Novel reducing TBM (Tunnel Boring Machine) cutterhead

Abstract

The utility model relates to a novel reducing TBM cutter head which comprises a cutter head body, a center block is installed in the middle of the front face of the cutter head body, a plurality of edge block pieces are evenly arranged on the portion, on the periphery of the center block, of the cutter head body in the circumferential direction of the center block, and each edge block piece and the center block are welded together after being connected through a bolt. Supporting rib plates are installed on the side block pieces and the center block, and slag sliding channels are formed in the supporting rib plates. A plurality of cutter box seats are uniformly welded on an edge block piece on the front surface of the cutter head main body, each cutter box seat is provided with a hobbing cutter, and all the hobbing cutters are integrally arranged in a spiral track; a plurality of groups of front scrapers are also arranged on the front surface of the cutter head main body; and a plurality of groups of back scrapers are also arranged on the back surface of the cutter head main body. The cutter head has the advantages that by redesigning the edge block pieces and utilizing and transforming the old center block, the cutter head can be subjected to rapid reducing adjustment so as to meet the construction requirements of tunnels with different diameters and the like.

Description

Technical Field

[0001] The utility model relates to a novel variable-diameter TBM cutterhead, belonging to the field of cutterheads. Background Technique

[0002] The common diameter range of the cutterheads of tunnel boring machines is 3 - 15 m. In the construction of rail subways, the most commonly used diameter is about 6 m. The outer diameter of the segment is 6 m. Combining with the TBM construction technology, the required excavation diameter of the cutterhead is 6.3 m. In the second-phase project of Qingdao Subway, the segment diameter is changed to 6.2 m, then the excavation diameter of the cutterhead is 6.5 m. One type of segment diameter corresponds to one type of cutterhead. The cost of manufacturing a new cutterhead is about 2 million yuan. For more than a dozen units, it will cost more than 20 million yuan. Moreover, most TBM cutterheads have only tunnelled four or five kilometers and far from reaching their service life. Therefore, it is particularly important to carry out variable-diameter innovation design for cutterheads with similar diameters, which can save raw materials, reduce product costs, shorten the R & D cycle of new cutterheads, and promote the serialization, modularization and parameterization design of TBM products.

[0003] China Railway Engineering Corporation has disclosed a TBM diameter-expanding cutterhead, which consists of a central cutterhead and a peripheral cutterhead. During the diameter-expanding process, the peripheral cutterhead pops out and can rotate together with the central cutterhead to achieve diameter expansion.

[0004] Most domestic ones use newly manufactured cutterheads to achieve the variable-diameter function of the cutterhead. Although there is a diameter-changing method using the central block of the old cutterhead abroad, due to the different structures of the cutterhead body and different construction requirements, its diameter-changing idea cannot be copied.

[0005] The disadvantages of the existing cutterheads are as follows:

[0006] 1. Cost problem: The cost of newly manufacturing a cutterhead is expensive. Especially when the segment diameter changes, it is necessary to re-design and manufacture, increasing the project cost.

[0007] 2. Resource waste: Most TBM cutterheads are replaced after tunnelling a short distance and their service life is not fully utilized.

[0008] 3. Long design cycle: The R & D and manufacturing cycle of new cutterheads is long, affecting the project progress. Content of the Utility Model

[0009] To overcome the defects of the prior art, the utility model provides a novel variable-diameter TBM cutterhead. The technical solution of the utility model is as follows:

[0010] A novel variable-diameter TBM cutterhead, comprising a cutterhead body, a central block is installed in the middle of the front of the cutterhead body, and several side block members are evenly arranged on the cutterhead body around the central block along the circumferential direction of the central block. Each of the side block members is welded together after being bolted to the central block; support rib plates are installed on both the side block members and the central block, and slag-chute channels are formed on the support rib plates; several cutter box seats are evenly welded on the side block members on the front of the cutterhead body, and a hob is installed on each of the cutter box seats. All the hobs are arranged in a spiral track as a whole; several front scrapers are also installed on the front of the cutterhead body, and several rear scrapers are installed on the back of the cutterhead body. All the front scrapers and rear scrapers are arranged along the edge of the cutterhead body; the connection pin holes of the connection flange plates of the central block and the side block members are reamed to a diameter of 86 mm.

