An open-face tunnel boring machine segment positioning system

Abstract

This utility model discloses an open-type shield tunneling machine segment positioning system for positioning box culvert segments. The system includes an open-type shield tunneling machine and positioning cylinders. The open-type shield tunneling machine includes a front shield body and a rear shield body. The top and rear of the rear shield body are open. Several positioning cylinders are arranged in a matrix on the bottom plate and side plates of the rear shield body. Pressure plate cylinders and segment pressure plates are installed inside the rear shield body. Multiple pressure plate cylinders are arranged in a matrix. The base of the pressure plate cylinder is fixed to the front of the rear shield body, and the telescopic rod is connected to the segment pressure plate. The pressure plate cylinder drives the segment pressure plate to move longitudinally. The advantages of this utility model are: accurate positioning and rapid assembly of box culvert segments are achieved by controlling the extension and retraction of the positioning cylinders with a measurement system; compared with manually adjusting the crane's slings for box culvert segment positioning, the system has high construction efficiency, good safety, and low construction cost, resulting in good economic benefits.

Description

Technical Field

[0001] This utility model relates to the technical field of open-face tunnel boring machines, and in particular to a tunnel segment positioning system for open-face tunnel boring machines. Background Technology

[0002] Open-face (open-type, U-shaped) tunnel boring machines (TBMs) replace cut-and-cover or irregular-shaped shield tunneling methods with open-face shield tunneling or propulsion methods to construct precast box culverts and U-shaped channels underground. Open-face TBMs are suitable for constructing or renovating box culverts and channels in harsh conditions such as confined spaces, close proximity to buildings, and geological formations prone to sudden inrushes and piping. The open-face TBM involves excavating the soil with the front shield and assembling box culvert or U-shaped channel sections with the rear shield to form a complete box culvert or U-shaped channel.

[0003] During the assembly of box culvert sections, a crane (usually a truck crane) is used to lift the box culvert section into the rear shield of the open-face tunnel boring machine. The crane uses its swing arm or its own movement to align the box culvert section with the sides of the already installed box culvert sections. Then, the box culvert section is lifted or lowered to the assembly position using the hook. Due to the difficulty of accurately positioning the box culvert section with the crane, it usually requires 4 groups of 2 people each, for a total of 8 workers, to operate the hand-operated hoists on the slings to change the sling length and align the box culvert section to be assembled with the already installed sections. Precise alignment of the bolt holes for the box culvert sections is achieved. At this point, appropriate pressure is applied by extending the section pressure plate and pressure plate cylinder inside the shield to press the box culvert section to be installed onto the already installed box culvert section, preventing the box culvert section to be installed from sliding or shifting. After the bolts are installed, the bottom and sides of the assembled box culvert section to be installed are grouted with cement quick-setting mortar of appropriate strength. After complete filling and solidification of the quick-setting mortar, and after the box culvert section is fixed, the excavation of the next section begins. This process is repeated to complete the excavation and installation of the entire box culvert.

[0004] As can be seen from the above construction process, when the box culvert section to be installed is hoisted to the assembly position, eight workers are required to be under the crane boom to operate the slings and hand-operated hoists to change the length of the slings to achieve precise alignment of the box culvert section to be installed with the bolt holes of the already installed box culvert section. This construction method is dangerous and inefficient. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a positioning system for open-face tunnel boring machines (TBMs). This system comprises an open-face TBM, positioning cylinders, a measurement system, a grouting system, and a crane. Positioning cylinders are installed on the rear shield of the open-face TBM to support and fix the culvert sections, thus quickly completing the assembly and positioning of the culvert sections. After the culvert section to be installed is lifted into the approximate assembly position on the rear shield by the crane, the measurement system acquires the assembly and positioning data of the culvert section. The control system adjusts the positioning cylinders to position the culvert section in the assembly position. The positioning culvert section is then pushed forward to the previously installed culvert section by the section pressure plate and pressure plate cylinder inside the rear shield. Once the position is confirmed to be accurate, appropriate pressure is applied, the culvert section bolts are installed and tightened, and the gap between the culvert section and the rear shield is filled with quick-setting grout provided by the grouting system. The excavation gap is also filled with slow-setting grout provided by the grouting system, achieving efficient assembly of the culvert sections and ensuring rapid and safe tunneling of the open-face TBM.

