TBM (Tunnel Boring Machine) dual-mode deslagging switching device and method for identifying tunneling in underpressure mode

Abstract

The invention relates to the technical field of tunnel boring machine construction, and discloses a TBM dual-mode deslagging switching device and method for recognizing tunneling in an underpressure mode. The technical problem that in the prior art, equipment dual-mode conversion opportunity is difficult to sense under the under-voltage condition is solved. The system comprises a multi-source working condition sensing module which is integrally installed on a TBM host and a rear support and is used for collecting tunneling state data in real time; the multi-source working condition sensing module is electrically connected with the decision-making and control center, the decision-making and control center is electrically connected with the dual-mode cooperative execution mechanism, and the system further comprises a sensing module and an adjusting device which are used for sensing the undervoltage condition and adjusting the undervoltage condition. According to the system and the method, the long screw conveyor and the belt conveyor can be intelligently decided and controlled to cooperatively work under the complex geological downhill tunneling working condition on the basis of multi-source information fusion, and it is ensured that the tunneling process is safe, continuous and efficient.

Description

Technical Field

[0001] This invention relates to the field of tunnel boring machine (TBM) construction technology, and in particular to a dual-mode muck discharge switching device and method for identifying TBMs operating under under-pressure conditions. Background Technology

[0002] Tunneling under complex geological conditions characterized by deep burial, water abundance, and fractured rock, especially on steep downhill sections, presents significant risks for TBM construction, including water inrush, mudslides, and surrounding rock instability. Traditional single-shield TBMs are typically equipped with a single belt conveyor muck removal system, but this is insufficient to effectively address issues such as muck inrush at the bottom of the cutterhead and difficulties in controlling pressure at the tunnel face.

[0003] To address this issue, existing technologies propose adding a long screw conveyor system to the TBM, forming a dual muck removal mode of "belt conveyor + long screw conveyor". Chinese patent document CN201910287514.2 discloses a multi-mode closed TBM and its construction method suitable for long mountain tunnels. It includes a main unit and supporting systems, the latter comprising a muck transportation system and a grouting system. The shield body houses a main drive, forming a chamber between the main drive and the cutterhead. A mud circulation pipeline is installed on the chamber, connecting to the mud circulation system. The main drive is equipped with a telescopic sealing device and a central screw conveyor. A bottom-mounted screw conveyor is located at the bottom of the shield body, with the front end of the central screw conveyor located within the telescopic sealing device. The central screw conveyor and the bottom-mounted screw conveyor are connected to the muck transportation system or the mud circulation system.

[0004] However, existing modification schemes mainly focus on the modification of mechanical structures, and are significantly lacking in terms of the dynamic switching logic, collaborative control strategies, and intelligent decision-making based on real-time geological perception under complex working conditions for the two muck removal modes. Operators often rely on experience to judge, and improper switching timing may lead to serious accidents such as screw conveyor blockage, belt slippage, uncontrolled soil chamber pressure, or even machine flooding, making it impossible to achieve true "steady tunneling".

[0005] Open-face or single-shield TBMs rely on struts to firmly support the tunnel walls during excavation, providing enormous propulsive reaction force and torque. Stable strut support is a prerequisite for safe and efficient TBM excavation. However, when traversing adverse geological sections such as fractured zones, weak surrounding rock, uneven weathering, or areas with large cavities, strut support often faces challenges: Insufficient bearing capacity of the support surface, under-pressure: When the struts support weak or fractured rock surfaces, they cannot provide sufficient friction, causing the struts to slip or sink, preventing the TBM from obtaining the required propulsive force, and in severe cases, even leading to overall machine instability. Localized damage to the surrounding rock: The huge concentrated load of the struts may crush localized weak rock masses, causing support failure and exacerbating the loosening and damage of the tunnel walls, affecting the quality of tunnel completion.

[0006] Currently, the mainstream methods used in the industry to address these issues have significant limitations: Passive reactive handling: Current technology only allows operators to intervene after the support shoe has already slipped, sunken, or experienced abnormal pressure. Common solutions include repeatedly raising and lowering the support shoe to find a better support point, inserting steel plates or timber under the support shoe plates, or temporarily grouting the surrounding rock in front of the support shoe. These methods are all post-hoc remedies, time-consuming and labor-intensive, severely disrupting normal tunneling cycles, and the grouting requires time to solidify, making it extremely inefficient. Lack of proactive detection capabilities: Existing support shoes can only monitor their own cylinder pressure and displacement, unable to predict the geological conditions and bearing capacity of the upcoming support position (i.e., the tunnel wall in front) before support action occurs. Operators are left unaware of the geological conditions at the support point, leading to blind support and high risk.

[0007] Therefore, there is an urgent need for an innovative technical solution to detect, pre-support, and adaptively adjust the geological conditions of the TBM support site before the main support shoe arrives at the support position, so as to fundamentally improve the TBM's ability to pass through complex geological conditions and the continuity of tunneling. Summary of the Invention

[0008] In view of the above technical problems, this disclosure provides a dual-mode slag removal switching device and method for identifying TBMs tunneling under under-pressure mode. This solves the problem that in the prior art, the support shoes of traditional TBMs only passively provide feedback on the effectiveness of the support after the main support shoe actually provides support. The sensing time is delayed. If slippage or subsidence occurs, it means that the geological conditions no longer meet the requirements and the equipment is in a risky or faulty state. Only post-event remedial measures can be adopted. Furthermore, traditional adjustment measures are lacking, resulting in low construction efficiency.

