Reconfigurable rock breaking cutterhead with adjustable configuration and pose, tunneling equipment and method

Abstract

The application discloses a reconfigurable rock breaking cutter head with adjustable configuration and pose, tunneling equipment and method, which comprises a center carrier, a circumferentially hinged cutter carrier arm, a configuration driving and locking mechanism, and an independent cutter translation and rotation mechanism integrated on the carrier arm; through carrier arm angle adjustment, a continuous reconfiguration of a plane, a conical surface and a special-shaped working surface can be realized, and through decoupled cutter position and pose adjustment, the installation radius and the inclination angle can be independently optimized; a composite rock breaking expansion module and a multi-source state monitoring system matched with a unified interface can realize multi-mode rock breaking and multi-parameter collaborative optimization. The tunneling equipment carrying the cutter head can dynamically adjust the configuration and parameters according to the stratum, and cooperates with an equivalent action angle matching method and a cutter spacing-penetration depth optimization method to realize efficient and low-consumption tunneling in a complex hard rock stratum. The application can adapt to various geological conditions without replacing the cutter head, significantly improves the stratum adaptability and construction efficiency of the equipment, and is suitable for various hard rock tunnels and underground engineering.

Description

Technical Field

[0001] This invention relates to the field of tunnel and underground engineering hard rock tunneling equipment technology, specifically to a reconfigurable rock-breaking cutterhead with adjustable configuration and posture, tunneling equipment equipped with the cutterhead, and a rock-breaking construction method. It can be applied to the efficient tunneling and geological adaptive control of various mechanical rock-breaking equipment such as TBMs, shield tunneling machines, and cantilever hard rock tunneling machines. Background Technology

[0002] As railway, highway, water conservancy and hydropower, mining, and urban underground space engineering continue to develop towards long distances, deep burial, high-strength hard rock, and complex geological conditions, TBMs, tunnel boring machines, and cantilever mechanical rock breaking equipment are facing higher demands on the adaptability of cutterhead structures, the matching of cutter and rock mass interaction, and the optimization of operating parameters. Fixed geometric cutterhead configurations struggle to simultaneously achieve rock breaking efficiency and construction stability in strata with varying hardness and integrity, becoming a core bottleneck restricting the improvement of tunneling efficiency in complex strata.

[0003] The optimization paths for existing engineering cutterheads can be broadly categorized into three types: overall cutterhead replacement, overall cutterhead attitude deflection, and single-blade installation angle adjustment. These solutions address issues such as cutterhead adaptation to specific geological formations and single-blade cutting angle adjustment, providing an important foundation for the development of hard rock tunneling technology.

[0004] However, existing technologies still have several shortcomings in meeting the comprehensive engineering application needs of planar cutterheads, conical cutterheads, continuous undercutting cutterheads, and other non-planar cutterheads: First, the working face geometry of most engineering cutterheads is fixed. Planar rock breaking, conical rock breaking, and irregular rock breaking usually rely on replacing different overall cutterheads and adjusting the overall machine attitude. It is difficult to continuously change the macroscopic configuration of the cutterhead under the same rotation reference, resulting in long cutterhead replacement cycles, high costs, and an inability to adapt to working conditions with frequent changes in strata. Second, the cutter position adjustment, cutter spacing adjustment, and cutter installation tilt angle adjustment in existing cutterheads are mostly single-level adjustments. They lack a multi-level adjustment structure that is independent of each other, namely "overall working face configuration of the cutterhead - spatial position of a single cutter - local attitude of a single cutter". It is difficult to distinguish the independent and coupled effects of changes in the cone angle of the cutterhead and changes in the cutting attitude of a single cutter on the rock breaking effect, and it is impossible to fully release the synergistic rock breaking potential of multi-level parameters. Third, linear cutting, rotary rolling, and composite trajectory tunneling are often implemented separately using different equipment or methods, making it difficult to quickly switch rock-breaking motion modes under the same equipment and cutterhead reference, resulting in insufficient flexibility in dealing with complex strata. Fourth, some composite rock-breaking schemes are specifically designed for a single auxiliary method, with auxiliary components fixed to the cutterhead and nozzle structure. The equipment-level mechanical installation, power supply, and synchronous data interface lack universality, hindering the comparative application of different auxiliary rock-breaking methods such as high-pressure water, laser, and ultrasonic on the same equipment. Fifth, although existing equipment can collect data such as triaxial force, thrust, torque, or displacement, it lacks a unified parameter correlation and coordinated control mechanism when configuration changes, local cutter posture changes, stratum conditions changes, motion mode changes, and auxiliary rock-breaking parameter changes occur simultaneously. This hinders the establishment of a systematic quantitative relationship between "cutterhead configuration—cutter posture—rock mass state—operating parameters—rock-breaking response," making it difficult to achieve full-parameter geological adaptive optimization.

[0005] Therefore, there is an urgent need for an engineered rock-breaking equipment that uses a reconfigurable cutterhead as its core, unifying the adjustment of the macroscopic geometry of the cutterhead, the local position and attitude of the cutter, multi-mode rock-breaking motion, and composite rock-breaking interfaces into a single high-rigidity cutterhead system, so as to achieve the switchable, optimizable, and adaptive application of multiple rock-breaking modes under a unified equipment standard.

[0006] It should be noted that the analysis of the above technical information is the result of creative labor. The detailed description of it in the background section is only intended to deepen the understanding of the non-obviousness of the overall background of this application by those skilled in the art, and should not be regarded as an admission or in any form an implication that the above technical information constitutes prior art known to those skilled in the art. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a reconfigurable rock-breaking cutterhead, tunneling equipment, and method with adjustable configuration and posture. It solves the technical problems of poor geological adaptability of existing fixed-configuration cutterheads, inability to independently decouple and adjust macroscopic configuration and single-blade posture, difficulty in switching between multiple rock-breaking modes, insufficient scalability of composite rock-breaking, and difficulty in multi-parameter collaborative optimization. It achieves continuous reconfigurability of the cutterhead working face shape, layered decoupling control of cutter parameters, and flexible switching of multiple motion modes, thereby improving the adaptability and rock-breaking efficiency of hard rock tunneling equipment to complex geological formations.

