A rapid in-situ repair device for continuous belt penetration damage in TBMs

Abstract

This invention relates to the field of belt breakage repair technology, specifically disclosing a rapid in-situ repair device for through-stretch damage on continuous TBM belts. The device includes a cleaning and grinding mechanism, a cutting and peeling mechanism, a glue spraying mechanism, a hot-repair granule filling mechanism, and an ultrasonic rolling welding machine. The cutting and peeling mechanism cuts the surface rubber of the belt; the glue spraying mechanism sprays adhesive; the hot-repair granule filling mechanism fills the through-stretch damage with molten repair material; and the ultrasonic rolling welding machine includes ultrasonic vibrating rollers symmetrically arranged above and below the belt, which press carbon fiber cloth onto the cutting area. A linear actuator drives each working mechanism to move along the width of the belt. Each working mechanism includes the cleaning and grinding mechanism, the cutting and peeling mechanism, the glue spraying mechanism, the hot-repair granule filling mechanism, and the ultrasonic rolling welding machine. This solution addresses the current problems of long repair time and low post-repair strength in the repair of through-stretch damage on continuous TBM belts.

Description

Technical Field

[0001] This invention relates to the field of belt breakage repair technology, specifically to a rapid in-situ repair device for continuous belt penetration damage in TBMs. Background Technology

[0002] In long tunnel TBM construction, continuous belt conveyors are the core equipment for transporting excavated soil. Since TBM excavation distances often reach several kilometers to tens of kilometers, their continuous belts, to meet load-bearing requirements, typically employ a rubber composite structure with multiple steel wire ropes arranged along the conveying direction. During excavated soil transport, large rocks, grouting pipes, pipe roof pipes, and other sharp, hard objects falling from the tunnel boring machine can easily embed and scratch the belt, causing the rubber layer between adjacent steel wire ropes to tear, forming what is known as a "penetrating wound." In reality, the length of a penetrating wound can range from a few meters to hundreds of meters or even kilometers.

[0003] Currently, traditional methods for repairing penetrating damage include cold bonding repair, hot vulcanization repair, mechanical jointing, and thermoplastic repair. However, cold bonding repair is only suitable for small-area damage and cannot withstand the high-intensity stress of penetrating damage. While hot vulcanization repair offers higher strength, it is complex, time-consuming, and requires stopping the machine to cut the belt, severely impacting construction progress. Mechanical jointing and thermoplastic repair are only temporary solutions with low repair strength and short lifespan. Furthermore, traditional repair methods are slow, significantly impacting TBM construction progress. Replacing the entire belt for long-length penetrating damage generates substantial rubber and wire rope waste, leading to resource waste and environmental pollution. Additionally, the transportation and replacement of new belts are energy-intensive and produce high carbon emissions, failing to meet the "dual-carbon" goals and green construction requirements.

[0004] Among the existing publicly available technologies, there are also some belt repair technologies, such as the "A Quick Repair Device for Conveyor Belts" with patent publication number CN214726674U. This technology discloses a repair method and device that uses "cleaning-high pressure blowing-grinding-secondary blowing-adhesive spraying". However, the repair method of this technology only relies on adhesive spraying, and the tensile strength and tear resistance of the repaired belt are far from the level of the original belt, especially unable to cope with the extremely long penetrating damage under TBM construction.

[0005] Another patent, CN102211411A, entitled "Repair Method for Large Angle Belt Fracture," discloses a repair method that employs "cleaning-applying adhesive-attaching-venting." This method is essentially a cold bonding process, and the repaired section of the belt also suffers from low strength. Summary of the Invention

[0006] The present invention aims to provide an in-situ rapid repair device for continuous belt penetration damage in TBMs, in order to solve the problems of long repair time and low strength after repair in current TBM continuous belt penetration damage repair. The present invention designs an in-situ rapid repair device for continuous belt penetration damage in TBMs, realizing in-situ continuous repair without disassembling the belt, improving the applicability and operation convenience of repair, reducing waste and carbon emissions, and adapting to the construction needs of long tunnel TBMs.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A rapid in-situ repair device for through-belt penetration damage in TBMs includes a frame with a cleaning and polishing mechanism mounted on it. The cleaning and polishing mechanism is used to clean and polish the belt. The device also includes a cutting and peeling mechanism, an adhesive spraying mechanism, a hot repair granule filling mechanism, and an ultrasonic rolling welding machine arranged sequentially along the belt conveying direction. The cutting and peeling mechanism is used to cut the surface rubber of the belt. The adhesive spraying mechanism is used to spray adhesive onto the cutting area. The hot repair granule filling mechanism is used to fill the through-belt penetration damage with molten repair material. The through-belt penetration damage is located in the middle of the cutting area. The ultrasonic rolling welding machine includes ultrasonic vibrating rollers symmetrically arranged about the top and bottom of the belt. The ultrasonic vibrating rollers are used to press carbon fiber cloth onto the cutting area. It also includes a linear mover for driving each working mechanism to move along the width of the belt; each working mechanism includes a cleaning and grinding mechanism, a cutting and peeling mechanism, a glue spraying mechanism, a hot repair particle filling mechanism, and an ultrasonic rolling welding machine; the linear mover is set independently for each mechanism or shared by multiple mechanisms.

