Manipulator for changing cutter of shield machine

Abstract

This invention discloses a cutterhead changing robot for a tunnel boring machine (TBM), relating to the field of tunnel construction technology. The TBM cutterhead changing robot includes a mounting base, a folding arm, a cutterhead changing device, and an adaptive adjustment module. One end of the folding arm is connected to the mounting base. The cutterhead changing device includes a mounting housing and a bolt removal mechanism, a trapezoidal wedge removal mechanism, a square wedge removal mechanism, and a clamping mechanism disposed on the mounting housing. The mounting housing is rotatably connected to the other end of the folding arm. The bolt removal mechanism includes a removal module, a gripping module, and a storage module. The adaptive adjustment module is electrically connected to the folding arm and the cutterhead changing device. The technical solution provided by this invention improves cutterhead changing efficiency, with an average single cutterhead changing time of ≤10 minutes.

Description

Technical Field

[0001] This invention relates to the field of tunnel construction technology, and in particular to a cutterhead changing robot for a tunnel boring machine. Background Technology

[0002] As a large-scale tunnel boring machine (TBM), the cutter head of a TBM directly contacts the soil and rock during excavation, enduring high-intensity friction and impact, leading to widespread cutter wear and breakage. To ensure the normal operation of the TBM and the progress of the project, timely inspection and replacement of the cutters is a necessary and frequent task. Existing TBM cutter-changing robots mostly adopt a conventional combination structure of "base + robotic arm + disassembly components," which has the following core defects: 1) Bolt disassembly lacks a torque feedback mechanism, easily leading to bolt stripping or cutter damage due to excessive torque, while insufficient torque prevents effective disassembly; 2) Poor interoperability of various mechanisms, requiring independent step-by-step control of bolt disassembly, gripping, and storage, resulting in low operational efficiency; 3) Poor adaptability to complex working conditions within the soil chamber (such as cutter installation position deviations and inconsistent wedge specifications), relying on manual calibration; 4) The robotic arm's stress state cannot be monitored in real time, and long-term operation can easily lead to structural fatigue damage due to overload. The safety risks and efficiency problems of manual cutter changing, combined with the technical defects of existing robotic arms, affect the tunnel construction progress. Therefore, there is an urgent need for a tunnel boring machine cutter changer with adaptive adjustment capabilities, precise control functions, and coordinated linkage of various mechanisms to solve multiple pain points of existing technologies. Summary of the Invention

[0003] The main objective of this invention is to propose a cutterhead changing robot for tunnel boring machines, aiming to improve cutterhead changing efficiency.

[0004] To achieve the above objectives, the present invention proposes a tunnel boring machine cutter changer robot, which includes a mounting base, a folding arm, a cutter changer device, and an adaptive adjustment module; One end of the folding arm is connected to the mounting base, and the folding arm has a built-in torque sensor for monitoring the force state of the folding arm. The tool changing device includes a mounting housing and a bolt removal mechanism, a trapezoidal wedge removal mechanism, a square wedge removal mechanism, and a clamping mechanism disposed on the mounting housing. The mounting housing is rotatably connected to the other end of the folding arm via a rotary joint. The rotary joint has a built-in angle encoder, which is used to control the rotation angle of the mounting housing. The bolt removal mechanism includes a removal module, a gripping module, a storage module, and a synchronous linkage component, which is connected to the removal module, the gripping module, and the storage module respectively. The disassembly module includes a bolt remover, a rotary drive, a first linear drive, and a bolt torque feedback unit. The bolt remover has a bolt sleeve. The rotary drive is connected to the bolt remover and drives the bolt sleeve to rotate. The first linear drive is connected to the rotary drive and drives the rotary drive to move the bolt sleeve along a first direction. The bolt torque feedback unit is electrically connected to the rotary drive and the adaptive adjustment module. The gripping module includes a gripper and a second linear drive connected to each other. The second linear drive drives the gripper to move along a second direction. The gripper has a built-in first pressure sensor for detecting the gripping force of the gripper. The tool changing device also includes a tool status detection module, which includes a laser rangefinder, an ultrasonic flaw detector, and a data transmission unit. The laser rangefinder is used to detect the wear of the tool edge, the ultrasonic flaw detector is used to detect cracks and defects in the tool body, and the data transmission unit transmits the detection data to the adaptive adjustment module in real time. When the tool wear exceeds a preset value or cracks are detected, the adaptive adjustment module controls the tool changing device to perform a tool changing operation. The storage module includes a connected storage unit and a drive assembly, the storage unit being spaced apart from the bolt remover, and the drive assembly driving the storage unit to move along a first direction; The adaptive adjustment module is electrically connected to the folding arm and the tool changing device. The adaptive adjustment module is used to dynamically adjust the support force of the folding arm and the working position of the tool changing device according to the detection data of the bolt torque feedback unit and the torque sensor. The first direction is orthogonal to the second direction.

[0005] In one embodiment, the mounting base includes a first drive module, a second drive module, a third drive module, and a fourth drive module connected in sequence. The first drive module drives the second drive module to move along a first horizontal direction, the second drive module drives the third drive module to move along a second horizontal direction, the third drive module is connected to the folding arm and drives the folding arm to extend and retract along the second horizontal direction, and the fourth drive module is used to drive the folding arm to rise and fall in a vertical direction. The first horizontal direction and the second horizontal direction are orthogonal, and the first, second, third, and fourth drive modules are all electrically connected to the adaptive adjustment module. The mounting base also includes a laser positioning sensor, which is electrically connected to the adaptive adjustment module and is used to detect the relative position of the mounting base and the cutting tool.

