A TBM early warning system for coping with fault fracture and joint concentration and a stuck TBM rescue excavation method

Abstract

The application provides a TBM advanced warning system for dealing with fault fracture and joint concentration and a stuck excavation method, the advanced warning system comprises a geophysical prospecting detection system, a drilling system and a central control and warning platform, the geophysical prospecting detection system is used for physically prospecting the surrounding rock in front of the excavation face to obtain and process geological data to generate a preliminary geological forecast; the drilling system is used for drilling and coring operation according to the drilling site indicated by the preliminary geological forecast to obtain core samples and perform verification analysis to generate accurate geological information; the central control and warning platform is used for coordinating and controlling the operation process of the geophysical prospecting detection system and the drilling system and performing fusion analysis based on the preliminary geological forecast and the accurate geological information to generate a targeted excavation decision scheme and a safety warning signal. The application has the beneficial effect of solving the collapse and machine sticking accidents caused by fault fracture zones and joint concentration zones in TBM excavation.

Description

Technical Field

[0001] This invention relates to the field of tunnel and underground engineering construction, and in particular to an advanced early warning system for TBMs dealing with fault fractures and dense joints, and a method for TBMs to escape from jamming during tunneling. Background Technology

[0002] In recent years, tunnel construction in my country has been booming, with an increasing proportion of projects using full-face tunnel boring machines (TBMs). A TBM typically consists of a main shaft, cutterhead, propulsion system, soil-throwing system, control system, and support system. It moves by excavating a circular tunnel underground, simultaneously removing and transporting rock, soil, and other materials from the excavation face to the surface. A TBM is a new and advanced type of tunnel construction machinery that uses rotating cutters to excavate while simultaneously breaking up the surrounding rock to form the entire tunnel cross-section. Compared to traditional drill-and-blast methods, TBMs offer advantages such as high excavation efficiency, high-quality tunnel completion, and minimal disturbance to the surrounding rock. However, TBMs face significant challenges in complex geological conditions, such as fault fracture zones and areas with dense joints. The instability of these strata can lead to rockfalls, machine jamming, and other safety accidents during excavation, severely impacting construction progress and operational safety. With the increasing demand for underground space development, higher requirements are being placed on the adaptability and safety of TBMs under adverse geological conditions.

[0003] With the continuous construction and opening of high-speed railway tunnels in my country, they inevitably traverse fault-bounded and densely jointed geological formations in high-altitude, cold plateau regions. During tunnel construction, when these fault-bounded and densely jointed areas are subjected to external loads and reach a critical deformation level, intense deformation concentration occurs in localized areas where fracture surfaces are about to form. This transforms the previously uniform or near-uniform deformation field into an extremely non-uniform one, manifesting as discontinuous deformation development—a phenomenon known as deformation localization. This often leads to serious accidents such as TBMs getting stuck, buried, or even rendered unusable, necessitating a halt to excavation and subsequent extrication. As geological conditions in tunnel excavation become increasingly complex, tunneling in fault-bounded and densely jointed areas is unavoidable. Traditional TBM systems are too large, and due to structural limitations, their construction and support flexibility is poor, frequently causing jams, delays, and even machine damage. Furthermore, current early warning systems are sluggish, and monitoring and analysis capabilities are outdated. Whether support methods can effectively prevent large deformations of fractured and jointed surrounding rock remains unknown. When facing faulted and densely jointed strata, firstly, the lack of high-precision geological advance detection capabilities makes it difficult to accurately predict geological conditions ahead, resulting in slow response of TBMs when encountering complex strata. Secondly, existing methods for TBMs to escape from stuck conditions are mostly reactive, lacking proactive prevention and rapid, effective escape strategies. Furthermore, existing tunneling methods are not flexible enough to adapt to changes in geological conditions, failing to adjust promptly to strata variations and increasing construction risks. Therefore, it is necessary to design a method that can effectively predict and resolve TBM stuck problems encountered during construction in faulted and fractured zones, rockburst formations, etc., reducing the risk of stuck conditions and enabling escape, which is of great significance for improving TBM construction efficiency. Summary of the Invention

[0004] To address the problems in the prior art, this invention provides an advanced early warning system for TBMs dealing with fault fracturing and dense joints, comprising a geophysical exploration system, a drilling system, and a central control and early warning platform. The geophysical exploration system and the drilling system are communicatively connected, and the central control and early warning platform is communicatively connected to both the geophysical exploration system and the drilling system. The geophysical exploration system is used to conduct physical exploration of the surrounding rock in front of the tunneling face in order to obtain and process geological data and generate preliminary geological forecasts. The drilling system is used to perform core drilling operations based on the drilling sites indicated by the preliminary geological forecast, in order to obtain core samples and perform verification analysis to generate accurate geological information. The central control and early warning platform is used to coordinate and control the operation of the geophysical exploration system and the drilling system, and to perform fusion analysis based on the preliminary geological forecast and the precise geological information to generate targeted tunneling decision-making schemes and safety early warning signals.