[0009] According to one aspect of this disclosure, a dual-mode slag removal switching device for TBMs operating under under-pressure conditions is provided. The system includes a multi-source working condition sensing module integrated and installed on the TBM main unit and its supporting equipment for real-time acquisition of tunneling status data; the multi-source working condition sensing module is electrically connected to the decision and control center, which is electrically connected to the dual-mode collaborative execution mechanism; it also includes a sensing module and adjustment equipment for sensing and adjusting undervoltage conditions; the sensing module includes a simulated support shoe, which is installed in front of the TBM main support shoe for real-time pre-simulation of support at the next support position of the main support shoe; the adjustment equipment is connected to the simulated support shoe and is used to locally adjust the surrounding rock in front of the simulated support shoe based on the sensing data of the simulated support shoe. The multi-source working condition sensing module includes a geological sensing unit, a soil silo status monitoring unit, a slag discharge monitoring unit, and an equipment attitude and position unit; The decision-making and control center includes industrial computers and programmable logic controllers; The dual-mode collaborative execution mechanism includes a long screw conveyor control module, a belt conveyor control module, a slag improvement linkage module, and a soil silo pressure adjustment module.

[0010] The sensing module also includes at least three rows and three columns of pressure sensing components mounted in a uniform array on the detection plate of the simulated support boot, for real-time sensing of pressure distribution and changes during the operation of the simulated support boot. The outer surface of the detection plate is also equipped with a waterproof and shock-absorbing protective layer, and the detection plate is movably mounted on the support surface of the simulated support boot via a fixing plate.

[0011] The adjustment device is movably mounted on the fixed plate. The adjustment device includes a rubber layer with a cavity, a support frame mounted outside the rubber layer, and a drilling mechanism movably mounted on the support frame, which is used for local drilling and grouting reinforcement of under-pressure or areas.

[0012] In some embodiments of this disclosure, the geological sensing unit includes a microseismic monitoring sensor, a ground-penetrating radar probe, and a drilling measurement mechanism located at the front of the cutterhead or shield, for advanced sensing of the degree of rock fragmentation and changes in water content ahead.

[0013] In some embodiments of this disclosure, the soil silo status monitoring unit includes multiple earth pressure sensors, soil temperature sensors, moisture content sensors, and a soil silo visualization camera installed on the soil silo partition.

[0014] In some embodiments of this disclosure, the slag discharge monitoring unit includes a current or torque sensor and a screw conveyor speed sensor installed on the drive motor of the screw conveyor; a weighing sensor, a misalignment sensor, and a slippage sensor installed on the belt conveyor; and a video monitoring mechanism installed at the screw conveyor discharge port and the belt conveyor receiving port.

[0015] In some embodiments of this disclosure, the device attitude and position unit includes a TBM guiding mechanism for providing real-time data on tunneling mileage, slope, and pitch angle.

[0016] In some embodiments of this disclosure, the long screw conveyor control module is used to control the start-up, stop-up, forward and reverse rotation, speed, and gate opening of the long screw conveyor; the belt conveyor control module is used to control the start-up, stop-up, and speed of the belt conveyor; the slag improvement linkage module is used to adjust the injection ratio and injection point of foam and bentonite, wherein the injection point includes the soil chamber and the screw conveyor cylinder; and the soil chamber pressure regulating module is used to control the soil chamber pressure, the injection of sealing grease, and the pressurization of the soil chamber using the foam mechanism.

[0017] In some embodiments of this disclosure, the decision and control center is pre-installed with a dual-mode slag discharge intelligent decision-making algorithm and a multi-dimensional working condition evaluation model, which are used to receive all data from the multi-source working condition perception module and at least evaluate the slag inrush risk index, pressure building capacity index, slag discharge efficiency matching degree, and equipment health index. The slag inrush risk index is calculated based on geological sensing data, the difference between the current bottom and top pressure of the soil chamber, and the screw compressor current fluctuation rate. The pressure-building capacity index is calculated based on the average pressure of the soil silo, the injection data of the slag improvement mechanism, and the gate opening of the screw conveyor. The slag discharge efficiency matching degree is the ratio of the theoretical slag discharge amount calculated at the current tunneling speed to the actual slag discharge amount of the belt conveyor calculated by the weighing sensor; The equipment health index is based on a combination of screw conveyor torque, belt conveyor load, and main drive torque data.

