution, the support frame serves as the main support for the entire device. One or more rotary gear rings can be installed on it. The rotary mechanism can travel along the circumference of the rotary gear ring, thus approaching any segment within the tunnel. The protective mechanism, vibrator, and assembly mechanism can travel synchronously with the rotary mechanism. The vibrator then breaks and disassembles the segment to be repaired or replaced. At the same time, the protective mechanism supports adjacent segments, and the assembly mechanism can assemble new segments to replace the original segments after they have been broken and dismantled.

[0011] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the rotary mechanism includes a rotary gear driven by a rotary motor, a rotary plate connected to the rotary gear, and a limiting wheel connected to the rotary plate. The rotary gear meshes with the teeth on one side of the circumferential surface of the rotary gear ring, and the limiting wheel engages with the other side of the circumferential surface of the rotary gear ring through frictional rolling or tooth meshing. This technical solution is a further optimization of the above technical solution, providing a preferred rotary mechanism in which the rotary gear acts as the driving wheel driven by the rotary motor, capable of moving along the teeth on the rotary gear ring, while the limiting wheel is the driven wheel of the rotary mechanism. It can be either a roller that engages with the rotary gear ring through frictional rolling or a gear that meshes with the rotary gear ring. The rotary gear and the limiting wheel are located on the inner and outer sides of the rotary gear ring, respectively, and together they clamp the two sides of the rotary gear ring.

[0012] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the rotary gear meshes with the teeth on the inner circumferential surface of the rotary gear ring or the teeth on the outer circumferential surface. This technical solution provides two preferred rotary mechanisms: one is where the rotary gear, acting as the driving wheel, meshes with the gear on the inner circumferential surface of the rotary gear ring. As shown in the above embodiments, in this case, the limiting wheel, acting as the driven wheel, rolls or meshes with the outer circumferential surface of the rotary gear ring; the other is the opposite structural form, where the rotary gear, acting as the driving wheel, meshes with the gear on the outer circumferential surface of the rotary gear ring. As shown in the above embodiments, in this case, the limiting wheel, acting as the driven wheel, rolls or meshes with the inner circumferential surface of the rotary gear ring.

[0013] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the rotary mechanism includes two rotary gears, each connected to a rotary motor. The two rotary gears are located on the left and right sides of the rotary gear ring, or on the same side of the rotary gear ring. The two rotary motors are connected by a connecting rod and also connected to the rotary plate through the connecting rod. This technical solution is a further upgrade of the above technical solution, setting two rotary gears as the driving wheels in the rotary mechanism. In this case, the limiting wheels as driven wheels can be two, one, or multiple. The two rotary gears and the rotary gears and the rotary plate are connected to each other by connecting rods, forming a more stable rotary mechanism. When the two rotary gears are arranged on the left and right sides of the rotary gear ring, the entire rotary mechanism can clamp the rotary gear ring in the left-right direction through the two rotary gears, and also clamp the rotary gear ring in the inward and outward direction through the cooperation of the rotary gears and the limiting wheels, thus making the cooperation between the entire rotary mechanism and the rotary gear ring more stable and reliable. When two rotary gears are arranged on the same side of the rotary gear ring, the two rotary gears and several limit wheels clamp the rotary gear ring. Although the stability is weaker compared with the technical solution where the gears are located on both sides of the rotary gear ring, it still has considerable stability.

[0014] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the two rotary gears form a set of drive gears and are located on the same side of the rotary gear ring. A symmetrical set of drive gears is provided on the other side of the rotary gear ring. The two rotary motors of this other set of drive gears are connected by a connecting rod and also connected to the rotary plate through the connecting rod. This technical solution is a further upgrade of the above technical solution. The rotary gear ring is clamped in the left-right direction by two rotary gears, and in the inward and outward directions by the cooperation of the rotary gears and the limiting wheels. The four rotary gears, several limiting wheels, connecting rods, and the rotary plate constitute a rotary mechanism, further improving the stability of the entire rotary mechanism when moving along the rotary gear ring, as well as its stability when the rotary mechanism is stationary relative to the rotary gear ring.