[0006] The objective of this utility model is achieved through the following technical solution:

[0007] An open-type tunnel boring machine (TBM) segment positioning system is provided for positioning box culvert segments. The system includes an open-type TBM and positioning cylinders. The open-type TBM includes a front shield and a rear shield. The top and rear of the rear shield are open. The bottom plate and side plates of the rear shield are provided with a plurality of positioning cylinders arranged in a matrix. The interior of the rear shield is equipped with pressure plate cylinders and segment pressure plates. The pressure plate cylinders are arranged in a matrix. The base of the pressure plate cylinder is fixed to the front of the rear shield, and the telescopic rod is connected to the segment pressure plate. The pressure plate cylinder drives the segment pressure plate to move in the longitudinal direction.

[0008] The system also includes a measurement system and targets. At least three targets are arranged on the box culvert section. Any three targets are not collinear. At least three targets are selected as measurement targets. The measurement system is used to measure the position of the measurement targets.

[0009] The system also includes a calibration target used to correct measurement errors in the measurement system.

[0010] The system also includes a grouting system, which includes a fast-setting grout distribution valve group and a slow-setting grout distribution valve group. The fast-setting grout distribution valve group is used to control the output of fast-setting grout, and the slow-setting grout distribution valve group is used to control the output of slow-setting grout.

[0011] The system also includes a hydraulic system, through which the positioning cylinder is driven.

[0012] The system also includes a control system, through which the measuring system, the hydraulic system, and the grouting system are all controlled.

[0013] The system also includes a crane, which lifts the box culvert sections using slings.

[0014] The advantages of this utility model are:

[0015] 1. Construction takes place only inside an open-type tunnel boring machine, causing no impact on road traffic or the surrounding environment;

[0016] 2. Injecting retarding grout can suppress the spalling and collapse of the strata around the excavation part of the tunnel boring machine, reduce the friction on the outer surface of the tunnel boring machine, suppress the stress release of the strata, and result in less strata deformation.

[0017] 3. By using a measurement system to control the extension and retraction of the positioning cylinder, accurate positioning of the box culvert pipe sections can be achieved, enabling rapid assembly;

[0018] 4. Grouting at the bottom of the box culvert pipe section is completed by injecting quick-setting grout to fix the box culvert pipe section and complete the installation of the box culvert pipe section;

[0019] 5. Compared with manually adjusting the crane's slings to position box culvert sections, this method offers higher construction efficiency, better safety, lower construction costs, and better economic benefits. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the open-type shield tunneling machine pipe section positioning system of this utility model;

[0021] Figure 2 This is a top view of the positioning cylinder of this utility model.

[0022] Figure 3 This is a side view of the positioning cylinder of this utility model.

[0023] Figure 4 This is a rear view of the positioning cylinder of this utility model after installation;

[0024] Figure 5 This is a construction diagram illustrating step S1 of the pipe segment positioning method for the open-type tunnel boring machine of this utility model.

[0025] Figure 6 This is a construction diagram illustrating step S2 of the pipe segment positioning method for the open-type tunnel boring machine of this utility model;

[0026] Figure 7 This is a construction diagram illustrating step S3 of the pipe segment positioning method for the open-type tunnel boring machine of this utility model.