[0005] As a further improvement of the present invention, the geophysical exploration system includes a sensor group, a data acquisition module, and a data processor. The sensor group is communicatively connected to the data acquisition module, and the data processor is communicatively connected to the data acquisition module. The sensor group is used to collect physical signals of the surrounding rock in front of the tunneling face. The data acquisition module is used to acquire and convert the received physical signals and send them to the data processor. The data processor is used to receive and process the data sent by the data acquisition module, and generate preliminary geological forecast information to be uploaded to the central control and early warning platform.

[0006] As a further improvement of the present invention, the sensor group includes at least one of an ultrasonic sensor, a vibration sensor, an electromagnetic wave sensor, a strain sensor, and a temperature sensor; the geophysical exploration system uses the seismic wave reflection method for exploration. The central control and early warning platform communicates with the TBM's control system through the advanced geological prediction system interface set in the TBM, and is used to send the generated safety early warning signals and tunneling parameter decision suggestions to the TBM's control system.

[0007] As a further improvement of the present invention, the drilling system includes a hydrodynamic down-the-hole hammer drill rig and a top-hammer pipe roof drill rig. The hydrodynamic down-the-hole hammer drill rig is equipped with a core sampling device, which, by changing the drill bit, can perform crushing drilling operations for constructing advance detection holes and advance stress relief holes, as well as drilling and core sampling operations. The core sampling device includes a drill rod and a core sampler connected to its bottom end. The core sampler includes an outer casing, an inner casing, and a core sampler head. The top-hammer pipe roof drill rig is used for constructing pipe roofs, advance anchor bolts, and advance small guide pipes. As a further improvement of the present invention, the hydrodynamic down-the-hole drill has a drilling diameter of 95mm, a drilling depth greater than 50 meters, and a pure drilling speed greater than 0.5 meters / minute; the hydrodynamic down-the-hole drill can also be used to construct Ф108 pipe roofs; the top hammer pipe roof drill has a drilling depth greater than 40m and an average pure drilling speed greater than 1m / min within 30m; the top hammer pipe roof drill is used to construct Ф89 pipe roofs.

[0008] As a further improvement of the present invention, the central control and early warning platform also includes a data analysis and early warning module, which performs the following steps: Step 1: Receive and analyze the data from the geophysical exploration system and the drilling system; Step 2: Use computer software to process the data and obtain a three-dimensional model of the underground rock and soil mass; Step 3: Analyze the distribution of faults and joints based on the 3D model and make predictions; generate corresponding tunneling plans and early warning information based on the processing results of geophysical exploration data. The tunneling plans include tunneling speed plans, tunneling direction plans, drill bit pressure plans, and grouting plans. The early warning information includes fault fracture early warning information and joint concentration zone early warning information; dynamically optimize the tunneling plans and generate corresponding construction decisions based on the test and analysis results of the core samples obtained from drilling.

[0009] As a further improvement of the present invention, the central control and early warning platform adopts a three-level forecasting and early warning mechanism, which includes: Macro-level forecasting: Predicting overall geological trends based on engineering geological methods; Long-term forecast level: Based on engineering geological methods, TSP detection and advanced drilling results, predict adverse geological bodies within a range of 50 to 200 meters in front of the tunnel face; Short-term forecast level: Based on BEAM testing, HSP detection, ground-penetrating radar, CT testing, advanced drilling and empirical methods, predict adverse geological bodies within a range of 0-50 meters in front of the tunnel face.

[0010] This invention also discloses a method for TBM to overcome jamming and entrapment in fault fracture and dense joint formation during tunneling, comprising: Step S1: The TBM connects to the advanced early warning system described in this invention through the advanced geological prediction system interface. Before tunneling, the advanced early warning system uses a comprehensive detection method combining geophysical exploration and drilling to conduct advanced geological exploration of the tunnel section and obtain information on the geological structure and surrounding rock. The comprehensive detection method covers the entire tunnel section. Step S2: When the TBM encounters a fault fracture zone and / or a densely jointed zone, the advanced early warning system issues an early warning signal. If the early warning signal indicates that the TBM is encountering the first fracture zone, horizontal and vertical steel meshes are set up at the TBM tunneling face. The TBM uses the shield steel mesh system, emergency shotcrete system, and arch frame system to quickly pass through, while simultaneously executing step S5. If the early warning signal indicates that the TBM is encountering the second fracture zone or water-rich altered rock strata, then step S3 is executed. Step S3: Install horizontal and vertical steel meshes at the TBM excavation face to enhance the strength and stability of the reinforced structure; Step S4: Perform advance grouting and pipe roof support with multiple pipe roof drilling rigs at a depth of more than 30m in front of the tunnel face to achieve advance support; Step S5: A rapid slag removal system is installed in the TBM main unit, the lower part of the connecting bridge and the invert arch laying area. The rapid slag removal system is used to directly lift the slag material in the area to the upper platform of the connecting bridge and transfer it to the downstream belt conveyor.

