TBM cutterhead, TBM equipment and rock breaking methods

Abstract

This invention belongs to the field of tunnel boring machines (TBMs), specifically disclosing a TBM cutterhead, TBM equipment, and a rock-breaking method. The TBM cutterhead includes a panel and multiple sets of rock-breaking mechanisms distributed circumferentially along the panel. Each rock-breaking mechanism includes a cutter assembly and auxiliary rock-breaking components. The auxiliary rock-breaking components include a first auxiliary module and a second auxiliary module. The first auxiliary module includes multiple air nozzles radially distributed along the panel. The second auxiliary module includes fixed water nozzles, adjustable water nozzles, and an adjustment component for adjusting the orientation angle of the adjustable water nozzles. Multiple fixed and adjustable water nozzles are located on the same radius of the panel and are spaced apart. The cutter assembly, the second auxiliary module, and the first auxiliary module are sequentially distributed along the rotation direction of the panel. Using this invention, the problem of needing to change cutters multiple times, reducing construction efficiency, can be solved in tunnel excavation with varying geological conditions.

Description

Technical Field

[0001] This invention belongs to the field of tunnel boring, specifically involving TBM cutterhead, TBM equipment and rock breaking method. Background Technology

[0002] A tunnel boring machine (TBM) is a tunnel construction machine that uses rotating cutters to cut and break rock, forming the entire tunnel cross-section. It is the core equipment for constructing deep, long tunnels. Its rock-breaking efficiency and engineering cost directly depend on the adaptability of the cutterhead system to geological conditions. For long-distance hard rock sections, it is necessary to use high-density, large-diameter, high-strength heavy-duty cutters and strengthen the rigidity and wear resistance of the overall cutterhead structure. However, when such cutterheads are used in medium-hard or soft rock sections, the driving energy required for the strengthened heavy-duty cutters is high, and the rock-breaking capacity far exceeds the actual needs, resulting in energy waste. On the other hand, conventional cutters used in medium-hard or soft rock sections also suffer from insufficient rock-breaking capacity in hard rock sections.

[0003] In existing technologies, geological conditions are usually determined based on advanced geological forecasts, and then manual decisions are made to change the type of cutting tools to suit different geological conditions. For tunnel excavation with variable geological conditions, multiple tool changes are required, which reduces construction efficiency. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a TBM cutterhead, TBM equipment, and rock-breaking method to solve the problem of reduced construction efficiency caused by the need for multiple cutter replacements in tunnel excavation under varying geological conditions.

[0005] According to embodiments of the present invention, the present invention adopts the following technical solution:

[0006] The TBM cutterhead includes a panel and multiple rock-breaking mechanisms distributed circumferentially along the panel. Each rock-breaking mechanism includes a cutter assembly and an auxiliary rock-breaking assembly. The auxiliary rock-breaking assembly includes a first auxiliary module and a second auxiliary module. The first auxiliary module includes multiple air nozzles radially distributed along the panel. The second auxiliary module includes a fixed water nozzle, an adjustable water nozzle, and an adjustment mechanism for adjusting the orientation angle of the adjustable water nozzle. Multiple fixed and adjustable water nozzles are located on the same radius of the panel and are spaced apart. The cutter assembly, the second auxiliary module, and the first auxiliary module are sequentially distributed along the rotation direction of the panel. It also includes a vortex... The system includes pipes, air pipes, a water tank, water pipes, a high-pressure pump set, and a low-pressure pump set. A high-pressure pipe connects the high-pressure pump set to the water tank, and a low-pressure pipe connects the low-pressure pump set to the water tank. The outlets of both the high-pressure and low-pressure pump sets are connected to water pipes, and a three-way valve is installed at the connection point. The three-way valve is used to adjust the connection between the water pipe and the high-pressure or low-pressure pump set. The water pipe is also connected to both fixed and adjustable water nozzles. The vortex tube includes an air inlet, a hot air outlet, and a cold air outlet. An air pipe connects the hot air outlet and the air nozzle. A quench pipe connects to the cold air outlet and is wound around the outer wall of the high-pressure pipe. An air inlet connects to an air inlet pipe, on which a preheating element is installed to preheat the incoming gas.

[0007] Compared with the prior art, the present invention has the following beneficial effects:

[0008] 1. When breaking rocks, you can choose from the following three modes:

[0009] A. The pure mechanical mode, which uses only the cutting tool assembly to break rocks, can handle conventional rock (soft rock) geology.

[0010] B. The hydraulic-mechanical mode of high-pressure water jet combined with the cutting tool assembly can be used to deal with medium-hard rock geology. Specifically, by setting up a high-pressure pump group, the tunnel face can be treated by the jet of high-pressure water, which will pre-damage the rock structure to a certain extent and reduce the force required for subsequent cutting by the cutting tool assembly.

[0011] C. The hydraulic mechanical mode based on large temperature difference, which selects hot air heating - high-pressure quench water jet - cutting tool assembly, can cope with hard rock geology. Specifically, hot air and cold air are generated simultaneously through vortex tubes. The cold air can quench the high-pressure water. After the hot air heats the working face, the huge temperature difference created by the high-pressure jet of quench water on the working face can greatly damage the rock structure. At the same time, the force of the high-pressure jet further damages the rock structure, reducing the force required for subsequent cutting by the cutting tool assembly. The low temperature difference generation and hydraulic jet are combined synchronously in the second auxiliary module, instead of setting up two separate systems for low temperature cooling and hydraulic jet, which simplifies the structure and improves construction efficiency.

[0012] In this solution, the cutting tool assembly weakens the rock in medium-hard rock and hard rock geological environments by combining hydraulic or thermo-hydraulic methods. This reduces the force required for subsequent cutting by the cutting tool assembly, eliminating the need to replace the heavy-duty roller cutter to break the rock, reducing downtime for replacement and improving construction efficiency.