[0015] Based on the above technical solutions, as a preferred embodiment of the tunnel segment replacement device, the protective mechanism includes a protective plate and a telescopic drive device and a support and guide assembly connected between the protective plate and the rotating mechanism. This technical solution provides a preferred implementation of the protective mechanism. The telescopic drive device is used to drive the protective plate closer to or further away from the tunnel segments, while the support and guide assembly not only supports and limits the protective plate together with the telescopic drive device but also guides the telescopic drive device. More preferably, both ends of the telescopic drive device are hinged to the protective plate and the rotating plate, respectively, while the fixed component in the support and guide assembly is fixedly connected to the rotating plate, and the movable component is fixedly connected to the protective plate. In a direction perpendicular to the vertical telescopic direction, there is a certain amount of movement between the fixed component and the movable component.

[0016] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the telescopic drive device is a telescopic hydraulic cylinder, a telescopic electric cylinder, or a telescopic pneumatic cylinder, and the support and guide assembly includes a sleeve and a telescopic rod that is inserted into the sleeve.

[0017] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the bottom of the support frame is connected to a traveling wheel with its own traveling motor, and the top is connected to a lifting device for hoisting the segments. Several traveling wheels are symmetrically arranged about the vertical plane of the support frame, and the space between the traveling wheels on the left and right sides is a segment transfer channel.

[0018] Based on the above technical solutions, as a preferred technical solution for the tunnel segment replacement device, the rotary gear ring is provided with three parts. The middle rotary gear ring is provided with two rotary mechanisms for arranging the vibrator and the assembly mechanism, respectively, and the front and rear rotary gear rings are provided with two rotary mechanisms for arranging the protective mechanism.

[0019] A method for replacing tunnel segments, using the tunnel segment replacement device described in any of the above technical solutions, performs the following operations: driving a support frame to move back and forth within the tunnel to the segment to be repaired or replaced; driving a rotary mechanism with a vibrator to move along a rotary gear ring to a specified angle position, so that the vibrator points towards the segment to be repaired or replaced; driving a rotary mechanism with a protective mechanism to move along a rotary gear ring to a specified angle position, so that the protective mechanism points towards the position requiring protection.

[0020] When the protective mechanism is in place, the vibrator starts working and gradually breaks up the segments to be repaired or replaced. In the tunnel cross section direction, after a part of the segment to be repaired or replaced is broken up by vibration, the rotary mechanism with the vibrator is driven to rotate along the rotary gear ring at a certain angle to continue vibration. In the tunnel axial direction, after a part of the segment to be repaired or replaced is broken up by vibration, the entire support frame or the rotary gear ring with the vibrator is driven to move in the front-back direction to continue vibration.

[0021] During the movement of the support frame, the protective mechanism is in a retracted state; when the segment to be repaired or replaced is completely removed, the rotary mechanism with the assembly mechanism is driven to move along the rotary gear ring, and the new segment is installed in place of the removed segment in cooperation with the assembly mechanism.

[0022] Compared with existing technologies, the tunnel segment replacement device and method proposed in this invention have the following significant advantages: The tunnel segment replacement device of this invention is applicable to all types of tunnels with segments. The protective mechanism, vibrator, and assembly mechanism are adapted to the rotary gear ring through a rotary mechanism, solving the problem of severely damaged or misaligned segments being unable to be repaired or replaced, and avoiding the problem of falling debris affecting tunnel construction safety when segments are damaged. During the operation of the tunnel segment replacement device, the tunnel boring machine does not need to stop, and there is no waiting gap from segment vibration to assembly, resulting in high efficiency. Timely repair and replacement of segments ensures construction safety and the subsequent safe use of the tunnel. Attached Figure Description

[0023] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 A schematic diagram of one embodiment of a tunnel segment replacement device;

[0025] Figure 2 for Figure 1 A side view of the tunnel segment replacement device in operation.

[0026] Figure 3 for Figure 1 Cross-section of the tunnel segment replacement device in operation Figure 1 ;

[0027] Figure 4 for Figure 1 Cross-section of the tunnel segment replacement device in operation Figure 2 ;

[0028] Figure 5 A schematic diagram of one embodiment of the rotary mechanism;

[0029] Figure 6 for Figure 5 The main view;

[0030] Figure 7 This is a schematic diagram of one implementation of a protective mechanism.