[0008] The technical solution of this invention is as follows:

[0009] A reconfigurable rock-breaking cutterhead with adjustable configuration and posture includes a central support body, several circumferentially arranged cutter support arms, configuration hinges, a configuration drive mechanism, a configuration locking mechanism, and a cutter posture adjustment system mounted on each cutter support arm. The central support body connects to the main drive output of the tunneling equipment and defines the rotation axis. Each cutter support arm is hinged to the central support body via a corresponding configuration hinge. The configuration drive mechanism acts between the central support body and the cutter support arm to adjust the configuration angle of the cutter support arm relative to the cutterhead reference plane, thereby reconfiguring the geometry of the cutterhead working surface. The configuration locking mechanism locks the target configuration angle of the cutter support arm. The cutter posture adjustment system includes independent cutter translation and cutter rotation mechanisms, which are used to adjust the installation radius and installation tilt angle of the cutter, respectively, achieving decoupling of positional and orientation degrees of freedom.

[0010] The beneficial effects of this solution are as follows: by adjusting the angle of the articulated bearing arm, the macroscopic configuration of the cutterhead working face can be continuously reconstructed, and different formations can be adapted without replacing the entire cutterhead; at the same time, in conjunction with an independent tool position and posture adjustment mechanism, a two-level adjustment system of "macroscopic configuration - local tool position - local tool posture" is formed, which provides a structural basis for multi-parameter collaborative rock breaking optimization and ensures that different configuration working conditions have consistent power chain and support stiffness.

[0011] Furthermore, the configuration angles of each tool support arm can be adjusted synchronously, in groups, or independently, allowing the cutter head working surface to be reconstructed into a plane, a conical surface with different cone angles, or a non-planar irregular surface. When multiple tool support arms are at the same reference angle, a planar cutter head working condition is formed; when multiple tool support arms form a non-zero tilt angle in the same direction, a conical cutter head working condition is formed; when different tool support arms adopt different tilt angles, a non-planar irregular cutter head working condition is formed. Continuous reconstruction of the macroscopic working surface configuration of the cutter head can be achieved without replacing the entire cutter head.

[0012] The beneficial effects of this solution are: it supports multiple configuration adjustment modes, and can adopt conical, planar, and asymmetrical irregular configurations for different working conditions such as homogeneous hard rock, fractured strata, and interbedded soft and hard layers, which greatly improves the geological adaptability of the cutterhead and meets the complex and ever-changing engineering construction needs.

[0013] Furthermore, the tool translation mechanism includes a guide pair and a translation drive component arranged along the tool support arm, used to adjust the tool spacing and installation radius; the tool rotation mechanism is disposed between the movable tool holder and the tool box, used to adjust the inclination angle of the hob axis relative to the local tool disc surface; both are provided with independent drive sources, which can be set, locked separately and operated in combination.

[0014] The beneficial effects of this scheme are: the tool position adjustment and attitude adjustment are completely decoupled, and can be controlled and locked independently. It is possible to study the independent influence and coupling effect of tool spacing and installation tilt angle on rock breaking effect separately, avoid parameter confusion caused by mixed adjustment of different geometric factors, and provide support for refined rock breaking parameter matching.

[0015] Furthermore, the tool position adjustment system also includes a detachable modular tool mounting assembly, which can be adapted to replace disc hobs of different diameters, cutting edges, or materials.

[0016] The advantages of this solution are: the modular tool interface is compatible with a variety of mainstream engineering hobbing cutter specifications, and the tool type can be flexibly changed according to the formation wear characteristics and rock breaking requirements, thereby improving the versatility and ease of maintenance of the cutterhead and reducing on-site operation and maintenance costs.

[0017] Furthermore, the cutterhead device also includes a composite rock-breaking extension system, which has a unified mechanical mounting position, power supply interface and data synchronization interface, and is compatible with at least one of high-pressure water jet assisted rock-breaking module, laser assisted rock-breaking module, ultrasonic assisted rock-breaking module and microwave assisted rock-breaking module, supporting the comparative application and time-series coordinated control of different assisted rock-breaking technologies.

[0018] The beneficial effects of this solution are: the universal interface can be quickly adapted to a variety of auxiliary rock breaking technologies, and composite rock breaking upgrades can be achieved without large-scale modifications to the cutterhead body. It also facilitates comparison of the synergistic effects of different auxiliary methods under the same equipment benchmark, thereby improving the equipment's expandability and engineering applicability.

[0019] Furthermore, the configuration drive mechanism adopts a hydraulic cylinder, electric cylinder, lead screw mechanism or gear and worm gear mechanism; the configuration locking mechanism adopts a mechanical locking pin, wedge locking, hydraulic locking or brake, which is used to lock the tool bearing arm under the target configuration angle, so that the rock breaking load is mainly transmitted through the tool bearing arm and the central bearing body, avoiding the adjustment actuator from bearing heavy load for a long time.

[0020] The advantages of this solution are: multiple driving and locking methods can be flexibly selected according to the equipment load level and control precision requirements; the locking structure can effectively transmit rock-breaking heavy loads and ensure the structural rigidity and operational reliability of the cutterhead under strong impact and high load conditions.

[0021] Furthermore, the cutterhead device also includes a multi-source condition monitoring system, which includes at least a triaxial force sensor, a thrust sensor, a torque sensor, a speed sensor, and a displacement sensor, and can be expanded to include a vibration sensor, a temperature sensor, an acoustic emission sensor, and a cutter wear measurement unit, for synchronously acquiring mechanical, kinematic, structural, and thermal response data during the rock breaking process.

[0022] The beneficial effects of this scheme are as follows: synchronous acquisition of multi-source data can provide comprehensive data support for tunneling parameter optimization, tool performance evaluation, and fault early warning, and facilitate the establishment of quantitative relationships between multiple parameters and rock breaking response, supporting intelligent adaptive tunneling control.

[0023] The present invention also provides a tunneling equipment, including a shield body, a main beam, a main drive system, a propulsion system, a muck removal system, and a reconfigurable rock-breaking cutterhead with adjustable configuration and posture as described in any of the above; the reconfigurable rock-breaking cutterhead is connected to the output end of the main drive system, the main drive system is connected to the propulsion system through the main beam, and the muck removal system is arranged on the rear side of the cutterhead for discharging rock muck.