[0013] 2. In this solution, the temperature difference is generated through vortex tubes. Vortex tubes can simultaneously produce hot and cold air with a significant temperature difference. After rapid cooling with high-pressure water, a large temperature difference can be created in the rock. Furthermore, vortex tubes only require the introduction of compressed gas to simultaneously generate hot and cold air, unlike systems that require separate designs for each. This simplifies the structure. Moreover, TBM cutterheads may operate under conditions of strong vibration, high dust concentrations, humidity, and water immersion. Vortex tubes have no moving parts, and the working medium is only air, eliminating risks of fire, explosion, poisoning, and radiation. They are suitable for confined tunnel construction environments and offer extremely high reliability compared to complex heat sources such as lasers, plasma, burners, and microwaves, thus better meeting construction safety requirements.

[0014] By preheating the compressed gas introduced into the inlet through the preheating component, the inlet temperature of the compressed gas is increased. According to experimental verification, when using a vortex tube, preheating the compressed gas entering the vortex tube allows the compressed gas to enter the vortex tube at a certain temperature, which can more efficiently complete the separation of hot and cold gases within the vortex tube, improve the overall energy utilization rate, and achieve a greater temperature difference effect.

[0015] 3. Through the design of high-pressure and low-pressure pump sets, the high-pressure pump set can generate high-pressure water jets to assist the cutter assembly in rock breaking. Simultaneously, the adjustable water nozzle design allows it to be aimed at the working face or the cutter assembly. If aimed at the cutter assembly, it can simultaneously cool the cutter assembly during construction. The low-pressure pump set can use the adjustable water nozzle for cooling or cleaning the cutter assembly.

[0016] In this solution, the second auxiliary module can not only assist in rock breaking, but also achieve cooling or cleaning. It has a higher utilization rate of water flow and adjustable water nozzles, improving the multi-functionality and practicality of the device, meeting various needs within a limited space, and will not occupy additional panel space.

[0017] Furthermore, the nozzle of the fixed water nozzle is conical with its free end being the small-diameter end; the nozzle of the adjustable water nozzle has a fan-shaped cross-section with its free end being the large-diameter end.

[0018] Furthermore, the adjusting component includes an adjusting plate rotatably connected to the panel, the rotation axis of the adjusting plate being parallel to the rotation axis of the panel; and an adjustable water nozzle hinged to the adjusting plate, the hinge axis of the adjustable water nozzle being radially along the panel.

[0019] Furthermore, it also includes a monitoring mechanism for monitoring the status of the rock-breaking mechanism. The monitoring mechanism includes a first monitoring component for detecting the wear status of the tool assembly and a second monitoring component for monitoring the internal pressure and flow rate of the air nozzle, fixed water nozzle, and adjustable water nozzle.

[0020] Furthermore, the air pipe includes a main air pipe and branch air pipes that are respectively connected to the air nozzles of each group of first auxiliary modules. The branch air pipes are all fixed on the panel and converge at the center of the panel to connect with the main air pipe. An air inlet is connected to the main air pipe. The air inlet includes a fixed ring and a rotating ring rotatably connected to the fixed ring. The main air pipe is connected to the rotating ring, and the fixed ring is connected to the hot air outlet. The water pipe includes a main water pipe and branch water pipes that are respectively connected to the fixed water nozzles and adjustable water nozzles of each group of second auxiliary modules. The branch water pipes are all fixed on the panel and converge at the center of the panel to connect with the main water pipe. The main water pipe passes through the middle of the air inlet. A rotary joint is provided at the connection between the main water pipe and the high-pressure pump group and the low-pressure pump group.

[0021] Furthermore, the panel is provided with several reinforcing ribs along its circumference, and the reinforcing ribs are set on both sides of the gas distribution pipe and the water distribution pipe.

[0022] According to embodiments of the present invention, the present invention also employs the following technical solutions:

[0023] TBM equipment includes a TBM cutterhead and a main drive mechanism for driving the movement of the TBM cutterhead.

[0024] Furthermore, it also includes a cooling assembly for cooling the main drive mechanism, the cooling assembly including a cooling pipe for introducing cooling water or cooling oil, and a preheating component including a preheating pipe connected to the cooling pipe or for exchanging heat with the cooling pipe that has absorbed waste heat.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] In this solution, the waste heat generated by the main drive mechanism during construction is utilized. The cooling pipe absorbs the waste heat generated by the main drive mechanism, exchanges heat through the preheating pipe and the cooling pipe, and then preheats the intake pipe through the preheating pipe, thereby realizing the utilization of waste heat and improving the overall energy utilization rate.

[0027] According to embodiments of the present invention, the present invention also employs the following technical solutions:

[0028] Rock breaking methods, using TBM equipment, including hard rock mode, medium-hard rock mode and conventional mode;

[0029] The hard rock mode includes the following steps: starting the vortex tube, starting the high-pressure pump set, aligning the adjustable water nozzle with the working face, heating the working face with the air nozzle, rapidly cooling the working face with the adjustable water nozzle and the fixed water nozzle, and cutting the working face with the tool assembly.

[0030] The medium-hard rock mode includes the following steps: without starting the vortex tube, start the high-pressure pump group, turn off the adjustable water nozzle or adjust the adjustable water nozzle to align with the cutter assembly, fix the water nozzle to spray high pressure onto the face, and cutter assembly to cut the face.

[0031] The standard mode includes the following steps: without starting the vortex tube or the high-pressure pump unit, the tool assembly cuts the face of the tunnel.

[0032] Furthermore, it also includes a cleaning mode and a cooling mode. The cleaning mode and cooling mode include the following steps: start the low-pressure pump group, turn off the fixed water nozzle, adjust the adjustable water nozzle to aim at the tool assembly or panel, and the adjustable water nozzle cleans or cools the tool assembly.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] In this solution, different modes can be selected for rock breaking according to different geological conditions. Rock breaking can be completed without replacing the heavy-duty cutter, which reduces downtime for replacement and improves construction efficiency. Attached Figure Description

[0035] Figure 1 This is a front view of the TBM cutter head according to an embodiment of the present invention.