[0031] Explanation of icon numbers:

[0032] Supporting framework 1;

[0033] Rotary gear ring 4;

[0034] Rotary mechanism 5: Rotary gear 5-1, rotary motor 5-2, connecting rod 5-3, limit roller 5-4, rotary plate 5-5;

[0035] Protective mechanism 6: telescopic cylinder 6-1, sleeve 6-2, telescopic rod 6-3, protective plate 6-4;

[0036] Vibrator 7;

[0037] Assembly mechanism 8;

[0038] Segment 9;

[0039] 10 hoists. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the core concept of the present invention and the following embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] These embodiments are provided to make the application thorough and complete, and to fully express the scope of the application to those skilled in the art. It should be noted that, unless otherwise specifically stated, the relative arrangement of components and steps, material composition, numerical expressions, and values ​​illustrated in these embodiments should be interpreted as merely exemplary and not as limiting.

[0042] It should be noted that, in the description of this application, unless otherwise stated, "several" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "axial," "radial," etc., indicating orientation or positional relationships are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0043] Furthermore, the terms "first," "second," and similar terms used in this application do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. "Vertical" is not strictly vertical, but within the permissible margin of error. "Parallel" is not strictly parallel, but within the permissible margin of error. Terms such as "including" or "contains" mean that the element preceding the word encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well.

[0044] It should also be noted that, in the description of this application, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application depending on the specific circumstances. When a specific device is described as being located between a first device and a second device, an intermediary device may or may not be present between the specific device and the first or second device.

[0045] All terms used in this application have the same meaning as understood by one of ordinary skill in the art to which this application pertains, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant art, and not as idealized or highly formalized, unless expressly defined herein.

[0046] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0047] One object of the present invention is to provide a device for replacing severely damaged or misaligned tunnel segments.

[0048] To achieve the above objectives, the tunnel boring machine of the present invention comprises: a support frame, which serves as a support structure for a segment replacement device; traveling wheels, installed at the bottom of the support frame, which travel on the segments within the tunnel and are driven by a traveling motor; a slewing gear ring, mounted and fixed on the support frame, which serves as the rotation track for the slewing mechanism; in the slewing mechanism, a slewing motor drives a slewing gear to mesh and travel on the inner side of the slewing gear ring; a connecting rod connecting two slewing gears and a slewing plate into a single unit; a limiting roller, installed below the slewing plate, which travels on the outer surface of the slewing gear ring; and a slewing plate, which serves as a protective mechanism, a vibrator, and a mounting mechanism. The structure consists of a base; a protective mechanism mounted on a rotating plate to prevent large gravel from falling during vibration and to support adjacent tunnel segments; a protective plate connected to a telescopic rod and a deep hydraulic cylinder, with the distance between the protective plate and the tunnel segment adjusted by extending and retracting the cylinder; one end of the telescopic rod inserted into a sleeve mounted on the rotating plate, providing guidance and support for the vibrator used to break up damaged tunnel segments; and an assembly mechanism for assembling new tunnel segments. A hoist mounted on a support frame can lift tunnel segments from the transport vehicle and place them at the bottom of the tunnel.

[0049] In the segment replacement device of the present invention, as described above, the device travels along the segment via a support frame. When it reaches the position of the segment to be replaced, the slewing mechanism of the vibrator rotates on a rotary gear ring, causing the vibrator to point at the angle of the segment to be replaced. Simultaneously, the slewing mechanism of the protective mechanism rotates, causing the protective plate to point at a suitable angle. When the protective plate extends, it is positioned on both sides of the crushing position of the vibrator, serving to prevent loose debris from falling. The traveling wheels allow the vibrator to move back and forth along the tunnel axis, and the slewing mechanism allows the vibrator to rotate at any position along the circumference of the tunnel cross-section. By adjusting the position of the vibrator, the position of the segment to be replaced is cleared. The new segment is transported to the support frame, and the hoist unloads the segment from the transport vehicle and places it into the tunnel. The slewing mechanism of the assembly mechanism rotates to the bottom of the tunnel, the assembly mechanism grabs the segment, and then runs to the position to be replaced for assembly.