[0011] As a further improvement of the present invention, if the TBM gets stuck during the tunneling process, it will automatically untangle itself using an automatic untangling system. This automatic untangling system consists of sensors, a data acquisition unit, a controller, and actuators. The controller is connected to the data acquisition unit, the controller, and the actuators. The sensors are connected to the data acquisition unit and are used to collect data when the TBM gets stuck. The data acquisition unit transmits the data collected by the sensors to the controller for processing. The controller determines the location and status of the stuck machine based on the data transmitted by the data acquisition unit and automatically untangles it using the actuators.

[0012] As a further improvement of the present invention, the cutterhead of the TBM used in this method is equipped with multiple pipe roof drilling rigs; The TBM's main belt width is greater than 1400mm, and the drive system adopts a dual drive form of hydraulic motor and reducer; The TBM's main drive uses a large reduction ratio reducer with i=26, with a main drive power of 16×350kW, a rated torque of 19800kN.m, a get-out-of-trouble torque of 29800kN.m, and a maximum total thrust of 37177kN. The TBM's auxiliary propulsion system includes: prefabricated steel segments, guide seats, and an adjustable support mechanism. The prefabricated steel segments are assembled inside the shield to provide propulsion reaction force to the auxiliary propulsion cylinders in single-shield tunneling mode. The guide seats are installed in the area of ​​each set of auxiliary propulsion cylinders to connect the shield and the gearbox to transmit propulsion reaction force. The adjustable support mechanism is located at the lower part of the saddle frame and includes telescopic outriggers and small support boots. The adjustable support mechanism is used to realize the up-down and left-right adjustment and roll correction of the TBM. The sealing system of the TBM's main drive includes a sealing structure, sealing grease, a dust seal, a grease port, and a wear-resistant ring for the main bearing seal. The sealing structure includes an outer seal and an inner seal. The outer seal has at least four first lip seals, and the inner seal has at least four second lip seals. The outer and inner seals are lubricated with sealing grease. The dust seal is located outside the sealing structure of the main drive and is used to block mud and sand media. The grease port is located inside the sealing cavity and is used to connect an external grease supply device to inject erosion-resistant grease. The erosion-resistant grease is HBW grease containing fibers. The wear-resistant ring of the main bearing seal of TBM is made of integral forging and heat-treated; the contact position between the wear-resistant ring and the first lip seal and the second lip seal is adjustable; the installation structure of the wear-resistant ring is reserved with 2 to 3 adjustment margins, which can be adjusted by adding or replacing the gasket.

[0013] The beneficial effects of this invention are: 1. It solves the problem of collapse and machine jamming accidents that are easily caused by fault fracture zones and densely jointed zones during TBM excavation. This situation is very common in the field of tunnel and underground engineering construction and has a great impact on construction progress and safety; 2. It realizes the advanced prediction of fault fracture zones and densely jointed zones; by carrying an advanced geological prediction system and establishing a comprehensive advanced prediction method combining geophysical exploration and drilling, it performs real-time intelligent monitoring and analysis of fault fracture zones and densely jointed zones to predict the risks of encountering these problems during tunnel excavation; 3. For the excavation of small fault fracture zones, it adopts the method of continuous initial support, bottom arch assisted propulsion, synchronous excavation and support, and rapid passage for timely support. For large fault fracture zones, methods such as controllable slag feeding, super-strong scrambling, and speed-limited high-thrust tunneling are used to achieve machine scrambling and avoid interruptions in the tunneling process; 4. Improved TBM working efficiency and safety; Through this invention, TBMs can more effectively cope with the tunneling difficulties of fault fracture and dense joint zones, thereby improving construction efficiency, while avoiding machine scrambling and other safety accidents, and ensuring the safety of construction personnel. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the advanced early warning system of this invention; Figure 2 This is a schematic diagram of the drilling rig layout of the drilling system of the present invention; Figure 3 This is a schematic diagram of the rapid support system configured in the L1 area of ​​the present invention; Figure 4 This is a schematic diagram of emergency spray mixing in zone L1 of the present invention; Figure 5 This is a schematic diagram of the dual-motor drive of the main belt conveyor of the present invention; Figure 6 This is a cross-sectional view of the outer seal of the present invention; Figure 7 This is a cross-sectional view of the inner seal of the present invention; Figure descriptions: 11-Hydropower down-the-hole hammer drill, 12-Top hammer pipe roof drill, 13-Anchor bolt drilling system, 14-Rebar row system, 15-Arch frame installation system, 16-Emergency spraying system, 2-Main unit belt conveyor, 21-Reducer system, 22-Hydraulic motor system, 3-Outer seal, 31-Outer dustproof seal, 32-Outer seal grease lubrication chamber CA1-24, 33-Outer seal grease lubrication chamber FA1-24, 34-Outer seal grease lubrication chamber OA1-24, 35-Outer seal grease leakage chamber LA1-8, 36-Outer lip seal, 4-Inner seal, 41-Inner dustproof seal, 42-Inner seal grease lubrication chamber CIA1-24, 43-Inner seal grease lubrication chamber FIA1-24, 44-Inner seal grease lubrication chamber OIA1-24, 45-Inner seal grease lubrication chamber LIA1-8, 46-Inner seal lip seal. Detailed Implementation