[0036] Figure 2 for Figure 1 Enlarged view of section A.

[0037] Figure 3 This is a rear view of the TBM cutter head according to an embodiment of the present invention.

[0038] Figure 4 This is a top view of the TBM cutter head according to an embodiment of the present invention.

[0039] In the diagram: 1. Panel; 2. Cutting tool assembly; 3. Edge hobbing cutter; 4. Main hobbing cutter; 5. Air nozzle; 6. Fixed water nozzle; 7. Adjustable water nozzle; 8. Reinforcing rib; 9. Air distribution pipe; 10. Water distribution pipe; 11. Connecting pipe; 12. Main air pipe; 13. Main water pipe; 14. Rotating ring; 15. Fixed ring; 16. Hot air outlet; 17. Air inlet; 18. Preheating pipe; 19. Quenching pipe; 20. High-pressure pump set; 21. Low-pressure pump set; 22. Low-pressure pipe; 23. High-pressure pipe; 24. Water tank; 25. Adjusting plate; 26. T-connector; 27. Vortex tube; 28. Electric heating structure; 29. ​​Air inlet pipe. Detailed Implementation

[0040] The present invention will be further described in detail below with reference to the accompanying drawings, and specific embodiments are given.

[0041] In a first aspect, embodiments of the present invention disclose a TBM cutter head, specifically including the following embodiments:

[0042] like Figure 1 As shown, the TBM cutterhead includes a panel 1 and multiple sets of rock-breaking mechanisms distributed circumferentially along the panel 1. Each rock-breaking mechanism includes a cutter assembly 2 and auxiliary rock-breaking components. A conventional TBM cutterhead typically includes a main cutter 4 located in the center of the panel 1, multiple sets of auxiliary cutters distributed circumferentially along the panel 1, and multiple edge cutters 3 located at the edges of the panel 1. In this embodiment, the cutter assembly 2 refers to the auxiliary cutters. Each rock-breaking mechanism's cutter assembly 2 includes multiple auxiliary cutters distributed radially along the panel 1. In this embodiment, the improvement to the TBM cutterhead is limited to the distribution of the cutter assembly 2 (i.e., auxiliary cutters) and the auxiliary rock-breaking components. No improvement is made to the specific installation of the cutter assembly 2. No improvement is made to the placement of the main cutter 4 and edge cutters 3 on parts of the panel 1 other than the auxiliary cutters, or to whether additional auxiliary cutters are added. The cutters are designed to withstand the strength requirements of soft rock geological environments. Specific cutter installation methods are existing technologies and will not be elaborated upon.

[0043] The auxiliary rock-breaking component includes a first auxiliary module and a second auxiliary module. The first auxiliary module includes multiple air nozzles 5 radially distributed along the panel 1. The air nozzles 5 are wide-angle solid cone nozzles as used in the prior art, and are made of high-temperature resistant materials (capable of withstanding 400-500℃, such as stainless steel). Valves for opening or closing the air nozzles 5 are installed inside each air nozzle.

[0044] Combination Figure 2 As shown, the second auxiliary module includes a fixed water nozzle 6, an adjustable water nozzle 7, and an adjusting component for adjusting the orientation angle of the adjustable water nozzle 7. The nozzle of the fixed water nozzle 6 is conical with a small-diameter free end to ensure that high-pressure water can form a high-pressure jet when sprayed through the fixed water nozzle 6. The fixed water nozzle 6 can be a gemstone nozzle used in industrial cutting, as is available in the prior art. The nozzle cross-section of the adjustable water nozzle 7 is fan-shaped with a large-diameter free end, meaning that a slit-like opening can be formed at the open end of the adjustable water nozzle 7 to ensure that the water sprayed from the adjustable water nozzle 7 has a certain diffusion area. The adjustable water nozzle 7 can be a fan-shaped nozzle, as is available in the prior art. Both the fixed water nozzle 6 and the adjustable water nozzle 7 are equipped with valves for opening or closing.

[0045] The adjusting mechanism includes an adjusting plate 25 rotatably connected to the panel 1, with the rotation axis of the adjusting plate 25 parallel to the rotation axis of the panel 1. An adjustable water nozzle 7 is hinged to the adjusting plate 25, with its hinge axis along the radial direction of the panel 1. Rotation of the adjustable water nozzle 7 allows it to be aligned with the cutter assembly 2 located to its side or with the working face. Rotation of the adjusting plate 25 also allows the adjustable water nozzle 7 to swing within a certain range while aligned with the cutter assembly 2, spraying water onto more cutters. In actual design, a micro motor or motor is installed on the panel 1 to drive the rotation of the adjusting plate 25, and the adjusting plate 25 is equipped with a micro motor or motor to drive the adjustable water nozzle 7.

[0046] Fixed water nozzles 6 and adjustable water nozzles 7 are located on the same radius of panel 1, and multiple fixed water nozzles 6 and adjustable water nozzles 7 are provided, with intervals between them. Figure 1 As shown in the example, along the direction from the center to the edge of panel 1, the sequence is: adjustable water nozzle 7 - fixed water nozzle 6 - adjustable water nozzle 7 - fixed water nozzle 6.

[0047] The cutting tool assembly 2, the second auxiliary module, and the first auxiliary module are distributed sequentially along the rotation direction of panel 1. Taking the division of panel 1 into five equal fan-shaped areas as an example, each fan-shaped area is equipped with a rock-breaking mechanism. Each rock-breaking mechanism includes the cutting tool assembly 2, the second auxiliary module, and the first auxiliary module distributed in a clockwise direction. Therefore, every time panel 1 rotates counterclockwise one full circle (the counterclockwise direction referred to here is the direction seen by the operator when facing panel 1, i.e.) Figure 1 (As shown in the direction), the first auxiliary module, the second auxiliary module, and the cutter assembly 2 of each rock breaking mechanism will sequentially pass through the face of the working face to process it.