[0008] Preferably, as an improvement, the cleaning and polishing mechanism includes a high-pressure cleaning component, a polishing component, and a drying component symmetrically arranged on the upper and lower surfaces of the belt; the high-pressure cleaning component includes a high-pressure water nozzle; the polishing component includes a grinding wheel and a grinding wheel lifter, the grinding wheel lifter being used to move the grinding wheel away from or closer to the belt, the grinding wheel of the grinding wheel having a V-shaped grinding profile for grinding out a groove with a V-shaped cross-section; the drying component includes a high-pressure blower.

[0009] Preferably, as an improvement, the cutting and peeling mechanism includes cutting components symmetrically arranged on the upper and lower surfaces of the belt. Each cutting component includes a feed driver, an ultrasonic vibrator, and a cutter mounted on the output end of the ultrasonic vibrator. The feed driver is used to control the cutting depth of the cutter on the belt surface.

[0010] Preferably, as an improvement, the glue spraying mechanism includes two glue spraying components, each of which includes a spray gun, and the two spray guns are symmetrically arranged about the upper and lower surfaces of the belt; The hot repair granule filling mechanism includes two hot repair granule extrusion assemblies. Each hot repair granule extrusion assembly includes a melt extruder, an extrusion nozzle, and a lifting driver. The melt extruder is used to feed molten rubber repair material to the extrusion nozzle, and the lifting driver is used to move the extrusion nozzle away from or closer to the belt. The two extrusion nozzles are symmetrically arranged about the upper and lower surfaces of the belt. The fiber jetting mechanism includes two fiber jetting components, each of which includes the nozzle. The two nozzles are symmetrically arranged about the upper and lower surfaces of the belt.

[0011] Preferably, as an improvement, the adhesive spraying assembly further includes a spray gun lifter for moving the spray gun away from or towards the belt.

[0012] Preferably, as an improvement, the hot repair granule extrusion assembly and / or the fiber jetting assembly include a hopper, the hopper of the hot repair granule extrusion assembly being connected to a melt extruder, and the hopper of the fiber jetting assembly being connected to a nozzle.

[0013] Preferably, as an improvement, it also includes a support plate located after the ultrasonic rolling welding machine process, the support plate being used to support the belt.

[0014] Preferably, as an improvement, it also includes a visual inspection module located in the post-process of the ultrasonic rolling welding machine. The visual inspection module is connected to the control system and is used to acquire surface image data of the repaired belt. The control system determines whether the repair is qualified based on the surface image data of the belt.

[0015] Preferably, as an improvement, the ultrasonic rolling welding machine includes a pressure regulating mechanism for adjusting the pressure of the ultrasonic vibrating roller pressing the belt.

[0016] Compared with the prior art, the technical principles and advantages of the present invention are as follows: 1. When using this solution, after a through-slip damage occurs on the TBM continuous conveyor belt, a linear motion device moves each working mechanism to the position directly opposite the through-slip damage. Then, a cleaning and grinding mechanism cleans the area around the through-slip damage. After cleaning, the edges of the through-slip damage are ground. Next, a cutting mechanism cuts off a certain width of the belt's surface rubber near the through-slip damage to form a cutting area. Then, a spraying mechanism sprays adhesive onto the cutting area. After spraying, a hot-repair granule filling mechanism fills the through-slip damage with molten rubber repair material to fill the missing rubber area. Finally, carbon fiber cloth is covered on the surface of the through-slip damage to enhance the strength of the repaired belt. In the bonding of the carbon fiber cloth, an ultrasonic vibrating roller with an ultrasonic vibration module is used to roll and compact the belt and carbon fiber cloth from both above and below, and then ultrasonically welds them together, achieving fusion between the carbon fiber cloth and the original remaining rubber layer of the belt, thus improving the tensile strength and tear resistance of the repaired belt.

[0017] 2. This invention employs a spray-adhesive, hot-repair particle filling, and fiber spraying process. The process involves sequentially spraying adhesive onto the exposed cutting area, filling the penetration wound with molten hot-repair material, and spraying short-cut basalt fibers onto the exposed cutting area. Finally, an ultrasonic rolling welding machine welds carbon fiber cloth onto the short-cut basalt fibers. In this method, the adhesive ensures high bonding strength between the repair layer formed by the repair device and the original belt interface. The hot-repair particles fill the rubber-deficient area of ​​the penetration wound, and the short-cut fibers form a mesh-like tear-resistant structure, further enhancing the tensile and tear strength of the repaired belt.