[0015] This invention relates to an advanced early warning system and a method for extricating stuck TBMs when encountering fault fracture zones and densely jointed areas, and pertains to the field of tunnel and underground engineering construction. It primarily addresses the challenges of TBMs encountering fault fracture zones and densely jointed areas, which are most prone to collapse and jamming accidents, through advanced early warning and extrication methods. Advanced prediction of fault fracture zones and densely jointed areas is achieved primarily by incorporating an advanced geological prediction system, establishing a comprehensive advanced prediction method combining geophysical exploration and drilling for real-time intelligent monitoring and analysis. The cutterhead used in the excavation method for fault fracture zones and densely jointed areas includes multiple pipe roof drilling rigs for advanced grouting and pipe roof support at a depth greater than 30m in front of the tunnel face; for small fault fracture zones, continuous initial support and bottom arch-assisted propulsion are used, with simultaneous excavation and support for rapid passage; and for large fault fracture zones, controllable muck intake, superior extrication capabilities, and speed-limited high-thrust excavation are employed to achieve extrication from stuck TBMs. It can effectively address the challenges of tunneling in fault-fractured and densely jointed geological zones, improving the efficiency and safety of TBM operations.

[0016] This invention proposes an advanced early warning system and a stuck tunneling method for TBMs to cope with fault fracture and dense joints, which includes two parts: the design of an advanced early warning system combining TBM geophysical exploration and drilling and a targeted design for stuck tunneling.

[0017] I. Advanced early warning systems, such as Figure 1 As shown.

[0018] This invention discloses an advanced early warning system for TBM to cope with fault fracturing and dense joints, including a geophysical exploration system, a drilling system and a central control and early warning platform. The geophysical exploration system and the drilling system are communicatively connected, and the central control and early warning platform is communicatively connected to the geophysical exploration system and the drilling system respectively. Geophysical exploration system: Used to conduct physical exploration of the surrounding rock in front of the tunneling face to obtain and process geological data and generate preliminary geological forecasts. The geophysical exploration system uses the seismic wave reflection method for exploration. The seismic wave reflection geophysical exploration method can realize high-precision and high-efficiency exploration and monitoring of the surrounding rock of the tunneling section, and intelligently analyze and process the exploration data to provide targeted tunneling plans and real-time early warnings, thereby ensuring the safe and efficient tunneling of the TBM in fault fracture and joint concentration areas.

[0019] The geophysical exploration system includes a sensor array, a data acquisition module, and a data processor. The sensor array and the data acquisition module are communicatively connected, and the data processor is also communicatively connected to the data acquisition module. Sensor array: Used to collect physical signals of the surrounding rock ahead of the tunnel face. Before TBM excavation, the sensor array is installed in the excavation section. The sensor array should include various sensors such as ultrasonic sensors, vibration sensors, electromagnetic wave sensors, strain sensors, and temperature sensors to acquire geological information and various physical parameters of the tunnel surrounding rock. The sensors collect the physical parameters of the surrounding rock in real time and transmit the data to the data processing device for processing and analysis. Simultaneously, the sensors can also monitor safety issues such as rock cuttings blockage, stuck drills, and gas explosions that occur during the excavation process.

[0020] Data acquisition module: used to acquire and convert the received physical signals and send them to the data processor; Data processor: Used to receive and process data sent by the data acquisition module, and generate preliminary geological forecast information to be uploaded to the central control and early warning platform.

[0021] Drilling system: Used to conduct drilling and coring operations based on drilling sites indicated by preliminary geological forecasts, in order to obtain core samples for verification and analysis, and generate accurate geological information; like Figure 2 As shown, the drilling system includes a hydrodynamic down-the-hole hammer drill 11 and a top-hammer pipe roof drill 12. The hydrodynamic down-the-hole hammer drill 11 is equipped with a core sampling device. By changing the drill bit, it can perform crushing drilling operations for constructing advance detection holes and advance stress relief holes, as well as drilling and core sampling operations. The core sampling device includes a drill rod and a core sampler connected to its bottom end. The core sampler includes an outer casing, an inner casing, and a core sampler head. The top-hammer pipe roof drill 12 is used to construct pipe roofs, advance anchor bolts, and advance small guide pipes. Based on the geophysical exploration results, two advanced drilling rig systems were configured: the Shuidongli down-the-hole hammer 11 and the top hammer pipe roof drilling rig 12. Suitable drilling locations were selected for core sampling. These two advanced drilling rig systems were deployed on the main beam of the L1 area to achieve pipe roof, advanced anchor bolt, and advanced small guide pipe support within a 150° range at the tunnel top, as well as advanced detection in front of the cutterhead, while also serving as stress relief holes. Core sampling provides information on the actual condition of the underground rock and soil, including its mechanical properties, joint conditions, and fault locations.

[0022] Before tunneling, a geological exploration is conducted on the tunnel section to obtain information on the structure and properties of the surrounding rock and to develop a corresponding construction plan. The geological exploration should cover the entire tunnel section and employ various exploration methods, such as drilling, surveying, and ground-penetrating radar.