[0048] Combination Figure 4 As shown, the TBM cutterhead also includes a vortex tube 27, an air pipe, a water tank 24, a water pipe, a high-pressure pump set 20, and a low-pressure pump set 21. The water tank 24 is used for water storage. A high-pressure pipe 23 connects the high-pressure pump set 20 and the water tank 24. The high-pressure pump set 20 is used to deliver the water in the water tank 24 at high pressure to the second auxiliary module for ejection. The high-pressure pump set 20 can be a booster pump set equipped with a booster system, as used in the prior art, to pressurize the water flow. A low-pressure pipe 22 connects the low-pressure pump set 21 and the water tank 24. The low-pressure pump set 21 is used to normally deliver the water in the water tank 24 to the second auxiliary module. The low-pressure pump set 21 can be a conventional plunger pump set, as used in the prior art.

[0049] The vortex tube 27 includes an air inlet 17, a hot air outlet 16, and a cold air outlet. After compressed gas is introduced into the air inlet 17, the compressed gas reacts within the vortex tube 27, separating hot and cold air. The hot gas exits from the hot air outlet 16, and the cold air exits from the cold air outlet. In actual design, TBM equipment is generally equipped with an air compressor. The air inlet 17 can be connected to the existing air compressor within the TBM equipment via a pipeline. Alternatively, an additional air compressor can be added to supply air to the vortex tube 27.

[0050] A gas pipe connects the hot gas outlet 16 and the gas nozzle 5, used to deliver hot gas to the gas nozzle 5 for ejection. A quench pipe 19 connects to the cold gas outlet. The quench pipe 19 is wound around the outer wall of the high-pressure pipe 23. Cold gas separated from the vortex tube 27 enters the quench pipe 19, which is used to rapidly cool the water in the high-pressure pipe 23. In actual design, after the quench pipe 19 cools the water in the high-pressure pipe 23, a nozzle can be connected to the opening of the quench pipe 19, allowing the nozzle to blow air towards equipment such as the high-pressure pump group 20 and the low-pressure pump group 21 for air cooling. Alternatively, the gas in the quench pipe 19 can be directly discharged without further treatment. In actual use, since the industrial-grade vortex tube 27 can generate cold air temperatures as low as below zero, in order to avoid the water in the high-pressure pipe 23 freezing directly, it is necessary to adjust and control the cold air temperature in the vortex tube 27 during use. Specifically, by selecting the model of the vortex tube 27, controlling the pressure and flow rate of the compressed air, and selecting the high cold flow rate (large cooling capacity) mode, the cold air temperature can be kept within the range of 1-3℃. Alternatively, the temperature of the cold air discharged from the cold air outlet can be kept below zero. The quench tube 19 is first heat-exchanged at the high-pressure pump group 20 and other equipment before being wound onto the high-pressure pipe 23. This can both cool the high-pressure pump group 20 and prevent the directly discharged cold air temperature from being too low.

[0051] The outlets of both the high-pressure pump set 20 and the low-pressure pump set 21 are connected to the water pipe, and a three-way valve is installed at the connection point. The three-way valve is used to adjust the connection between the water pipe and the high-pressure pump set 20 or the low-pressure pump set 21. The water pipe is also connected to the fixed water nozzle 6 and the adjustable water nozzle 7. By switching the connection between the low-pressure pump set 21 or the high-pressure pump set 20 and the water pipe through the three-way valve, the output of high-pressure water and low-pressure water can be switched.

[0052] In another embodiment of the present invention, in actual use, the panel 1 rotates. The high-pressure pump group 20, the low-pressure pump group 21, the water tank 24, the vortex tube 27 and other components are preferably fixedly installed behind the panel 1, rather than directly installed on the panel 1 and rotating with the panel 1. For this reason, it is necessary to design the assembly method of various pipes on the first auxiliary module and the second auxiliary module.

[0053] Specifically, in combination Figure 3 , Figure 4As shown, the air pipe includes a main air pipe 12 and branch air pipes 9 that are connected to the air nozzles 5 of each group of first auxiliary modules. The branch air pipes 9 are all fixed on the panel 1 and converge at the center of the panel 1 to connect with the main air pipe 12. That is, each of the first auxiliary modules of the five rock breaking mechanisms is provided with a branch air pipe 9. The branch air pipes 9 are fixed on the panel 1 along the radial direction of the panel 1, and the five branch air pipes 9 are all connected to the main air pipe 12 at the center of the panel 1.

[0054] The main air pipe 12 can extend from near the center of the panel 1 and connect with the hot air outlet 16 of the vortex tube 27. In this embodiment, an air inlet is connected to the main air pipe 12. The air inlet includes a fixed ring 15 and a rotating ring 14 rotatably connected to the fixed ring 15. The main air pipe 12 and the rotating ring 14 are connected, and the fixed ring 15 is connected to the hot air outlet 16. In a specific design, the fixed ring 15 and the rotating ring 14 have interconnected air passages inside, and a sealing gasket is installed on the contact surface of the fixed ring 15 and the rotating ring 14.

[0055] In this embodiment, the main air pipe 12 is not actually located at the center of the panel 1, but is offset from the center. To facilitate the connection of all branch air pipes 9 to the main air pipe 12, the ends of the branch air pipes 9 facing the center of the panel 1 are connected to the main air pipe 12 by a flexible connecting pipe 11, which is not fixed to the panel 1. The main air pipe 12 will move in a circular trajectory as the panel 1 rotates. During the movement of the main air pipe 12, it drives the rotating ring 14 to rotate, while the fixed ring 15 is fixedly set, and the vortex tube 27 can also be fixedly set. The hot air from the hot air outlet 16 passes through the fixed ring 15, the rotating ring 14, the main air pipe 12, and the branch air pipes 9 in sequence before being discharged from the air nozzle 5.

