Auxiliary rock breaking device with cutterhead

Abstract

The invention discloses a cutterhead-assisted rock breaking device. The cutterhead-assisted rock breaking device comprises an excitation unit and various sensors, according to the arrangement of the cutter head, independent excitation units are symmetrically installed on the two sides of each hob, a distributed excitation layout is formed, and multi-point independent controllable high-frequency vibration output is achieved. A closed-loop feedback control link is formed by various sensors, and real-time monitoring of the high-frequency vibration state is achieved. By the adoption of the technical scheme, the technical problems that when an existing TBM conducts tunneling in a complex rock stratum, the efficiency is low and a cutter is abnormally abraded due to uneven distribution of rock breaking force are solved.

Description

Technical Field

[0001] This invention belongs to the field of hard rock tunnel excavation technology, specifically relating to a cutterhead-assisted rock-breaking device. Background Technology

[0002] In the field of hard rock tunneling, auxiliary rock-breaking technology has become an important research direction to improve the rock-breaking efficiency of cutterheads in full-face tunnel boring machines (TBMs) and reduce cutter wear. Vibration-impact assisted rock-breaking is widely studied as an effective method. Existing technologies have proposed integrating vibration-impact modules onto the cutterhead of a full-face TBM to assist cutterhead rock-breaking. For example, by setting an independent vibration-impact module in the blank area of ​​the cutterhead panel, this module typically includes an impact rod and a vibrator, with its output end connected to the impact rod, enabling the application of high-frequency vibration-impact loads to the rock mass. This design aims to induce fatigue cracks in the rock mass through vibration-impact, thereby reducing the propulsion resistance during cutterhead rock-breaking and ultimately improving rock-breaking efficiency and reducing cutter wear. Furthermore, further innovative attempts combine vibration-impact with other rock-breaking technologies. For example, TBM cutterhead designs have emerged that combine microwave heating, high-pressure water jetting, and vibration-impact for auxiliary hard rock breaking. In these designs, the vibration-impact device is typically installed on the cutterhead panel between adjacent cutters to achieve a synergistic effect of multiple rock-breaking mechanisms.

[0003] Although existing vibration-assisted rock breaking technology has shown certain application potential, several technical shortcomings still need to be addressed in practical engineering applications. First, the output characteristics of existing excitation devices are relatively fixed, lacking effective real-time adjustment capabilities and making it difficult to adaptively adjust to the complex and variable rock conditions (such as rock hardness and fracture development) during tunneling. This results in unstable rock breaking efficiency in strata with significant lithological variations, failing to consistently maintain the cutterhead in optimal rock breaking condition. Second, existing technologies generally lack real-time monitoring and balanced control methods for the overall stress state of the cutterhead and the load distribution of each cutter. Due to the heterogeneity of the rock mass and the complexity of the interaction between the cutterhead and the rock wall, the actual stress on each cutter often varies significantly during tunneling, easily leading to uneven wear or abnormal damage to individual cutters due to overload. Existing systems struggle to identify and actively adjust for this uneven load phenomenon. Furthermore, some existing hydraulic vibration systems often neglect the influence of pipeline effects (i.e., transient pressure fluctuations in hydraulic pipelines) on the system output characteristics during modeling and analysis. However, under high-frequency excitation conditions, such pressure fluctuations become very significant. If these fluctuations are not considered in system design and control, they will lead to a decrease in model prediction accuracy, thereby affecting the actual control effect and the stability of the output waveform. Furthermore, although some studies have attempted to improve the output capability of excitation systems by using structures such as parallel dual valves, existing technologies have not yet provided a complete control strategy and system solution for how to deeply couple and optimize the excitation action with the real-time stress state of the cutter head, rock mass characteristic identification, and the global efficiency of the cutterhead system. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a cutterhead-assisted rock-breaking device, which solves the technical problems of low efficiency and abnormal cutter wear caused by uneven rock-breaking force distribution when existing TBMs are tunneling in complex rock formations. It can sense the rock-breaking status in real time, intelligently adjust the excitation parameters, and ensure uniform distribution of rock-breaking force, so as to meet the requirements of TBMs for efficient, low-consumption, and long-life tunneling under complex geological conditions.

[0005] To achieve the above objectives, the present invention provides the following solution: A cutterhead-assisted rock-breaking device includes: an excitation unit and multiple sensors; wherein, in the cutterhead arrangement, independent excitation units are symmetrically installed on both sides of each cutter to form a distributed excitation layout, realizing multi-point independent and controllable high-frequency vibration output; multiple sensors constitute a closed-loop feedback control link to realize real-time monitoring of the high-frequency vibration state.

[0006] Preferably, the excitation unit includes a hydraulic cylinder, an excitation block, and a spring, forming a multi-point high-frequency vibration output system.

[0007] Preferably, the multiple sensors include: an oil pressure sensor installed in the oil inlet and outlet oil lines of the hydraulic cylinder and a displacement sensor integrated inside the hydraulic cylinder; wherein, the oil pressure sensor monitors the magnitude of the output force of the excitation unit in real time; and the displacement sensor measures the amplitude of the reciprocating motion of the hydraulic cylinder piston in real time.