[0006] In one embodiment, the folding arm includes a first connecting portion, a second connecting portion, a first telescopic arm, a second telescopic arm, a telescopic stroke locking mechanism, and a buffer and shock absorption assembly. The first connecting portion is connected to the mounting base. One end of the first telescopic arm is rotatably connected to the first connecting portion via the buffer and shock absorption assembly. The other end of the first telescopic arm is rotatably connected to the second telescopic arm. The end of the second telescopic arm away from the first telescopic arm is rotatably connected to the second connecting portion. The second connecting portion is rotatably connected to the mounting housing. The telescopic stroke locking mechanism is located at the connection between the first telescopic arm and the second telescopic arm and is used to lock the telescopic stroke of the telescopic arm. The buffer and shock absorption assembly has a built-in elastic damping element, which is used to absorb the vibration and impact force during tool changing operations.

[0007] In one embodiment, the gripper includes a first mounting plate, a first gripper disposed on the first mounting plate, and a first gripper drive member. The first mounting plate is connected to a second linear drive member, and the first gripper drive member drives the first gripper to grip or release a bolt; and / or The storage device includes a second mounting plate, a second gripper disposed on the second mounting plate, and a second gripper drive member. The second mounting plate is connected to the drive assembly, and the second gripper drive member drives the second gripper to clamp or release the bolt.

[0008] In one embodiment, the driving assembly includes a guide rail, a slider, a lead screw, and a drive motor. The guide rail is disposed on the mounting housing, the slider is slidably disposed on the guide rail, the storage device is connected to the slider, the lead screw is threaded through the storage device, and the drive motor is connected to the lead screw, driving the lead screw to rotate.

[0009] In one embodiment, the trapezoidal wedge disassembly mechanism includes a trapezoidal wedge electromagnet, a wedge angle adaptive adsorption unit, a trapezoidal wedge moving plate, and a trapezoidal wedge storage plate. The trapezoidal wedge electromagnet is disposed on the bolt remover. The wedge angle adaptive adsorption unit is connected to the trapezoidal wedge electromagnet. The wedge angle adaptive adsorption unit is used to adjust the adhesion state of the adsorption surface according to the tilt angle of the trapezoidal wedge. The trapezoidal wedge electromagnet is used to adsorb the trapezoidal wedge. The trapezoidal wedge moving plate is movably disposed on the mounting housing along the second direction. The trapezoidal wedge moving plate is provided with an elastic pusher. The elastic pusher is used to flexibly push the trapezoidal wedge into the trapezoidal wedge storage plate.

[0010] In one embodiment, the square wedge disassembly mechanism includes a square wedge electromagnet, a position calibration sensor, a square wedge moving plate, and a square wedge storage plate. The square wedge electromagnet is movably mounted on the mounting housing via a fine-tuning drive. The position calibration sensor is electrically connected to the square wedge electromagnet and is used to detect the actual position of the square wedge and guide the square wedge electromagnet to attract it. The square wedge moving plate is movably mounted on the mounting housing and is used to push the square wedge into the square wedge storage plate.

[0011] In one embodiment, the clamping mechanism includes four clamping parts, four clamping drive members, and a flexible adaptive control unit; the four clamping parts are arranged in a rectangular array on the mounting housing, each clamping drive member is connected to one of the clamping parts, and the clamping surface of the clamping part is provided with an elastic buffer layer and a second pressure sensor; the flexible adaptive control unit is electrically connected to the second pressure sensor and the clamping drive members, and the flexible adaptive control unit is used to adjust the output force of each clamping drive member according to the clamping force data detected by the second pressure sensor.

[0012] In one embodiment, the tool changing device further includes an explosion-proof camera, which is disposed near the clamping mechanism; and / or The tool changing device also includes an infrared rangefinder, which is located near the bolt removal mechanism.

[0013] In one embodiment, the adaptive adjustment module includes a data processing unit, a drive control unit, and a feedback adjustment unit. The data processing unit is used to receive detection data from the torque sensor, the angle encoder, and the bolt torque feedback unit, and calculate adjustment parameters using a preset algorithm. The drive control unit is used to control the movement state of the mounting base, the folding arm, and the tool changing device according to the adjustment parameters. The feedback adjustment unit is used to monitor the adjustment effect in real time and dynamically correct the parameters.