[0056] The outlets of both the high-pressure pump group 20 and the low-pressure pump group 21 are connected to water pipes, and a three-way valve is installed at the connection point. The three-way valve is used to adjust the connection between the water pipe and the high-pressure pump group 20 or the low-pressure pump group 21. The water pipes are also connected to the fixed water nozzles 6 and the adjustable water nozzles 7. Specifically, the water pipes include a main water pipe 13 and branch water pipes 10 that are connected to the fixed water nozzles 6 and the adjustable water nozzles 7 of each group of second auxiliary modules. The branch water pipes 10 are all fixed on the panel 1 and converge at the center of the panel 1 to connect with the main water pipe 13. The main water pipe 13 passes through the middle of the air inlet to avoid mutual interference between the air inlet and the main water pipe 13. A rotary joint is provided at the connection point between the main water pipe 13 and the high-pressure pump group 20 and the low-pressure pump group 21.

[0057] Each of the five sets of rock-breaking mechanisms' second auxiliary modules is equipped with a water distribution pipe 10. The water distribution pipe 10 is fixed to the panel 1 radially. All five water distribution pipes 10 are connected to the main water pipe 13 at the center of the panel 1. The main water pipe 13 extends from the center of the panel 1 and connects to the high-pressure pump group 20 and the low-pressure pump group 21. In this embodiment, the outlet ends of the high-pressure pump group 20 and the low-pressure pump group 21 are connected to the main water pipe 13 via a three-way pipe 26. A three-way valve is installed inside the three-way pipe 26, and a rotary joint is installed at the connection between the three-way pipe 26 and the main water pipe 13. After the main water pipe 13 passes through the rotating ring 14 and the fixed ring 15, the main water pipe 13 is located at the center of the panel 1. The main water pipe 13 rotates with the panel 1, while the three-way pipe 26, the high-pressure pump group 20, the low-pressure pump group 21, etc., do not move. In the actual design process, in order to avoid the temperature of the main water pipe 13 and the main gas pipe 12 affecting each other, the outer walls of the main water pipe 13 and the main gas pipe 12 are wrapped with a heat insulation layer.

[0058] In another embodiment of the present invention, during actual design, the panel 1 of the TBM cutterhead generally needs to have a slag inlet (not shown in the figure) for rock to enter, so that the cut rock enters the TBM equipment and is transported out for processing. To prevent the gas distribution pipe 9 and water distribution pipe 10 on the panel 1 from being damaged when the rock enters, in this embodiment, several reinforcing ribs 8 are provided on the panel 1 along its circumference to increase the strength of the panel 1. The reinforcing ribs 8 are set on both sides of the gas distribution pipe 9 and water distribution pipe 10. The gas distribution pipe 9 and water distribution pipe 10 are held in place by the reinforcing ribs 8 protruding from the panel 1. When the rock enters or exits the panel 1, it will also collide with the reinforcing ribs 8, thereby reducing damage to the gas distribution pipe 9 and water distribution pipe 10. In actual design, protective covers can also be provided on the reinforcing ribs 8 to further improve the protection of the gas distribution pipe 9 and water distribution pipe 10.

[0059] In the actual design process, the slag inlet can be opened at the required position on panel 1 as needed. Since the main cutter 4 is installed at the center of panel 1, it is generally not opened at the center of panel 1. Therefore, the connecting pipe 11, main air pipe 12, main water pipe 13, etc. located near the center of panel 1 may be less affected. Of course, a hard protective shell can also be set to wrap and protect the connecting pipe 11, main air pipe 12, main water pipe 13, etc.

[0060] In another embodiment of the present invention, a monitoring mechanism for monitoring the state of the rock-breaking mechanism is also included. The monitoring mechanism includes a first monitoring component for detecting the wear state of the cutter assembly 2 and a second monitoring component for monitoring the internal pressure and flow rate of the air nozzle 5, the fixed water nozzle 6, and the adjustable water nozzle 7.

[0061] Specifically, the first monitoring component includes an RFID tag installed in each hob of the tool assembly 2. The RFID tag is pre-embedded at the wear limit depth of the hob's cutter ring. When the wear reaches this point, the RFID tag is damaged, and the signal disappearance can be detected. This indicates that the hob has worn to its limit and needs to be replaced. In actual use, the first monitoring component assists manual inspection, and with regular manual inspection, it is possible to better determine whether the hob needs to be replaced.

[0062] The second monitoring component includes pressure sensors and flow sensors installed on the air distribution pipe 9 and water distribution pipe 10. These sensors detect the pressure and flow rate on each pipe branch. By measuring changes in pressure and flow rate within the pipes, the system can determine whether any pipes are blocked or otherwise faulty. When the air nozzle 5, fixed water nozzle 6, or adjustable water nozzle 7 experiences blockages or other problems, the pressure and flow rate within the pipes will also change. This allows the system to indirectly assist manual monitoring of the operation of the air nozzle 5, fixed water nozzle 6, and adjustable water nozzle 7.

[0063] Secondly, embodiments of the present invention disclose a TBM device, specifically including the following embodiments:

[0064] The TBM equipment includes a TBM cutterhead, a main drive mechanism for driving the TBM cutterhead's movement, and a cooling assembly for cooling the main drive mechanism. In this embodiment, the movement trajectory of the TBM cutterhead is not modified, therefore the main drive mechanism is also not modified. It can be designed entirely with reference to the main drive mechanism of existing TBM equipment. For example, the main drive mechanism includes a main drive motor for driving the panel 1 to rotate, a reduction gearbox, and a bearing structure for bearing the axial thrust of the panel 1. As long as the main drive mechanism can drive the panel 1 to complete the rotation and can support the panel 1 to bear the load (e.g., axial thrust), it is acceptable.