[0024] The beneficial effects of this solution are as follows: the tunneling equipment equipped with a reconfigurable cutterhead can dynamically switch the cutterhead configuration and cutter parameters according to the geological conditions, and can complete the method conversion without stopping the machine to replace the cutterhead, which significantly improves the tunneling efficiency and construction safety in complex strata, and reduces project costs and schedule risks.

[0025] The present invention also provides a tunneling method, employing a reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to any of the above-mentioned configurations, comprising the following steps:

[0026] S1. Based on the rock strength, joint characteristics and geological conditions of the stratum to be excavated, determine the target working face configuration of the cutterhead, the installation position and posture of the cutter, and the tunneling operation parameters.

[0027] S2, control the configuration drive mechanism to adjust the configuration angle of each tool bearing arm, form the target tool head working surface shape and then lock it through the configuration locking mechanism;

[0028] S3 controls the tool translation mechanism and the tool rotation mechanism respectively, adjusting the tool's installation radius and installation angle to the target values;

[0029] S4 drives the cutterhead to rotate and advance axially, continuously rolling and breaking the rock in the formation, and simultaneously discharging rock debris;

[0030] S5 adjusts the cutterhead configuration and cutter position parameters in real time according to changes in the strata during tunneling, matching the corresponding tunneling thrust and rotation speed to maintain the optimal rock breaking state.

[0031] The beneficial effects of this solution are: the construction process is deeply matched with the reconfigurable characteristics of the cutterhead, enabling closed-loop control of formation prediction, parameter setting, and dynamic adjustment, giving full play to the multi-level adjustment advantages of the reconfigurable cutterhead, and ensuring rock breaking efficiency and construction stability under different geological conditions.

[0032] Furthermore, during the tunneling process, the equivalent action angle decomposition method is used to quantitatively match the cutterhead configuration angle and the cutter installation angle. By matching the equivalent cutting linear velocity and single-rotation penetration to a unified kinematic benchmark, and combining the dimensionless matching model of cutter spacing-penetration and crack penetration index, the operating parameters are optimized in real time with the goal of minimizing rock breaking energy and fully coordinating crushing.

[0033] The beneficial effects of this scheme are as follows: by using quantitative parameter matching and optimization methods, the independent and synergistic effects of cutterhead configuration and cutter posture can be accurately separated, achieving global optimization of multiple parameters, effectively reducing rock breaking energy, reducing cutter wear, and improving the economy and energy efficiency of tunneling construction.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] (1) Achieve continuous reconfigurability of the macroscopic configuration of the cutterhead. Multiple tool support arms can adjust their configuration angles around the same drive rotation axis. This allows for the construction of approximate planar surfaces, cone surfaces with different cone angles, and non-planar irregular working surfaces without replacing the entire cutterhead with different types. This ensures that different configuration working conditions have consistent power chains, support stiffness, and rotation references, and can quickly adapt to formations with different hardness and integrity.

[0036] (2) A three-level independent adjustment system of "macro configuration - local cutter position - local cutter posture" is formed. The cutter head configuration drive mechanism, the cutter translation mechanism and the cutter rotation mechanism act on different kinematic pairs, which can respectively adjust the independent and coupled effects of the cutter head cone angle, cutter spacing / installation radius and cutter installation angle on the rock breaking response, avoiding the mixing of different geometric factors in the same adjustment action, and realizing refined rock breaking parameter matching.

[0037] (3) Linear propulsion, rotary rolling and composite trajectory rock breaking share the same cutterhead system. By selectively or collaboratively controlling the cutterhead rotation, axial propulsion and working face feed, multiple motion modes can be switched on the same cutterhead, reducing the working condition differences caused by the switching of construction methods and improving the flexibility of construction in complex strata.

[0038] (4) It is particularly suitable for continuous bottom cutting rock breaking construction. By setting the macroscopic configuration of the conical cutter head, the single cutter inclination angle and the cutter position, a continuous rock breaking trajectory with rolling, lateral extrusion and bottom cutting effects can be constructed. The synergistic effect of cone angle, cutter inclination angle, cutter spacing and cutting speed on crack propagation and rock ridge spalling can be brought into play, and the specific energy of hard rock breaking can be significantly reduced.

[0039] (5) The ground stress state and the cutterhead configuration can be combined independently. The cutterhead configuration adjustment does not change the overall load-bearing system of the equipment. The tunneling effect of planar cutterhead, conical cutterhead and irregular cutterhead can be compared under the same ground stress conditions. It can also adapt to different ground stress strata under the same cutterhead configuration and establish a multi-dimensional matching relationship between geological conditions and equipment parameters.

[0040] (6) It can cover parameter optimization for single cutter, multi-cutter and whole cutterhead scale. The cutter mounting components and cutter support arms adopt a modular design, which can adjust the number and arrangement of cutters according to construction needs, taking into account both local cutter parameter optimization and overall cutterhead synergistic rock breaking efficiency improvement.

[0041] (7) The composite rock breaking extension has a platform interface. High-pressure water, laser and ultrasonic auxiliary modules can share mechanical installation benchmarks, power supply interfaces and time synchronization interfaces, so that different auxiliary technologies can be compared and adapted with the same mechanical rock breaking benchmark, avoiding the cost of modifying equipment separately for each composite rock breaking method.

[0042] (8) It can control the performance and wear life of cutting tools. By adjusting the specifications, cutting edge shape, material, installation posture, linear speed, normal load and rock mineral composition of the hob, the optimal wear characteristics can be obtained, providing a basis for the selection of hob materials and structures and the optimization of construction parameters.

[0043] (9) Multi-source data have unified working condition identification. The system synchronizes configuration angle, cutter position, cutter posture, operating parameters and auxiliary rock breaking parameters with triaxial force, torque, vibration, temperature and other data in a unified manner, which facilitates parameter response surface analysis, tunneling performance index evaluation and numerical model calibration.