[0023] Based on the geological exploration results, a core sampling point was selected, and the device proposed in this invention was used for core sampling. The device includes a drill pipe and a core sampler. The core sampler consists of an outer casing, an inner casing, and a core sampler head. After drilling to the core sampling point, the weight and vibration of the core sampler are used to embed the core sampler head into the rock and rotate it, loading the rock core into the inner casing. Afterward, the drill pipe is removed, the inner casing of the core sampler rises, the inner casing is removed, and the retrieved rock core is placed in a sample bag.

[0024] The hydrodynamic down-the-hole vertical drilling rig 11 offers excellent drilling straightness and high construction efficiency. With a 95mm borehole diameter, it can drill to depths greater than 50m with a pure drilling speed greater than 0.5m / min. It can complete Ф108 pipe roof construction and can also be used for long-distance advanced detection hole construction and long-distance advanced stress relief hole construction. Equipped with a coring drill bit, it can be used for advanced fixed-point coring.

[0025] The top hammer type pipe roof drilling rig 12 is easy to operate, has high construction efficiency, and has an effective drilling depth of more than 40m. The average pure drilling speed within 30m is >1m / min. It can be used for advanced anchor bolt machine and advanced small guide pipe construction and can complete Ф89 pipe roof construction.

[0026] Central control and early warning platform: used to coordinate and control the operation of geophysical exploration and drilling systems, and to generate targeted tunneling decision-making schemes and safety early warning signals based on the fusion analysis of preliminary geological forecasts and accurate geological information.

[0027] The central control and early warning platform communicates with the TBM's control system through the advanced geological forecasting system interface set up in the TBM, and sends the generated safety early warning signals and tunneling parameter decision suggestions to the TBM's control system.

[0028] The central control and early warning platform also includes a data analysis and early warning module, which performs the following steps: Step 1: Receive and analyze data from the geophysical exploration system and drilling system; Step 2: Use computer software to process the data and obtain a three-dimensional model of the underground rock and soil mass; Step 3: Analyze and predict the distribution of faults and joints based on the 3D model; generate corresponding tunneling plans and early warning information based on the processed geophysical exploration data. The tunneling plans include tunneling speed, tunneling direction, drill bit pressure, and grouting schemes, while the early warning information includes warnings of fault fracturing and concentrated joint areas. Simultaneously, analyze and test the obtained rock cores, and adjust the tunneling plan based on the results. Furthermore, implement appropriate construction measures based on the structure and properties of the rock cores.

[0029] Three-dimensional models are used to provide early warnings of the distribution of faults and joints, enabling timely detection of geological problems.

[0030] The central control and early warning platform adopts a three-level forecasting and early warning mechanism, which includes: Macro-level forecasting: Predicting overall geological trends based on engineering geological methods; Long-term forecast level: Based on engineering geological methods, TSP detection and advanced drilling results, predict adverse geological bodies within a range of 50 to 200 meters in front of the tunnel face; Short-term forecast level: Based on BEAM testing, HSP detection, ground-penetrating radar, CT testing, advanced drilling and empirical methods, forecast unfavorable geological bodies within a range of 0 to 50 meters in front of the tunnel face.

[0031] The three-level forecasting and early warning mechanism constitutes a comprehensive geological forecasting system for tunnel construction, enabling advanced forecasting of adverse geological formations.

[0032] Following an early warning, the TBM can adjust its construction plan to minimize the impact on geological issues, while simultaneously implementing necessary safety measures to ensure the safety of construction personnel. Based on data processing and analysis results, the advanced early warning system provided by this invention can monitor changes in the surrounding rock in real time, provide early warning signals, and ensure tunneling safety and efficiency by adjusting the TBM's tunneling parameters in a timely manner.

[0033] The advanced early warning system of the present invention has the following advantages: 1. Overall, it can identify various adverse geological conditions, provide early warning of geological disasters, and assist in tunneling decision-making at least 0-100m. At the same time, the advanced geological forecasting work will not occupy the TBM tunneling time. The geophysical exploration method, which combines long and short methods, can achieve geological forecasting at about 100m ahead, and the drilling method can achieve geological forecasting at 30-50m ahead, forming a comprehensive forecasting system for adverse geological conditions ahead that combines long and short methods.

[0034] 2. Reserve an interface for an advanced geological prediction system. The specific implementation is as follows: First, before construction, thorough geological exploration and investigation are required to determine the tunnel's geological conditions and structure, which will be used to develop and design an interface for the advanced geological prediction system. Second, interface design with the TBM control system is performed to seamlessly integrate the advanced geological prediction system with the TBM control system, ensuring real-time data transmission and control, so that control parameters can be adjusted promptly and necessary countermeasures can be taken during tunneling. Finally, after completing the interface design, system verification and debugging are required to ensure the system's stability and reliability.