[0065] During the movement of the drive panel 1, the main drive mechanism generates heat from the friction of the bearings, the motor, and the lubricating oil in the lubrication system. In actual design, a cooling system is provided, such as a conventional water cooling system or air cooling system to cool down the heat-generating components. In this embodiment, the main cooling system built into the TBM equipment in the prior art is not modified, but only the waste heat in the cooling system is utilized.

[0066] The following description uses motor cooling as an example. The cooling component includes cooling pipes installed around the motor. Cooling water (or cooling oil) is circulated through the cooling pipes. The cooling water absorbs the heat generated by the motor and becomes hot. Conventionally, the length of the cooling pipes is designed so that the cooling water cools down naturally during circulation and then re-enters the cooling cycle.

[0067] Combination Figure 4As shown, in this embodiment, the air inlet 17 is connected to the air inlet pipe 29. A preheating component for preheating the incoming gas is installed on the air inlet pipe 29. The preheating component includes a preheating pipe 18 that connects to the cooling pipe or exchanges heat with the cooling pipe that has absorbed residual heat. The preheating pipe 18 can be a part of the original cooling pipe connection route, meaning that a portion of the original cooling pipe is routed to the air inlet pipe 29 and in close contact with it, for example, directly wrapped around the outside of the air inlet pipe 29. This section of the cooling pipe is called the preheating pipe 18, which can directly transfer the heat absorbed by the cooling water in the cooling pipe to the air inlet pipe 29, preheating the air inlet pipe 29. In actual use, even without using the vortex tube 27, this design extends the path of the cooling pipe, allowing the cooling water to cool down during circulation.

[0068] Of course, the preheating pipe 18 can also be an additional pipe designed between the cooling pipe and the air intake pipe 29, and the preheating pipe 18 is filled with water. By utilizing the heat transfer efficiency of water, the water in the preheating pipe 18 first contacts the cooling pipe for heat exchange, and then contacts the air intake pipe 29 for heat exchange. This design will cause a certain amount of heat loss.

[0069] In actual design, not only can the heat from the motor's cooling system be recovered, but the heat recovery from the cooling system in the main drive mechanism can also be designed with reference to the above example. For example, the preheating pipe 18 can be designed to pass through all the components in the main drive mechanism that generate waste heat in sequence for heat exchange. After multiple heat absorptions at each stage, all waste heat can be recovered, improving the cooling efficiency of the main drive mechanism. At the same time, the preheating pipe 18 can significantly increase the preheating temperature of the gas in the intake pipe 29.

[0070] By utilizing the waste heat generated during the construction of the main drive mechanism, the compressed gas entering the vortex tube 27 can be preheated when using the vortex tube 27. The preheated compressed gas can then enter the vortex tube 27, allowing for more efficient separation of hot and cold gases and improving the overall energy utilization rate.

[0071] In another embodiment of the invention, a temperature sensor for temperature measurement is installed on the intake pipe 29. The preheating component also includes an electric heating structure 28 (e.g., a heating wire wound around the outer wall of the intake pipe 29) installed on the intake pipe 29. The temperature sensor monitors the intake air temperature in the intake pipe 29 in real time. When the preheating temperature of the compressed gas by the recovered waste heat can meet the construction requirements, the electric heating structure 28 is not needed. When a larger temperature difference is required, and the waste heat recovery cannot meet the preheating requirements, the intake pipe 29 is further heated by the electric heating mechanism. In actual design, the intake air temperature control of the intake pipe 29 can be connected to the main control system of the TBM equipment, or an additional controller can be set up to receive the temperature signal from the temperature sensor and control the opening and closing of the electric heating structure 28.

[0072] The impact of temperature difference on rock breaking varies depending on the rock conditions. Therefore, the temperature difference design needs to be selected based on the actual construction situation and rock conditions. Then, based on whether the inlet air temperature after initial preheating by the preheating pipe 18 meets the required temperature difference, it is determined whether to use an additional electric heating structure 28 to further preheat the inlet pipe 29, thus reducing energy waste. Furthermore, since the cold air temperature needs to be combined with high-pressure water to achieve jetting, the cold air temperature is not necessarily better the lower it is; rather, it needs to generate a temperature difference while meeting certain low-temperature requirements. This step of the design incorporates the utilization of waste heat from the TBM equipment and allows for the selection of further additional heating based on the actual inlet air temperature, resulting in high energy utilization and compatibility with TBM equipment.

[0073] Thirdly, embodiments of the present invention disclose a rock-breaking method, specifically including the following embodiments:

[0074] Rock breaking methods include hard rock mode, medium-hard rock mode and conventional mode. In actual use, a control system can be designed to switch between the three modes, or the switching of modes can be controlled manually. The specific mode to be selected for rock breaking can be determined based on the judgment of geological conditions by advanced geological forecasting, or it can be selected manually after the judgment of geological conditions.

[0075] The hard rock model is applicable to hard rock environments and includes the following steps:

[0076] As panel 1 rotates, the first auxiliary module, the second auxiliary module, and the tool assembly 2 process the rock in sequence.

[0077] When the vortex tube 27 is activated, compressed gas enters the vortex tube 27 and hot gas and cold gas are separated inside the vortex tube 27. The hot gas is discharged from the gas nozzle 5, which first heats the working face at high temperature. In this embodiment, an application example of the vortex tube 27 is given: when the compressed air inlet pressure is set to 120 psig and the cold air flow rate is set to 80%, the compressed air enters the vortex tube 27. The temperature drop at the cold air outlet can reach 55°F, and the temperature rise at the hot air outlet 16 can reach 195°F. Taking the ambient temperature of 20°C as the initial temperature of the compressed air, the cold air at the cold air outlet is about -11°C, and the hot air at the hot air outlet 16 is about 127°C. After eliminating certain energy losses and errors, although the temperature of the cold air in the quench tube 19 reaches below zero, as long as the outer wall of the quench tube 19 and the high-pressure tube 23 is covered with a certain thickness of insulation cotton to reduce the heat transfer efficiency, the water temperature in the high-pressure tube 23 can be kept low enough and will not freeze. The temperature difference between the hot air discharged from the hot air outlet 16 and the cold water discharged from the high-pressure tube 23 can reach about 100°C.