[0014] In the technical solution of this invention, the overall positioning of the tool changing device is achieved through a folding arm, offering a wide adjustment range and high flexibility. The bolt removal mechanism, trapezoidal wedge removal mechanism, square wedge removal mechanism, and clamping mechanism enable the removal of bolts, trapezoidal wedges, square wedges, and cutters, improving tool changing efficiency and reducing tunnel boring machine downtime. Furthermore, the bolt removal mechanism is equipped with a gripping module and a storage module, allowing bolts to be stored during removal without needing to be moved to other locations, further improving tool changing efficiency. The closed-loop control of the bolt torque feedback unit and the rotary drive component precisely controls the bolt removal torque, preventing stripping or tool damage, with a torque control accuracy error ≤ ±5%. The synchronous linkage component achieves automated linkage of bolt removal, gripping, and storage, reducing operation time by more than 30% compared to existing robotic arms, eliminating the need for manual intervention. The adaptive adjustment module, combined with data feedback from torque sensors and angle encoders, dynamically adapts to tool installation deviations (maximum adaptation deviation ±10mm) and complex working conditions, reducing manual calibration steps. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of a structure of an embodiment of the tunnel boring machine cutter changing robot provided by the present invention; Figure 2 This is a schematic diagram of another embodiment of the shield tunneling machine cutterhead changing robot provided by the present invention; Figure 3 A schematic diagram of a structure of an embodiment of the mounting base provided by the present invention; Figure 4 A schematic diagram of another embodiment of the mounting base provided by the present invention; Figure 5 A schematic diagram of a folding arm according to an embodiment of the present invention; Figure 6 This is a schematic diagram of a structure of an embodiment of the tool changing device provided by the present invention; Figure 7 A schematic diagram of another embodiment of the tool changing device provided by the present invention; Figure 8 This is a schematic diagram of a structure of an embodiment of the tool changing device (hidden mounting housing) provided by the present invention; Figure 9 This is a schematic diagram of the structure of an embodiment of the gripper provided by the present invention; Figure 10 This is a schematic diagram of a storage device according to an embodiment of the present invention.

[0017] Explanation of icon numbers: 1000. Tunnel Boring Machine Cutter Changer; 100. Mounting Base; 1. First Drive Module; 2. Second Drive Module; 3. Third Drive Module; 200. Folding Arm; 4. First Connecting Part; 5. Second Connecting Part; 6. First Telescopic Arm; 7. Second Telescopic Arm; 300. Cutter Changer Device; 8. Bolt Remover; 801. Bolt Sleeve; 9. Rotary Drive Component; 10. First Linear Drive Component; 11. Gripper; 1101. First Mounting Plate; 1102. First Gripper; 1103. First Gripper Drive Component ; 12. Second linear drive; 13. Storage unit; 1301. Second mounting plate; 1302. Second gripper; 1303. Second gripper drive; 14. Drive assembly; 15. Trapezoidal wedge electromagnet; 16. Trapezoidal wedge moving plate; 17. Trapezoidal wedge storage plate; 18. Square wedge electromagnet; 19. Square wedge moving plate; 20. Square wedge storage plate; 21. Clamping part; 22. Clamping drive; 23. Explosion-proof camera; 24. Infrared rangefinder; 25. High-pressure water gun; 26. Mounting housing.

[0018] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0021] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0022] This invention proposes a shield tunneling machine cutter changer robot 1000.

[0023] Please see Figure 1 , Figure 2 , Figure 6 as well as Figure 7In one embodiment of the present invention, the shield tunneling machine cutter changer 1000 includes a mounting base 100, a folding arm 200, a cutter changer device 300, and an adaptive adjustment module. One end of the folding arm 200 is connected to the mounting base 100, and the folding arm 200 has a built-in torque sensor for monitoring the force state of the folding arm 200. The cutter changer device 300 includes a mounting housing 26 and a bolt removal mechanism, a trapezoidal wedge removal mechanism, a square wedge removal mechanism, and a clamping mechanism disposed on the mounting housing 26. The mounting housing 26 and the other end of the folding arm 200 are rotatably connected via a rotary joint, and the rotary joint has a built-in angle encoder for controlling the cutter changer. The rotation angle of the housing 26; the bolt removal mechanism includes a removal module, a gripping module, a storage module, and a step linkage component, with the synchronous linkage component connected to the removal module, gripping module, and storage module respectively; the removal module includes a bolt remover 8, a rotary drive 9, a first linear drive 10, and a bolt torque feedback unit. The bolt remover 8 has a bolt sleeve 801. The rotary drive 9 is connected to the bolt remover 8 and drives the bolt sleeve 801 to rotate. The first linear drive 10 is connected to the rotary drive 9 and drives the rotary drive 9 to move the bolt sleeve 801 along a first direction. The bolt torque feedback unit is connected to the rotary drive 9. The adaptive adjustment module is electrically connected; the gripping module includes a gripper 11 and a second linear drive 12 connected to each other. The second linear drive 12 drives the gripper 11 to move along a second direction. The gripper 11 has a built-in first pressure sensor, which is used to detect the clamping force of the gripper 11; the tool changing device 300 also includes a tool status detection module, which includes a laser rangefinder, an ultrasonic flaw detector, and a data transmission unit. The laser rangefinder is used to detect the wear of the tool edge, the ultrasonic flaw detector is used to detect cracks and defects in the tool body, and the data transmission unit transmits the detection data to the adaptive adjustment module in real time. When the detection... When the tool wear exceeds a preset value or cracks appear, the adaptive adjustment module controls the tool changer 300 to perform a tool change operation; the storage module includes a connected storage unit 13 and a drive assembly 14. The storage unit 13 is spaced apart from the bolt remover 8, and the storage unit 13 is connected to the drive assembly 14. The drive assembly 14 drives the storage unit 13 to move along the first direction; the adaptive adjustment module is electrically connected to the folding arm 200 and the tool changer 300. The adaptive adjustment module is used to dynamically adjust the support force of the folding arm 200 and the working position of the tool changer 300 according to the detection data of the bolt torque feedback unit and the torque sensor; wherein, the first direction and the second direction are orthogonal.