[0018] A method for identifying the dual-mode muck removal switching of a TBM tunneling under under-pressure mode includes the following steps: S1: Sensing Pressure: During TBM tunneling, a pressure sensing component is installed on the detection plate of the simulated support shoe to collect pressure data of the simulated support shoe in real time, analyze the pressure change curve and slope, and use the pressure value of the pressure sensing component changing in an arithmetic sequence and whether the slope of the curve is greater than 5 as the basis for judging the underpressure state. When the slope is greater than 5, it is judged as an underpressure state, and adjustment is made with the help of the adjustment component; local grouting treatment is performed on the underpressure area; after the grouting adjustment is completed, the pressure data is continuously monitored until the pressure change curve tends to stabilize. S2. Real-time monitoring and data fusion: During the TBM tunneling process, tunneling status data is continuously collected through multi-source working condition sensing modules and transmitted to the decision-making and control center in real time; S3. Operating Condition Assessment and Mode Prediction: Based on the received data, the decision-making and control center calculates the current moment's slag inrush risk index, pressure building capacity index, slag discharge efficiency matching degree, and equipment health index. S4. Generate switching decision: Based on the indices calculated in step S2, generate a slag discharge mode switching decision according to preset decision rules; the decision rules include: a. Decision-making mode dominated by belt conveyor: When the slag inrush risk index is lower than the low risk threshold and the pressure building capacity index is lower than the effective pressure building threshold, it is judged as a relatively stable formation. Maintain or switch to continuous slag discharge by belt conveyor as the main mode, and use long screw conveyor as an auxiliary intermittent start to clean the bottom slag. b. Decision-making mode dominated by long screw conveyor: When the slag inrush risk index is higher than the high risk threshold, or the pressure building capacity index is higher than the effective pressure building threshold, or the slag discharge efficiency matching degree shows that the belt conveyor is overloaded, it is determined that pressure control slag discharge state should be entered to stabilize the working face, and the slag discharge should be switched to long screw conveyor as the main mode. The soil chamber pressure is precisely controlled by adjusting the screw conveyor speed and the gate, and the belt conveyor is responsible for transporting the slag discharged by the screw conveyor. c. Decision to use a mixed transition mode: When the index is in the middle threshold range, or when the working conditions are detected to be changing rapidly, the mixed transition mode of the screw conveyor and the belt conveyor working in proportion is started. The screw conveyor runs at a lower speed and undertakes part of the slag discharge and pressure regulation functions. The belt conveyor runs synchronously and the output of the two is dynamically adjusted to achieve a smooth transition of the mode. S5. Safety Interlock and Collaborative Execution: Before issuing the mode switching command based on the decision of S4, check the safety interlock conditions, including the target equipment readiness status, the position of relevant valve groups, and the pressure of the earth chamber. After confirming that the safety interlock conditions are met, send the step-by-step execution command to the dual-mode collaborative execution mechanism to complete the pump and valve switching, equipment start-up and shutdown, parameter adjustment actions, and monitor the switching process in real time. S6. Dynamic Optimization and Learning: Records the complete data chain, decision basis, and actual effects before and after each mode switch, including changes in tunneling speed, pressure stability, and equipment load. Optimizes internal evaluation model thresholds and decision rules through machine learning algorithms.

[0019] The beneficial effects of this invention are as follows: 1. Intelligent decision-making to reduce risks: By integrating multi-source information and model calculations, it can replace manual experience-based judgment, predict risks such as slag inrush and pressure loss earlier and more accurately, and initiate response modes in advance (such as switching to long screw press mode to build pressure), which greatly improves the safety of downhill tunneling in adverse geological conditions such as tuff interlayers, fractured zones, and water-rich areas.

[0020] 2. Smooth and coordinated switching to ensure continuous tunneling: The proposed "hybrid transition mode" and strict interlocking control process avoid the drastic impact on the tunneling rhythm when switching modes, reduce downtime caused by switching, and achieve true "steady tunneling".

[0021] 3. Adaptive and self-learning: The system has the ability to accumulate data and learn, and can self-optimize according to the geological characteristics of specific projects, so that the control strategy becomes more and more in line with the actual working conditions and improves the overall tunneling efficiency.

[0022] 4. Fully leverage the efficiency of the modified equipment: This invention is a deep empowerment and intelligent upgrade of the TBM mechanical modification scheme described in the background information, so that the newly added long screw conveyor, earth pressure sensor, and slag improvement system no longer work in isolation, but are integrated into an intelligent closed loop to maximize their effectiveness.

[0023] By constructing an advanced detection and proactive adjustment system, this invention changes the traditional model of TBMs passively dealing with support shoe problems in adverse geological conditions, achieving a revolutionary leap from post-construction remediation to pre-construction treatment. This significantly improves the TBM's maneuverability and tunneling efficiency in complex geological conditions. Within the tunneling cycle, this invention utilizes simulated support shoes to identify and address under-pressure positions in advance, overlapping the treatment time with the tunneling time. This drastically reduces unplanned downtime caused by support shoe problems, effectively improving equipment utilization and progress indicators. Simultaneously, it clears obstacles for the main support shoe in advance, ensuring it receives stable and reliable support reaction force each time, fundamentally avoiding tunneling interruptions caused by repeated slippage and attitude adjustments, achieving truly continuous and smooth advancement.

[0024] This invention significantly enhances the safety and risk control capabilities of TBM construction. Before the main support shoe bears load, it accurately determines the load-bearing capacity distribution and weak points of the support surface, providing crucial decision-making basis for main control. This includes adjusting support positions, reducing thrust, and initiating support in advance, thereby avoiding major safety risks such as sudden slippage and overall machine instability caused by blind support. Furthermore, by using drilling mechanisms to instantly reinforce locally weak areas, it prevents further crushing and loosening of the surrounding rock under the enormous load of the main support shoe, protecting the integrity of the tunnel walls, reducing the risk of collapse, and improving long-term construction safety.

[0025] Improving construction standards and the scientific basis of decision-making. The pressure distribution cloud map generated by array-type pressure sensing provides engineers with an intuitive and quantitative assessment report of surrounding rock quality, upgrading traditional experience-based judgment to data-driven decision-making. This reduces absolute reliance on operator experience and lowers the probability of human error, representing a key step in the evolution of TBMs towards self-adaptation.

[0026] This invention generates significant economic benefits. It directly reduces downtime, saves substantial equipment and labor costs, and avoids major accidents, saving enormous handling costs. Simultaneously, by ensuring on-time or even early completion of the project, it brings significant social and overall project economic benefits. Attached Figure Description

[0027] Figure 1 A schematic diagram of the adjustment equipment structure for the dual-mode slag removal switching device of a TBM tunneling under under-pressure mode; Figure 2 A schematic diagram of another perspective of the adjustment equipment for the dual-mode slag removal switching device of a TBM tunneling under under-pressure mode; Figure 3 A schematic diagram of the adjustment equipment of the dual-mode slag removal switching device of the TBM tunneling under under-pressure mode from another perspective. Figure 4 A schematic diagram of the simulated support shoe structure for a TBM dual-mode slag removal switching device during under-pressure tunneling; The components shown in the diagram are as follows: 1. Simulation support shoe; 2. Adjustment device; 3. Detection plate; 4. Waterproof and shock-absorbing protective layer; 5. Fixing plate; 6. Rubber layer; 7. Support frame; 8. Drilling mechanism; 9. Pressure sensing component. Detailed Implementation