[0035] This invention discloses a method for TBM (Tunnel Boring Machine) to overcome jamming in fault-fractured and densely jointed tunneling conditions, effectively preventing geological problems and ensuring the safety and smooth progress of tunnel excavation projects. To achieve the above objectives, the technical solution of this invention is as follows: Step S1: The TBM connects to the advanced geological prediction system via an interface with the advanced early warning system. Before tunneling, the advanced early warning system uses a comprehensive exploration method combining geophysical exploration and drilling to conduct advanced geological exploration of the tunnel section, obtain information on geological structure and surrounding rock, and formulate advanced support types and schemes based on the characteristics of the tunnel face. The advanced early warning system will conduct detailed geological exploration and data analysis to understand the geological conditions, distribution and properties of faults and joints, and formulate corresponding construction plans and support schemes based on the analysis results.

[0036] Step S2: When the TBM encounters a fault fracture zone and / or a densely jointed zone, the advanced early warning system issues an early warning signal. If the early warning signal indicates that the TBM is encountering the first fracture zone, horizontal and vertical steel meshes are set up at the TBM tunneling face. The TBM uses the shield steel reinforcement system 14 (steel reinforcement angle not less than 250°), the emergency shotcrete system 16, and the arch frame installation system 15 to quickly pass through, while simultaneously executing step S5. If the early warning signal indicates that the TBM is encountering the second fracture zone or water-rich altered rock strata, then step S3 is executed. The first fracture zone is a smaller fracture zone, and the second fracture zone is a larger fracture zone. When encountering a larger fracture zone or water-rich altered rock strata, the machine is prone to jamming, and the ability to provide rapid support and advanced support is required.

[0037] The TBM's L1 zone configuration integrates a mechanical spray mixing system with a steel arch frame gear ring.

[0038] Step S3: Install horizontal and vertical steel meshes at the TBM excavation face to enhance the strength and stability of the reinforced structure; Step S4: Perform advanced grouting and pipe roof support with multiple pipe roof drilling rigs at a depth of more than 30m in front of the tunnel face to achieve advanced support; High-efficiency pipe roof support: TBM is equipped with pipe roof drilling rigs to achieve pipe roof support. The support position is implemented inside the top shield without the need for excavation, achieving all-round high-efficiency pipe roof operation and multi-layer cross support.

[0039] Step S5: Install a rapid slag removal system in the TBM main unit, under the connecting bridge and invert arch laying area. The rapid slag removal system is used to directly lift the slag material in the area to the upper platform of the connecting bridge and transfer it to the downstream belt conveyor.

[0040] If the TBM gets stuck during tunneling, it will automatically untangle itself using its equipped automatic untangling system. The automatic untangling system consists of sensors, a data acquisition unit, a controller, and actuators. The controller is connected to the data acquisition unit, the controller, and the actuators. The sensors are connected to the data acquisition unit and are used to collect data when the TBM gets stuck. The data acquisition unit transmits the data collected by the sensors to the controller for processing. The controller determines the location and status of the stuck machine based on the data transmitted by the data acquisition unit and automatically untangles it using the actuators.

[0041] The cutter head, main belt, main drive and auxiliary propulsion system are designed specifically for this purpose, and the equipment is inspected and maintained to ensure the stability and reliability of the equipment operation.

[0042] The cutterhead of the TBM used is equipped with multiple pipe roof drilling rigs; like Figure 5 As shown, the TBM's main conveyor belt is designed for fault fracture zones and mudslide / sand inrush strata where the slag output is uncontrollable, easily causing the conveyor belt to overload and shut down, resulting in a huge amount of manual slag removal work. The main conveyor belt with a width greater than 1400mm effectively prevents slag from falling. At the same time, it adopts a dual drive system of "hydraulic motor + reducer" (capable of withstanding radial force), which ensures balanced force distribution and large unblocking torque, effectively realizing the anti-stagnation technology of the main conveyor belt, greatly preventing the main drive from jamming and improving work efficiency.

[0043] The TBM's main drive uses a large reduction ratio reducer with i=26 to achieve greater off-road torque. The main drive power is 16×350kW, the rated torque is 19800kN.m, the off-road torque is 29800kN.m, and the maximum total thrust is 37177kN. The configuration is equivalent to that of the previous 12m class TBM. The TBM's auxiliary propulsion system includes: modular steel segments, guide seats, and an adjustable support mechanism. The modular steel segments are assembled inside the shield to provide propulsion reaction force to the auxiliary propulsion cylinders in single-shield tunneling mode. The guide seats are installed in the area of ​​each set of auxiliary propulsion cylinders to connect the shield and the gearbox to transmit propulsion reaction force. The adjustable support mechanism is located at the lower part of the saddle frame and includes telescopic outriggers and small support shoes. The adjustable support mechanism is used to realize the up-down and left-right adjustment and rolling correction of the TBM. The auxiliary propulsion system is designed inside the shield, powered by assembled steel segments, and supports single-shield tunneling. During tunneling, steel segments are assembled inside the shield, providing propulsion reaction force. A guide seat is added to each auxiliary propulsion cylinder area, connecting the shield and the gearbox to transmit propulsion reaction force. Retractable outriggers and small support shoes are added to the lower part of the saddle, allowing for vertical, horizontal, and roll correction.