[0027] like Figures 1-7 As shown in the figure, the markings represent:

[0028] 1. Rear shield body, 2. Box culvert pipe section, 3. Positioning cylinder, 4. Front shield body, 5. Pipe section pressure plate, 6. Pressure plate cylinder, 7. Measurement system, 7-1 Measurement target, 7-2 Calibration target, 8. Control system, 10. Reaction frame, 11. Hydraulic system, 12. Grouting system, 12-1 Grouting system valve group, 12-1a Quick-setting grout distribution valve group, 12-1b Retarded grout distribution valve group, 12-2 Quick-setting grout A liquid tank, 12-3 Quick-setting grout B liquid tank, 12-4 Retarded grout A liquid tank, 12-5 Retarded grout B liquid tank, 12-6 Clean water tank, 12-7 Grouting pipe, 13. Suspension cable, 14 Quick-setting grout, 15 Retarded grout, 16. Launching shaft, 17. Receiving shaft, 18. Open shield control system, 19. Pipe section positioning remote control management system. Detailed Implementation

[0029] The features and other related features of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments, so as to facilitate the understanding of those skilled in the art:

[0030] Example: Figures 1-4 As shown, this embodiment relates to an open-type shield tunneling machine segment positioning system for positioning box culvert segment 2. The system mainly includes an open-type shield tunneling machine, positioning cylinders 3, a measurement system 7, a control system 8, a hydraulic system 11, a grouting system 12, and a crane. The open-type shield tunneling machine includes a front shield 4 and a rear shield 1. The front shield 4 is used for excavating soil. The top and rear of the rear shield 1 are open. Several positioning cylinder mounting holes arranged in a matrix are provided on the bottom plate and side plates of the rear shield 1, and each positioning cylinder mounting hole is equipped with a positioning cylinder 3. The positioning cylinder mounting holes are closed by cover plates. The positioning cylinder 3 on the bottom plate of the body 1 is arranged vertically and is used to adjust the vertical position of the box culvert section 2. The positioning cylinder 3 on the side plate of the rear shield body 1 is arranged horizontally and is used to adjust the horizontal position of the box culvert section 2. The rear shield body 1 is equipped with a section pressure plate 5 and a pressure plate cylinder 6. There are multiple pressure plate cylinders 6, and the multiple pressure plate cylinders 6 are arranged in a matrix. A single pressure plate cylinder 6 is arranged longitudinally and is used to adjust the longitudinal position of the box culvert section 2. The base of the pressure plate cylinder 6 is fixed to the front of the rear shield body 1, and the telescopic rod is connected to the section pressure plate 5. The pressure plate cylinder 6 drives the section pressure plate 5 to move in the longitudinal (front and back) direction.

[0031] At least three targets are arranged on the box culvert section 2, and any three targets are not collinear. In this embodiment, nine targets are arranged on the box culvert section 2. Three of the nine targets are selected as measurement targets 7-1. The position of the three measurement targets 7-1 is measured using the measurement system 7 (total station, laser measuring instrument, etc.). The three measurement targets 7-1 can ensure that the six degrees of freedom of the box culvert section 2 can be measured. Different numbers and positions of targets can be selected as measurement targets 7-1 according to the requirements to further improve the measurement accuracy. The measurement error of the measurement system 7 can be corrected by calibrating target 7-2. The calibration target 7-2 and the measurement target 7-1 are located behind and in front of the measurement system 7, respectively.