[0028] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example 1

[0029] This example discloses a dual-mode slag removal switching device for TBMs operating under under-pressure conditions. (See also...) Figures 1 to 4 , It includes a multi-source working condition sensing module integrated and installed on the TBM main unit and its supporting equipment, used to collect tunneling status data in real time; the multi-source working condition sensing module is electrically connected to the decision and control center, and the decision and control center is electrically connected to the dual-mode collaborative execution mechanism, and also includes a sensing module and adjustment equipment for sensing and adjusting undervoltage conditions; the sensing module includes a simulated support shoe 1, which is installed in front of the TBM main support shoe, used to simulate support for the next support position of the main support shoe in real time; the adjustment equipment 2 is connected to the simulated support shoe 1, used to locally adjust the surrounding rock in front of the simulated support shoe 1 based on the sensing data of the simulated support shoe 1; The multi-source working condition sensing module includes a geological sensing unit, a soil silo status monitoring unit, a slag discharge monitoring unit, and an equipment attitude and position unit; The decision-making and control center includes industrial computers and programmable logic controllers; The dual-mode collaborative actuator includes a long screw conveyor control module, a belt conveyor control module, a slag improvement linkage module, and a soil silo pressure regulation module.

[0030] The sensing module also includes at least three rows and three columns of pressure sensing components 9 installed in a uniform array on the detection plate 3 of the simulated support boot, for real-time sensing of pressure distribution and changes during the operation of the simulated support boot. A waterproof and shock-absorbing protective layer 4 is also installed on the outer surface of the detection plate. The detection plate 3 is movably installed on the support surface of the simulated support boot via a fixing plate 5.

[0031] The adjustment device 2 is movably mounted on the fixed plate 5. The adjustment device includes a rubber layer 6 with a cavity, a support frame 7 mounted outside the rubber layer 6, and a drilling mechanism 8 movably mounted on the support frame 7. It is used for local drilling and grouting reinforcement of under-pressure or areas.

[0032] The geological sensing unit includes microseismic monitoring sensors, ground-penetrating radar probes, and drilling measurement mechanisms located at the front of the cutterhead or shield, used to detect changes in the degree of rock fragmentation and water content ahead of the cutterhead.

[0033] The soil silo condition monitoring unit includes multiple earth pressure sensors, soil temperature sensors, moisture content sensors, and a soil silo visualization camera installed on the soil silo partition.

[0034] The slag discharge monitoring unit includes a current or torque sensor and a screw speed sensor installed on the drive motor of the screw conveyor; a weighing sensor, a belt misalignment sensor, and a slippage sensor installed on the belt conveyor; and a video monitoring mechanism installed at the screw conveyor discharge port and the belt conveyor receiving port.

[0035] The equipment attitude and position unit includes a TBM guidance mechanism, which provides real-time data on tunneling mileage, slope, and pitch angle.

[0036] The long screw conveyor control module controls the start / stop, forward / reverse rotation, speed, and gate opening of the long screw conveyor; the belt conveyor control module controls the start / stop and speed of the belt conveyor; the slag improvement linkage module adjusts the injection ratio and injection points of foam and bentonite, including the soil silo and the screw conveyor cylinder; the soil silo pressure regulation module controls the soil silo pressure, the injection of sealing grease, and the pressurization of the soil silo using the foam mechanism. The decision and control center is pre-installed with a dual-mode intelligent decision-making algorithm for slag discharge and a multi-dimensional working condition evaluation model. It is used to receive all data from the multi-source working condition perception module and evaluate at least the slag inrush risk index, pressure building capacity index, slag discharge efficiency matching degree, and equipment health index. The slag inrush risk index is calculated based on geological perception data, the difference between the current bottom and top pressure of the soil chamber, and the screw compressor current fluctuation rate. The pressure-building capacity index is calculated based on the average pressure of the soil silo, the injection data of the slag improvement mechanism, and the gate opening of the screw conveyor. The slag discharge efficiency matching degree is the ratio of the theoretical slag discharge amount calculated at the current tunneling speed to the actual slag discharge amount of the belt conveyor calculated by the weighing sensor; The equipment health index is based on a combination of screw conveyor torque, belt conveyor load, and main drive torque data.