[0018] 3. Through optimized design of the cleaning and grinding mechanism, symmetrical V-shaped grooves are created on the through-wound, improving the smoothness of the through-wound edges and increasing the contact area between the through-wound and the filling rubber repair material. This enhances the bonding strength between the rubber repair material and the original belt near the through-wound. Furthermore, the symmetrical and interconnected V-shaped grooves create an upper and lower funnel shape for the through-wound cross-section, facilitating accurate and rapid filling of the through-wound with molten rubber repair material by the hot-patch filling mechanism. Additionally, the grinding wheel lifter on the cleaning and grinding mechanism ensures that the wheel is kept away from the belt when repair is not required, facilitating normal belt use. The symmetrical structure allows for simultaneous repair on both sides, ensuring repair efficiency and improving the strength of the repaired belt.

[0019] 4. This invention connects the ultrasonic vibrator to the cutter of the cutting and peeling mechanism. After the feed driver controls the feed depth, the presence of the ultrasonic vibrator ensures that the cutter can quickly and smoothly peel off the surface rubber of the belt. This ensures the flatness of the cutting area and makes the cut rubber a continuous strip of rubber skin. This makes it easy to send the cut rubber skin out of the cutting area through the traction component, which facilitates the entire repair device to perform in-situ rapid and continuous repair of the conveyed belt.

[0020] 5. The adhesive spraying mechanism, the hot repair particle filling mechanism, and the fiber spraying mechanism of the present invention all include working parts symmetrically arranged on the upper and lower surfaces of the belt, so that during the repair process, the repair operation is carried out simultaneously on the upper and lower surfaces of the belt near the through-damage, which further improves the bonding strength between the repair material and the original structure of the belt while ensuring that the repair efficiency is not affected.

[0021] 6. The spray gun lifter of this invention allows for convenient height adjustment based on the adhesive application; the presence of the hopper allows for timely replenishment of hot repair particles and basalt fiber as needed. Furthermore, the inclusion of various lifting mechanisms, such as the grinding wheel lift, feed driver, and pressure adjustment mechanism, allows the output ends of each working mechanism to be moved away from the belt when the belt is not requiring repair. This ensures that the presence of the repair device does not affect the normal operation of the TBM continuous belt conveyor. When repair is needed, each lifting mechanism drives the corresponding working mechanism to perform the repair work, thereby achieving in-situ continuous repair of the belt.

[0022] 7. The present invention provides a support plate after the ultrasonic rolling welding machine, so that after the belt is repaired, the support plate supports the belt, which is equivalent to extending the shaping time of the belt after repair and helping to improve the strength of the repaired belt.

[0023] 8. The present invention includes a visual inspection module and a control system, which enable the repaired condition to be automatically identified and judged by the visual inspection module and the control system, thereby improving the degree of automation. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of Embodiment 1 of the present invention.

[0025] Figure 2 This is a schematic diagram of the cleaning and polishing mechanism in Embodiment 1 of the present invention.

[0026] Figure 3 yes Figure 2 A partially enlarged schematic diagram (the grinding wheel lifter is mounted on a separate linear actuator).

[0027] Figure 4This is a schematic diagram of the cutting and peeling mechanism, the integrated module of adhesive spraying-thermal repair particle filling-fiber spraying, and the ultrasonic rolling welding machine in Embodiment 1 of the present invention.

[0028] Figure 5 yes Figure 4 The front view (the belt is shown as a dashed line in the figure).

[0029] Figure 6 This is a schematic diagram of one of the cutting components of the ultrasonic cutting and peeling mechanism in Embodiment 1 of the present invention.

[0030] Figure 7 This is a schematic diagram of the structure of the various components located above the belt in the integrated device for spraying adhesive, hot repair granules filling and fiber spraying in Embodiment 1 of the present invention (the spray gun lifter is installed on an independent linear mover).

[0031] Figure 8 This is a schematic diagram of the ultrasonic vibration roller and belt above the belt in the ultrasonic rolling welding machine of Embodiment 1 of the present invention.

[0032] Figure 9 This is a three-dimensional structural diagram of the two image acquisition units of the visual inspection module in Embodiment 1 of the present invention mounted on an independent linear motion device.

[0033] Figure 10 This is a schematic diagram of the cross-section of the belt after repair according to Embodiment 1 of the present invention.

[0034] Figure 11 This is a schematic diagram of the cutting assembly and traction assembly in Embodiment 2 of the present invention.