[0044] (10) The equipment has strong long-term expansion capabilities. Its core innovation is based on a reconfigurable kinematic chain and a unified interface system. When adding new roller cutter specifications, cutter head types, measurement sensors or auxiliary rock breaking modules, there is no need to change the basic load-bearing and control architecture of the cutter head, which is conducive to forming a long-term reusable equipment technology system. Attached Figure Description

[0045] To more clearly illustrate the embodiments of this technical solution, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this technical solution. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0046] Figure 1 This is a schematic diagram of the assembly structure of the reconfigurable cutter head according to an embodiment of the present invention;

[0047] Figure 2 This is a schematic diagram of the cutter head rotary transmission structure according to an embodiment of the present invention;

[0048] Figure 3 This is a side view of a planar cutterhead according to an embodiment of the present invention;

[0049] Figure 4 Figure 5 shows a schematic diagram of the tool pose adjustment system according to an embodiment of the present invention.

[0050] Figure 5 This is a schematic diagram of the tool rotation mechanism according to an embodiment of the present invention;

[0051] Figure 6 This is a schematic diagram showing the installation position of the auxiliary rock-breaking module according to an embodiment of the present invention;

[0052] Figure 7 A diagram showing the change in cutter head configuration and cutter pose angle according to an embodiment of the present invention;

[0053] Figure 8 A schematic diagram of the rock-breaking operation state according to an embodiment of the present invention;

[0054] Explanation of reference numerals in the attached drawings: 10-Main drive box; 11-Main drive system; 12-Cutterhead taper drive system; 13-Cutterhead rotary drive mechanism; 14-Rotary drive shaft; 15-Rotary gear ring; 16-Cutter support arm; 17-Translation track; 18-Cutter angle rotary drive; 19-Cutter; 20-Cutter box; 21-Moving cutter holder; 22-Cutter translation drive; 23-Cutter rotation center; 24-Auxiliary rock breaking installation interface; 25-Propulsion system. Detailed Implementation

[0055] 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 core concept of the present invention and the following embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0056] All terms used in this application have the same meaning as understood by one of ordinary skill in the art to which this application pertains, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant art, and not as idealized or highly formalized, unless expressly defined herein.

[0057] It should be noted that techniques, methods and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods and equipment should be considered part of the instruction manual.

[0058] Example 1: Implementation of a reconfigurable rock-breaking cutterhead foundation structure with adjustable configuration and pose.

[0059] This embodiment is a basic implementation scheme for the cutter head device, such as... Figure 1 , Figure 2 and Figure 3 As shown, the reconfigurable rock-breaking cutterhead with adjustable configuration and posture includes a central support body, a cutterhead taper drive system 12, a cutterhead rotation drive mechanism 13, a rotation drive shaft 14, a rotation gear ring 15, a cutter support arm 16, and a cutter posture adjustment system.

[0060] The central support body serves as the central support component of the cutterhead. Its back is fixedly connected to the output end of the main drive system 11 of the tunneling equipment. The drive components of the main drive system 11 are housed within the main drive box 10, which is slidably connected to the main beam of the tunneling equipment via the propulsion system 25. Multiple cutter support arms 16 are arranged radially around the central support body. The root of each cutter support arm 16 is hinged to the central support body via a configuration hinge, and the hinge axis has a predetermined spatial relationship with the cutterhead rotation axis.

[0061] The cutter head taper drive system 12 serves as a configuration drive mechanism, with one end hinged to the central support body and the other end hinged to the tool support arm 16. It changes the configuration angle of the tool support arm 16 through extension, retraction, or rotation. When the configuration angles of multiple tool support arms 16 change, the axial and / or radial positions of each tool's point of action relative to the common cutter head reference plane change accordingly. This causes the working envelope of the actual rotating cutter head to be continuously or hierarchically reconstructed from a plane or approximately plane into conical surfaces with different taper angles, or to form a non-planar irregular envelope through unequal configuration angles.

[0062] In some embodiments, the configuration angles of each tool support arm 16 can be adjusted synchronously, or they can be adjusted in groups or independently. When multiple tool support arms 16 are at the same reference angle and the points of action of each tool are approximately coplanar, a planar tool head or a near-planar tool head working condition can be formed; when multiple tool support arms 16 form a non-zero tilt angle in the same direction and the points of action of each tool are distributed on the same conical envelope surface, a conical tool head working condition can be formed; when different tool support arms 16 adopt different tilt angles, different radial positions, or different axial positions, a non-planar irregular tool head or a locally asymmetrical tool head working condition can be formed, and the macroscopic working surface configuration of the tool head can be changed without replacing the tool head with a different geometric type.

[0063] In some embodiments, the cutter head taper drive system 12 can employ a hydraulic cylinder, electric cylinder, lead screw mechanism, gear-worm gear mechanism, or other mechanism capable of outputting controllable angular displacement. To ensure high rigidity during rock-breaking loading, after the configuration angle is adjusted to the target value, the cutter bearing arm 16 can be locked by a configuration locking mechanism, so that the rock-breaking load is mainly transmitted through the cutter bearing arm 16, the central bearing body, and the drive, rather than being borne solely by the angle adjustment actuator for a long period of time. In other embodiments, the configuration locking mechanism can be implemented using a mechanical locking pin, wedge locking, hydraulic locking, brake, or self-locking transmission mechanism.

[0064] Example 2: Implementation of Layered Decoupled Tool Position Adjustment

[0065] This embodiment, based on Embodiment 1, further refines the specific structure of the tool pose adjustment system. For example... Figure 4 , Figure 5 As shown, the tool position adjustment system is mounted on the tool support arm 16 and includes a tool translation mechanism, a tool rotation mechanism, and a tool mounting assembly. The tool mounting assembly includes a movable tool holder 21 connected to the tool translation mechanism 5 and disposed within a slide rail. The movable tool holder 21 is connected to a tool box 20 via a slewing support. The tool 19 is rotatably mounted within the tool box 20 via a tool shaft. The tool rotation mechanism 9 is disposed between the movable tool holder 21 and the tool box 20.

[0066] The tool translation mechanism includes a translation track 17, a movable tool holder 21, and a tool translation drive 22, all mounted on the tool support arm 16. The movable tool holder 21, after moving along the translation track 17, can be positioned by mechanical clamping, hydraulic clamping, or a self-locking transmission. By changing the position of one or more movable tool holders, adjustments to the tool spacing, tool radius, non-uniform tool placement, staggered tool placement, and the construction of different cutting trajectory spacings can be achieved.