[0050] Therefore, according to the present invention, it is possible to replace severely damaged or misaligned tunnel segments. This avoids the decrease in tunnel load-bearing capacity caused by damaged segments, which could lead to leakage and collapse. It also reduces misalignment between tunnel segments, ensuring the proper functioning of the tunnel in subsequent operations.

[0051] Specific embodiments are described below:

[0052] A tunnel segment replacement device, such as Figure 1 , Figure 2 , Figure 4 As shown, it includes a support frame 1 and several rotary gear rings 4 disposed on the support frame 1. The support frame 1 can be moved by a traction device, or by a pushing device, and can also be equipped with self-propelled drive wheels.

[0053] The rotary gear ring 4 is directly connected to the support frame 1 or connected via a linear drive mechanism. When the rotary gear ring 4 is connected to the support frame 1 via the linear drive mechanism, the position of the rotary gear ring 4 relative to the support frame 1 can be changed by the linear drive mechanism, allowing the rotary gear ring 4 to move relative to the support frame 1 in the front-back direction of the tunnel. The linear drive mechanism can be a hydraulic cylinder, an electric cylinder, or a traction device consisting of a winch and a pulley block.

[0054] Each rotary gear ring 4 is equipped with a rotary mechanism 5 that travels along the rotary gear ring 4. At least one rotary mechanism 5 is equipped with a radially telescopic protective mechanism 6. At least one rotary mechanism 5 is equipped with a vibrator 7. At least one rotary mechanism 5 is equipped with an assembly mechanism 8. The vibrator 7 is used to vibrate and break the damaged pipe segment 9. The protective mechanism 6 is used to support the pipe segment 9 adjacent to the damaged pipe segment 9. The assembly mechanism 8 is used to assemble a new pipe segment 9.

[0055] The structure of the vibrator 7 and the assembly mechanism 8 is the same as that of the prior art. Those skilled in the art can select the corresponding type of vibrator and assembly mechanism according to actual needs. This embodiment will not be described in detail.

[0056] In this embodiment, the support frame 1 serves as the main support for the entire device. One or more rotary gear rings 4 can be installed on it. The rotary mechanism 5 can travel around the rotary gear ring 4, thus approaching any segment in the tunnel. The protective mechanism 6, vibrator 7, and assembly mechanism 8 can travel synchronously with the rotary mechanism 5. The vibrator 7 breaks and disassembles the segment 9 to be repaired or replaced. At the same time, the protective mechanism 6 supports the adjacent segment 9. The assembly mechanism 8 can assemble the new segment 9 to the position after the original segment 9 has been broken and dismantled for replacement.

[0057] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 1 , Figure 5 and Figure 6 As shown, the rotary mechanism 5 includes a rotary gear 5-1 driven by a rotary motor 5-2, a rotary plate 5-5 connected to the rotary gear 5-1, a limit wheel connected to the rotary plate 5-5, the rotary gear 5-1 meshing with the gear teeth on one side of the rotary gear ring 4, and the limit wheel engaging with the other side of the rotary gear ring 4 through frictional rolling or tooth meshing.

[0058] This embodiment is a further optimization of the above embodiment, providing a preferred rotary mechanism 5, wherein the rotary gear 5-1 serves as the driving wheel driven by the rotary motor 5-2, and can travel along the teeth on the rotary gear ring 4, while the limiting wheel is the driven wheel of the rotary mechanism, which can be either a roller that frictionally rolls with the rotary gear ring 4 or a gear that meshes with the rotary gear ring; the rotary gear 5-1 and the limiting wheel are located on the inner and outer sides of the rotary gear ring 4 respectively, and the two work together to clamp the two sides of the rotary gear ring 4.

[0059] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 1 , Figure 5 , Figure 6As shown, the rotary gear 5-1 meshes with the gear teeth on the inner circumferential surface or the outer circumferential surface of the rotary gear ring 4. This embodiment provides two preferred rotary mechanisms 5. One is that the rotary gear 5-1, as the driving wheel, meshes with the gear on the inner circumferential surface of the rotary gear ring 4. As can be seen from the above embodiment, in this case, the limiting wheel, as the driven wheel, rolls or meshes with the outer circumferential surface of the rotary gear ring 4. The other is the opposite structure, that is, the rotary gear 5-1, as the driving wheel, meshes with the gear on the outer circumferential surface of the rotary gear ring 4. As can be seen from the above embodiment, in this case, the limiting wheel, as the driven wheel, rolls or meshes with the inner circumferential surface of the rotary gear ring 4.

