Plasma Torch Tunnel Boring System

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Solution Overview

Problem

Existing tunnel boring machines are large, slow, labor-intensive, and expensive, making them difficult to move between locations and costly to operate.

Innovation Solution

A tunnel boring system utilizing plasma torches, comprising a cutting head with multiple plasma torches arranged in a horseshoe shape, a tractor for propulsion, and a disposal system using vacuum suction to remove spoils, allowing for efficient tunnel boring and surface smoothing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional tunnel boring machines are used, then tunnel excavation can be performed, but the machines are large, slow, and expensive to operate

Engineering Contradiction:

Improvetunnel boring speedVSAvoidmachine size and complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical cutting wheels with plasma torches that use thermal energy to melt and vaporize rock. This substitution of mechanical systems with thermal/energy-based systems enables faster boring speeds while reducing machine size, as plasma torches can be directed precisely without requiring large rotating cutters

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the fundamental operating parameters from mechanical force and rotation to plasma temperature and energy density. By controlling plasma power, gas flow rates, and torch positioning, the system achieves rapid material removal with a compact configuration rather than large mechanical structures

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If traditional tunnel boring machines are used, then tunnel excavation can be performed, but they are difficult to move between locations

Engineering Contradiction:

Improvemobility between locationsVSAvoidmachine size

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

By replacing heavy mechanical cutting wheels with lightweight plasma torches mounted on movable carriages, the system dramatically reduces overall machine weight and size. The plasma generation equipment can be compact and modular, enabling easy transport and rapid deployment at different tunnel locations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The tunnel boring system is divided into modular segments including separate plasma torches, carriages, and support structures. This segmentation allows individual components to be transported independently and assembled at the work location, greatly improving mobility compared to monolithic traditional tunnel boring machines

Inventive Principle:

Principle #1Segmentation

3Productivity

If traditional tunnel boring machines are used, then tunnel excavation can be performed, but operational costs are significant

Engineering Contradiction:

Improveoperational efficiencyVSAvoidoperational cost

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The replacement of mechanical cutting with plasma processing eliminates wear on cutting tools, reduces maintenance requirements, and enables continuous operation without the downtime associated with mechanical tool changes and repairs. Although plasma consumes electrical energy, the overall operational cost decreases due to higher productivity and reduced maintenance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Plasma torches can operate continuously without the interruptions inherent in mechanical cutting systems. The plasma process maintains steady-state operation with consistent material removal rates, maximizing productive work time and reducing idle periods for tool changes, maintenance, and adjustments

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enables fast and efficient tunnel boring through various rock types, reduces operational costs, and allows for easy adjustment of tunnel diameter by swapping cutting heads, while also smoothing tunnel surfaces using repurposed silica spoils.

Implementation Method 1

utilizing ultra high temperature rotating plasma torches

Methodology Applied

Scientific EffectPlasma: Plasma

Implementation Method 2

high power laser and laser mechanical earth removing equipment

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

a disposal system using vacuum suction to remove spoils

Methodology Applied

Scientific EffectVacuum suction: Suction

Implementation Method 4

The stream may be a gas stream, a water stream, or a steam stream. The cooling effect from the air and/or water jets is particularly useful in rock with high silica content

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentEP4328417B1Tunnel boring system

Publication Date: 2025.05.07 EARTHGRID PBC

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AI summary

A plasma tunnel boring machine including a plurality of plasma torches on the cutting head, and a plurality of nozzles on the cutting head to provide a stream to cool an area while the plasma torches are active, and a tractor providing propulsion to the cutting head, the tractor to move the cutting head to cut a tunnel.