TBM Hob Cutter Quick-Release Mounting Mechanism
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Solution Overview
Problem
The existing cutter replacement methods in tunnel construction are labor-intensive, time-consuming, and pose safety hazards due to reliance on manual operations, limiting the efficiency and safety of tunnel construction, especially under complex geological conditions.
Innovation Solution
A new-type easily replaceable hob cutter system featuring a cutter holder and hob connected via a telescopic tensioning mechanism or locking mechanism, allowing for quick disassembly and assembly, facilitating automation of cutter replacement and improving safety by reducing manual labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation is used for cutter replacement, then flexibility and adaptability are maintained, but safety hazards increase and construction efficiency decreases
Solution Approach 1:
The cutter replacement system performs replacement operations autonomously without requiring manual intervention. The robotic arm automatically grasps, transports, and installs cutters based on pre-programmed sequences, making the system self-sufficient in the hazardous tunnel environment.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system. The robotic arm with specialized end effectors substitutes human operators, eliminating exposure to safety hazards while maintaining precise mechanical control over cutter replacement operations.
2Productivity
If traditional C-shaped blocks and bolts connection method is used, then connection reliability is high, but disassembly and assembly require multi-person cooperation and are time-consuming
Solution Approach 1:
The connection structure is divided into modular components: quick-release lugs on the cutter holder, corresponding receiving features on the tool apron, and simple fastening elements. This segmentation allows individual components to be easily manipulated by the robotic arm without requiring complex multi-step disassembly procedures.
Solution Approach 2:
The connection system transitions from a static, permanently fixed arrangement to a dynamic, quickly reversible connection. The quick-release mechanism allows the cutter to be rapidly detached and reattached, enabling frequent replacements without time-consuming operations while maintaining secure connection during use.
3Loss of time
If multi-person cooperation is required for cutter replacement, then operational reliability is maintained, but labor intensity increases and time consumption increases
Solution Approach 1:
The robotic system autonomously performs all cutter replacement tasks including approaching the cutter, grasping it with the end effector, transporting it to the storage rack, and installing new cutters. This self-service capability eliminates the need for multiple operators coordinating complex manual procedures.
Solution Approach 2:
The robotic arm serves multiple functions: it positions cutters during installation, grasps and removes worn cutters, transports them to storage, and can perform inspection tasks. This multi-functionality consolidates what previously required multiple specialized operators into a single automated system.
Data Source
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AI summary
Provided are a new-type easily replaceable hob cutter system and a mounting method therefor. The system comprises a cutter holder (1) and a hob (4), the hob (4) being connected to the cutter holder (1) by means of a cutter shaft holder (2), and the cutter shaft holder (2) being fixedly connected to the cutter holder (1) by means of a telescopic tensioning mechanism (3) or a locking mechanism (5). The hob cutter system is designed to have three parts including the cutter holder, the cutter shaft holder, and the locking mechanism or the telescopic tensioning mechanism, so as to change the structure of a conventional cutter system, which makes the hob mounting, locking and removal process simpler, facilitates the automation of cutter replacement, and provides technical support for the efficient and safe "substituting labor with machine" operation mode for the cutter detection and cutter replacement operations.