[0035] The reference numerals in the accompanying drawings include: 1. Gantry frame; 2. Cleaning and grinding mechanism; 3. High-pressure water nozzle; 4. High-pressure blower; 5. Grinding wheel lifter; 6. Grinding wheel machine; 7. Cutting and peeling mechanism; 8. Cutter; 9. Ultrasonic vibrator; 10. Feed driver; 11. Pinch roller; 12. Receiving frame; 13. Guide roller; 14. Spray glue-heat repair granule filling-fiber spraying integrated module; 15. Spray gun; 16. Spray gun lifter; 17. Heat repair granule hopper; 18. High-speed blower; 19. Fiber hopper; 20. Nozzle; 11. Extrusion nozzle; 12. Lifting driver; 13. Melt extruder; 14. Composite reinforcing layer; 15. Heat repair fusion layer; 16. Ultrasonic rolling welding machine; 17. Carbon fiber cloth; 18. Ultrasonic vibrating roller; 19. Pressure adjustment mechanism; 20. Lifting plate; 10. Continuous belt; 11. Penetrating wound; 12. Belt wire rope; 13. Vision inspection module; 14. Image acquisition unit. Detailed Implementation

[0036] The following detailed description illustrates the specific implementation method: Example 1 The basics are as follows: Figures 1 to 10 As shown.

[0037] Combination Figure 1 A rapid in-situ repair device for through-stretch damage on a TBM continuous belt is installed on the return section of the TBM continuous belt (in the return section, the TBM continuous belt does not bear weight and is in a straight state). It includes a frame and a cleaning and grinding mechanism 2, a cutting and peeling mechanism 3, a glue spraying mechanism, a hot repair particle filling mechanism, a fiber spraying mechanism, an ultrasonic rolling welding machine 5, a support plate 6, and a vision inspection module 8 arranged sequentially along the belt conveying direction.

[0038] A gantry frame 1 is fixed on the frame. The gantry frame 1 spans above the return section of the continuous belt. The cutting and peeling mechanism 3 is an ultrasonic cutting and peeling mechanism. The glue spraying mechanism, the hot repair particle filling mechanism, and the fiber spraying mechanism are integrated in the same area. The glue spraying mechanism, the hot repair particle filling mechanism, and the fiber spraying mechanism integrated in the same area are called the glue spraying-hot repair particle filling-fiber spraying integrated module 4.

[0039] The cleaning and polishing mechanism 2, the ultrasonic cutting and peeling mechanism 3, the glue spraying-heat repair particle filling-fiber spraying integrated module 4, the ultrasonic rolling welding machine 5, and the vision inspection module 8 are all equipped with independent linear movers. The linear movers are fixed on the gantry frame 1 (that is, fixed on the frame). The linear movers are used to drive the corresponding mechanism or module to move laterally along the width of the belt so that the working mechanism can be aligned with the penetrating wound for operation. In this embodiment, the linear movers adopt a screw drive structure.

[0040] The lifting plate 6 is fixed on the gantry frame 1. The lifting plate 6 is located on the lower surface of the continuous belt. The top surface of the lifting plate 6 that contacts the belt is a wear-resistant plate, and the wear-resistant plate is in contact with the lower surface of the continuous belt.

[0041] Combination Figure 1 and Figure 9 The visual inspection module 8 is installed behind the support plate 6. The visual inspection module 8 includes two image acquisition units 81, located above the upper surface of the belt and below the lower surface, respectively. This allows for the acquisition of image data from both the repaired upper and lower surfaces of the belt using the vertically positioned image acquisition units 81. The image acquisition units 81 are mounted on corresponding linear actuators to facilitate movement along the belt width. In this embodiment, the image acquisition unit 81 is a camera. The visual inspection module 8 is connected to a control system, which is also connected to the cleaning and polishing mechanism 2, the ultrasonic cutting and peeling mechanism 3, the glue spraying-thermal repair particle filling-fiber spraying integrated module 4, and the ultrasonic rolling welding machine 5. Furthermore, the control system is connected to an encoder for acquiring the continuous belt running speed.

[0042] 1. Cleaning and Grinding Mechanism 2 Combination Figures 1 to 3 In one embodiment, the cleaning and polishing mechanism 2 includes a high-pressure cleaning component, a polishing component, and a drying component symmetrically arranged on the upper and lower surfaces of the continuous belt. The high-pressure cleaning component is equipped with a high-pressure water nozzle 21 capable of adjusting the spray angle. In one embodiment, there are multiple high-pressure water nozzles 21, which are arranged along the width of the belt. Alternatively, in another embodiment, the spray range of the high-pressure water nozzle 21 can be adjusted to cover the penetrating wound and the area surrounding the penetrating wound (e.g., covering an area of ​​5-10 cm around the penetrating wound). The high-pressure water nozzle 21 is mounted on an independent linear actuator to drive the high-pressure nozzle 45 to be aligned with the area where the penetrating wound is located.