[0037] A method for identifying the dual-mode muck removal switching of a TBM tunneling under under-pressure mode includes the following steps: S1: Sensing Pressure: During TBM tunneling, a pressure sensing component is installed on the detection plate of the simulated support shoe to collect pressure data of the simulated support shoe in real time, analyze the pressure change curve and slope, and use the pressure value of the pressure sensing component changing in an arithmetic sequence and whether the slope of the curve is greater than 5 as the basis for judging the underpressure state. When the slope is greater than 5, it is judged as an underpressure state, and adjustment is made with the help of the adjustment component; local grouting treatment is performed on the underpressure area; after the grouting adjustment is completed, the pressure data is continuously monitored until the pressure change curve tends to stabilize. S2. Real-time monitoring and data fusion: During the TBM tunneling process, tunneling status data is continuously collected through multi-source working condition sensing modules and transmitted to the decision-making and control center in real time; S3. Operating Condition Assessment and Mode Prediction: Based on the received data, the decision-making and control center calculates the current moment's slag inrush risk index, pressure building capacity index, slag discharge efficiency matching degree, and equipment health index. S4. Generate switching decision: Based on the indices calculated in step S2, generate a slag discharge mode switching decision according to preset decision rules; the decision rules include: a. Decision-making mode dominated by belt conveyor: When the slag inrush risk index is lower than the low risk threshold and the pressure building capacity index is lower than the effective pressure building threshold, it is judged as a relatively stable formation. Maintain or switch to continuous slag discharge by belt conveyor as the main mode, and use long screw conveyor as an auxiliary intermittent start to clean the bottom slag. b. Decision-making mode dominated by long screw conveyor: When the slag inrush risk index is higher than the high risk threshold, or the pressure building capacity index is higher than the effective pressure building threshold, or the slag discharge efficiency matching degree shows that the belt conveyor is overloaded, it is determined that pressure control slag discharge state should be entered to stabilize the working face, and the slag discharge should be switched to long screw conveyor as the main mode. The soil chamber pressure is precisely controlled by adjusting the screw conveyor speed and the gate, and the belt conveyor is responsible for transporting the slag discharged by the screw conveyor. c. Decision to use a mixed transition mode: When the index is in the middle threshold range, or when the working conditions are detected to be changing rapidly, the mixed transition mode of the screw conveyor and the belt conveyor working in proportion is started. The screw conveyor runs at a lower speed and undertakes part of the slag discharge and pressure regulation functions. The belt conveyor runs synchronously and the output of the two is dynamically adjusted to achieve a smooth transition of the mode. S5. Safety Interlock and Collaborative Execution: Before issuing the mode switching command based on the decision of S4, check the safety interlock conditions, including the target equipment readiness status, the position of relevant valve groups, and the pressure of the earth chamber. After confirming that the safety interlock conditions are met, send the step-by-step execution command to the dual-mode collaborative execution mechanism to complete the pump and valve switching, equipment start-up and shutdown, parameter adjustment actions, and monitor the switching process in real time. S6. Dynamic Optimization and Learning: Records the complete data chain, decision basis, and actual effects before and after each mode switch, including changes in tunneling speed, pressure stability, and equipment load. Optimizes internal evaluation model thresholds and decision rules through machine learning algorithms.

[0038] Preparatory work before the installation of the long screw press: To ensure efficient and smooth installation and commissioning of the long screw press after its arrival on site, this specific on-site preparation plan has been formulated. This section focuses on process-related preparatory work, aiming to create all necessary conditions for the smooth installation of the equipment.

[0039] Modification of the main belt conveyor, (1) Preparatory work before the installation of the long screw conveyor The project used self-made tooling welded and fixed to the longitudinal beams on both sides of the assembly machine's traveling beam as lifting points for the main unit's belt conveyor. In addition, two 5-ton hand-operated hoists were used as power sources to raise the overall height of the main unit's belt conveyor by at least 1 meter, creating the prerequisites for subsequent modification work on the main unit's belt conveyor and installation of the long screw conveyor.

[0040] (1) Specific implementation process: ① Material preparation: Cut H-beams to the relevant specifications and dimensions according to the design drawings, and transport them into the tunnel for assembly. ② After reaching the preset pause mileage for tunneling, transport the materials required for the tooling to the equipment bridge area and weld and assemble them at the relevant parts of the assembly machine's traveling beam. ③ Disconnect the main conveyor belt. ④ Use lifting tools to lift the drive end of the main conveyor belt to a height of 1 meter. ⑤ After the main conveyor belt is lifted into place, use I-beams or square timber to support the key nodes of the belt support. ⑥ After the long screw conveyor is installed, modify the main conveyor belt structure according to the modification drawings provided by China Railway Equipment. ⑦ Vulcanize the belt to restore the slag discharge capacity.

[0041] (2) Specific modifications: 1) Modify the front, middle and rear supports of the main conveyor belt; 2) Shorten the head by 500mm and modify the head hopper of the conveyor belt; 3) Adjust the conveyor belt angle by 4° to 5° and reposition and adjust the entire conveyor belt tunnel.

[0042] After the belt is modified, (1) Preparatory work before the installation of the long screw conveyor. After disconnecting the rear-mounted belt at the crossbeam of the second telescopic section on the driven end, sequentially remove the driven roller, buffer bed, and all upper and lower belt supports and rollers before the second telescopic section on the driven end of the rear-mounted belt. Collect the return belt and secure it to the ventilation duct support at the end of trailer #1 using two 5t hand-operated hoists. This creates the prerequisites for subsequent modifications to the rear-mounted belt and the installation of the long screw conveyor. See the diagram below for specific securing details.

[0043] (1) Specific implementation process: ① Disconnect the belt (pay attention to selecting the belt break point, and try to cut off the part where the subsequent matching belt has a high degree of damage). ② After disconnecting at the crossbeam of the second expansion joint at the driven end, remove the driven roller of the subsequent matching belt, the buffer bed, and all the upper and lower belt supports and rollers in front of the second expansion joint at the driven end in sequence. ③ Use a hand hoist or other auxiliary tools to collect the disconnected belt and fix it at the ventilation duct support at the end of trailer #1. ④ After the long screw conveyor is installed, modify the belt structure according to the modification drawings provided by China Railway Equipment. ⑤ Vulcanize the belt to restore the slag discharge capacity.

[0044] (2) Specific modifications: 1) Newly manufactured rear frame and buffer roller assembly of the rear-mounted conveyor belt; 2) Newly manufactured support for the conveyor belt at the connecting bridge and No. 1 trailer; 3) Newly manufactured water collection tank at the tail of the rear-mounted conveyor belt; 4) Newly manufactured frame of the arc section of the rear-mounted conveyor belt; 5) Adjusted the angle of the front support of the conveyor belt from 5° to 7° and repositioned it inside the tunnel, mainly for the rear of the assembly beam, equipment bridge, and the area of ​​No. 1 trolley.