[0032] The grouting system 12 includes a grouting system valve assembly 12-1, a quick-setting grouting A liquid tank 12-2 (containing quick-setting grouting A liquid and equipped with a stirrer), a quick-setting grouting B liquid tank 12-3 (containing quick-setting grouting B liquid), a slow-setting grouting A liquid tank 12-4 (containing slow-setting grouting A liquid and equipped with a stirrer), a slow-setting grouting B liquid tank 12-5 (containing slow-setting grouting B liquid), a clean water tank 12-6 (containing clean water), and a grouting pipe 12-7. The grouting system valve assembly 12-1 consists of a quick-setting grout distribution valve assembly 12-1a and a slow-setting grout distribution valve assembly 12-1b. The quick-setting grouting A liquid tank 12-2, the quick-setting grouting B liquid tank 12-3, and the clean water tank 12-6 are all connected to the quick-setting grout distribution valve assembly 12-1a via delivery pipes. Next, quick-setting grouting liquid A, quick-setting grouting liquid B, and clean water are mixed to obtain quick-setting grout 14. Quick-setting grout 14 is composed of cement, bentonite, stabilizer, accelerator, water, and water glass. The retarded grouting liquid A tank 12-4, retarded grouting liquid B tank 12-5, and clean water tank 12-6 are all connected to the retarded grout distribution valve group 12-1b through delivery pipes. Retarded grouting liquid A, retarded grouting liquid B, and clean water are mixed to obtain retarded grout 15. Retarded grout 15 is composed of cement, clay, polymer, bentonite, water, and water glass. Multiple grouting pipes 12-7 are connected to both quick-setting grout distribution valve group 12-1a and retarded grout distribution valve group 12-1b for conveying quick-setting grout 14 and retarded grout 15. In this embodiment, the bottom plate and side plates of the front shield 4 and the bottom plate and side plates of the rear shield 1 are each provided with no less than two grouting holes (connected to the grouting pipe 12-7 on the slow-setting grout distribution valve group 12-1b) to realize the grouting operation between the shield (front shield 4 and rear shield 1) and the excavated soil. The bottom and side parts of the box culvert section 2 are each provided with no less than two grouting holes (connected to the grouting pipe 12-7 on the fast-setting grout distribution valve group 12-1a) to realize the grouting operation between the box culvert section 2 and the rear shield 1 and between the box culvert section 2 and the excavated soil.

[0033] like Figures 1-7 As shown, this embodiment also includes a method for positioning tunnel segments of an open-type tunnel boring machine, which mainly includes the following steps:

[0034] S1: As Figures 1-5 As shown, a reaction frame 10 is installed in the starting shaft 16, and the first box culvert section 2 is lifted to the installation position using the sling 13 of the crane (truck crane). At this time, the first box culvert section 2 is installed in the rear shield body 1 of the open shield machine.

[0035] The position of the first box culvert section 2 is monitored in real time using the measurement system 7, and the position of the first box culvert section 2 is adjusted by the positioning cylinders 3 of the open shield machine until the first box culvert section 2 is positioned in the design position. At this time, the measurement system 7 and the calibration target 7-2 are both set on the reaction frame 10. According to the positioning requirements of the box culvert section 2, four positioning cylinders 3 arranged in a rectangle are selected on the bottom plate and side plates of the rear shield body 1 (the unselected positioning cylinders 3 are closed by cover plates) to adjust the position of the box culvert section 2. The measurement data of the measurement system 7 is compared with the design parameters to determine the extension and retraction stroke data of the four positioning cylinders 3 arranged in a rectangle on the bottom plate and side plates of the rear shield body 1. The hydraulic system 11 is controlled by the control system 8 to complete the extension and retraction of the positioning cylinders 3. The measurement system 7 performs continuous measurement and continuously feeds back the measurement data to the control system 8 until the positioning cylinders 3 position the box culvert section 2 in the design position.

[0036] The pressure plate cylinder 6 and the pipe section pressure plate 5 of the open-type tunnel boring machine are used to apply pressure to the first box culvert pipe section 2 to ensure that the first box culvert pipe section 2 is close to the reaction frame 10 and does not move relative to it. Among them, the control system 8 controls the extension of the pressure plate cylinder 6 to drive the pipe section pressure plate 5 to squeeze the first box culvert pipe section 2.

[0037] Positioning cylinder 3 retracts and returns to its original position. Grouting system 12 is used to inject quick-setting grout 14 to fill the gap between the bottom of the first box culvert section 2 and the rear shield body 1 of the open shield machine. At the same time, quick-setting grout 14 is injected around the opening of the starting shaft 16 to seal the opening and complete the installation of the first box culvert section 2.