[0043] The grinding assembly includes a grinding wheel machine 24 and a grinding wheel lifter 23. The grinding wheel lifter 23 is installed at the output end of a corresponding linear actuator. This independent linear actuator drives the grinding wheel lifter 23 and the grinding wheel machine 24 to move along the belt width direction to ensure that the grinding wheel of the grinding wheel machine is aligned with the through wound. The grinding wheel machine 24 is fixedly installed at the output end of the grinding wheel lifter 23 so that the grinding wheel machine 24 can be moved away from or closer to the belt. The grinding wheel of the grinding wheel machine 24 has a V-shaped grinding profile to grind out a groove with a V-shaped cross-section. In this embodiment, the two inclined sides of the V-shaped grinding profile are symmetrical about the grinding wheel. The V-shaped flared opening of the V-shaped groove machined by the grinding wheel on the belt faces outward. The upper and lower grinding assemblies form a double V-shaped groove with both flared openings facing outward on the through wound cross-section of the belt, and the two V-shaped grooves on the through wound cross-section are connected. In one embodiment, the grinding wheel machine 24 grinds the edge of the through wound to form a V-shaped groove with a depth of 3-5 mm and an angle of 60°.

[0044] Each drying assembly includes multiple high-pressure blowers 22 symmetrically arranged on the upper and lower surfaces of a continuous belt. The multiple high-pressure blowers 22 cover the width of the belt from the vertical direction.

[0045] II. Ultrasonic cutting and peeling mechanism 3 Combination Figures 4 to 6 In one embodiment, the ultrasonic cutting and peeling mechanism 3 includes cutting components symmetrically arranged on the upper and lower surfaces of the belt. Each cutting component includes a feed driver 33, an ultrasonic vibrator 32, and a cutter 31 mounted on the output end of the ultrasonic vibrator 32. The feed driver 33 is mounted on a corresponding linear actuator. This independent linear actuator is used to drive the cutter of the cutting component to align with the penetrating wound. The ultrasonic vibrator 32 is mounted on the output end of the feed driver 33. The feed driver 33 is used to control the cutting depth of the cutter 31 on the belt surface. In this embodiment, the cutter 31 is a high-speed steel blade. In a specific embodiment, the width of the high-speed steel blade 31 is 120 mm. The feed driver 33 adopts an electric lead screw.

[0046] III. Glue Spraying - Heat Repair Particle Filling - Fiber Spraying Integrated Module 4 Combination Figure 4 , Figure 5 and Figure 7 In one embodiment, the adhesive spraying-thermal repair particle filling-fiber spraying integrated module 4 includes an adhesive spraying mechanism comprising two adhesive spraying components. Each adhesive spraying component includes a high-pressure spray gun 41 and a spray gun lifter 411. The spray gun lifter 411 is used to move the high-pressure spray gun 41 away from or closer to the belt. In this embodiment, the spray gun lifter 411 is installed on the output end of an independent linear actuator. The independent linear actuator drives the high-pressure spray gun 41 and the spray gun lifter 411 to move along the width direction of the belt so that the high-pressure spray gun 41 can be aligned with the area to be repaired. The output end of the spray gun lifter 411 is equipped with the high-pressure spray gun 41. The spray gun lifter 411 drives the high-pressure spray gun 41 to rise and fall, thereby controlling the width of the spraying area. The two high-pressure spray guns 41 are symmetrically arranged about the upper and lower surfaces of the belt. In this embodiment, the spray gun lifter 411 is also symmetrically arranged about the upper and lower surfaces of the belt. The hot repair granule filling mechanism includes two hot repair granule extrusion assemblies. Each hot repair granule extrusion assembly includes a hot repair granule hopper 42, a melt extruder 47, an extrusion nozzle 46, and a lifting drive 461. The hot repair granule hopper 42 is connected to the melt extruder 47 to provide hot repair granules to the melt extruder 47. The melt extruder 47 has a heating and spiral extrusion structure so that the melt extruder 47 heats the rubber repair granules to a molten state and then the spiral extrusion structure extrudes the molten rubber repair material from the extrusion nozzle 46. The lifting drive 461 is used to move the extrusion nozzle 46 away from or closer to the belt. The two extrusion nozzles 46 are symmetrically arranged about the upper and lower surfaces of the belt. The fiber jetting mechanism includes two fiber jetting assemblies. Each fiber jetting assembly includes a nozzle 45 and a fiber hopper 44. The two nozzles 45 are symmetrically arranged about the upper and lower surfaces of the belt. Each nozzle 45 is used to jet the chopped basalt fibers from the fiber hopper 44 to the cut exposed area. The nozzles 45 are connected to a high-speed fan 43. In this embodiment, the lifting drive of the hot repair granule extrusion assembly and the nozzle 45 of the fiber jetting assembly, located on the same side of the belt, are mounted on the same support frame. This support frame is mounted on an independent linear actuator. The linear actuator drives the hot repair granule filling mechanism and the fiber jetting mechanism to move along the belt width direction so that the extrusion nozzle 46 and the nozzle 45 can be aligned with the area to be repaired.