[0024] Mounting base 100 serves as the fixed foundation for the entire robotic arm and is typically installed at an appropriate location on the tunnel boring machine to provide stable support for the robotic arm.

[0025] One end of the folding arm 200 is connected to the mounting base 100, and the other end is connected to the tool changing device 300. Through the combination of multiple joint degrees of freedom, the tool changing device 300 can move flexibly and be precisely positioned in three-dimensional space. The bolt removal mechanism is the core component of the tool changer 300, which includes a removal module, a gripping module, and a storage module.

[0026] The disassembly module includes a bolt remover 8, a rotary drive 9, and a first linear drive 10. The bolt remover 8 has a bolt sleeve 801 at its front end for fitting the bolt head. The rotary drive 9 (such as a rotary motor) is connected to the bolt remover 8 and drives the bolt sleeve 801 to rotate, thereby loosening the bolt. The first linear drive 10 is connected to the rotary drive 9 and drives the rotary drive 9 and the bolt sleeve 801 to move along a first direction.

[0027] The gripping module includes a gripper 11 and a second linear drive 12. The gripper 11 is used to grip and release bolts. The second linear drive 12 is connected to the gripper 11 and drives the gripper 11 to move along a second direction, realizing the transfer of bolts between the storage module and the disassembly module. The first and second directions are orthogonal, which optimizes space utilization and allows the device to operate flexibly in confined environments. Both the first linear drive 10 and the second linear drive 12 are hydraulic telescopic couplings.

[0028] The storage module includes a storage unit 13 and a drive assembly 14. The storage unit 13 is used to store spare bolts and is spaced apart from the bolt remover 8 to avoid interference. The drive assembly 14 is connected to the storage unit 13 and drives the storage unit 13 to move along a first direction to provide or receive bolts at different locations.

[0029] The synchronous linkage component includes a linkage controller, a stroke sensor, and an electromagnetic reversing valve. The stroke sensor is located on the first linear drive 10 and the second linear drive 12 to detect the positions of the bolt sleeve 801 and the gripper 11. The linkage controller is electrically connected to the stroke sensor and the electromagnetic reversing valve. When the bolt sleeve 801 completes bolt disassembly (the stroke sensor detects that the bolt sleeve 801 has returned to the preset position), the linkage controller controls the second linear drive 12 to drive the gripper 11 to move to the bolt position through the electromagnetic reversing valve. After the gripping is completed, the controller then controls the drive component 14 to drive the storage unit 13 to move to the handover position, realizing seamless linkage of "disassembly-grip-storage". The whole process does not require manual triggering and the degree of automation is significantly improved.

[0030] The workflow of the tool condition detection module is as follows: Before the tool change operation, the folding arm 200 moves the tool condition detection module to the tool position. The laser rangefinder emits a laser to the blade surface and calculates the wear amount based on the distance difference of the reflected light (detection accuracy ≤ 0.01mm). The ultrasonic flaw detector emits ultrasonic waves to the tool body and determines whether there are cracks based on the waveform changes of the reflected waves. The data transmission unit transmits the detection data to the adaptive adjustment module in real time. The adaptive adjustment module determines whether the tool needs to be replaced. If the tool needs to be replaced, the tool change process is started; otherwise, it returns to the standby state.

[0031] The trapezoidal wedge disassembly mechanism is used to disassemble trapezoidal wedges, the square wedge disassembly mechanism is used to disassemble square wedges, and the clamping mechanism is used to grip the hobbing cutter.

[0032] In the technical solution of this invention, the overall positioning of the tool changing device 300 is achieved through the folding arm 200, which has a wide adjustment range and high flexibility. The bolt removal mechanism, trapezoidal wedge removal mechanism, square wedge removal mechanism, and clamping mechanism enable the removal of bolts, trapezoidal wedges, square wedges, and cutters, improving tool changing efficiency and reducing tunnel boring machine downtime. Furthermore, the bolt removal mechanism is equipped with a gripping module and a storage module, allowing bolts to be stored during removal without needing to be moved to other locations, further improving tool changing efficiency. The closed-loop control of the bolt torque feedback unit and the rotary drive component 9 precisely controls the bolt removal torque, preventing stripping or tool damage, with a torque control accuracy error ≤ ±5%. The synchronous linkage component achieves automated linkage of bolt removal, gripping, and storage, reducing operation time by more than 30% compared to existing robotic arms, eliminating the need for manual intervention. The adaptive adjustment module, combined with data feedback from torque sensors and angle encoders, dynamically adapts to tool installation deviations (maximum adaptation deviation ±10mm) and complex working conditions, reducing manual calibration steps.