[0067] The tool rotation mechanism is located between the movable tool holder 21 and the tool box 20, and includes a slewing bearing or shaft, a tool angle rotation drive 18, and an angle locking component. The rotation mechanism causes the tool box to rotate around a partial rotation axis, thereby changing the angle of the hob shaft relative to the tool support arm 16. Different hobs can use the same angle or different angles to simulate working conditions such as upright mounting, inclined mounting, lateral offset, and continuous undercutting.

[0068] The cutter mounting assembly adopts a detachable modular structure, allowing for the replacement of disc cutters with different diameters, cutter ring shapes, or materials. While ensuring the installation interface and load capacity are matched, it can also be replaced with other mechanical rock-breaking cutter modules for specific working conditions. In some embodiments, 14-inch, 17-inch, 19-inch, and 21-inch cutters can be configured, with space or interfaces reserved for larger cutter sizes.

[0069] Furthermore, the cutter head configuration adjustment mechanism and the tool rotation mechanism act on different kinematic pairs: the former, under the condition that the central support body maintains a predetermined rotation axis relationship, changes the macroscopic configuration angle of multiple tool support arms 16 relative to the central support body, thereby changing the spatial envelope of the multiple tool action points that actually rotate with the central support body; the latter changes the local attitude angle of a single tool relative to the corresponding tool support arm 16, causing the single tool to deflect relative to the tool rotation center 23. Thus, the "macroscopic configuration change of cutter head plane / conical / non-planar surface" and the "single tool mounting angle change" can be set, locked, and combined for application.

[0070] Example 3: Multi-motion mode rock breaking implementation method

[0071] This embodiment, based on Embodiment 1, illustrates the specific implementation of the three basic rock-breaking motion modes. This embodiment uses different combinations of cutterhead rotation, axial propulsion, and working face feed to form at least three basic relative motion modes on the same cutterhead. Furthermore, the three basic modes share the same cutterhead mounting reference, the same drive system, and the same data acquisition system, eliminating the need to replace dedicated components for different modes. This reduces parameter deviations caused by changes in system stiffness and sensor references between different construction modes.

[0072] The first type is the linear propulsion rock breaking mode: the rotational degree of freedom of the cutter head is locked or the single / multi-blade assembly is kept in a set spatial posture. The target penetration amount or normal load is established by the propulsion system, and then the working face feed mechanism drives the rock mass to move in a straight line relative to the cutter, thereby completing single or multi-blade linear rolling, wire cutting and repetitive cutting operations.

[0073] The second type is the rotary rolling rock breaking mode: the working face is kept in a set position, and the propulsion system presses the reconfigurable cutterhead against the rock mass. At the same time, the rotary drive device drives the cutterhead to rotate, thereby realizing continuous rotary rolling rock breaking of planar cutterhead, conical cutterhead or irregular cutterhead.

[0074] The third type is the composite trajectory rock breaking mode: at least two of the rotary drive device, the propulsion drive device and the working face feed mechanism move synchronously, so that the cutter relative to the rock mass forms a composite trajectory obtained by the superposition of rotation, axial propulsion and translational motion. It can be used to realize variable tool spacing trajectory, spiral / oblique trajectory, continuous bottom cutting trajectory or local repetitive cutting trajectory for rock breaking.

[0075] In some implementations, the working face feed can also be set with a second translational degree of freedom to change the cutting trajectory position or form a two-dimensional combined trajectory, further expanding the types of composite trajectories.

[0076] Example 4: Implementation of the Composite Rock-Breaking and Expanding System

[0077] This embodiment, based on Embodiment 1, further illustrates the specific structure of the composite rock-breaking and expansion system. For example... Figure 6 As shown, the cutterhead device also includes a composite rock-breaking extension system. The composite rock-breaking extension system has a unified mechanical mounting position, power supply interface and data synchronization interface near the cutter action area. Corresponding to the auxiliary rock-breaking installation interface 24, a high-pressure water jet auxiliary module, a laser auxiliary module and / or an ultrasonic auxiliary module can be installed according to construction needs.

[0078] In some embodiments, the high-pressure water jet auxiliary module includes a nozzle, a nozzle position adjustment component, and a high-pressure water supply pipeline. The nozzle's front-to-back position, lateral position, incident angle, and target distance relative to the roller are adjustable.

[0079] In other embodiments, the laser-assisted module includes a laser output head and a position adjustment bracket, which can be used to apply localized heat to the rock surface before or during the action of the roller cutter.

[0080] In another possible implementation, the ultrasonic auxiliary module includes an ultrasonic transducer or vibration transmission assembly for applying ultrasonic vibrations to the rock mass, cutting tool, or local rock surface.

[0081] The composite rock-breaking extension module can operate in sequence according to the following steps: "auxiliary pretreatment - mechanical rock breaking", "auxiliary action and mechanical rock breaking are carried out simultaneously", or "auxiliary action after mechanical rock breaking". The control system records the start and stop times, action positions and action parameters of the auxiliary module in a unified manner with the mechanical rock-breaking working conditions, so as to match the optimal collaborative rock-breaking mode and obtain the lowest rock-breaking specific energy.

[0082] Example 5: Implementation of Multi-Source State Monitoring and Cooperative Control

[0083] This embodiment further refines the specific implementation of multi-source state monitoring and collaborative control based on Embodiment 1.

[0084] The multi-source condition monitoring system is used to simultaneously acquire information on mechanical load, kinematic parameters, structural response, thermal response, and rock failure process. It includes at least a triaxial force sensor for acquiring the cutter's normal force, rolling force, and lateral force, as well as corresponding sensors for acquiring the cutterhead thrust, torque, rotational speed, feed displacement, or penetration depth.

[0085] In some implementations, the multi-source condition monitoring system may also include vibration sensors, temperature sensors, high-speed cameras, acoustic emission sensors, power / current acquisition units, and tool wear measurement units to acquire vibration acceleration and spectrum, tool ring / bearing temperature rise, crack initiation and propagation process, acoustic emission events, instantaneous power consumption, and changes in tool ring size and mass.