[0047] In one embodiment, the fiber hopper 44 of the basalt fiber spraying assembly is filled with 20mm chopped basalt fibers.

[0048] IV. Ultrasonic Rolling Welding Machine 5 Combination Figure 4, Figure 5 and Figure 8 In one embodiment, the ultrasonic rolling welding machine 5 includes ultrasonic vibrating rollers 52 symmetrically arranged in the vertical direction of a continuous belt. The ultrasonic vibrating rollers 52 have a built-in 25kHz ultrasonic vibration module, and the ultrasonic rolling welding machine 5 is equipped with a pressure regulating mechanism 53 for adjusting the pressure of the ultrasonic vibrating rollers 52. The pressure regulating mechanism 53 can also be used to move the ultrasonic vibrating rollers 52 away from the belt. In this embodiment, the pressure regulating mechanism 53 is a roller lifter that moves the ultrasonic vibrating rollers 52 away from or closer to the belt. The roller lifter in this embodiment adopts a screw motor. In order to realize the movement of the ultrasonic vibrating rollers 52 in the belt width direction to adapt to the repair of penetrating wounds at different positions, the pressure regulating mechanism 53 is installed on the corresponding linear mover. The ultrasonic vibrating rollers 52 are used to press the carbon fiber cloth 51 with the same width as the cutting area onto the cutting area that has been sprayed with adhesive.

[0049] In one embodiment, the linear velocity of the ultrasonic vibrating roller 52 of the ultrasonic rolling welding machine 5 is consistent with the running speed of the continuous belt.

[0050] This embodiment also provides a method for in-situ rapid repair of penetration damage on a continuous TBM conveyor belt. Before repair, a gantry frame is placed over the continuous TBM conveyor belt, and the frame height is adjusted to ensure that each working mechanism maintains a reasonable distance from the belt surface. Based on the width of the continuous belt and the location of the penetration damage, the positions of the cleaning and grinding mechanism 2, the ultrasonic cutting and peeling mechanism 3, the adhesive spraying-thermal repair particle filling-fiber spraying integrated module 4, and the ultrasonic rolling welding machine 5 are adjusted using a linear motion device to ensure that each working mechanism is precisely aligned with the penetration damage area. The spraying range of the high-pressure water nozzle 21, the grinding trajectory of the grinding wheel 24, and the blowing range of the high-pressure blower 22 in the cleaning and grinding mechanism 2 are set; the cutting path of the ultrasonic cutting and peeling mechanism 3 is set; the material spraying and filling range of the adhesive spraying-thermal repair particle filling-fiber spraying integrated module 4 is set; and the activation timing of the ultrasonic vibration roller 52 and its ultrasonic vibration module in the ultrasonic rolling welding machine 5 is set. The encoder is calibrated through the control system to ensure that the speed error of each working mechanism meets the working requirements, so that the lifting plate 6 fits against the lower surface of the continuous belt 7.

[0051] Specifically, when the belt tear and slag leakage monitoring device detects a penetration wound, the TBM cutterhead stops tunneling, the continuous belt 7 stops operating, and the residual slag around the penetration wound is manually cleaned; rubber repair granules and chopped basalt fibers are respectively filled into the corresponding hoppers of the adhesive spraying-hot repair granule filling-fiber spraying integrated module 4, and carbon fiber cloth 51 is prepared (wherein the carbon fiber cloth 51 can be wound on a unwinding drum, and after the ultrasonic rolling welding machine 5 is started, the unwinding drum continuously releases the carbon fiber cloth 51). The continuous belt 7 is started, and the control system collects the running speed of the continuous belt 7. It controls the working parameters of the cleaning and grinding mechanism 2, the ultrasonic cutting and peeling mechanism 3, the glue spraying-thermal repair particle filling-fiber spraying integrated module 4, and the ultrasonic rolling welding machine 5 to ensure that the rotation speed of the grinding wheel 24, the ultrasonic vibration frequency, the discharge speed of the extruder 46, and the rotational linear speed of the ultrasonic vibrating roller 52 are matched with the running speed of the continuous belt 7. At the same time, a human-machine interface is provided to display the working status of each mechanism in real time and issue an alarm signal when a fault occurs.