[0033] Specifically, in one embodiment of the present invention, please refer to... Figure 3 and Figure 4The mounting base 100 includes a first drive module 1, a second drive module 2, a third drive module 3, and a fourth drive module connected in sequence. The first drive module 1 drives the second drive module 2 to move along a first horizontal direction, the second drive module 2 drives the third drive module 3 to move along a second horizontal direction, the third drive module 3 is connected to the folding arm 200, and the third drive module 3 drives the folding arm 200 to extend and retract along the second horizontal direction. The fourth drive module is used to drive the folding arm 200 to rise and fall vertically. The first and second horizontal directions are orthogonal. The first drive module 1 is a guide rail slider structure driven by a hydraulic push device, the second drive module 2 is a lead screw slider structure driven by a motor, and the third drive module 3 is a gear and rack structure driven by a motor. The first drive module 1 enables overall movement, while the second and third drive modules 2 and 3 enable two-stage extension and retraction, allowing the folding arm 200 and the tool changer 300 to be positioned at the work station. This decomposes the two degrees of freedom of movement in the horizontal plane onto three modules, allowing the entire robot's range of motion to cover a wide working area. The first drive module 1, the second drive module 2, the third drive module 3, and the fourth drive module are all electrically connected to the adaptive adjustment module, thereby achieving coordinated adjustment of multi-directional motion. The mounting base 100 is also equipped with a laser positioning sensor, which is electrically connected to the adaptive adjustment module. The laser positioning sensor is used to detect the relative position of the mounting base 100 and the cutting tool. When the detected position deviation exceeds 0.5mm, the adaptive adjustment module controls each drive module to perform micro-compensation. Furthermore, the first drive module 1, the second drive module 2, the third drive module 3, and the fourth drive module are all equipped with precision ball screw pairs and vibration dampers. The transmission accuracy error of the precision ball screw pairs is ≤0.02mm, and the vibration dampers are used to absorb the vibration transmission during tunnel boring machine excavation.

[0034] Furthermore, in one embodiment of the present invention, please refer to... Figure 5The folding arm 200 includes a first connecting part 4, a second connecting part 5, a first telescopic arm 6, a second telescopic arm 7, a telescopic stroke locking mechanism, and a buffer and shock absorption assembly. The first connecting part 4 is connected to the mounting base 100. One end of the first telescopic arm 6 is rotatably connected to the first connecting part 4 through the buffer and shock absorption assembly. The other end of the first telescopic arm 6 is rotatably connected to the second telescopic arm 7. The end of the second telescopic arm 7 away from the first telescopic arm 6 is rotatably connected to the second connecting part 5. The second connecting part 5 is rotatably connected to the mounting housing 26. The telescopic stroke locking mechanism is located at the connection between the first telescopic arm 6 and the second telescopic arm 7 and is used to lock the telescopic stroke of the telescopic arm. The buffer and shock absorption assembly has a built-in elastic damping element, which is used to absorb the vibration and impact force during tool changing operations. Specifically, the first connecting part 4 is connected to the first telescopic arm 6 via a cylindrical steering mechanism driven by a motor, enabling the rotation of the first telescopic arm 6. The first telescopic arm 6 and the second telescopic arm 7 rotate via a cylinder-driven linkage mechanism. The second telescopic arm 7 rotates via a motor-driven movable connector, enabling the rotation of the second connecting part 5. A cylindrical rotator is installed on the second connecting part 5 and is connected to the mounting housing 26, enabling the rotation of the tool changing device 300. The buffer and shock absorption components and the telescopic stroke locking mechanism can reduce the impact of operational vibration on the equipment, extend its service life, and prevent positioning deviations caused by excessive extension or retraction of the telescopic arm.

[0035] Specifically, in one embodiment of the present invention, please refer to... Figure 9 The gripper 11 includes a first mounting plate 1101, a first gripper 1102 disposed on the first mounting plate 1101, and a first gripper drive 1103. The first mounting plate 1101 is connected to a second linear drive 12. The first gripper drive 1103 drives the first gripper 1102 to clamp or release bolts. The first mounting plate 1101 is directly connected to the second linear drive 12 and is driven by the second linear drive 12 to move along a second direction, realizing the lifting and lowering of the entire gripper 11. The first gripper 1102 is disposed on the first mounting plate 1101. The first gripper drive 1103 (e.g., a pneumatic cylinder, electric push rod, or hydraulic cylinder) is fixed on the first mounting plate 1101, and its output end is connected to the first gripper 1102, driving the first gripper 1102 to perform clamping or releasing actions, thereby reliably gripping or releasing bolts. The first mounting plate 1101 provides a stable and reliable mounting base, ensuring the structural rigidity of the gripper 11 during movement. The first gripper 1102 and the first gripper drive 1103 enable controllable gripping of the bolt.

[0036] Furthermore, in one embodiment of the present invention, please refer to... Figure 10The storage device 13 includes a second mounting plate 1301, a second gripper 1302 disposed on the second mounting plate 1301, and a second gripper drive 1303. The second mounting plate 1301 is connected to a drive assembly 14, and the second gripper drive 1303 drives the second gripper 1302 to clamp or release bolts. The second mounting plate 1301 serves as a support platform for the storage device 13 and is connected to the drive assembly 14. The drive assembly 14 drives the storage device 13 to move along a first direction, thereby enabling the storage device 13 to switch between different positions. The second gripper 1302 is mounted on the second mounting plate 1301, and the second gripper drive 1303 (e.g., a pneumatic cylinder, an electric push rod, or a hydraulic cylinder) is fixed to the second mounting plate 1301 to drive the second gripper 1302 to perform clamping or releasing actions. By controlling the second gripper 1302 through the second gripper drive 1303, bolts can be reliably fixed to the second mounting plate 1301. The storage device 13 can be configured as two, with the two storage devices 13 spaced apart along the first direction.

