Flexible-Arm Boring Machine for Arbitrary Cross-Section Excavation
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Solution Overview
Problem
Conventional rock tunnel boring machines are limited to excavating circular cross-sections, making them inflexible and inefficient for projects requiring diverse or changing cross-sectional shapes, leading to increased costs, resource wastage, and prolonged construction periods under complex geological conditions.
Innovation Solution
A robot-supported multi-cutterhead boring machine with a flexible-arm system, utilizing coupled torques of multiple cutterheads and an intelligent robot arm to adjust cutterhead positions and postures, enabling excavation of tunnels with any cross-sectional shape while reducing stress on key components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional circular boring machine is used for excavation, then the structure is simple and reliable, but the excavation cross-section is limited to circular shape and cannot adapt to diverse cross-section requirements
Solution Approach 1:
The cutterhead is divided into multiple independent cutter units that can be individually positioned and controlled. Each cutter unit can be adjusted to different positions and angles, allowing the formation of various cross-sectional shapes including rectangular, horseshoe-shaped, and other customized sections, thereby resolving the contradiction between adaptability and structural simplicity
Solution Approach 2:
The boring machine employs dynamic adjustment mechanisms that allow real-time modification of cutterhead configuration. The cutter units can be dynamically repositioned during operation to adapt to different excavation requirements, enabling the machine to transition between various cross-sectional shapes without requiring complete redesign, thus improving adaptability while maintaining operational simplicity
2Adaptability or versatility
If the excavation cross-section is determined early in the project, then the boring machine can be optimized for that specific shape, but it becomes difficult to change cross-section later and reduces flexibility for different project requirements
Solution Approach 1:
The system enables dynamic reconfiguration of the cutterhead arrangement during excavation operations. Multiple cutter units can be independently adjusted to different positions and orientations, allowing the boring machine to switch between various cross-sectional shapes mid-project, thereby maintaining high productivity while achieving cross-section adaptability
Solution Approach 2:
The boring machine allows continuous adjustment of geometric parameters such as cutter spacing, cutter angle, and cutter depth. By changing these parameters, the machine can transform the excavation cross-section from one shape to another without interrupting operations or requiring complete redesign, thus resolving the contradiction between changeability and productivity
3Productivity
If a single cutterhead structure is used, then the device complexity is low, but the working efficiency is limited and large reactive torque is generated requiring increased component size and thickness
Solution Approach 1:
The single cutterhead is segmented into multiple independent cutter units, each capable of operating independently or in coordination. This segmentation allows for more efficient rock breaking and excavation by distributing the cutting action across multiple points, thereby improving productivity without requiring excessive increases in individual component size
Solution Approach 2:
The multiple cutter units are arranged and controlled to generate counterbalancing reactive torques that offset each other. By coordinating the rotation directions and speeds of different cutter units, the system reduces the net reactive torque on the boring machine, allowing for more efficient operation without requiring oversized components to handle excessive torque loads
4Ease of manufacture
If the boring machine is designed for a specific cross-section, then the structure can be optimized for that shape, but it causes increased project cost when excavating diverse cross-sections due to extra excavation and backfilling requirements
Solution Approach 1:
The boring machine is designed with universal cutterhead configuration capabilities that can form multiple cross-sectional shapes including circular, rectangular, horseshoe-shaped, and customized sections. This multi-functionality allows a single machine to handle diverse project requirements without requiring extra excavation or backfilling operations, thereby reducing material waste and project costs while maintaining ease of cross-section formation
Data Source
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Figure 3~4
Figure 5
AI summary
Disclosed is a robot (4)-supported flexible-arm boring machine capable of excavating a tunnel with any cross-section, comprising a cutterhead and cutter system (1) and a main beam (6). A rear portion of the main beam (6) is connected to a front portion of a rear gripper (8) by means of a thrust cylinder (7); a rear portion of the rear gripper (8) is connected to a rear support (9); and a front portion of the main beam (6) is flexibly connected to the cutterhead and cutter system (1) by means of a robot (4).