[0086] The collaborative control system synchronizes all sensors using a unified clock or timestamp, and associates and stores the cutter head configuration angle, single cutter position, single cutter attitude angle, cutter spacing, cutter specifications, operating parameters, and auxiliary rock breaking parameters with the measurement data.

[0087] Based on the collected data, the rock breaking volume per unit time, rock breaking amount per unit cutting length, rock breaking specific energy, effective crushing volume ratio, cutter load fluctuation coefficient, vibration frequency band energy, temperature rise rate, wear amount per unit rock breaking volume, as well as torque penetration index (TPI) and field penetration index (FPI) can be calculated, providing data support for the optimization of tunneling parameters.

[0088] Example 6: Hard rock tunneling equipment equipped with a reconfigurable cutterhead

[0089] This embodiment is a complete engineering equipment implementation plan. The hard rock tunneling equipment includes a shield body, main beam, main drive system 11, propulsion system 25, muck removal system, and a reconfigurable rock-breaking cutterhead whose configuration and posture are coordinated and adjustable.

[0090] The reconfigurable rock-breaking cutterhead, with its adjustable configuration and posture, is fixedly mounted at the front output end of the main drive system. The main drive system incorporates a cutterhead rotation drive mechanism 13, a rotation drive shaft 14, and a rotation gear ring 15, providing the cutterhead with the torque and speed required for rock breaking. The main drive system is mounted at the front end of the main beam, and the propulsion system acts between the main drive system and the main beam, providing axial tunneling thrust to the cutterhead. The shield body, as the external load-bearing structure of the equipment, works in conjunction with the surrounding rock of the tunnel to provide reaction force while simultaneously protecting the internal equipment.

[0091] The slag discharge system is located in the slag bin area behind the cutterhead and includes a scraper, a chute, and a conveying mechanism. After the rock slag crushed by the cutterhead falls into the slag bin, it is scraped into the chute by the scraper and then conveyed to the outside of the tunnel by the conveying mechanism, thus achieving continuous slag discharge.

[0092] The collaborative control system is connected to the main drive, propulsion system, cutterhead configuration drive, cutter position and posture adjustment unit and various sensors. It can automatically control the cutterhead configuration, cutter position and posture and tunneling operation parameters according to preset geological parameters or real-time feedback data, so as to realize intelligent adaptive tunneling.

[0093] The tunneling equipment described in this embodiment can be applied to various hard rock underground engineering projects such as railway tunnels, hydraulic tunnels, and mine roadways. When facing homogeneous hard rock sections, the cutterhead is adjusted to a large-cone-angle cone configuration, combined with an optimized cutter inclination angle, to achieve efficient and low-consumption rock breaking. When facing fault fracture zones, it quickly switches to a planar cutterhead configuration to increase the cutter contact area, reduce the cutter penetration depth, and minimize the risk of edge collapse and eccentric loading. When facing alternating layers of soft and hard rock, an asymmetrical irregular configuration is adopted, with rock breaking parameters matched in different zones to ensure stable tunneling. The entire process requires no disassembly or replacement of the cutterhead; configuration switching can be completed solely through electrical or hydraulic control, significantly improving the construction efficiency in complex strata.

[0094] Example 7, Rock Breaking Construction Foundation Method

[0095] This embodiment describes a foundation construction method for a reconfigurable rock-breaking cutterhead with adjustable configuration and orientation as described above, specifically including the following steps:

[0096] S1, Working Condition Determined. Based on advanced geological forecasts and design objectives, determine the rock type, stratigraphic structure, geostress conditions, rock-breaking motion mode, cutterhead target configuration, cutter specifications and position parameters, and whether to use an auxiliary rock-breaking module.

[0097] S2, Macroscopic configuration setting of the cutter head. The control configuration drive mechanism changes the configuration angle of each tool support arm 16 relative to the central support body, so that the tool action point forms a plane, a cone, or a preset non-planar envelope surface, and locks the configuration.

[0098] S3, Local tool parameter setting. Controls the tool translation mechanism to change the tool position and tool spacing, and controls the tool rotation mechanism to change the single tool mounting posture; if necessary, replace hobs with different specifications, different cutting edges, or different materials.

[0099] S4, Motion Mode Setting. Select at least one of the following modes: linear rock breaking mode, rotary rolling rock breaking mode, and combined trajectory rock breaking mode, and set the propulsion amount / thrust, cutterhead speed, tunneling speed, and construction continuity parameters.

[0100] S5, Composite Rock Breaking Condition Setting. When performing composite rock breaking construction, install and set the operating position, operating parameters, and start / stop sequence of the high-pressure water jet, laser, and / or ultrasonic auxiliary modules.

[0101] S6, execute rock breaking and synchronous data acquisition. The control equipment performs rock breaking according to the set working conditions, and simultaneously acquires at least one of the following parameters: triaxial force, thrust, torque, displacement, velocity, vibration, temperature, and auxiliary rock breaking parameters.

[0102] S7. Post-construction measurement and evaluation. Collect rock debris, measure the width and depth of the rock groove, the volume of broken rock, the residual rock ridge, and the particle size distribution of rock fragments; measure the wear of the cutting roller, and evaluate the rock breaking efficiency, unit energy consumption, load characteristics, and cutting tool performance based on online data.

[0103] S8, Dynamic Adaptive Adjustment. Maintaining consistency in all operating parameters except the target variable, it sequentially adjusts the cutterhead macro-configuration, cutter local pose, operating parameters, or auxiliary rock-breaking conditions according to formation changes, continuously maintaining optimal rock-breaking conditions.

[0104] Example 8: Multi-parameter collaborative optimization construction method

[0105] Based on Example 7, this embodiment provides a refined construction method for quantifying the configuration-pose coupling effect and optimizing the tool spacing. All quantitative calculation methods and formulas are reflected in this embodiment.

[0106] To quantitatively distinguish the independent and interactive effects of macroscopic cutterhead configuration changes and local cutter mounting posture changes on the rock-breaking process, the first... For the hob, define the cone angle of the tool bearing arm relative to the cone as... The mounting angle of the hob relative to the local reference of the tool bearing arm is defined as follows: The circumferential azimuth angle of the tool position about the axis of rotation is defined as follows: .