[0037] Specifically, in one embodiment of the present invention, the drive assembly 14 includes a guide rail, a slider, a lead screw, and a drive motor. The guide rail is disposed on the mounting housing 26, the slider is slidably disposed on the guide rail, the lead screw is threaded through the guide rail, the drive motor is connected to the lead screw, and the drive motor drives the lead screw to rotate. The storage device 13 is connected to the slider. The guide rail provides precise guidance and a stable support foundation for the entire linear motion. The slider reciprocates along the first direction on the guide rail. The storage device 13 is directly or fixedly connected to the slider through a connector. The drive motor is a servo motor, and its output shaft is connected to one end of the lead screw to drive the lead screw to perform precise forward and reverse rotation. The lead screw is threadedly connected to the storage device 13, thereby converting the rotational motion of the lead screw into the linear motion of the storage device 13. The lead screw transmission mechanism itself has high motion accuracy, and combined with the precise control of the servo motor, it can accurately stop the storage device 13 at a preset working position.

[0038] Furthermore, in one embodiment of the present invention, please refer to... Figure 6 and Figure 8The trapezoidal wedge disassembly mechanism includes a trapezoidal wedge electromagnet 15, a wedge angle adaptive adsorption unit, a trapezoidal wedge moving plate 16, and a trapezoidal wedge storage plate 17. The trapezoidal wedge electromagnet 15 is mounted on the bolt disassembly device 8. The wedge angle adaptive adsorption unit is connected to the trapezoidal wedge electromagnet 15. The wedge angle adaptive adsorption unit is used to adjust the adhesion state of the adsorption surface according to the tilt angle of the trapezoidal wedge. The trapezoidal wedge electromagnet 15 is used to adsorb the trapezoidal wedge. The trapezoidal wedge moving plate 16 is movably mounted on the mounting housing 26 along the second direction. The trapezoidal wedge moving plate 16 is provided with an elastic push block, which is used to flexibly push the trapezoidal wedge into the trapezoidal wedge limiting plate. The trapezoidal wedge electromagnet 15 is directly mounted on the bolt disassembly device. The bolt sleeve 801 itself can be used as the core and mounting carrier of the electromagnet. That is, the bolt sleeve 801 is made of magnetic material and has a coil wound around it, or the annular electromagnet is integrated on the outer periphery of the bolt sleeve 801, realizing functional reuse and structural simplification. A trapezoidal wedge storage plate 17 is fixedly installed inside the mounting housing 26. The storage plate forms a receiving space that matches the shape of the trapezoidal wedge. A trapezoidal wedge moving plate 16 is movably mounted on the mounting housing 26 along a second direction and is driven by a hydraulic telescoping device to push the trapezoidal wedge, which has been picked up and transported to its position by the trapezoidal wedge electromagnet 15, into the trapezoidal wedge storage plate 17. It should be noted that when removing the trapezoidal wedge, it will have a certain tilt angle. The wedge angle adaptive adsorption unit can adjust the angle of the adsorption surface of the trapezoidal wedge electromagnet 15 according to the tilt angle of the trapezoidal wedge, so that the adsorption surface of the trapezoidal wedge electromagnet 15 contacts the trapezoidal wedge as closely as possible, ensuring sufficient suction to adsorb the trapezoidal wedge.

[0039] Specifically, in one embodiment of the present invention, please refer to... Figure 8The square wedge disassembly mechanism includes a square wedge electromagnet 18, a position calibration sensor, a square wedge moving plate 19, and a square wedge storage plate 20. The square wedge electromagnet 18 is movably mounted on the mounting housing 26 via a fine-tuning drive. The square wedge electromagnet 18 is used to attract square wedges. The position calibration sensor is electrically connected to the square wedge electromagnet 18 and is used to detect the actual position of the square wedge and guide the square wedge electromagnet 18 to attract it. The square wedge moving plate 19 is movably mounted on the mounting housing 26 and is used to push the square wedge into the square wedge storage plate 20. The square wedge electromagnet 18 is movably mounted within the mounting housing 26 via a hydraulic telescoping mechanism. It utilizes the electromagnetic force generated after energization to attract the square wedge, thereby achieving the gripping and release of the square wedge. A square wedge storage plate 20 is fixedly installed inside the mounting housing 26, forming a receiving space that matches the shape of the square wedge. A square wedge moving plate 19 is movably installed inside the mounting housing 26 and is driven by a hydraulic telescoping device to push the square wedge, which has been picked up and transported to its position by the square wedge electromagnet 18, into the square wedge storage plate 20. A position calibration sensor can detect the actual position of the square wedge in real time, thereby guiding the square wedge electromagnet 18 to accurately adsorb the square wedge, ensuring the accuracy and force of adsorption. Furthermore, with the simultaneous installation of a position calibration sensor and a wedge angle adaptive adsorption unit, wedges of different sizes can be precisely disassembled, greatly improving adaptability.