[0044] like Figure 6-7As shown, the sealing system of the TBM's main drive includes a sealing structure, sealing grease, a dust seal, a grease interface, and a wear-resistant ring for the main bearing seal. The sealing structure includes an outer seal 4 and an inner seal. The outer seal 4 is equipped with at least four first lip seals 36, and the inner seal is equipped with at least four second lip seals 46, increasing the safety factor of the seal. The outer seal 4 and the inner seal are sealed and lubricated with sealing grease to ensure that water, dust, and other contaminants do not enter the main bearing and gearbox. A dust seal structure is added outside the seal: the dust seal is set outside the main drive seal to prevent external media such as mud and sand from entering the seal. At the same time, in order to cope with harsh geological conditions such as mud and water inrush, an interface for HBW grease (containing fiber and waterproof erosion) for labyrinth tunnel boring machines is reserved, which can be selected as needed. In the case of large mud and water inrush or mud and sand inrush strata, the grease distribution is more uniform and full, and the erosion resistance is improved. The grease interface is set inside the sealing cavity to connect to an external grease supply device to inject erosion-resistant grease.

[0045] The wear-resistant ring of TBM's main bearing seal is made of integral forging and heat-treated, resulting in high wear resistance. The contact position between the wear-resistant ring and the lip seal can be adjusted to improve the service life of the sealing system. It is designed to allow for 2 to 3 adjustments, which can be made by adding gaskets or other means.

[0046] Its construction methods include: Regularly inspect and maintain the reinforced structure to ensure the effectiveness of the reinforcement.

[0047] During tunneling, if geological problems such as faults and joints are found to affect the normal operation of the TBM, work should be stopped immediately for drilling exploration, and a corresponding timely support plan should be developed based on the exploration results. When implementing timely support, attention should be paid to protecting the TBM equipment and personnel safety, while ensuring construction efficiency and quality. The location and type of timely support should be determined according to the tunneling progress and rock mass conditions. Special support measures should be implemented in areas with concentrated faults and joints.

[0048] Before tunneling, the support materials are inspected and tested to ensure their strength and stability.

[0049] During the tunneling process, the condition of the support structure should be checked in a timely manner, and emergency measures should be taken immediately if any abnormalities are found.

[0050] In cases of machine entrapment or other similar situations, the support structure should be inspected and repaired promptly to ensure its stability.

[0051] After the tunneling is completed, the support structure is inspected and evaluated to determine whether reinforcement or replacement is needed.

[0052] For areas with concentrated faults and joints, the support structure should be inspected and maintained regularly to ensure its stability and safety.

[0053] Record and analyze the usage of support materials to continuously improve support measures and material selection.

[0054] During the support process, coordination and cooperation with other procedures should be strengthened to ensure the smooth progress of the support work.

[0055] Through the above technical solution, the present invention realizes an advanced support and timely support construction method for TBM to deal with the jamming and extrication of the machine in fault fracture and joint concentrated areas, which can effectively prevent the occurrence of geological problems and ensure the safety and smooth progress of tunnel excavation projects.

[0056] The present invention provides a method for TBM to overcome jamming and entrapment in fault fracture and dense joint formation during tunneling, which can: Geological exploration: Before tunneling, a comprehensive geological exploration combining geophysical exploration and drilling is conducted on the tunnel section to obtain information on the structure and properties of the surrounding rock and to formulate corresponding construction plans. The geological exploration should cover the entire tunnel section and employ various exploration methods, such as drilling, surveying, and seismic exploration.

[0057] Advanced Early Warning System: Install an advanced early warning system. Reserve an interface for a geological forecasting system in advance and install an advanced early warning system in front of the TBM. This system consists of sensors, a data acquisition unit, and a data processor. The sensors collect data on the displacement, deformation, and pressure of the surrounding rock ahead of the TBM. The data acquisition unit transmits the data to the data processor for processing. The processor predicts the changing trends of the rock mass ahead and identifies potential faults, joints, and other problems based on the collected data, and issues early warning signals.

[0058] Advanced protection: Based on the early warning signals issued by the advanced warning system, timely advanced protection measures are taken. A rapid support system is configured in the L1 area. When encountering long fault fracture zones or jointed strata, the machine is prone to jamming, requiring the capability for both rapid and advanced support. Advanced grouting and multiple pipe roof drilling rigs are used for pipe roof support at a depth greater than 30m in front of the tunnel face to achieve advanced support. Simultaneously, methods such as strengthening support and pre-treatment are employed to prepare in advance and ensure the safe tunneling of the TBM.

[0059] To extricate the TBM from jamming, an automatic unblocking system is in place. This system consists of sensors, a data acquisition unit, a controller, and actuators. The sensors collect data on the TBM when it is jammed, the data acquisition unit transmits the data to the controller for processing, and the controller determines the location and status of the jammed TBM based on the data, and automatically unblocks it via the actuators.

[0060] Hazard elimination is crucial. During TBM tunneling, the data from the advanced early warning system should be continuously monitored, and corresponding measures should be taken based on the data to ensure safe TBM tunneling. If a dangerous situation is detected, tunneling should be stopped immediately, and appropriate elimination measures should be taken until the dangerous factors are eliminated before resuming tunneling.