[0060] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 6 As shown, the rotary mechanism 5 includes two rotary gears 5-1, each connected to a rotary motor 5-2. The two rotary gears 5-1 are located on the left and right sides of the rotary gear ring 4 or on the same side of the rotary gear ring 4. The two rotary motors 5-2 are connected by a connecting rod 5-3 and are also connected to the rotary plate 5-5 by the connecting rod 5-3. This embodiment is a further upgrade of the above embodiment, setting two rotary gears 5-1 as the driving wheels in the rotary mechanism 5. At this time, the limiting wheels as driven wheels can be two, one, or multiple. The two rotary gears 5-1 and the rotary gears 5-1 and the rotary plate 5-5 are connected to each other by the connecting rod 5-3, forming a more stable rotary mechanism 5. When the two rotary gears 5-1 are arranged on the left and right sides of the rotary gear ring 4, the entire rotary mechanism 5 can clamp the rotary gear ring 4 in the left and right directions through the two rotary gears 5-1, and also clamp the rotary gear ring 4 in the inward and outward directions through the cooperation of the rotary gears 5-1 and the limiting wheels, thus making the cooperation between the entire rotary mechanism 5 and the rotary gear ring 4 more stable and reliable. When the two rotary gears 5-1 are arranged on the same side of the rotary gear ring 4, the two rotary gears 5-1 and several limiting wheels clamp the rotary gear ring 4. Although the stability is weaker compared to the embodiment where the gears are located on both sides of the rotary gear ring 4, it still has considerable stability.

[0061] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 5As shown, the two rotary gears 5-1 form a set of drive gears and are located on the same side of the rotary gear ring 4. Another set of drive gears is symmetrically arranged on the other side of the rotary gear ring 4. The two rotary motors 5-2 of the other set of drive gears are connected by a connecting rod 5-3 and are also connected to the rotary plate 5-5 via the connecting rod 5-3. This embodiment is a further upgrade of the above embodiment. The rotary gear ring 4 is clamped in the left-right direction by the two rotary gears 5-1, and in the inward and outward directions by the cooperation of the rotary gears 5-1 and the limiting wheels. The four rotary gears 5-1, along with several limiting wheels, connecting rods 5-3, and the rotary plate 5-5, constitute the rotary mechanism 5, further improving the stability of the entire rotary mechanism 5 when it travels along the rotary gear ring 4, and its stability when it is stationary relative to the rotary gear ring 4.

[0062] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 7 As shown, the protective mechanism 6 includes a protective plate 6-4 and a telescopic drive device and a support and guide assembly connected between the protective plate 6-4 and the rotary mechanism 5. This embodiment provides a preferred implementation of the protective mechanism 6. The telescopic drive device is used to drive the protective plate 6-4 closer to or away from the tunnel segment 9, while the support and guide assembly can both support and limit the protective plate 6-4 together with the telescopic drive device, and also guide the telescopic drive device.

[0063] More preferably, such as Figure 7 As shown, the two ends of the telescopic drive device are hinged to the protective plate 6-4 and the rotating plate 5-5 respectively. The fixed part in the support guide assembly is fixedly connected to the rotating plate 5-5, and the movable part is fixedly connected to the protective plate 6-4. In the direction perpendicular to the vertical telescopic direction, there is a certain amount of movement between the fixed part and the movable part.

[0064] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, the telescopic drive device is a telescopic hydraulic cylinder 6-1, a telescopic electric cylinder, or a telescopic pneumatic cylinder, and the support and guide assembly includes a sleeve 6-2 and a telescopic rod 6-3 that is inserted into and cooperates with the sleeve 6-2.

[0065] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 1 As shown, the support frame 1 has wheels 3 with built-in motors 2 connected to its bottom and a lifting device for hoisting the tunnel segments 9 connected to its top. The lifting device can be either a manual hoist or an electric hoist. Several wheels 3 are symmetrically arranged about the central vertical plane of the support frame 1, and the space between the wheels 3 on the left and right sides serves as a tunnel segment transfer channel.