[0040] Furthermore, in one embodiment of the present invention, please refer to... Figure 6The clamping mechanism includes four clamping parts 21, four clamping drive members 22, and a flexible adaptive control unit. The four clamping parts 21 are arranged in a rectangular array on the mounting housing 26. Each clamping drive member 22 is connected to one clamping part 21. The clamping surface of the clamping part 21 is provided with an elastic buffer layer and a second pressure sensor. The flexible adaptive control unit is electrically connected to the second pressure sensor and the clamping drive members 22. The flexible adaptive control unit is used to adjust the output force of each clamping drive member 22 according to the clamping force data detected by the second pressure sensor. The four clamping parts 21 are arranged in a rectangular array on the mounting housing 26. Each clamping part 21 includes a chuck that adapts to the shape of the object being clamped. The four clamping drive members 22 are connected to the four clamping parts 21 one-to-one. Each clamping drive member 22 can independently drive the clamping part 21 to perform clamping or releasing actions. The four-point rectangular array clamping method forms a stable, statically determinate structure, effectively constraining the tool's degrees of freedom in all directions and preventing it from moving, rotating, or wobbling during bolt and wedge assembly / disassembly. The elastic buffer layer is made of polyurethane with a Shore A hardness of 85-90. The flexible adaptive control unit dynamically adjusts the output force of each clamping drive 22 based on the clamping force data detected by the second pressure sensor, ensuring a uniform distribution of clamping force across the four clamping parts 21 (force deviation ≤ ±10%), and maintaining the clamping force within a preset safety range (500-800N) to prevent damage to the tool surface or loosening of the clamp.

[0041] Specifically, in one embodiment of the present invention, please refer to... Figure 7 The tool changer 300 also includes an explosion-proof camera 23, which is positioned close to the clamping mechanism. The explosion-proof camera 23 is used to acquire real-time visual information about the tool change process. It captures the current state of the tool, the positions of the bolts and wedges, and the relative positions of each actuator and the target component. Furthermore, the explosion-proof camera 23 can be safely used in the flammable and explosive gas environment that may exist within the tunnel boring machine's earth chamber.

[0042] Furthermore, in one embodiment of the present invention, please refer to... Figure 6 The tool changing device 300 also includes an infrared rangefinder 24, which is positioned near the bolt removal mechanism. The infrared rangefinder 24 accurately measures the distance between itself and objects in front of it in a non-contact manner by emitting an infrared beam and receiving its reflected signal. Through the cooperation of the infrared rangefinder 24 and the explosion-proof camera 23, the position of the tool changing device 300 can be precisely located, thereby enabling tool changing operations.

[0043] Specifically, in one embodiment of the present invention, please refer to... Figure 6The cutterhead changing device 300 also includes a high-pressure water gun 25 mounted on the mounting housing 26, which is located near the clamping mechanism. The high-pressure water gun 25 is connected to the high-pressure water pump system via pipeline. During shield tunneling, components such as cutters, bolts, and wedges are usually covered by dense mud and gravel. The high-pressure water gun 25 can remove the mud and dirt covering the bolt heads, trapezoidal wedges, and square wedges before disassembly and assembly operations, exposing the working face.

[0044] Specifically, in one embodiment of the present invention, the adaptive adjustment module includes a data processing unit, a drive control unit, and a feedback adjustment unit. The data processing unit receives detection data from a torque sensor, an angle encoder, and a bolt torque feedback unit, and calculates adjustment parameters using a preset algorithm. The drive control unit controls the movement of the mounting base 100, the folding arm 200, and the tool changer 300 according to the adjustment parameters. The feedback adjustment unit monitors the adjustment effect in real time and dynamically corrects the parameters. The workflow of the adaptive adjustment module is as follows: 1. A torque sensor detects the force data of the folding arm 200 in real time, an angle encoder detects the rotation angle of the mounting housing 26, and a bolt torque feedback unit detects the disassembly torque; 2. The data processing unit receives the above data and compares it with preset thresholds (such as the standard bolt disassembly torque, the maximum bearing capacity of the folding arm 200, and the optimal working angle of the mounting housing 26); 3. If the bolt torque exceeds the preset threshold, the drive control unit immediately controls the rotary drive component 9 to stop rotating to prevent bolt stripping; if the folding arm 200 is overloaded, the fourth drive module is controlled to adjust the height of the folding arm 200 to distribute the force; if the tool installation position deviation is detected, the folding arm 200 and the rotary joint are finely adjusted to align the tool changer 300 with the working position; 4. The feedback adjustment unit continuously monitors the adjusted state until all data meet the preset range to ensure accurate operation.