[0061] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A method for TBM (Tunnel Boring Machine) to overcome jamming in fault fracture and dense joints, employing an advanced early warning system. The advanced early warning system includes a geophysical exploration system, a drilling system, and a central control and early warning platform. The geophysical exploration system and the drilling system are communicatively connected, and the central control and early warning platform is communicatively connected to both the geophysical exploration system and the drilling system. The geophysical exploration system is used to conduct physical exploration of the surrounding rock ahead of the tunneling face to obtain and process geological data, generating preliminary geological forecasts. The drilling system is used to perform core drilling operations according to the drilling sites indicated by the preliminary geological forecasts to obtain core samples for verification and analysis, generating accurate geological information. The central control and early warning platform is used to coordinate and control the operation of the geophysical exploration system and the drilling system, and to perform fusion analysis based on the preliminary geological forecast and the precise geological information to generate targeted tunneling decision-making schemes and safety early warning signals. Its features include... The method for extricating stuck tunneling machines includes: Step S1: The TBM connects to the advanced early warning system via the advanced geological prediction system interface. Before tunneling, the advanced early warning system uses a comprehensive detection method combining geophysical exploration and drilling to conduct advanced geological exploration of the tunnel section and obtain information on the geological structure and surrounding rock. The comprehensive detection method covers the entire tunnel section. Step S2: When the TBM encounters a fault fracture zone and / or a densely jointed zone, the advanced early warning system issues an early warning signal. If the early warning signal indicates that the TBM is encountering the first fracture zone, then horizontal and vertical steel meshes are set up on the TBM tunneling face. The TBM uses the shield steel bar system (14), emergency spraying system (16), and arch frame system (15) to pass through quickly, and simultaneously executes step S5. If the early warning signal indicates that the TBM is encountering the second fracture zone or water-rich altered rock strata, then execute step S3. Step S3: Install horizontal and vertical steel meshes at the TBM excavation face to enhance the strength and stability of the reinforced structure; Step S4: Perform advance grouting and pipe roof support with multiple pipe roof drilling rigs at a depth of more than 30m in front of the tunnel face to achieve advance support; Step S5: A rapid slag removal system is installed in the TBM main unit, the lower part of the connecting bridge and the invert arch laying area. The rapid slag removal system is used to directly lift the slag material in the area to the upper platform of the connecting bridge and transfer it to the downstream belt conveyor.

2. The method for extricating stuck tunneling machines according to claim 1, characterized in that, If the TBM gets stuck during tunneling, it will automatically untangle itself using its equipped automatic untangling system. This system consists of sensors, a data acquisition unit, a controller, and actuators. The controller is connected to the data acquisition unit, the controller, and the actuators. The sensors are connected to the data acquisition unit and are used to collect data when the TBM gets stuck. The data acquisition unit transmits the data collected by the sensors to the controller for processing. The controller determines the location and status of the stuck TBM based on the data transmitted by the data acquisition unit and automatically untangles it using the actuators.

3. The method for extricating stuck tunneling machines according to claim 1, characterized in that, The TBM cutterhead used in this method is equipped with multiple pipe roof drilling rigs; The TBM's main belt width is greater than 1400mm, and the drive system adopts a dual drive form of hydraulic motor and reducer; The TBM's main drive uses a large reduction ratio reducer with i=26, with a main drive power of 16×350kW, a rated torque of 19800kN.m, a get-out-of-trouble torque of 29800kN.m, and a maximum total thrust of 37177kN. The auxiliary propulsion system of the TBM includes: modular steel segments, guide seats, and adjustable support mechanisms. The modular steel segments are assembled inside the shield to provide propulsion reaction force to the auxiliary propulsion cylinders in single-shield tunneling mode. The guide seats are installed in the area of ​​each set of auxiliary propulsion cylinders to connect the shield and the gearbox to transmit propulsion reaction force. The adjustable support mechanism is located at the lower part of the saddle frame. The adjustable support mechanism includes telescopic outriggers and small support boots. The adjustable support mechanism is used to realize the vertical and horizontal adjustment and rolling correction of the TBM. The sealing system of the TBM's main drive includes a sealing structure, sealing grease, a dust seal, a grease port, and a wear-resistant ring for the main bearing seal. The sealing structure includes an outer seal (4) and an inner seal. The outer seal (4) is provided with at least four first lip seals (36), and the inner seal is provided with at least four second lip seals (46). The outer seal (4) and the inner seal are sealed and lubricated with sealing grease. The dust seal is located outside the sealing structure of the main drive and is used to block mud and sand media. The grease port is located inside the sealing cavity and is used to connect an external grease supply device to inject erosion-resistant grease. The erosion-resistant grease is HBW grease containing fibers. The wear-resistant ring of the main bearing seal of TBM is made of integral forging and heat treatment; the contact position between the wear-resistant ring and the first lip seal (36) and the second lip seal (46) is adjustable; the installation structure of the wear-resistant ring is reserved with 2 to 3 adjustment margins, which can be adjusted by adding or replacing the gasket.

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