[0045] Dismantling of the short screw conveyor: (1) Lifting point arrangement: Lifting points are set at the top and sides of the cross beam. The specific arrangement is the same as the lifting point arrangement for the installation of the short screw conveyor. (2) Step-by-step process for the overall dismantling of the short screw conveyor. Step 1: Disconnect pipelines and connections. Hydraulic lines: ① Confirm that the system has been depressurized. ② Disconnect the hydraulic hoses from the screw motor, gate valve, and telescopic cylinder. ③ Immediately seal all disconnected ports (including the screw side and valve assembly side) with clean plugs or blind flanges to prevent contamination.

[0046] Electrical wiring: ① Disconnect the wiring of the screw conveyor motor, speed sensor, and limit switch. ② Properly wrap the wire ends with insulating tape and mark them. Lubrication and grease injection lines: ① Close the branch valves and disassemble them, then seal the pipe openings.

[0047] Water injection pipeline: ① Close the valve and disassemble it to drain the remaining water.

[0048] Step 2: Set up and fix the lifting points. Install the lifting points: ① On the cross beam structure inside the shield body, set at least 2 main lifting points (one at the front and one in the middle) for the hand-operated hoist.

[0049] Pre-hanging the hoist: ① Hang the hand chain hoist, with the wire rope sling around the screw conveyor housing (avoid pressing on the threads or thin walls), apply slight force, but do not lift it yet.

[0050] Step 3: Disassemble the connecting flange and disassemble the tail bracket: ① First, disassemble the bracket that fixes the tail of the screw conveyor to the equipment bridge or shield body and then further fix the connection.

[0051] Disassembling the front flange: ① Using a hydraulic wrench or extension rod, loosen the bolts connecting the main flange to the shield front shield (earth chamber wall) in a diagonal sequence. ② Leave the last 2-3 bolts loosened, but not removed. ③ Place jacks or support blocks under the screw conveyor to support its weight.

[0052] Step 4: Remove the screw conveyor and finally separate: ① Remove all flange bolts and check to confirm that the screw conveyor and the shield are no longer connected.

[0053] Synchronous operation: ① The commanding personnel simultaneously operate the hand-operated hoist to slowly and steadily pull the screw conveyor backward.

[0054] Process monitoring: ① Monitor the gap between the screw conveyor and surrounding components throughout the process, and strictly prohibit collisions (especially with the inner wall of the shield and the segment assembly machine).

[0055] Tail support: ① As the screw conveyor moves out, its tail gradually sinks. It is necessary to use sleepers or support blocks to support it in time to prevent "head bumping".

[0056] (3) Disassembly and transportation: The short screw conveyor is dismantled and laid flat. Auxiliary equipment such as guide chains and pre-set lifting points are used to transfer it to the equipment bridge area. After disassembly, it is transported out of the tunnel using a TBM segment crane and segment transport vehicle. It is placed in a designated area outside the tunnel and will be assembled after the long screw conveyor components arrive.

[0057] 1) Disassembly: ① Drive end: When disassembling the drive end of the short screw conveyor, safety locking must be performed first, the power source must be completely cut off and a warning sign must be hung, and the connection between the drive unit and the gearbox or drive shaft must be disconnected. During disassembly, special pullers and hydraulic tools must be used in accordance with regulations, and special care must be taken to protect the main shaft connection end face and the keyway mating parts. Rough knocking is strictly prohibited. Before disassembly, key positions such as the base positioning block and coupling alignment mark must be clearly marked and the original installation clearance must be recorded. All high-strength connecting bolts that have been removed should be immediately counted and classified and stored. Precision mating surfaces must be coated with anti-rust oil and covered with protective covers to ensure that the core drive components are intact during the disassembly process, laying the foundation for subsequent maintenance or installation work.

[0058] Before disassembling the drive end, two 5-ton hand chain hoists must be used to secure it to prevent it from falling and causing injury to personnel or equipment when the key shaft of the drive end breaks.

[0059] ② Screw Section: Before dismantling the short screw compressor screw section, all residual material inside and outside the screw must be thoroughly cleaned to ensure no material buildup affects operational safety. During dismantling, the connecting bolts between the screw sections must be loosened and removed sequentially in a diagonal order. Use a special lifting screw to apply force evenly to separate the flange faces; it is strictly forbidden to use a pry bar to forcibly wed in. Before dismantling, clear matching marks must be made on the mating surfaces of adjacent screw section flanges, and the condition of the seals must be recorded. All removed high-strength bolts, nuts, and gaskets should be immediately stored in sets and clearly labeled. The precision sealing surfaces of the flanges must be fitted with protective plates to ensure they are not bumped or corroded during hoisting and storage, creating favorable conditions for subsequent maintenance or system reconfiguration.

[0060] ③ Screw Shaft: During the dismantling of the screw shaft of the short screw press, a special lifting tool must be used to maintain the shaft's balance. A hydraulic jack or a special puller should be used to apply force smoothly along the axial direction. The use of oblique pulling or pry bars is strictly prohibited. Before dismantling, matching marks must be made on key locations such as the bearing housing, sealing components, and connecting flanges, and the original installation clearances and positioning dimensions must be recorded. All dismantled bearings, sealing rings, and connecting parts should be immediately classified, stored, and clearly labeled. The threaded section and precision surfaces of the screw shaft must be coated with anti-rust grease and fitted with a special protective sleeve to ensure that core components are not deformed or damaged during dismantling.