[0078] Experimental verification shows that as the intake air temperature gradually increases, the average increase in cooling temperature effect is much greater than the average increase in heating temperature effect. After preheating the intake pipe 29 through the preheating pipe 18, with the compressed air inlet pressure and cold air flow settings unchanged, when the intake air temperature reaches approximately 80-90℃, the temperature difference between the cold and hot air can reach 200℃, and the cold air temperature remains around 0℃. Further increasing the intake air temperature—that is, by further collecting waste heat from the TBM system through the preheating pipe 18 to preheat the intake pipe 29—can further increase the temperature difference. This setting can be adjusted according to actual construction conditions to ensure the temperature difference meets construction requirements. In actual use, in addition to preheating the intake air temperature, adjusting the compressed air inlet pressure and the percentage of cold air flow can also control the final exhaust temperatures of cold and hot air to achieve the desired temperature difference for construction.

[0079] In practical use, when waste heat collection cannot meet the demand, further heating can be achieved through the electric heating structure 28 installed on the intake pipe 29. Only a small increase in the intake temperature is needed to achieve a significant increase in the exhaust hot air temperature, resulting in higher heat conversion efficiency. Furthermore, the heating within the TBM equipment is not affected by the harsh operating conditions of the cutterhead. The impact of temperature difference on rock breaking varies depending on the rock conditions. Therefore, the temperature difference design needs to be selected based on the actual construction situation and rock conditions. Then, based on whether the intake temperature after initial preheating by the preheating pipe 18 meets the required temperature difference, it can be determined whether to use the additional electric heating structure 28 to further preheat the intake pipe 29, thus reducing energy waste. Furthermore, since the cold air temperature needs to be combined with high-pressure water to achieve spraying, the cold air temperature is not necessarily better the lower it is. Instead, it needs to generate a large temperature difference while meeting the low temperature requirements within a certain range. This step of the design introduces the utilization of waste heat from the TBM equipment, and can also select whether to further heat it based on the actual intake air temperature. By preheating, the starting temperature of the hot air is increased, so that a large temperature difference sufficient for efficient rock breaking can still be obtained while meeting the safe temperature of the cold air. The energy utilization rate is high, which is suitable for the safety and energy consumption coordination requirements when using TBM equipment.

[0080] The high-pressure pump unit 20 is started, drawing water from the water tank 24 and spraying it out from the adjustable water nozzle 7 and the fixed water nozzle 6. The cold air distributed from the vortex tube 27 rapidly cools the water, resulting in low-temperature water that has a significant temperature difference with the hot air ejected from the air nozzle 5. The adjustable water nozzle 7 is adjusted to be aimed at the working face, and the adjustable water nozzle 7 and the fixed water nozzle 6 rapidly cool the working face. The fixed water nozzle 6 is a gemstone nozzle used for industrial cutting. Together with the high-pressure water drawn by the high-pressure pump unit 20, it forms a high-pressure water jet that has a damaging and cutting effect on the rock. The low temperature of the water flow further assists in further damaging the rock. The adjustable water nozzle 7 is a fan-shaped nozzle, which can expand the range of the sprayed low-temperature water, cooling a large area of ​​the working face and creating a large temperature difference to damage the rock.

[0081] By first heating at high temperature and then cooling with low temperature water, a huge temperature difference is created in the rock face, which damages the rock structure. Combined with the high-pressure water jet cutting at the fixed water nozzle 6, the rock structure is further damaged. Finally, as the panel 1 rotates, the cutter assembly 2 cuts the rock face.

[0082] In this mode, the water temperature sprayed from both the fixed water nozzle 6 and the adjustable water nozzle 7 is relatively low. The wide-area spray from the adjustable water nozzle 7 will also cause some water to act on the panel 1 and the blade assembly 2, which will have a certain cooling effect. At the same time, the sprayed water flow will always have a dust-reducing effect.

[0083] The medium-hard rock model is applicable to medium-hard rock environments and includes the following steps:

[0084] In this mode, the first auxiliary module is not used when the vortex tube 27 is not activated.

[0085] Start the high-pressure pump unit 20, and close the adjustable water nozzle 7 or adjust the adjustable water nozzle 7 to align with the cutter assembly 2. The high-pressure pump unit 20 draws water from the water tank 24 and sprays it out from the fixed water nozzle 6. The fixed water nozzle 6 sprays water at high pressure onto the working face, which has a damaging and cutting effect on the rock. Then, as the panel 1 rotates, the cutter assembly 2 cuts the working face.

[0086] In this mode, if the adjustable water nozzle 7 is aligned with the tool assembly 2, the tool assembly 2 can be cooled down simultaneously.

[0087] The standard mode is suitable for soft rock environments and includes the following steps:

[0088] The vortex tube 27 is not activated; in this mode, the first auxiliary module is not used. The high-pressure pump unit 20 is not activated; in this mode, the fixed water nozzle 6 is not used.

[0089] As panel 1 rotates, the face of the tunnel is cut using only the tool assembly 2.

[0090] In this mode, the adjustable water nozzle 7 can be turned off or adjusted to be aligned with the tool assembly 2. If the adjustable water nozzle 7 is aligned with the tool assembly 2, the tool assembly 2 can be cooled down simultaneously.

[0091] In another embodiment of the invention, a cleaning mode and a cooling mode are also included.

[0092] The cleaning mode is used to clean panel 1 and tool assembly 2, and specifically includes the following steps:

[0093] Start the low-pressure pump unit 21, close the fixed water nozzle 6, first adjust the adjustable water nozzle 7 to align with the tool assembly 2, then rotate the adjustment plate 25 so that the adjustable water nozzle 7 sprays the tool assembly 2, panel 1 and other components during the rotation, and then assist manual cleaning.