[0008] Preferably, during operation, the central control system outputs control commands based on real-time working conditions, drives the motor to operate at a set frequency, and drives the hollow main shaft inside the hydraulic vibrator to rotate through the coupling; during the rotation of the hollow main shaft, the hydraulic oil circuit is periodically switched, so that high-pressure oil alternately enters the left and right chambers of the hydraulic cylinder, pushing the piston to perform high-frequency reciprocating motion; the piston is rigidly connected to the excitation block, and then transmits the mechanical vibration to the roller cutter, so that the roller cutter is superimposed with axial high-frequency excitation force on the basis of continuous rolling and rock breaking.

[0009] As a preferred option, the hollow spindle adopts a multi-layer valve sleeve structure.

[0010] Preferably, the axis of the hydraulic cylinder is parallel to the axis of the hob; the exciter block and the hydraulic cylinder are connected by a ball joint; and the spring assembly is placed between the hydraulic cylinder and the exciter block.

[0011] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention, combined with multi-sensor intelligent sensing, effectively ensures that the TBM cutterhead can achieve efficient and uniform rock breaking under complex rock conditions, and significantly extend the cutterhead's service life. Simultaneously, by dynamically analyzing sensor feedback data, this invention adjusts the output frequency and amplitude of each excitation cylinder in real time, utilizing the hydraulic impact effect and resonance rock-breaking mechanism to significantly improve the system's rock-breaking efficiency and force distribution uniformity. In summary, this invention has outstanding engineering application value in achieving efficient and intelligent operation of the cutterhead-assisted rock-breaking device and provides reliable support for the technological upgrading of TBM tunneling equipment. Attached Figure Description

[0012] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments are 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 these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the cutterhead-assisted rock-breaking device according to an embodiment of the present invention; Figure 2 This is a hydraulic schematic diagram of the cutterhead-assisted rock-breaking device according to an embodiment of the present invention. Detailed Implementation

[0014] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0015] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0016] Example 1 like Figure 1 , 2 As shown, this invention provides a cutterhead-assisted rock-breaking device, comprising: a roller cutter 1, a vibrating block 2, a spring 3, a hydraulic cylinder 4, a hydraulic vibrator 5, a coupling 6, a motor 7, an overflow valve 8, a high-pressure filter 9, a hydraulic pump 10, a low-pressure filter 11, an oil cylinder 12, an oil pressure sensor 13, and a displacement sensor 14. In the cutterhead arrangement, an independent vibrating unit is symmetrically installed on both sides of each roller cutter, forming a distributed vibrating layout to achieve multi-point independent and controllable high-frequency vibration output.

[0017] During system operation, the central control system outputs control commands based on real-time operating conditions, driving motor 7 to operate at a set frequency. This, in turn, drives the hollow main shaft inside the hydraulic vibrator 5 to rotate via coupling 6. This main shaft employs a multi-layer valve sleeve structure, periodically switching the hydraulic oil circuit during rotation. This allows high-pressure oil to alternately enter the left and right chambers of hydraulic cylinder 4, pushing the piston in a high-frequency reciprocating motion. The piston is rigidly connected to the excitation block 2, which in turn transmits the mechanical vibration to the roller cutter 1. This causes the roller cutter 1 to superimpose axial high-frequency excitation force on top of continuous rolling and rock-breaking, thereby inducing localized fatigue fracture of the rock and effectively reducing the pushing resistance and cutter wear during rolling and rock-breaking.

[0018] To further enhance the system's intelligence and adaptability during rock breaking, this invention integrates multiple sensors to form a closed-loop feedback control system, enabling real-time monitoring of high-frequency vibration. These sensors include hydraulic pressure sensors installed on the inlet and outlet oil lines of hydraulic cylinder 4, and displacement sensors integrated within hydraulic cylinder 4. The hydraulic pressure sensors monitor the output force of each excitation unit in real time; by comparing hydraulic pressure data at different excitation points, the distribution of interaction forces between each cutter and the rock mass can be indirectly reflected. The displacement sensors directly measure the reciprocating amplitude of the piston in hydraulic cylinder 4, providing key parameters for real-time monitoring of the system's vibration state and resonance point identification.

[0019] The data collected by the aforementioned sensors is fused and analyzed by the central control system to dynamically assess the mechanical properties of the rock mass and the uniformity of the rock-breaking force distribution. When an abnormally high excitation force is detected at a certain point, it can be determined that the roller load is concentrated at that location, posing a risk of uneven wear or jamming. The system will automatically reduce the excitation intensity at that point and appropriately increase the excitation output in adjacent areas to achieve dynamic load balance. Simultaneously, by monitoring changes in vibration response and output amplitude, the system can automatically search for and lock the natural frequency of the rock mass, ensuring that the roller is always in a resonant rock-breaking state, thereby maximizing rock-breaking efficiency while reducing energy consumption.