[0038] S2: As Figures 1-4 as well as Figure 6As shown, the open-face shield tunneling machine advances forward to install the next culvert section 2. After the open-face shield tunneling machine reaches its destination, the control system 8 controls the retarded grout distribution valve group 12-1b in the grouting system 12 to inject retarded grout 15 into the excavated area around the open-face shield tunneling machine, eliminating potential risks of ground spalling and collapse, and releasing ground stress. At the same time, the control system 8 controls the rapid-setting grout distribution valve group 12-1a in the grouting system 12 to inject rapid-setting grout 14 into the culvert section 2 (the previous culvert section 2) that has detached from the rear shield body 1, filling the gap between the culvert section 2 and the soil, and completing the complete fixation of the culvert section 2. The culvert section 2 is then hoisted to the installation position using the crane's slings 13. The measurement system 7 monitors the positions of three measuring targets 7-1 and calibration targets 7-2 within the box culvert section 2 in real time. The calibration targets 7-2 / measurement system 7 are positioned on the reaction frame 10 or the box culvert section 2 according to the actual situation. Based on the design alignment parameters, the extension and retraction stroke data of the four positioning cylinders 3 arranged in a rectangular pattern on the bottom and side plates of the rear shield body 1 are determined. The control system 8 controls the hydraulic system 11 to complete the extension and retraction of the positioning cylinders 3. The measurement system 7 performs continuous measurement and continuously feeds back the measurement data to the control system 8 until the positioning cylinders 3 position the box culvert section 2 in the designed position. The control system 8 controls the extension of the pressure plate cylinder 6 to drive the section pressure plate 5 to apply pressure to the positioned box culvert section 2, ensuring that the box culvert section 2 is close to the previous box culvert section 2 and does not move relative to it. Positioning cylinder 3 retracts to its original position, and control system 8 controls the rapid-setting grout distribution valve group 12-1a in grouting system 12 to inject rapid-setting grout 14, filling the gap between the bottom of box culvert section 2 and the rear shield body 1, thus completing the installation of box culvert section 2. Repeat the above steps until the installation of the penultimate box culvert section 2 is completed.

[0039] S3: As Figures 1-4 as well as Figure 7As shown, after the open-face tunnel boring machine enters the receiving shaft 17, the final box culvert section 2 is hoisted to the installation position using the crane's slings 13. The measurement system 7 monitors the positions of the three measuring targets 7-1 and calibration targets 7-2 within the final box culvert section 2 in real time. At this time, both the calibration targets 7-2 and the measurement system 7 are positioned on the box culvert section 2. Based on the design alignment parameters and the determined extension and retraction stroke data of the four positioning cylinders 3 arranged in a rectangular pattern on the bottom and side plates of the rear shield body 1, the control system 8 controls the hydraulic system 11 to complete the extension and retraction of the positioning cylinders 3. The measurement system 7 performs continuous measurements and continuously feeds back the measurement data to the control system 8 until the positioning cylinders 3 position the final box culvert section 2 in the designed position. The control system 8 then controls the extension of the pressure plate cylinder 6 to drive the section pressure plate 5 to apply pressure to the positioned box culvert section 2, ensuring that the final box culvert section 2 is close to the previous box culvert section 2 without relative movement. Positioning cylinder 3 retracts to its original position. Control system 8 controls the grouting system 12's rapid-setting grout distribution valve group 12-1a to inject rapid-setting grout 14, filling the gap between the bottom of the last culvert section 2 and the rear shield 1. Simultaneously, rapid-setting grout 14 is injected around the opening of receiving well 17 to seal the gap between the well wall and the last culvert section 2, completing the installation of the last culvert section 2. Control system 8 controls the grouting system 12's rapid-setting grout distribution valve group 12-1a to inject rapid-setting grout 14 into the culvert section 2 (last culvert section 2) that has detached from the rear shield 1, filling the gap between the culvert section 2 and the soil, completing the complete fixation of the culvert section 2, and then backfilling the road structure layer, completing the installation of the entire culvert tunnel.