[0094] The cooling mode is used to cool tool assembly 2, and specifically includes the following steps:

[0095] Start the low-pressure pump set 21, close the fixed water nozzle 6, and adjust the adjustable water nozzle 7 to aim at the cutter assembly 2. The adjustable water nozzle 7 cools the cutter assembly 2. In the aforementioned medium-hard rock mode, cooling can also be achieved by using water pumped from the high-pressure pump set 20. In actual use, the applicability to the geological conditions should be prioritized before considering the cooling mode.

[0096] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0097] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A TBM cutter head, characterized in that, The device includes a panel and multiple rock-breaking mechanisms distributed circumferentially along the panel. Each rock-breaking mechanism includes a cutting tool assembly and an auxiliary rock-breaking assembly. The auxiliary rock-breaking assembly includes a first auxiliary module and a second auxiliary module. The first auxiliary module includes multiple air nozzles radially distributed along the panel. The second auxiliary module includes a fixed water nozzle, an adjustable water nozzle, and an adjustment component for adjusting the orientation angle of the adjustable water nozzle. Multiple fixed and adjustable water nozzles are located on the same radius of the panel and are spaced apart. The cutting tool assembly, the second auxiliary module, and the first auxiliary module are distributed sequentially along the rotation direction of the panel. It also includes a vortex tube, an air pipe, a water tank, a water pipe, a high-pressure pump set, and a low-pressure pump set. A high-pressure pipe connects the high-pressure pump set and the water tank, and a low-pressure pipe connects the low-pressure pump set and the water tank. The outlets of both the high-pressure and low-pressure pump sets are connected to the water pipes, and a three-way valve is installed at the connection point. The three-way valve is used to adjust the connection between the water pipe and the high-pressure or low-pressure pump set. The water pipe is connected to both the fixed and adjustable water nozzles. The vortex tube includes an air inlet, a hot air outlet, and a cold air outlet. An air pipe connects the hot air outlet and the air nozzle. A quench pipe connects to the cold air outlet and is wound around the outer wall of the high-pressure pipe. An air inlet connects to an air inlet pipe, and a preheating element for preheating the introduced gas is installed on the air inlet pipe.

2. The TBM cutter head according to claim 1, characterized in that, The fixed water nozzle has a conical nozzle with a small diameter end at its free end; the adjustable water nozzle has a fan-shaped nozzle cross-section with a large diameter end at its free end.

3. The TBM cutter head according to claim 1, characterized in that, The adjusting component includes an adjusting plate rotatably connected to the panel, the rotation axis of the adjusting plate being parallel to the rotation axis of the panel; and an adjustable water nozzle hinged to the adjusting plate, the hinge axis of the adjustable water nozzle being radially along the panel.

4. The TBM cutter head according to claim 1, characterized in that, It also includes a monitoring mechanism for monitoring the status of the rock-breaking mechanism. The monitoring mechanism includes a first monitoring component for detecting the wear status of the cutting tool assembly and a second monitoring component for monitoring the internal pressure and flow rate of the air nozzle, fixed water nozzle, and adjustable water nozzle.

5. The TBM cutter head according to claim 1, characterized in that, The air pipes include a main air pipe and branch air pipes that are connected to the air nozzles of each group of first auxiliary modules. The branch air pipes are all fixed on the panel and converge at the center of the panel to connect with the main air pipe. An air inlet is connected to the main air pipe. The air inlet includes a fixed ring and a rotating ring that is rotatably connected to the fixed ring. The main air pipe is connected to the rotating ring, and the fixed ring is connected to the hot air outlet. The water pipes include a main water pipe and branch water pipes that are connected to the fixed water nozzles and adjustable water nozzles of each group of second auxiliary modules. The branch water pipes are all fixed on the panel and converge at the center of the panel to connect with the main water pipe. The main water pipe passes through the middle of the air inlet. A rotary joint is provided at the connection between the main water pipe and the high-pressure pump group and the low-pressure pump group.

6. The TBM cutter head according to claim 5, characterized in that, The panel is provided with several reinforcing ribs along its circumference, and the reinforcing ribs are located on both sides of the gas distribution pipe and the water distribution pipe.

7. A TBM device, characterized in that, It includes the TBM cutterhead as described in any one of claims 1-6 and a main drive mechanism for driving the movement of the TBM cutterhead.

8. The TBM equipment according to claim 7, characterized in that, It also includes a cooling assembly for cooling the main drive mechanism, the cooling assembly including a cooling pipe for introducing cooling water or cooling oil, and a preheating component including a preheating pipe connected to the cooling pipe or for exchanging heat with the cooling pipe that has absorbed waste heat.

9. A rock-breaking method, characterized in that, Using the TBM equipment as described in claim 7, including hard rock mode, medium-hard rock mode and conventional mode; The hard rock mode includes the following steps: starting the vortex tube, starting the high-pressure pump set, aligning the adjustable water nozzle with the working face, heating the working face with the air nozzle, rapidly cooling the working face with the adjustable water nozzle and the fixed water nozzle, and cutting the working face with the tool assembly. The medium-hard rock mode includes the following steps: without starting the vortex tube, start the high-pressure pump group, turn off the adjustable water nozzle or adjust the adjustable water nozzle to align with the cutter assembly, fix the water nozzle to spray high pressure onto the face, and cutter assembly to cut the face. The standard mode includes the following steps: without starting the vortex tube or the high-pressure pump unit, the tool assembly cuts the face of the tunnel.

10. The rock-breaking method according to claim 9, characterized in that, It also includes a cleaning mode and a cooling mode. The cleaning mode and cooling mode include the following steps: start the low-pressure pump group, turn off the fixed water nozzle, adjust the adjustable water nozzle to aim at the tool assembly or panel, and the adjustable water nozzle cleans or cools the tool assembly.

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