| Full Face Tunnel Boring Machine (TBM), with mechanical-electric-hydraulic integration technique, is the most advanced high-tech equipment specialized in construction of large-scale tunnel projects and can accomplish Cutting, transportation of Rock and Soil and lining support, improvement of geological, rectification guidance and so on. As a key subsystem of TBM, segment erector is used for fixing concrete segments and segments lining. Improving the speed of segment erection that can affect the speed of shield excavation is able to speed up engineering construction progress, thus can save the cost of the construction. And the same time, the quality of segment erection in shield tunneling would have an important impact on underground water permeability and ground settlement. Nowadays, it is the power flow and characteristics that developing the newly multi-degree-of-freedom automatic segment erector in correspondence to the requirements of individualism. In many foreign countries, it has made thorough study of theory and design of segment erector and applied to many tunnel engineering widely. There are also many national enterprises such as NHI and universities such as Jilin University have done a large research works for them and made great progress, but there still are many drawbacks and difficult points needed to be solved. So China's development and production of Full Face Tunnel Boring Machine are still at an initial stage currently where greater disparity exists in design theory and production manufacturing technologies compared to foreign countries. So it is exigent to carry out the development high-tech of tunnel boring and the complete equipment for it. With the development of the high and new techniques, localization of TBM becomes a significant strategy for developing national industry.This paper focus on the key subsystem of small diameter TBM—segment erector, the principal design schemes of Whole Machine are determined. the mechanical system of segment erector is due to overall layout of whole TBM, especially structure limitation and requirements of engineering of screw conveyor and propulsion system. Therefore it is necessary to discuss mathematical model of optimum revolving mechanism of segment erector and selection of gear modification coefficient, and then the paper expounds the mechanical system which built on the software platform of SOLIDWORKS/ADAMS/ABAQUS. As a key subsystem of TBM, the newly segment erector with possess independent intellectual property is developed. The main accomplished works are as follows:1. By comprehensive analyzing the system composition of segment erector and functions effect and comparing the principal design schemes of TBM at home and abroad, a newly 6-DOFs automatic segment erector is researched and developed to accomplish both quick-cursory orientations including epicyclical rotation, radial-vertical hoist, horizontal feed-in, and accurate-inching orientations including transverse swing, longitudinal swing and sway.2. Considering the difficulties and influence factors of the design of revolving mechanism of small diameter TBM and comparing the advantages and disadvantages of bearing and revolving support, the Supporting Device of revolving mechanism of segment erector is designed. The optimized function toolbox in MATLAB software is applied in the solution. In this process, the mathematic models are created which include the objective function of minimum whole volume of the gear, the constraints of contact strength, structure limitation and requirements of engineering. This scheme can substitute revolving support with expensive price and inconvenient installation and has a practical significance on revolving mechanism of segment erector.3. Pinion gear should be made as small as possible and center distance should be as long as possible. Under the premise of large diameter and large module of Involutes Internal Gear Pair, indicating that relative sliding ratio of Involutes Internal Gear Pair relatively large. Therefore it is necessary to discuss mathematical model of optimum selection of gear modification coefficient. Based on the principle of selection of gear modification coefficient, the mathematic module for the Involutes Internal Gear Pair optimal design as the function of minimum relative sliding ratio is proposed, he design variable and restrain conditions are determined, and by solving the optimal module in the toolbox in MATLAB software, the optimal parameters of the Involutes Internal Gear Pair are obtained.4. By using of the CAD module of SOLIDWORKS, ADAMS, and the simulation software of multibody kinetics, Virtual Prototype model of the segment erector is created. At the same time we can get the subjects of various components and the dynamic characteristics of the drive components, provide boundary conditions for strength checking and provide a basis for the power system design, then after analyzing the dangerous condition of the system. FEA analysis of key components of the segment erector were carried out under the boundary conditions from dynamic simulation based on finite element analysis software ABAQUS. Lastly, the stress analysis and contacted analysis about key components is done. According to the analysis result, intensity inspection and structure optimization are executed.This paper, combining 863 plan project for Experimental Bench for Full Face Tunnel Boring Machine (project NO, 2007AA041806),by building the model of virtual prototypes and Finite element analysis technology, stresses and deformations of the vital parts are obtained. The results demonstrate that the design meets to working requirements. By mechanical-electric-hydraulic integration technique, the newly 6-DOFs automatic segment erector that maximum load is 1500kg of mini TBM is researched and developed. The new product is able to accomplish both quick-cursory orientations including epicyclical rotation, radial-vertical hoist, and horizontal feed-in and accurate-inching orientations including transverse swing, longitudinal swing and sway. This paper has a practical significance on research and development of the new product of this class. |
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