天井钻机的发展现状与前瞻

本文综述了国外天井钻机发展概况和主要厂家的产品特色，国内天井钻机研制情况和系列产品类型，并对产品类型，并对今后我国天井钻机发展中应着重解决的问题提出了看法。     

A Closer Look at the Design of Cutterheads for Hard Rock Tunnel-Boring Machines

The success of a tunnel-boring machine (TBM) in a given project depends on the functionality of all components of the system, from the cutters to the backup system, and on the entire rolling stock. However, no part of the machine plays a more crucial role in the efficient operation of the machine than its cutterhead. The design of the cutterhead impacts the efficiency of cutting, the balance of the head, the life of the cutters, the maintenance of the main bearing/gearbox, and the effectiveness of the mucking along with its effects on the wear of the face and gage cutters/muck buckets. Overall, cutterhead design heavily impacts the rate of penetration (ROP), rate of machine utilization (U), and daily advance rate (AR). Although there has been some discussion in commonly available publications regarding disk cutters, cutting forces, and some design features of the head, there is limited literature on this subject because the design of cutterheads is mainly handled by machine manufacturers. Most of the design process involves proprietary algorithms by the manufacturers, and despite recent attention on the subject, the design of rock TBMs has been somewhat of a mystery to most end-users. This paper is an attempt to demystify the basic concepts in design. Although it may not be sufficient for a full-fledged design by the readers, this paper allows engineers and contractors to understand the thought process in the design steps, what to look for in a proper design, and the implications of the head design on machine operation and life cycle.     

土压平衡盾构机刀盘电机控制系统的设计

为解决盾构机刀盘电机控制系统中存在的程序控制点多、逻辑复杂，易导致系统调试和维护不便的问题，将模块化编程技术应用于刀盘电机控制系统程序设计中。开展了刀盘电机控制系统结构分析，建立了刀盘运行状态和各个辅助系统之间的关系，提出了“将刀盘电机运行分成若干个状态，将各个辅助系统的条件采集过程设置为子程序”的状态机编程思想，子程序负责采集系统信息供给状态机决策使用，状态机完整描述了刀盘电机可能经过的各个状态并直接决定刀盘电机在该状态下所执行的动作。将该系统应用于实验型土压平衡盾构机中，并进行了大量的实验。研究结果表明，该系统完全满足土压平衡盾构机刀盘电机控制的需要，状态机编程可使整个程序构架更加清晰明了，易于调试和后期维护。     

基于PFC3D的北京砂卵石地层盾构刀盘选型及刀具布置数值模拟研究

砂卵石地层是一种典型的力学不稳定地层及强磨蚀性地层,盾构在该类地层中掘进通常会面临刀盘、刀具磨损严重,盾构推力与刀盘扭矩偏高且波动幅度大、地层变形不易控制等问题。砂卵石地层盾构掘进效率的高低及地层控制的好坏,刀盘选型及刀具配置是关键。以北京地铁新机场线“磁各庄站～1#风井”盾构区间为工程依托,利用PFC3D数值模拟及现场测试相结合的手段,研究刀盘开口率、刀具组合高差、先行刀刀间距等参数对盾构掘进效率及地层变形的影响。研究结果表明：相同掘进参数下大开口率辐条式刀盘比小开口率辐板式刀盘具有更好的掘进速度,小开口率辐板式刀盘掘进时引起的地表变形更小,对周围地层的扰动范围也更小;先行刀与切削刀的组合高差为70 mm时盾构掘进效率较高且扭矩较低;先行刀刀间距设定为300 mm时,盾构有较好的掘进效率和较低的刀盘扭矩。工程实践表明;要实现砂卵石地层盾构长距离高效掘进,大开口率辐条式刀盘设计及大高差梯次化刀具布置是基础,高贯入度、低转速的掘进控制是关键。研究结果可为类似工程的盾构刀盘选型与刀具布设提供借鉴。     

盾构切削混凝土桥桩刀盘荷载分析

依托北京地铁12号线盾构直接切削西坝河桥16根800桥桩工程,通过三维数值模拟和理论推导,对盾构法清障掘进面荷载展开研究。通过三维动态模拟,分析单个刀具逐次切混凝土荷载变化规律。基于等效原理与单刀切削荷载,提出一种对切桩刀具数、推力及扭矩的估算模型。并将此估算模型用于计算苏州地铁直接切削广济桥掘进面荷载,对比分析计算结果与精确叠加值在推力、扭矩方面的平均误差分别为10%、3.3%,验证了该估算模型的正确性。应用本文模型对盾构穿越西坝河桥各轴桩位掘进面切桩荷载进行预测分析,指出切桩工况主要对扭矩造成影响。研究结果可为类似地层盾构清障工程中掘进面荷载计算提供参考。     