[0020] Furthermore, the excitation units are arranged in a distributed, independently controllable layout. Each hob is symmetrically equipped with an excitation unit on both sides, including a hydraulic cylinder, excitation block, and spring, forming a multi-point high-frequency vibration output system. The specific installation method of the excitation units on the cutter head must fully consider the structural characteristics of the cutter head and the requirements of the working environment. The hydraulic cylinders are fixed to the reinforcing ribs of the cutter head panel via dedicated brackets, using 10.9-grade high-strength bolts to ensure connection reliability under severe vibration conditions. The excitation block is welded to the hob to ensure synchronous vibration between the excitation block and the hob.

[0021] In terms of spatial arrangement, the excitation units should be preferentially installed in the edge and front areas of the cutterhead, where the cutter rolls experience the most complex stresses and offer the greatest potential for improving rock-breaking efficiency. Specifically, the excitation units at the edge cutter rolls should adopt a full-time excitation mode, with the amplitude set to 80%-100% of the maximum value to effectively reduce propulsion resistance and prevent uneven wear; the excitation units in the front cutter roll area can adopt an intermittent excitation strategy, adaptively adjusting the excitation parameters according to the rock hardness. The hydraulic lines of all excitation units should be arranged radially along the back of the cutterhead, using a combination of high-pressure hoses and rigid pipes, with pipe clamps installed at key nodes to prevent fatigue fracture caused by vibration.

[0022] Regarding the installation details of the excitation unit, the hydraulic cylinder axis must be strictly parallel to the cutter head axis to ensure effective transmission of excitation force; a ball joint connection is used between the excitation block and the hydraulic cylinder to compensate for installation errors; a spring assembly is placed between the hydraulic cylinder and the excitation block to provide necessary preload and buffering. To reduce the impact of vibration on the cutterhead body, damping blocks are installed at each connection point. The excitation unit layout scheme, through reasonable spatial arrangement, reliable connection methods, and intelligent control strategies, achieves efficient vibration-assisted rock breaking without significantly altering the existing TBM cutterhead structure, providing effective technical support for TBM tunneling under complex geological conditions. This scheme maximizes rock breaking efficiency while also considering system reliability and ease of maintenance, demonstrating high engineering application value.

[0023] This invention provides the hardware foundation for subsequent intelligent adjustment through the combination of a vibration unit and multi-sensor intelligent sensing. The introduction of this system lays the groundwork for the following advantages: First, it provides the possibility of localized, efficient rock breaking. By equipping key cutting tools with independent vibration cylinders, energy can be precisely applied to the rock mass to be broken. Second, it provides a direct means of sensing the rock breaking state. The hydraulic pressure sensor installed on the vibration cylinder can reflect the output force at the vibration point in real time, while the displacement sensor can directly measure the vibration amplitude. These data provide crucial evidence for determining whether the system is operating at high efficiency. Third, it creates conditions for assessing load uniformity. By comparing the readings of the hydraulic pressure sensors at different vibration points, the differences in load on each cutting tool can be indirectly reflected. This difference sensing is a prerequisite for subsequent load uniform adjustment and avoiding excessive wear on individual cutting tools.

[0024] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made to the technical solutions of the present invention by those skilled in the art without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A cutterhead-assisted rock-breaking device, characterized in that, include: The device includes an excitation unit and multiple sensors. In terms of cutter head arrangement, independent excitation units are symmetrically installed on both sides of each hob, forming a distributed excitation layout to achieve multi-point independent and controllable high-frequency vibration output. Multiple sensors constitute a closed-loop feedback control loop to achieve real-time monitoring of the high-frequency vibration state.

2. The cutterhead-assisted rock-breaking device as described in claim 1, characterized in that, The excitation unit includes a hydraulic cylinder, an excitation block, and a spring, forming a multi-point high-frequency vibration output system.

3. The cutterhead-assisted rock-breaking device as described in claim 2, characterized in that, The system includes multiple sensors: an oil pressure sensor installed in the oil inlet and outlet lines of the hydraulic cylinder, and a displacement sensor integrated inside the hydraulic cylinder. The oil pressure sensor monitors the magnitude of the output force of the excitation unit in real time, while the displacement sensor measures the amplitude of the reciprocating motion of the hydraulic cylinder piston in real time.

4. The cutterhead-assisted rock-breaking device as described in claim 3, characterized in that, During operation, the central control system outputs control commands based on real-time working conditions, driving the motor to operate at a set frequency, and driving the hollow main shaft inside the hydraulic vibrator to rotate through the coupling; during the rotation of the hollow main shaft, the hydraulic oil circuit is periodically switched, so that high-pressure oil alternately enters the left and right chambers of the hydraulic cylinder, pushing the piston to perform high-frequency reciprocating motion; the piston is rigidly connected to the excitation block, thereby transmitting mechanical vibration to the roller cutter, so that the roller cutter is superimposed with axial high-frequency excitation force on the basis of continuous rolling and rock breaking.

5. The cutterhead-assisted rock-breaking device as described in claim 4, characterized in that, The hollow spindle adopts a multi-layer valve sleeve structure.

6. The cutterhead-assisted rock-breaking device as described in claim 5, characterized in that, The axis of the hydraulic cylinder is parallel to the axis of the hob; the exciter block and the hydraulic cylinder are connected by a ball joint; the spring assembly is placed between the hydraulic cylinder and the exciter block.

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