[0011] There are four side block members, and a total of twenty-one hobs are installed on the side block members.

[0012] A weld seam is formed between the side block member and the central block. After the side block member and the central block are assembled, the side block member and the central block are welded at the weld seam.

[0013] A slag collecting hopper is also arranged in the middle of the cutterhead body, and all the slag-chute channels face the slag collecting hopper.

[0014] Slag openings for facilitating the flow of muck are arranged on the support rib plates of the cutterhead body.

[0015] Grooves are also arranged on the support rib plates of the cutterhead body.

[0016] All the slag-chute channels are interconnected.

[0017] The advantages of the present utility model are as follows:

[0018] 1. Variable-diameter flexibility: By designing new side block members and reusing the old central block, the cutterhead can be quickly adjusted in diameter to meet the construction requirements of tunnels with different diameters.

[0019] 2. Structural stability: The connection method between the central block and the side block members provides sufficient structural stability and strength, ensuring the reliability and durability of the cutterhead during tunneling.

[0020] 3. Maintenance simplicity: The design of bolt connection allows for quick disassembly and replacement of cutterhead components, facilitating maintenance and repair and reducing downtime.

[0021] 4. Slag-chute efficiency: The slag-chute channels formed on the support rib plates help improve the discharge efficiency of muck and reduce blockage problems during construction.

[0022] 5. Tool layout optimization: The spiral trajectory setting of the hob provides a wider rock-breaking coverage range, improving the tunneling efficiency and the effectiveness of tool use.

[0023] 6. Comprehensive scraper coverage: The front and back scrapers are arranged along the edge of the cutter head, enhancing the ability to clean the muck on the cutter head surface and keeping the cutter head clean and the tunneling face clear.

[0024] 7. Local redesign of the connecting flange plate: The reaming design of the connecting pin holes of the connecting flange plates of the central block and the side block parts facilitates the positioning of the old central block and the newly manufactured side blocks, providing greater connection strength and adapting to high-intensity construction environments.

[0025] 8. Cost-effectiveness: This design allows for the retrofit and upgrade of existing cutter heads, reducing the cost of manufacturing a completely new cutter head due to changes in segment diameter.

[0026] 9. Improve construction safety: The optimized tool layout and support structure reduce potential safety risks during construction, such as tool breakage or cutter head damage. Description of the Drawings

[0027] Figure 1 is Figure 3 the K-K sectional view of.

[0028] Figure 2 is Figure 1 the rear view of.

[0029] Figure 3 is Figure 1 the side view of.

[0030] Figure 4 is the schematic diagram of the main structure of the present utility model.

[0031] Figure 5 is Figure 2 the H-H sectional view of.

[0032] Figure 6 is Figure 1 the schematic diagram of the central block structure.

[0033] Figure 7 is Figure 6 the side view of.

[0034] Figure 8 is Figure 6 the B-B sectional view of. Detailed Implementation Manner

[0035] The present utility model will be further described below in conjunction with specific embodiments, and the advantages and features of the present utility model will become clearer as the description progresses. However, these embodiments are merely exemplary and do not constitute any limitation to the scope of the present utility model. Those skilled in the art should understand that modifications or substitutions can be made to the details and forms of the technical solutions of the present utility model without departing from the spirit and scope of the present utility model, but such modifications and substitutions all fall within the protection scope of the present utility model.