全断面掘进机刀盘驱动转矩的确定

探讨了在不同的地质条件下,TBM刀盘驱动转矩的设计计算方法,有利于优化TBM的结构和总装机功率,提高TBM适应不同地质条件的能力,并以ROBB INS公司为辽宁大伙房输水隧洞工程设计、制造的BM264-311型掘进机为例,进行模拟计算,证明该计算方法是合理和有效的。     

转速受限条件下TBM刀盘混合驱动系统控制器设计

传统全断面硬岩隧道掘进机（tunnel boring machine, TBM）刀盘转速同步控制方法是针对变频电机单一驱动源进行设计的,直接应用于混合驱动型TBM刀盘驱动系统易导致齿轮齿圈发生严重的偏载,显著降低TBM刀盘传动系统的使用寿命和TBM设备完好率。考虑到实际掘进过程中对刀盘转速的限制和系统参数漂移,采用自适应控制策略,针对电液混合驱动型TBM刀盘驱动系统设计基于驱动源力矩控制的转速控制方法。建立了齿轮齿圈传动系统模型,系统的参数不确定性得到充分考虑。通过MATLAB/AMESim联合仿真表明,该自适应控制系统对参数漂移具有补偿作用,在精确控制刀盘转速的同时,实现了不同类型驱动源间的负载力矩分配,原系统中的偏载问题得到了解决。电液混合驱动型TBM刀盘驱动系统通过液压马达和变频电机两种驱动源驱动特性的互补,有效提高了其地质适应性,并对提高掘进速度有着重要的作用。     

Design theory of full face rock tunnel boring machine transition cutter edge angle and its application

At present, the inner cutters of a full face rock tunnel boring machine (TBM) and transition cutter edge angles are designed on the basis of indentation test or linear grooving test. The inner and outer edge angles of disc cutters are characterized as symmetric to each other with respect to the cutter edge plane. This design has some practical defects, such as severe eccentric wear and tipping, etc. In this paper, the current design theory of disc cutter edge angle is analyzed, and the characteristics of the rock-breaking movement of disc cutters are studied. The researching results show that the rotational motion of disc cutters with the cutterhead gives rise to the difference between the interactions of inner rock and outer rock with the contact area of disc cutters, with shearing and extrusion on the inner rock and attrition on the outer rock. The wear of disc cutters at the contact area is unbalanced, among which the wear in the largest normal stress area is most apparent. Therefore, a three-dimensional model theory of rock breaking and an edge angle design theory of transition disc cutter are proposed to overcome the flaws of the currently used TBM cutter heads, such as short life span, camber wearing, tipping. And a corresponding equation is established. With reference to a specific construction case, the edge angle of the transition disc cutter has been designed based on the theory. The application of TBM in some practical project proves that the theory has obvious advantages in enhancing disc cutter life, decreasing replacement frequency, and making economic benefits. The proposed research provides a theoretical basis for the design of TBM three-dimensional disc cutters whose rock-breaking operation time can be effectively increased.     

复杂岩石地层隧道掘进机操作特性分析

为提高掘进效率,改进掘进机与地层的匹配性设计,对掘进机的操作特性进行研究。基于重庆越江隧道盾构掘进试验,分析复杂岩石地层盾构刀盘扭矩、刀盘推力及转速的参数选用原则,在此基础上,分析主掘进参数与切深的关系。随后,对不同地层条件下刀盘扭矩与推力之间的匹配性进行分析,绘制了刀盘扭矩与推力之间的操作特性曲线,并用于分析和制定不同地层条件下的主掘进参数匹配方案。对于较软的泥岩,刀盘扭矩先达到最大值,而推力却不能发挥其最大能力;岩石强度增高,所需推力增加,在发挥扭矩能力的前提下,推力也能发挥其功能,从而使二者达到最佳操作关系;若岩石强度过高,推力保持在最大值,但切深很浅,滚刀旋转阻力减小,刀盘扭矩很难发挥最大能力。因此,应视地层软硬,根据刀盘推力与扭矩的操作特性对刀盘的主掘进参数进行合理设计,并在掘进过程中实时调整其匹配关系。     

大型盾构机刀盘法兰成形技术研究

通过对盾构机刀盘法兰锻件常规拼焊方案的详细分析,提出了一种全新的旋压扩孔成形理论,并应用该理论成功地将超大型盾构机刀盘法兰锻件国产化,解决了此类超大型盘形锻件的制造难题。