[0045] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A cutterhead changing robot for a tunnel boring machine, characterized in that, Includes mounting base, folding arm, tool changer, and adaptive adjustment module; One end of the folding arm is connected to the mounting base, and the folding arm has a built-in torque sensor for monitoring the force state of the folding arm. The tool changing device includes a mounting housing and a bolt removal mechanism, a trapezoidal wedge removal mechanism, a square wedge removal mechanism, and a clamping mechanism disposed on the mounting housing. The mounting housing is rotatably connected to the other end of the folding arm via a rotary joint. The rotary joint has a built-in angle encoder, which is used to control the rotation angle of the mounting housing. The bolt removal mechanism includes a removal module, a gripping module, a storage module, and a synchronous linkage component, which is connected to the removal module, the gripping module, and the storage module respectively. The disassembly module includes a bolt remover, a rotary drive, a first linear drive, and a bolt torque feedback unit. The bolt remover has a bolt sleeve. The rotary drive is connected to the bolt remover and drives the bolt sleeve to rotate. The first linear drive is connected to the rotary drive and drives the rotary drive to move the bolt sleeve along a first direction. The bolt torque feedback unit is electrically connected to the rotary drive and the adaptive adjustment module. The gripping module includes a gripper and a second linear drive connected to each other. The second linear drive drives the gripper to move along a second direction. The gripper has a built-in first pressure sensor for detecting the gripping force of the gripper. The tool changing device also includes a tool status detection module, which includes a laser rangefinder, an ultrasonic flaw detector, and a data transmission unit. The laser rangefinder is used to detect the wear of the tool edge, the ultrasonic flaw detector is used to detect cracks and defects in the tool body, and the data transmission unit transmits the detection data to the adaptive adjustment module in real time. When the tool wear exceeds a preset value or cracks are detected, the adaptive adjustment module controls the tool changing device to perform a tool changing operation. The storage module includes a connected storage unit and a drive assembly, the storage unit being spaced apart from the bolt remover, and the drive assembly driving the storage unit to move along a first direction; The adaptive adjustment module is electrically connected to the folding arm and the tool changing device. The adaptive adjustment module is used to dynamically adjust the support force of the folding arm and the working position of the tool changing device according to the detection data of the bolt torque feedback unit and the torque sensor. The first direction is orthogonal to the second direction.

2. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The folding arm includes a first connecting part, a second connecting part, a first telescopic arm, a second telescopic arm, a telescopic stroke locking mechanism, and a buffer and shock absorption assembly. The first connecting part is connected to the mounting base. One end of the first telescopic arm is rotatably connected to the first connecting part through the buffer and shock absorption assembly. The other end of the first telescopic arm is rotatably connected to the second telescopic arm. The end of the second telescopic arm away from the first telescopic arm is rotatably connected to the second connecting part. The second connecting part is rotatably connected to the mounting housing. The telescopic stroke locking mechanism is located at the connection between the first telescopic arm and the second telescopic arm, and is used to lock the telescopic stroke of the telescopic arm. The buffer and shock absorption assembly has a built-in elastic damping element, which is used to absorb the vibration and impact force during tool changing operations.

3. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The gripper includes a first mounting plate, a first gripper disposed on the first mounting plate, and a first gripper drive member. The first mounting plate is connected to the second linear drive member, and the first gripper drive member drives the first gripper to grip or release the bolt. and / or The storage device includes a second mounting plate, a second gripper disposed on the second mounting plate, and a second gripper drive member. The second mounting plate is connected to the drive assembly, and the second gripper drive member drives the second gripper to clamp or release the bolt.

4. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The drive assembly includes a guide rail, a slider, a lead screw, and a drive motor. The guide rail is disposed on the mounting housing, the slider is slidably disposed on the guide rail, the storage device is connected to the slider, the lead screw is threaded through the storage device, and the drive motor is connected to the lead screw, driving the lead screw to rotate.

5. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The trapezoidal wedge disassembly mechanism includes a trapezoidal wedge electromagnet, a wedge angle adaptive adsorption unit, a trapezoidal wedge moving plate, and a trapezoidal wedge storage plate. The trapezoidal wedge electromagnet is located on the bolt remover. The wedge angle adaptive adsorption unit is connected to the trapezoidal wedge electromagnet. The wedge angle adaptive adsorption unit is used to adjust the adhesion state of the adsorption surface according to the tilt angle of the trapezoidal wedge. The trapezoidal wedge electromagnet is used to adsorb the trapezoidal wedge. The trapezoidal wedge moving plate is movably located on the mounting housing along the second direction. The trapezoidal wedge moving plate is provided with an elastic pusher. The elastic pusher is used to flexibly push the trapezoidal wedge into the trapezoidal wedge storage plate.

6. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The square wedge disassembly mechanism includes a square wedge electromagnet, a position calibration sensor, a square wedge moving plate, and a square wedge storage plate. The square wedge electromagnet is movably mounted on the mounting housing via a fine-tuning drive. The position calibration sensor is electrically connected to the square wedge electromagnet and is used to detect the actual position of the square wedge and guide the square wedge electromagnet to attract it. The square wedge moving plate is movably mounted on the mounting housing and is used to push the square wedge into the square wedge storage plate.

7. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The clamping mechanism includes four clamping parts, four clamping drive components, and a flexible adaptive control unit. The four clamping parts are arranged in a rectangular array on the mounting housing. Each clamping drive component is connected to one of the clamping parts. The clamping surface of each clamping part is provided with an elastic buffer layer and a second pressure sensor. The flexible adaptive control unit is electrically connected to the second pressure sensor and the clamping drive components. The flexible adaptive control unit is used to adjust the output force of each clamping drive component according to the clamping force data detected by the second pressure sensor.

8. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The tool changing device further includes an explosion-proof camera, which is positioned close to the clamping mechanism; and / or The tool changing device also includes an infrared rangefinder, which is located near the bolt removal mechanism.

9. The shield tunneling machine cutterhead changing robot as described in claim 1, characterized in that, The adaptive adjustment module includes a data processing unit, a drive control unit, and a feedback adjustment unit. The data processing unit receives detection data from the torque sensor, the angle encoder, and the bolt torque feedback unit, and calculates adjustment parameters using a preset algorithm. The drive control unit controls the movement of the mounting base, the folding arm, and the tool changer according to the adjustment parameters. The feedback adjustment unit monitors the adjustment effect in real time and dynamically corrects the parameters.

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