[0066] Based on the above embodiments, as a preferred embodiment of the tunnel segment replacement device, such as... Figure 1and Figure 2 As shown, there are three rotary gear rings 4. The middle rotary gear ring 4 has two rotary mechanisms 5 for arranging the vibrator 7 and the assembly mechanism 8, respectively. The rotary gear rings 4 on the front and rear sides each have two rotary mechanisms 5 for arranging the protective mechanism 6.

[0067] As a preferred embodiment of the tunnel segment replacement device, such as Figures 1 to 7 As shown, it includes the following structural features: support frame 1, which is a support structure in the tunnel segment replacement device, used to support the rotary gear ring 4.

[0068] The walking motor 2 is the driving device for the walking wheel 3.

[0069] The traveling wheel 3 moves back and forth on the tunnel segment 9. It is installed at the bottom of the support frame 1 and has a certain angle with the tunnel centerline. The space between the two traveling wheels 3 on the left and right sides is sufficient for the transfer of one segment.

[0070] The rotary gear ring 4 is fixed on the support frame 1, providing a running track for the rotary mechanism 5.

[0071] The slewing mechanism 5, on the slewing gear ring 4, rotates 360 degrees around the center of the tunnel, providing support for the protective mechanism 6, the vibrator 7, and the assembly mechanism 8.

[0072] The rotary gear 5-1 meshes and rotates on the rotary gear ring 4.

[0073] The rotary motor 5-2 is the drive mechanism for the rotary gear 5-1 and can rotate in both directions.

[0074] Link 5-3 connects two rotary motors 5-2 and rotary plate 5-5, forming a stable frame.

[0075] The limiting roller 5-4 is installed below the rotary plate 5-5 and travels on the outer surface of the rotary gear ring 4.

[0076] The rotating plate 5-5 serves as the base for the protective mechanism 6, the vibrator 7, and the assembly mechanism 8.

[0077] Protective mechanism 6 prevents large pieces of gravel from falling during vibration and also supports adjacent segments; the number of protective mechanisms can be increased or decreased as needed.

[0078] Telescopic cylinder 6-1 adjusts the distance between the protective plate 6-4 and the tunnel segment.

[0079] Sleeve 6-2 provides guidance and support for telescopic rod 6-3.

[0080] Telescopic pole 6-3, connecting protective plate 6-4.

[0081] Protective plate 6-4 is used to clamp the segments and prevent them from falling off. Protective plate 6-4 can be made of materials such as hard nylon or steel plate.

[0082] Vibrator 7 is used to vibrate and break up damaged segments 9.

[0083] Assembly mechanism 8, assembling new tunnel segments 9.

[0084] Segment 9, the support for the tunnel, is a precast structure.

[0085] Using hoist 10 and unloading tools, the tunnel segments are unloaded from the transport vehicle and hoisted to the bottom of the tunnel.

[0086] A method for replacing tunnel segments, using the tunnel segment replacement device described in any of the above embodiments, performs the following operations: driving the support frame 1 to move back and forth in the tunnel to the segment 9 to be repaired and replaced; driving the rotary mechanism 5 with vibrator 7 to run along the rotary gear ring 4 to a specified angle position, so that the vibrator 7 points to the segment 9 to be repaired and replaced; driving the rotary mechanism 5 with protective mechanism 6 to run along the rotary gear ring 4 to a specified angle position, so that the protective mechanism 6 points to the position that needs to be protected;

[0087] When the protective mechanism 6 is in place, the vibrator 7 starts working and gradually breaks the segment 9 to be repaired or replaced. In the tunnel cross section direction, after a part of the segment 9 to be repaired or replaced is broken by vibration, the rotary mechanism 5 with vibrator 7 is driven to rotate a certain angle along the rotary gear ring 4 to continue vibration. In the tunnel axial direction, after a part of the segment 9 to be repaired or replaced is broken by vibration, the entire support frame 1 or the rotary gear ring 4 with vibrator 7 is driven to move in the front-back direction to continue vibration.

[0088] During the movement of the support frame 1, the protective mechanism 6 is in a retracted state; when the segment 9 to be repaired or replaced is completely removed, the rotary mechanism 5 with the assembly mechanism 8 is driven to move along the rotary gear ring 4, and the new segment 9 is installed in place of the removed segment 9 in cooperation with the assembly mechanism 8.