[0061] 2) Transportation. After the short screw conveyor system is dismantled and removed on-site, an orderly transfer procedure inside the tunnel and storage outside the tunnel must be immediately implemented. First, the dismantled core components, such as the drive end, cylinder sections, and screw shaft, are safely lifted and transported using a segment crane. During the lifting process, lifting operation specifications must be strictly followed. It must be confirmed that the lifting points are secure, the components are balanced, and the working radius is cleared. Finally, the components are safely transferred to a designated area outside the tunnel for temporary numbering and storage, and anti-collision measures are implemented. After all components of the long screw conveyor have been transported to the site and the foundation is in place, they are then assembled on-site with the main body of the long screw conveyor according to the assembly process instructions.

[0062] Dismantling of the shield platform, modification of the assembly machine's traveling beam, dismantling of the segment crane's traveling beam, and modification of the cutter beam. (1) Dismantling of the Zhongdun Platform: Before dismantling the Zhongdun platform, the gear oil plate heat exchanger and the cutterhead slag suction vacuum pump must be removed and moved to both sides of the platform. When moving the above equipment, care must be taken to protect the pipelines and joints. If it is necessary to remove them, plugs must be installed or other protective measures must be taken to prevent oil leakage or system contamination. After the Zhongdun platform equipment is removed, disconnect the bottom plate connecting bolts and use a 5-ton hand chain hoist to move the platform or raise it 1 meter as a whole.

[0063] (2) Modification of the traveling beam of the assembly machine: Before the longitudinal column support is installed, the upper and lower pipelines of the traveling beam of the assembly machine need to be sorted out or removed, which will create favorable conditions for the lifting of the screw conveyor.

[0064] After the longitudinal column supports are installed, the transverse support beam at the tail end of the jack can be removed. During removal, care must be taken to protect the bolt connection flanges and collect the corresponding bolts to create favorable conditions for the installation of the long screw conveyor. After the screw conveyor is installed, the transverse support beam must be restored before removing the longitudinal column supports.

[0065] (3) Remove the segment crane traveling beam. Disconnect the segment crane traveling beam from the support beam connection position and remove it from the side facing the tunneling direction from the disconnected position. Move the beam back to the disconnected position after limiting its position. This creates conditions for the installation of the long screw conveyor.

[0066] (4) Modify the cutter beam: remove all beam frame structures (including the arc beam) on the rear side of the cutter crane beam. After removing the arc beam, connect the rear straight beam to the crane beam inside the shield.

[0067] Auxiliary tooling processing and manufacturing (1) The support columns for the traveling beam of the assembly machine are fabricated using double-section 200H steel as the main material to make a portal frame structure. Due to the actual slope of the tunnel, a two-way diagonal bracing reinforcement structure is required to prevent overturning. The specific setup is shown in the figure below.

[0068] (2) Fabrication of the main unit belt lifting fixture: A triangular frame structure is made using double-section 200H steel as the main material, and double-section 325 seamless steel pipes are used as the top lifting beam to lift the drive end of the main unit belt. See the figure below for the specific layout.

[0069] Auxiliary Systems: Lubrication System: Position the main lubrication station, lay the main pipeline to the equipment interface, and purge and clean the pipeline. Cooling System: Lay the cooling water pipeline, pre-install flanges or quick couplings at the equipment interface, and conduct a pressure test on the pipeline to ensure no leakage. Interface Treatment: Clean, deburr, and rust-proof all mating surfaces between the equipment and the foundation, and connection interfaces between the equipment and external systems (such as flange faces and threaded holes), ensuring good contact.

[0070] Although some preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0071] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this application and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A dual-mode slag removal switching device for TBMs operating under under-pressure conditions, characterized in that: The system includes a multi-source working condition sensing module integrated and installed on the TBM main unit and its supporting equipment for real-time acquisition of tunneling status data; the multi-source working condition sensing module is electrically connected to the decision and control center, which is electrically connected to the dual-mode collaborative execution mechanism; it also includes a sensing module and adjustment equipment for sensing and adjusting undervoltage conditions; the sensing module includes a simulated support shoe, which is installed in front of the TBM main support shoe for real-time pre-simulation of support at the next support position of the main support shoe; the adjustment equipment is connected to the simulated support shoe and is used to locally adjust the surrounding rock in front of the simulated support shoe based on the sensing data of the simulated support shoe. The multi-source working condition sensing module includes a geological sensing unit, a soil silo status monitoring unit, a slag discharge monitoring unit, and an equipment attitude and position unit; The decision-making and control center includes industrial computers and programmable logic controllers; The dual-mode collaborative execution mechanism includes a long screw conveyor control module, a belt conveyor control module, a slag improvement linkage module, and a soil silo pressure adjustment module.

2. The dual-mode slag removal switching device for TBM tunneling under under-pressure mode as described in claim 1, characterized in that: The sensing module also includes at least three rows and three columns of pressure sensing components mounted in a uniform array on the detection plate of the simulated support boot, for real-time sensing of pressure distribution and changes during the operation of the simulated support boot. The outer surface of the detection plate is also equipped with a waterproof and shock-absorbing protective layer, and the detection plate is movably mounted on the support surface of the simulated support boot via a fixing plate.

3. The dual-mode slag removal switching device for TBM tunneling under under-pressure mode as described in claim 2, characterized in that: The adjustment device is movably mounted on the fixed plate. The adjustment device includes a rubber layer with a cavity, a support frame mounted outside the rubber layer, and a drilling mechanism movably mounted on the support frame, which is used for local drilling and grouting reinforcement of under-pressure or areas.