[0036] Refer to Figures 1 to 8 , the present utility model relates to a novel variable-diameter TBM cutterhead, including a cutterhead body. A center block 1 is installed in the middle of the front of the cutterhead body. On the cutterhead body around the center block 1, several side block members (the first side block member 2, the second side block member 3, the third side block member 4, and the fourth side block member 5) are evenly arranged along the circumferential direction of the center block 1. Each of the side block members is bolted to the center block 1 and then welded together; Support rib plates are installed on both the side block members and the center block 1. Among them, the support rib plate on the center block 1 is the center block support rib plate 12, and the support rib plate on the side block member is the side block member support rib plate 11. A slag chute 13 is formed on the support rib plate; Several cutter box seats 6 are evenly welded on the side block members on the front of the cutterhead body. A hob 7 is installed on each of the cutter box seats 6, and all the hobs 7 are arranged in a spiral track as a whole; A plurality of front scrapers 8 are also installed on the front of the cutterhead body, and a plurality of back scrapers 10 are installed on the back of the cutterhead body. All the front scrapers 8 and the back scrapers 10 are arranged along the edge of the cutterhead body; The positioning holes of the connecting flange plate of the center block 1 and the connecting flange plate 3-2 of the side block member are enlarged from the original diameter of 80 mm to a diameter of 86 mm. The front scrapers 8 and the back scrapers 10 are both welded to the cutterhead body through the scraper seat 9.

[0037] In the present utility model, through the improvement of the structure, the following technical effects are achieved:

[0038] Variable-diameter ability: By designing detachable side block members (welding is carried out after determining the corresponding dimensions in advance, so the welding of corresponding dimensions can be carried out in combination with the on-site situation), the diameter of the cutterhead can be flexibly adjusted to meet the requirements of different tunnel diameters.

[0039] Structural strength: The bolt connection and welding structure between the side block members and the center block provides strong structural stability and sufficient strength.

[0040] Maintenance convenience: The bolt connection design facilitates the quick disassembly and replacement of the cutterhead components, reducing the maintenance difficulty and time.

[0041] Efficient slag discharge: The design of the slag chute 13 on the support rib plate helps to efficiently discharge the crushed rock and soil from the surface of the cutterhead.

[0042] Tool layout optimization: The spiral trajectory layout of hob 7 provides a wider tunneling coverage range and improves tunneling efficiency.

[0043] Full scraper coverage: The front scraper 8 and the rear scraper 10 are arranged along the edge of the cutter head, enhancing the cleaning ability of the muck on the cutter head surface.

[0044] Improve construction safety: The optimized tool layout and support structure reduce potential safety risks during construction.

[0045] There are four side block parts. Compared with the original side blocks, the number and position of the tool boxes on the side blocks are optimized and adjusted. A total of twenty-one hobs 7 are installed on the side block parts, and hob stiffeners 3-1 for supporting the hobs are also installed at the positions of the hobs.

[0046] Weld seams are formed between the side block parts and the center block 1. After the side block parts and the center block are assembled, they are welded at the weld seams.

[0047] A slag collecting hopper is also provided in the middle of the cutter head body. All slag chutes 13 are oriented towards the slag collecting hopper, and all slag chutes 13 are interconnected.

[0048] Slag openings for facilitating the flow of muck are provided on the center block support stiffener 12 and the side block part support stiffener 11 to facilitate the flow of muck.

[0049] When the present utility model is being modified:

[0050] (1) Before reusing the center block, pre-treatment is first carried out, including crack repair welding inspection of the center block, ensuring that the original structural dimensions of length x width (mm): 3250x3250 remain unchanged, the connecting pin holes of the center block flange end face are reamed to ψ86, and damaged tool boxes are replaced;

[0051] (2) Design and manufacture of the side block parts. The excavation diameter is increased from 6300mm to 6500mm. To ensure the rock breaking effect, one more 19-inch tool is added.

[0052] (3) Optimize the tool trajectory. Taking the fourth side block part 5 as an example to illustrate the design process. After the tool positions are determined, the hob positions must be supported by hob stiffeners 3-1. Openings are provided on the hob stiffeners to facilitate the flow of muck, and the slopes on the stiffeners are beneficial for welding. In addition to the support and connection functions, the connecting flange panel 3-2 can also conduct muck diversion.