[0052] Driven by a continuous belt 7, the penetrating wound 70 enters the cleaning and grinding mechanism 2. The high-pressure water nozzle 21 removes the slag and oil stains from the surface of the penetrating wound. The grinding wheel 24 grinds along the edge of the penetrating wound 70 to form a V-shaped groove. The high-pressure blower 22 simultaneously dries the V-shaped groove and the surrounding surface.

[0053] The continuous belt 7 continues to convey, causing the penetrating wound 70 to enter the ultrasonic cutting and peeling mechanism 3. Under the synergistic action of the ultrasonic vibrator 32, the high-speed steel blade 31 of the ultrasonic cutting and peeling mechanism 3 symmetrically cuts the surface rubber of the belt along both sides of the penetrating wound 70, leaving a cutting area on the belt 7.

[0054] The continuous transmission of the continuous belt 7 allows the penetrating wound to enter the integrated module 4 of adhesive spraying-hot repair granule filling-fiber spraying. The high-pressure spray gun 41 sprays the conveyor belt adhesive onto the cut area. The rubber repair granules in the hot repair granule hopper 42 are heated and melted by the melt extruder 47 and then squeezed into the V-shaped groove on the penetrating wound through the extrusion nozzle 46 to form a hot repair fusion layer 49. The short chopped basalt fibers in the basalt fiber hopper 44 are blown onto the surface of the penetrating wound and the surface of the cut area through the nozzle 45 under the action of the airflow generated by the high-speed fan 43 to form a composite reinforcement layer 48.

[0055] The continuous belt 7 continues to drive the penetrating wound into the ultrasonic rolling welding machine 5, covering the surface of the composite reinforcement layer 48 with carbon fiber cloth 51. The ultrasonic vibration roller 52 of the ultrasonic rolling welding machine 5 presses the carbon fiber cloth 51 and the continuous belt 7 together under the synergistic action of the ultrasonic vibration module. The support plate 6 keeps in contact with the carbon fiber cloth 51 on the lower surface of the continuous belt 7, supporting the lower surface carbon fiber cloth 51 until the adhesive is initially cured.

[0056] A visual inspection module 8, located behind the lifting plate 6, scans the repair area to identify issues such as air bubbles in the adhesive layer and misalignment of the carbon fiber cloth 51. Air bubbles are identified by analyzing the surface unevenness of the belt surface in the acquired image data. If the belt surface shows unevenness, air bubbles are considered to be present. If a defective area is found, the control system issues an alarm and marks the location, requiring manual secondary repair. The continuous conveyor belt 7 moves the repair area away from the repair device, and the output ends of all mechanisms on the repair device are moved away from the belt to allow for its operation. The TBM resumes tunneling operations, and the repaired conveyor belt is directly put into normal excavation transportation.

[0057] The beneficial effects of the present invention are as follows: 1. In-situ precision repair designed in this invention: Multiple linear movers of the gantry frame 1 (shown as screw drive mechanism in the attached figure) can flexibly adjust each working mechanism along the width direction of the belt, which can not only adapt to belts of different widths, but also accurately connect to through wounds at different positions. In-situ continuous repair can be completed without disassembling the continuous belt, avoiding the operation of stopping the machine to cut the belt in traditional repair, and reducing the impact on the TBM construction progress.

[0058] 2. The repair structure designed in this invention is stable: the V-shaped groove ground by the grinding wheel 24 increases the contact area of ​​the filling material, combined with the composite reinforcement layer of "adhesive-rubber repair material-basalt fiber" and the double reinforcement of carbon fiber cloth 51, the stable support of the support plate 6 on the lower surface carbon fiber cloth 51, and the combination of the heat patch fusion layer 49 and the continuous belt steel wire rope 71, improve the bonding stability between the repair area and the original belt.

[0059] 3. The device designed in this invention contributes to green environmental protection: by repairing and replacing the traditional belt replacement, it reduces the generation of rubber and wire rope waste, reduces energy consumption in the transportation of new belts and on-site replacement, and meets the "dual carbon" target and green construction requirements.

[0060] Example 2 Combination Figure 11 The second embodiment is an improvement on the first embodiment. A traction assembly is installed on the frame. The traction assembly includes two pinch rollers 34 that rotate in opposite directions and the gap between the two pinch rollers 34 is adjustable. The traction assembly is used to transfer the continuous rubber sheet cut by the cutting assembly to the outside of the belt to avoid the cut waste rubber sheet affecting subsequent repairs. The cut rubber sheet is pulled by the traction assembly to the receiving frame 35 for reception.

[0061] In addition, in order to facilitate the smooth entry of the rubber sheet into the pinch rollers 34, a guide roller 36 is provided between the traction assembly and the cutter 31. Both the pinch rollers 34 and the guide roller 36 are rotatably mounted on the frame.