4. The dual-mode slag removal switching device for TBM tunneling under under-pressure mode as described in claim 1, characterized in that: The geological sensing unit includes a micro-vibration monitoring sensor, a ground-penetrating radar probe, and a measurement-while-drilling mechanism located at the front of the cutterhead or shield body, used to sense the degree of rock fragmentation and changes in water content ahead. The soil chamber status monitoring unit includes multiple earth pressure sensors, slag temperature sensors, moisture content sensors, and a soil chamber visualization camera installed on the soil chamber partition. The slag discharge monitoring unit includes a current or torque sensor and a screw conveyor speed sensor installed on the screw conveyor drive motor; a weighing sensor, a deviation sensor, and a slippage sensor installed on the belt conveyor; and a video monitoring mechanism installed at the screw conveyor discharge port and the belt conveyor receiving port.

5. The dual-mode slag removal switching device for TBM tunneling under under-pressure mode as described in claim 1, characterized in that: The equipment attitude and position unit includes a TBM guiding mechanism, which is used to provide real-time data on tunneling mileage, slope, and pitch angle.

6. The dual-mode slag removal switching device for TBM tunneling under under-pressure mode as described in claim 1, characterized in that: The long screw conveyor control module is used to control the start / stop, forward / reverse rotation, speed, and gate opening of the long screw conveyor; the belt conveyor control module is used to control the start / stop and speed of the belt conveyor; the slag improvement linkage module is used to adjust the injection ratio and injection point of foam and bentonite, the injection point including the soil chamber and the screw conveyor cylinder; the soil chamber pressure regulation module is used to control the soil chamber pressure, the injection of sealing grease, and the pressurization of the soil chamber using the foam mechanism.

7. The dual-mode slag removal switching device for TBM tunneling under under-pressure mode as described in claim 1, characterized in that: The decision and control center is pre-installed with a dual-mode slag discharge decision algorithm and a multi-dimensional working condition evaluation model, which are used to receive all data from the multi-source working condition perception module and evaluate at least the slag inrush risk index, pressure building capacity index, slag discharge efficiency matching degree, and equipment health index. The slag inrush risk index is calculated based on geological sensing data, the difference between the current bottom and top pressure of the soil chamber, and the screw compressor current fluctuation rate. The pressure-building capacity index is calculated based on the average pressure of the soil silo, the injection data of the slag improvement mechanism, and the gate opening of the screw conveyor. The slag discharge efficiency matching degree is the ratio of the theoretical slag discharge amount calculated at the current tunneling speed to the actual slag discharge amount of the belt conveyor calculated by the weighing sensor; The equipment health index is based on a combination of screw conveyor torque, belt conveyor load, and main drive torque data.

8. A method for identifying dual-mode muck discharge switching of a TBM tunneling under under-pressure mode, applicable to the dual-mode muck discharge switching device for a TBM tunneling under under-pressure mode as described in claim 1, characterized in that, Includes the following steps: S1: Sensing Pressure: During TBM tunneling, a pressure sensing component is installed on the detection plate of the simulated support shoe to collect pressure data of the simulated support shoe in real time, analyze the pressure change curve and slope, and use the pressure value of the pressure sensing component changing in an arithmetic sequence and whether the slope of the curve is greater than 5 as the basis for judging the underpressure state. When the slope is greater than 5, it is judged as an underpressure state, and adjustment is made with the help of the adjustment component; local grouting treatment is performed on the underpressure area; after the grouting adjustment is completed, the pressure data is continuously monitored until the pressure change curve tends to stabilize. S2. Real-time monitoring and data fusion: During the TBM tunneling process, tunneling status data is continuously collected through multi-source working condition sensing modules and transmitted to the decision-making and control center in real time; S3. Operating Condition Assessment and Mode Prediction: Based on the received data, the decision-making and control center calculates the current moment's slag inrush risk index, pressure building capacity index, slag discharge efficiency matching degree, and equipment health index. S4. Generate switching decision: Based on the indices calculated in step S2, generate a slag discharge mode switching decision according to preset decision rules; the decision rules include: a. Decision-making mode dominated by belt conveyor: When the slag inrush risk index is lower than the low risk threshold and the pressure building capacity index is lower than the effective pressure building threshold, it is judged as a relatively stable formation. Maintain or switch to continuous slag discharge by belt conveyor as the main mode, and use long screw conveyor as an auxiliary intermittent start to clean the bottom slag. b. Decision-making mode dominated by long screw conveyor: When the slag inrush risk index is higher than the high risk threshold, or the pressure building capacity index is higher than the effective pressure building threshold, or the slag discharge efficiency matching degree shows that the belt conveyor is overloaded, it is determined that pressure control slag discharge state should be entered to stabilize the working face, and the slag discharge should be switched to long screw conveyor as the main mode. The soil chamber pressure is precisely controlled by adjusting the screw conveyor speed and the gate, and the belt conveyor is responsible for transporting the slag discharged by the screw conveyor. c. Decision to use a mixed transition mode: When the index is in the middle threshold range, or when the working conditions are detected to be changing rapidly, the mixed transition mode of the screw conveyor and the belt conveyor working in proportion is started. The screw conveyor runs at a lower speed and undertakes part of the slag discharge and pressure regulation functions. The belt conveyor runs synchronously and the output of the two is dynamically adjusted to achieve a smooth transition of the mode. S5. Safety Interlock and Collaborative Execution: Before issuing the mode switching command based on the decision of S4, check the safety interlock conditions, including the target equipment readiness status, the position of relevant valve groups, and the pressure of the earth chamber. After confirming that the safety interlock conditions are met, send the step-by-step execution command to the dual-mode collaborative execution mechanism to complete the pump and valve switching, equipment start-up and shutdown, parameter adjustment actions, and monitor the switching process in real time. S6. Dynamic Optimization and Learning: Records the complete data chain, decision basis, and actual effects before and after each mode switch, including changes in tunneling speed, pressure stability, and equipment load. Optimizes internal evaluation model thresholds and decision rules through machine learning algorithms.

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