[0107] In a preferred coordinate description method, the first The local attitude transformation matrix of the hob can be expressed as:

[0108] (1)

[0109] in, , and These represent the rotation matrices about the corresponding coordinate axes. For different configurations of the articulated axes and tool rotation axis arrangements, the order of the rotation matrices and the rotation axes can be adjusted according to the actual mechanical kinematic chain. Let... Let be the feature direction vector of the hob in its zero pose state. Let be the feature direction vector corresponding to the construction state, then:

[0110] (2)

[0111] set up Let be the local normal vector of the rock surface at the current position of the cutting cutter. Then, the equivalent angle of action formed by the macroscopic cone angle and the local installation posture is... Defined as:

[0112] (3)

[0113] When macro configuration angle With local installation angle When they are located in the same adjustment plane, the above formula can be simplified to:

[0114] (4)

[0115] in, This is used to represent the directional relationship between the two-stage angle adjustments; it takes +1 for superposition in the same direction and -1 for compensation in opposite directions. Thus, the "cutter head taper" and "hob installation angle" can be transformed from two independent setting parameters into equivalent action angles that reflect the actual spatial action state of the tool, while still retaining... and Layered adjustability.

[0116] During construction, the multi-source testing system acquired the first... The three-dimensional load vector of the hob in the global coordinate system The normal force, rolling force, and lateral force in the local coordinate system of the hob are obtained through coordinate transformation corresponding to the actual pose of the hob:

[0117] (5)

[0118] in, , and These represent the local normal, rolling direction, and lateral load components of the hob, respectively. This approach avoids confusion regarding the force direction caused by directly comparing the global sensor output under different cone angles and tool mounting angles.

[0119] For any construction condition involving cutterhead rotation, drive propulsion, and rock box translation, the driving energy... It can be calculated uniformly based on the power integral of each active degree of freedom:

[0120] (6)

[0121] (7)

[0122] in, and These are the cutter head torque and angular velocity, respectively. and These are propulsion force and propulsion speed, respectively. and These represent the driving force and translation speed in the direction of rock box translation, respectively. The power term corresponding to the degree of freedom that does not participate in a certain construction mode is set to zero. This refers to the effective volume of fractured rock obtained after construction. The mechanical rock-breaking energy per unit volume.

[0123] To identify whether there is a synergistic effect between the cutter head cone angle and the hob mounting angle that is not simply superimposed, any measurable response quantity can be used. Establish two-factor interaction parameters:

[0124] (8)

[0125] The response quantity Rock breaking energy can be selected. Peak normal force, average lateral force, load fluctuation coefficient, fracture volume, residual rock ridge volume, vibration intensity, or tool wear. When considering indicators such as rock-breaking energy, load, or wear, where "smaller values ​​are better," This indicates that the combined operating conditions have beneficial synergy; when When considering indicators such as effective crushing volume, where "the larger the value, the better," This indicates that the combined operating conditions have a beneficial synergy.

[0126] Furthermore, a macroscopic cone angle can be established using a quadratic response surface. With local installation angle Response to the target Quantitative relationship:

[0127] (9)

[0128] in, This is a coupling coefficient characterizing the strength of the interaction between the macroscopic configuration of the cutterhead and the local attitude of the individual cutter. For construction aimed at minimizing rock-breaking energy, minimum peak load, or minimum lateral force, it can be used within the platform's allowance. , Within the range, the optimal parameter combination is searched based on the fitted model; when a stable extremum exists within the response surface, the candidate optimal combination can be obtained by the following formula:

[0129] (10)

[0130] Equivalent action angle decomposition and equivalent kinematic reference method

[0131] To further differentiate the rock-breaking differences caused by "overall cutterhead taper change" and "single-cutter local tilt angle change" when the geometric results are similar, this invention sets up an equivalent action angle decomposition comparison construction. The target equivalent action angle is predetermined. Construct multiple sets of different macroscopic cone angles and local installation angle So that each group satisfies:

[0132] (11)

[0133] For example, within the allowable parameter range, various decomposition methods such as "large cone angle + small local tilt angle", "medium cone angle + medium local tilt angle", and "small cone angle + large local tilt angle" can be used to make the hob have the same or similar equivalent operating angles. Then, keeping the rock, cutter spacing, linear velocity, penetration depth, and boundary load consistent, the triaxial force, crack propagation, fracture volume, specific energy, and lateral load were compared. If in Different under basically the same conditions If the combination still shows significant differences, these differences can be attributed to changes in the macroscopic spatial envelope of the cutterhead, the tool path, and the cooperative relationship among multiple tools, rather than simply changes in the equivalent tilt angle of a single tool.

[0134] Since changes in the cutter head cone angle can alter the actual radial projection position of each hob relative to the common axis of rotation, keeping the cutter head rotation speed constant could cause the hob linear velocity to change synchronously, thus masking the influence of the geometric configuration itself. Therefore, for the first... The actual radial distance of the hob relative to the common axis of rotation is determined based on the configuration angle and the translational position of the tool. And define the equivalent radius for working condition matching. :

[0135] (12)

[0136] in, For the first The weight of the hobbing cutter can be used for general comparison during construction. Different weights can also be assigned based on the target tool position, effective cutting length, or load percentage. This is to maintain the equivalent cutting speed under different tool head cone angles. Keeping constant, the angular velocity of the cutter head is controlled to satisfy:

[0137] (13)

[0138] If it is also required that different cone angle conditions have the same single-turn penetration depth... The driving propulsion speed is as follows:

[0139] (14)

[0140] Perform synchronous matching.

[0141] The above formulas can actively eliminate the additional effects of changes in average cutting speed and single-turn penetration when changing the cutterhead taper, so that different configurations have a unified kinematic reference.