[0089] As a preferred implementation method for tunnel segment replacement, the specific scheme and process are as follows:

[0090] As the tunnel boring machine continues to excavate after assembling the tunnel segments, damage may occur due to the passage of time, geological disturbances, and other unforeseen factors. If the damage is severe and cannot be repaired through simple repairs or grouting, the entire segment must be replaced. Similarly, if there is severe misalignment between adjacent segments 9, rendering the tunnel unusable, the entire segment must also be replaced.

[0091] When locating the segment to be replaced, the traveling motor 2 drives the traveling wheels 3 to move back and forth in the tunnel to the segment to be repaired and replaced. During this movement, the telescopic cylinder 6-1 in the protective mechanism 6 remains in the retracted state to avoid interference between the protective plate 6-4 and the tunnel.

[0092] The rotary mechanism 5 operates on the rotary gear ring 4 at a designated angle, causing the vibrator 7 to point towards the segment requiring vibration, maintenance, or replacement. The operation of the rotary mechanism 5 is as follows: the rotary motor 5-2 drives the rotary gear 5-1 to mesh and rotate with the rotary gear ring 4; the connecting rod 5-3 connects the rotary motor 5-2 and the rotary plate 5-5; four limiting rollers 5-4 are fixed on both sides of the rotary plate 5-5, providing support for it. When the rotary gear 5-1 meshes and rotates inside the rotary gear ring 4, the limiting rollers 5-4 roll freely on the outer surface of the rotary gear ring 4.

[0093] The slewing mechanism 5 runs on the slewing gear ring 4 to a specified angle position, so that the protective mechanism 6 points to the position that needs protection. The operation process of the protective mechanism 6 is as follows: protection is provided on both sides before and after the vibration position of the vibrator 7. The telescopic cylinder 6-1 slowly extends, the telescopic rod 6-3 extends out of the sleeve 6-2, the sleeve 6-2 provides guidance and support for the telescopic rod 6-3, and the protective plate 6-4 is slowly pushed out by the telescopic cylinder 6-1, approaching the segment 9, until it presses against the segment 9.

[0094] When the protective mechanism 6 is in position, the vibrator 7 begins operation, gradually breaking up the tunnel segments. The tunnel segments 9 have a certain width; once the area pointed to by the vibrator is broken, the travel motor 2 drives the travel wheels 3 to move forward and backward, re-vibrating the remaining segments until the entire segment is completely destroyed in the width direction. During this forward and backward movement, the telescopic cylinder 6-1 retracts, and the protective plate 6-4 detaches from the tunnel segments. In the tunnel cross-section direction, once a section of the tunnel segment is broken up by vibration, the slewing mechanism 5 is controlled to rotate at a certain angle to continue vibration until the segment requiring repair is completely removed.

[0095] The process of installing new tunnel segments is as follows: The tunnel segments to be installed are transported to the assembly area. A hoist is used to unload the segments from the transport vehicle and place them into the tunnel. The slewing mechanism drives the assembly mechanism to move above the segments to be assembled. The assembly mechanism grabs the segments, the slewing mechanism rotates to the required assembly position, and the assembly mechanism assembles the segments, completing the installation of the new tunnel segments.

[0096] All aspects not detailed in this invention are conventional technical means known to those skilled in the art.

[0097] The above content shows and describes the basic principles, main features, and beneficial effects of the present invention. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A tunnel segment replacement device, characterized in that: Includes a support frame (1) and several rotary gear rings (4) set on the support frame (1). Each rotary gear ring (4) is provided with a rotary mechanism (5) that travels along the rotary gear ring (4). At least one rotary mechanism (5) is provided with a radially telescopic protective mechanism (6). At least one rotary mechanism (5) is provided with a vibrator (7). At least one rotary mechanism (5) is provided with an assembly mechanism (8). The vibrator (7) is used to vibrate and break the damaged pipe segment (9). The protective mechanism (6) is used to support the pipe segment (9) adjacent to the damaged pipe segment (9). The assembly mechanism (8) is used to assemble a new pipe segment (9). The rotary mechanism (5) includes a rotary gear (5-1) driven by a rotary motor (5-2), a rotary plate (5-5) connected to the rotary gear (5-1), a limit wheel connected to the rotary plate (5-5), the rotary gear (5-1) meshing with the gear teeth on one side of the rotary gear ring (4), and the limit wheel rubbing and rolling or meshing with the other side of the rotary gear ring (4). The rotary mechanism (5) includes two rotary gears (5-1) respectively connected to rotary motors (5-2). The two rotary gears (5-1) are located on the left and right sides of the rotary gear ring (4) or on the same side of the rotary gear ring (4). The two rotary motors (5-2) are connected by a connecting rod (5-3) and connected to the rotary plate (5-5) by the connecting rod (5-3).