[0040] In addition, after the grouting of the retarding grout 15 and the quick-setting grout 14 is completed, the control system 8 controls the cleaning pump of the clean water tank 12-6 and the cleaning valve of the grouting system valve group 12-1 to clean the grouting pipe 12-7, eliminate the blockage of the grouting pipe 12-7, and ensure the smooth implementation of the next grouting operation.

[0041] The control system 8 acquires equipment status and pressure, flow, and temperature sensor information from the measurement system 7, hydraulic system 11, and grouting system 12 via a network (wireless, wired, or fiber optic). It then publishes equipment control information through the network to complete positioning and grouting control. Simultaneously, it exchanges information with the open-face shield control system 18 to achieve process linkage control of the pipe section pressure plate 5 and pressure plate cylinder 6. Furthermore, it exchanges information with the pipe section positioning remote control management system 19 (embedded within the open-face shield remote control management system) through the open-face shield control system 18 to achieve remote control of pipe section positioning and push notifications of accident hazard early warning and elimination plans.

[0042] The beneficial technical effects of this embodiment are as follows:

[0043] 1. Construction takes place only inside an open-type tunnel boring machine, causing no impact on road traffic or the surrounding environment;

[0044] 2. Injecting retarding grout can suppress the spalling and collapse of the strata around the excavation part of the tunnel boring machine, reduce the friction on the outer surface of the tunnel boring machine, suppress the stress release of the strata, and result in less strata deformation.

[0045] 3. By using a measurement system to control the extension and retraction of the positioning cylinder, accurate positioning of the box culvert pipe sections can be achieved, enabling rapid assembly;

[0046] 4. Grouting at the bottom of the box culvert pipe section is completed by injecting quick-setting grout to fix the box culvert pipe section and complete the installation of the box culvert pipe section;

[0047] 5. Compared with manually adjusting the crane's slings to position box culvert sections, this method offers higher construction efficiency, better safety, lower construction costs, and better economic benefits.

[0048] Although the above embodiments have described the concept and embodiments of the present invention in detail with reference to the accompanying drawings, those skilled in the art will recognize that various improvements and modifications can still be made to the present invention without departing from the scope of the claims, and therefore will not be elaborated here.

Claims

1. An open shield segment positioning system for the positioning of box culvert segments, characterized in that The system includes an open-type tunnel boring machine (TBM) and positioning cylinders. The open-type TBM includes a front shield and a rear shield. The top and rear of the rear shield are open. The bottom plate and side plates of the rear shield are equipped with a plurality of positioning cylinders arranged in a matrix. The interior of the rear shield is equipped with pressure plate cylinders and pipe section pressure plates. There are multiple pressure plate cylinders arranged in a matrix. The base of the pressure plate cylinder is fixed to the front of the rear shield, and the telescopic rod is connected to the pipe section pressure plate. The pressure plate cylinder drives the pipe section pressure plate to move in the longitudinal direction.

2. An open shield segment positioning system as claimed in claim 1, characterized in that The system also includes a measurement system and targets. At least three targets are arranged on the box culvert section. Any three targets are not collinear. At least three targets are selected as measurement targets. The measurement system is used to measure the position of the measurement targets.

3. An open shield segment positioning system as claimed in claim 2, wherein The system also includes a calibration target used to correct measurement errors in the measurement system.

4. An open shield segment positioning system as claimed in claim 2, wherein The system also includes a grouting system, which includes a fast-setting grout distribution valve group and a slow-setting grout distribution valve group. The fast-setting grout distribution valve group is used to control the output of fast-setting grout, and the slow-setting grout distribution valve group is used to control the output of slow-setting grout.

5. An open shield segment positioning system as claimed in claim 4, wherein The system also includes a hydraulic system, through which the positioning cylinder is driven.

6. An open shield segment positioning system as claimed in claim 5, wherein The system also includes a control system, through which the measuring system, the hydraulic system, and the grouting system are all controlled.

7. An open shield segment positioning system as claimed in claim 1, wherein The system also includes a crane, which lifts the box culvert sections using slings.

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