[0142] Relationship between cutter spacing, penetration depth, crack penetration and rock breaking energy

[0143] For multi-roller cutter collaborative rock breaking, this invention further provides a cutter spacing-penetration matching construction method. Let the effective cutter spacing between adjacent roll cutters be... The angular velocity of the cutter head is The driving axial propulsion speed is Then the equivalent penetration per revolution for:

[0144] (15)

[0145] Define dimensionless matching parameters for tool spacing and penetration. for:

[0146] (16)

[0147] Different Under these conditions, the geometric envelope volume between adjacent toolpaths is obtained through high-speed imaging, post-construction contour scanning, or 3D measurement. and the volume of residual rock ridges after construction And define the crack penetration / synergistic fracture index. :

[0148] (17)

[0149] The closer to 1, the fewer residual rock ridges between adjacent cutter paths, and the more complete the crack penetration and synergistic spalling. Combined with the rock breaking energy of formula (7) This expands the selection of cutter spacing and penetration depth from a single "whether it breaks" evaluation to a joint evaluation of "crack penetration degree - rock breaking energy consumption". For fixed rock and cutter conditions, the following can be established:

[0150] (18)

[0151] when Furthermore, when the extreme values ​​of the fitted parameters are within the range of the construction parameters, candidate low-energy-consumption matching parameters can be obtained:

[0152] (19)

[0153] The actual optimal operating condition can be further limited to: Not lower than the preset collaborative breakage threshold Within the range The minimum parameter combination. This method can also be extended to tool spacing. Penetration hob specifications and the angle of the cutter head configuration Multi-factor matching optimization.

[0154] All aspects not detailed in this invention are conventional technical means known to those skilled in the art.

[0155] The above content shows and describes the basic principles, main features, and beneficial effects of this technical solution. The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of this technical solution. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this technical solution should be included within the protection scope of this technical solution.

Claims

1. A reconfigurable rock-breaking cutterhead with adjustable configuration and pose, characterized in that, The system includes a central support, several circumferentially arranged tool carrier arms, a configuration hinge, a configuration drive mechanism, and a configuration locking mechanism, as well as a tool posture adjustment system mounted on each tool carrier arm. The central support is used to connect to the main drive output end of the tunneling equipment and determine the rotation axis. Each tool carrier arm is hinged to the central support through a corresponding configuration hinge. The configuration drive mechanism acts between the central support and the tool carrier arm to adjust the configuration angle of the tool carrier arm relative to the cutterhead reference plane to reconstruct the geometry of the cutterhead working surface. The configuration locking mechanism is used to lock the target configuration angle of the tool carrier arm. The tool posture adjustment system includes an independent tool translation mechanism and a tool rotation mechanism, which are used to adjust the installation radius and installation tilt angle of the tool, respectively, to achieve decoupling of positional and attitude degrees of freedom.

2. The reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to claim 1, characterized in that, The configuration angles of each tool support arm can be adjusted synchronously, in groups, or independently, so that the working surface of the tool head can be reconstructed into a plane, a conical surface with different cone angles, or a non-planar irregular surface.

3. The reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to claim 1 or 2, characterized in that, The tool translation mechanism includes a guide pair and a translation drive component arranged along the tool support arm, used to adjust the tool spacing and installation radius; the tool rotation mechanism is located between the movable tool holder and the tool box, used to adjust the tilt angle of the hob axis relative to the local tool disc surface; both are provided with independent drive sources, which can be set, locked, and operated in combination.

4. The reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to claim 3, characterized in that, The tool position adjustment system also includes a detachable modular tool mounting assembly, which can be adapted to replace disc hobs of different diameters, cutting edges or materials.

5. The reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to any one of claims 1, 2, and 4, characterized in that, It also includes a composite rock-breaking extension system, which has a unified mechanical installation position, power supply interface and data synchronization interface, and is compatible with at least one of the following: high-pressure water jet assisted rock-breaking module, laser assisted rock-breaking module, ultrasonic assisted rock-breaking module and microwave assisted rock-breaking module.

6. The reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to claim 5, characterized in that, The configuration drive mechanism adopts a hydraulic cylinder, electric cylinder, lead screw mechanism or gear and worm gear mechanism; the configuration locking mechanism adopts a mechanical locking pin, wedge locking, hydraulic locking or brake, and is used to bear the rock breaking load.

7. The reconfigurable rock-breaking cutterhead with adjustable configuration and pose according to any one of claims 1, 2, 4, and 6, characterized in that, It also includes a multi-source condition monitoring system, which includes at least a triaxial force sensor, a thrust sensor, a torque sensor, a speed sensor, and a displacement sensor, and can be expanded to include a vibration sensor, a temperature sensor, an acoustic emission sensor, and a tool wear measurement unit, for synchronously acquiring mechanical, kinematic, structural, and thermal response data during the rock breaking process.

8. A tunneling equipment, characterized in that, It includes a shield body, a main beam, a main drive system, a propulsion system, a slag removal system, and a reconfigurable rock-breaking cutterhead with adjustable configuration and posture as described in any one of claims 1 to 7; the reconfigurable rock-breaking cutterhead device is connected to the output end of the main drive system, the main drive system is connected to the propulsion system through the main beam, and the slag removal system is arranged on the rear side of the cutterhead for discharging rock slag.

9. A method for breaking rocks, characterized in that, A reconfigurable rock-breaking cutterhead with adjustable configuration and pose as described in any one of items 1 to 7. Includes the following steps: S1. Based on the rock strength, joint characteristics and geological conditions of the stratum to be excavated, determine the target working face configuration of the cutterhead, the installation position and posture of the cutter, and the tunneling operation parameters. S2, control the configuration drive mechanism to adjust the configuration angle of each tool bearing arm, form the target tool head working surface shape and then lock it through the configuration locking mechanism; S3 controls the tool translation mechanism and the tool rotation mechanism respectively, adjusting the tool's installation radius and installation angle to the target values; S4 drives the cutterhead to rotate and advance axially, continuously rolling and breaking the rock in the formation, and simultaneously discharging rock debris; S5 adjusts the cutterhead configuration and cutter position parameters in real time according to changes in the strata during tunneling, matching the corresponding tunneling thrust and rotation speed to maintain the optimal rock breaking state.

10. The rock-breaking construction method according to claim 9, characterized in that, During the tunneling process, the equivalent action angle decomposition method is used to quantitatively match the cutterhead configuration angle and the cutter installation angle. By matching the equivalent cutting linear velocity and single-rotation penetration to a unified kinematic benchmark, and combining the dimensionless matching model of cutter spacing-penetration and crack penetration index, the operating parameters are optimized in real time with the goal of minimizing rock breaking energy and fully coordinating crushing.

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