2. The tunnel segment replacement device according to claim 1, characterized in that: The rotary gear (5-1) meshes with the teeth on the inner circumferential surface of the rotary gear ring (4) or the teeth on the outer circumferential surface.

3. The tunnel segment replacement device according to any one of claims 1-2, characterized in that: The protective mechanism (6) includes a protective plate (6-4) and a telescopic drive device and a support guide assembly connected between the protective plate (6-4) and the rotary mechanism (5).

4. The tunnel segment replacement device according to claim 3, characterized in that: The telescopic drive device is a telescopic hydraulic cylinder (6-1), a telescopic electric cylinder, or a telescopic pneumatic cylinder. The support and guide assembly includes a sleeve (6-2) and a telescopic rod (6-3) that is inserted into the sleeve (6-2).

5. The tunnel segment replacement device according to any one of claims 1, 2, and 4, characterized in that: The support frame (1) is connected to a walking wheel (3) with its own walking motor (2) at the bottom and a lifting device for hoisting the segment (9) at the top. Several walking wheels (3) are symmetrically arranged about the vertical plane of the support frame (1), and the space between the walking wheels (3) on the left and right sides is the segment transfer channel.

6. The tunnel segment replacement device according to claim 5, characterized in that: The rotary gear ring (4) is provided in three parts. The middle rotary gear ring (4) is provided with two rotary mechanisms (5) for arranging the vibrator (7) and the assembly mechanism (8) respectively. The rotary gear rings (4) on the front and rear sides are provided with two rotary mechanisms (5) for arranging the protective mechanism (6).

7. The tunnel segment replacement device according to any one of claims 1, 2, 4, and 6, characterized in that: The two rotary gears (5-1) are a set of drive gears and are located on the same side of the rotary gear ring (4). Another set of drive gears is provided on the other side of the rotary gear ring (4). The two rotary motors (5-2) of the other set of drive gears are connected by a connecting rod (5-3) and connected to the rotary plate (5-5) by the connecting rod (5-3).

8. A method for replacing tunnel segments, characterized in that: The tunnel segment replacement device according to any one of claims 1-7 is used to perform the following operations: The drive support frame (1) moves back and forth in the tunnel to the segment (9) to be repaired and replaced; Drive the rotary mechanism (5) with vibrator (7) to run along the rotary gear ring (4) to the specified angle position, so that the vibrator (7) points to the segment (9) to be repaired and replaced. Drive the rotary mechanism (5) with the protective mechanism (6) to run along the rotary gear ring (4) to the specified angle position, so that the protective mechanism (6) points to the position that needs to be protected; When the protective mechanism (6) is in place, the vibrator (7) starts to work and gradually breaks up the pipe segments (9) to be repaired or replaced; In the tunnel section direction, after a part of the segment (9) to be repaired and replaced is broken by vibration, the rotary mechanism (5) with vibrator (7) is driven to rotate a certain angle along the rotary gear ring (4) to continue vibration; In the tunnel axial direction, after a section of the segment (9) to be repaired and replaced is broken by vibration, the entire support frame (1) or the rotary gear ring (4) with vibrator (7) is driven to move in the front-back direction to continue vibration. During the movement of the support frame (1), the protective mechanism (6) is in a retracted state; After the segment (9) to be repaired and replaced is completely removed, the rotary mechanism (5) with the assembly mechanism (8) is driven to move along the rotary gear ring (4) and, together with the assembly mechanism (8), install the new segment (9) to the position of the removed segment (9).

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