[0062] The above descriptions are merely embodiments of the present invention, and common knowledge such as specific technical solutions and / or characteristics are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A rapid in-situ repair device for continuous TBM belt penetration damage, comprising a frame, on which a cleaning and polishing mechanism is mounted, the cleaning and polishing mechanism being used to clean and polish the belt, characterized in that: It also includes a cutting and peeling mechanism, a glue spraying mechanism, a hot repair granule filling mechanism, and an ultrasonic rolling welding machine arranged sequentially along the belt conveying direction. The cutting and peeling mechanism is used to cut the surface rubber of the belt, the glue spraying mechanism is used to spray adhesive onto the cutting area, the hot repair granule filling mechanism is used to fill the molten repair material onto the penetration damage of the belt, the penetration damage is located in the middle of the cutting area, and the ultrasonic rolling welding machine includes ultrasonic vibrating rollers arranged symmetrically about the belt, the ultrasonic vibrating rollers are used to press carbon fiber cloth onto the cutting area; It also includes a linear mover for driving each working mechanism to move along the width of the belt; each working mechanism includes a cleaning and grinding mechanism, a cutting and peeling mechanism, a glue spraying mechanism, a hot repair particle filling mechanism, and an ultrasonic rolling welding machine; the linear mover is set independently for each mechanism or shared by multiple mechanisms.

2. The in-situ rapid repair device for continuous TBM belt penetration damage according to claim 1, characterized in that: It also includes a fiber spraying mechanism disposed between the hot repair particle filling mechanism and the ultrasonic rolling welding machine, the fiber spraying mechanism including a nozzle for spraying fibers into the cutting area.

3. The in-situ rapid repair device for continuous TBM belt penetration damage according to claim 2, characterized in that: The cleaning and polishing mechanism includes a high-pressure cleaning component, a polishing component, and a drying component symmetrically arranged on the upper and lower surfaces of the belt; the high-pressure cleaning component includes a high-pressure water nozzle; the polishing component includes a grinding wheel and a grinding wheel lifter, the grinding wheel lifter being used to move the grinding wheel away from or closer to the belt, the grinding wheel of the grinding wheel having a V-shaped grinding profile for grinding out a groove with a V-shaped cross-section; the drying component includes a high-pressure blower.

4. The in-situ rapid repair device for continuous TBM belt penetration damage according to claim 2, characterized in that: The cutting and peeling mechanism includes cutting components symmetrically arranged on the upper and lower surfaces of the belt. Each cutting component includes a feed driver, an ultrasonic vibrator, and a cutter installed at the output end of the ultrasonic vibrator. The feed driver is used to control the cutting depth of the cutter on the belt surface.

5. The in-situ rapid repair device for continuous TBM belt penetration damage according to claim 4, characterized in that: The glue spraying mechanism includes two glue spraying components, each of which includes a spray gun. The two spray guns are symmetrically arranged about the upper and lower surfaces of the belt. The hot repair granule filling mechanism includes two hot repair granule extrusion assemblies. Each hot repair granule extrusion assembly includes a melt extruder, an extrusion nozzle, and a lifting driver. The melt extruder is used to feed molten rubber repair material to the extrusion nozzle, and the lifting driver is used to move the extrusion nozzle away from or closer to the belt. The two extrusion nozzles are symmetrically arranged about the upper and lower surfaces of the belt. The fiber jetting mechanism includes two fiber jetting components, each of which includes the nozzle. The two nozzles are symmetrically arranged about the upper and lower surfaces of the belt.

6. The in-situ rapid repair device for continuous TBM belt penetration damage according to claim 5, characterized in that: The adhesive spraying assembly also includes a spray gun lifter, which is used to move the spray gun away from or towards the belt.

7. The in-situ rapid repair device for continuous TBM belt penetration damage according to claim 5, characterized in that: The hot repair granule extrusion assembly and / or the fiber jetting assembly include a hopper. The hopper of the hot repair granule extrusion assembly is connected to the melt extruder, and the hopper of the fiber jetting assembly is connected to the nozzle.

8. A rapid in-situ repair device for continuous belt penetration damage in TBMs according to any one of claims 1-7, characterized in that: It also includes a support plate located after the ultrasonic rolling welding machine process, the support plate being used to support the belt.

9. A rapid in-situ repair device for continuous TBM belt penetration damage according to any one of claims 1-7, characterized in that: It also includes a vision inspection module located in the downstream process of the ultrasonic rolling welding machine. The vision inspection module is connected to the control system. The vision inspection module is used to acquire surface image data of the repaired belt. The control system determines whether the repair is qualified based on the surface image data of the belt.

10. A rapid in-situ repair device for continuous TBM belt penetration damage according to any one of claims 1-7, characterized in that: The ultrasonic rolling welding machine includes a pressure regulating mechanism for adjusting the pressure of the ultrasonic vibration roller pressing the belt.

Images