[0053] (4) After the four side block parts are welded, heat treatment is carried out, then machining manufacturing is carried out, and finally the fitting of the four side blocks and the center block is carried out. The slag chutes at all scraper positions are unobstructed and can lead to the center position of the cutter head body.

[0054] Working principle of the present utility model:

[0055] Tunneling process: When the TBM advances, the hob 7 contacts the rock and breaks it, and the side block support rib plate 11 and the center block support rib plate 12 provide structural support.

[0056] Slag discharging process: The crushed rock and soil are discharged through the slag chutes 13 on the support rib plates. All the slag chutes 13 are interconnected and face the slag collecting hopper to achieve efficient slag discharging.

[0057] Tool maintenance: The hob 7 is installed on the tool box seat 6, enabling tool replacement from the back, and is supported by the hob rib plate 3-2 to extend the service life of the tool.

[0058] Function of the scraping knife: The front scraping knife 8 and the back scraping knife 10 remove the soil and slag attached to the cutter head surface to keep the cutter head clean and the tunneling face clear.

[0059] Usage method of the present utility model:

[0060] Installation and adjustment: According to the designed diameter of the tunnel, install side blocks of corresponding sizes and ensure the firmness of the bolt connection and welding between the side blocks and the center block 1.

[0061] Tunneling operation: Start the TBM to rotate the cutter head, and the hob 7 starts to break the rock.

[0062] Slag discharging management: Monitor the slag discharging situation of the slag chutes 13 to ensure smooth slag discharging and prevent blockage.

[0063] Tool maintenance: Regularly check the wear condition of the hob 7 and replace or maintain it as needed.

[0064] Scraping knife cleaning: Regularly clean the front scraping knife 8 and the back scraping knife 10 to keep them clean and operate efficiently.

[0065] The above are only the preferred specific embodiments of the present utility model, but the protection scope of the present utility model is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present utility model, according to the technical solution and the inventive concept of the present utility model, makes equivalent substitutions or changes, and all should be covered within the protection scope of the present utility model.

Claims

1. A novel variable diameter TBM cutterhead, comprising a cutterhead body, characterized in that: A center block is installed in the middle of the front side of the cutter disc body, and a number of side blocks are evenly arranged along the circumferential direction of the center block on the cutter disc body outside the center block, and each of the side blocks is welded together with the center block after being connected by bolts; support ribs are installed on the side blocks and the center block, and slag channels are formed on the support ribs; a number of tool box seats are evenly welded on the side blocks on the front side of the cutter disc body, and a roller is installed on each of the tool box seats, and all the rollers are arranged in a spiral trajectory; an array of front scrapers is also installed on the front side of the cutter disc body, and an array of back scrapers is also installed on the back side of the cutter disc body, and all the front scrapers and back scrapers are arranged along the edge of the cutter disc body; the connecting pin holes of the connecting flange plate of the center block and the connecting flange plate of the side blocks are expanded to a diameter of 86 mm.

2. The novel variable diameter TBM cutterhead according to claim 1 is characterized in that: There are four edge blocks, and a total of twenty-one rolling cutters are installed on the edge blocks.

3. The novel variable diameter TBM cutterhead according to claim 1 is characterized in that: A weld is formed between the side block and the center block. After the side block and the center block are assembled, the side block and the center block are welded at the weld.

4. The novel variable diameter TBM cutterhead according to claim 2 or 3, characterized in that: A slag collecting bucket is also arranged in the middle of the cutter disc body, and all slag sliding channels are oriented toward the slag collecting bucket.

5. The novel variable diameter TBM cutterhead according to claim 4 is characterized in that: The support ribs of the cutter disc body are provided with slag openings for facilitating the flow of slag.

6. The novel variable diameter TBM cutterhead according to claim 5 is characterized in that: A groove is also arranged on the supporting rib of the cutter disc body.

7. The novel variable diameter TBM cutterhead according to claim 5 is characterized in that: All slag sluice channels are interconnected.

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