發(fā)動機箱體結構設計及加工路線擬定
發(fā)動機箱體結構設計及加工路線擬定,發(fā)動機箱體結構設計及加工路線擬定,發(fā)動機,箱體,結構設計,加工,路線,線路,擬定
英文技術資料及中文翻譯
1.中文翻譯
掘進機箱體及組合機床
全斷面掘進機是集機械、電氣、液壓和自動控制于一體的世界上公認的快速地下開挖工程最有效的大型高技術成套施工裝備，是將掘進、移動、出碴和襯砌等多功能有機組合在一起的聯(lián)合機組，融合了新材料、新工藝、液壓、自動控制、信息、電子、電力、環(huán)保、人工智能、激光制導、遙測、遙感等高新技術。由于采用全斷面掘進機施工法具有快速、優(yōu)質、安全、對圍巖破壞小、利于環(huán)境保護、降低勞動強度及改善工作環(huán)境等特點，已廣泛用于引水、水電、鐵路、公路、煤礦、城市地鐵和管網(wǎng)以及軍事設施等方面的地下工程的施工。目前，全斷面掘進機已成為大型隧道施工工程的首選設備。它是實現(xiàn)掘進、巖渣裝運、洞壁支護等一次開挖成洞的高科技施工設備，是目前世界上最先進的隧道施工機械。
從隧道施工的實用概念出發(fā)，為了區(qū)別于其它開挖隧道的機械，我們通?？梢园阉淼谰蜻M機定義為：用機械能破碎或切削隧道掌子面、隨即將破碎或切削物質連續(xù)向后輸出并獲得預期的洞型、洞線的機器。
隧道掘進機按一次開挖斷面占全部斷面的比例分為全斷面掘進機和部分斷面掘進機兩種。全斷面掘進機主要包括全斷面巖石掘進機（也稱為TBM）和全斷面盾構機（一般稱為盾構機）。全斷面巖石掘進機主要用于具有一定自穩(wěn)能力的巖石地層的掘進，多用于野外的長隧道（如引水隧洞、鐵路隧道等）。而盾構機主要用于有水地層、軟弱不穩(wěn)定圍巖、對地表有嚴格沉降控制要求的城市地下工程或過江隧道工程的掘進。
全斷面巖石掘進機（TBM）主要分為敞開式、單護盾、雙護盾等幾種；盾構機主要分為土壓平衡、泥水平衡等幾種。兩者工作原理有一定區(qū)別。全斷面巖石掘進機的機頭與掌子面之間沒有形成密閉空間，按其用途，不需控制地表的沉降。其技術重點在高速、高可靠性的長距離掘破高強度巖石、地質適應能力強、準確定向、輸變電及通風除塵等方面。而盾構機機頭與掌子面之間形成了密閉空間，以平衡地層壓力，控制地表沉降是其重點。總體來說，全斷面巖石掘進機的技術難度大于盾構機。
全斷面掘進機作為地下空間開發(fā)的最現(xiàn)代化大型施工裝備，無疑是地下空間開發(fā)的主力設備。但從目前國內所有采用掘進機施工的工程來看，所使用的掘進機卻幾乎被國外制造商所占據(jù)，大部分是整機進口，少量的是在國內企業(yè)生產(chǎn)一部分機械件，其余均進口，在國內裝配。如任其這種現(xiàn)象發(fā)展，結果是我國的投資，卻拉動了別人的經(jīng)濟，讓外國人把錢全部賺走。
另一方面，由于國外公司控制著核心技術和集成技術，使TBM的價格居高不下，在很大程度上，制約了掘進機在隧道施工中的廣泛應用。因此，國內的施工企業(yè)期盼擁有自主知識產(chǎn)權的本土設備能早日問世。
全斷面掘進機是技術含量高和附加值高的產(chǎn)品，反映了一個國家的綜合國力和科技水平，是裝備制造業(yè)創(chuàng)新體系的重要組成部分。所以全斷面掘進機產(chǎn)業(yè)的發(fā)展，對于調整我國產(chǎn)業(yè)結構，帶動相關產(chǎn)業(yè)的發(fā)展，提高我國裝備制造業(yè)的水平將起重要作用。
從長遠的戰(zhàn)略發(fā)展角度考慮，我國不能一直依靠國外的設備和人才來開發(fā)地下空間。我國有如此巨大的掘進機市場，又作為裝備制造業(yè)的大國，絕不能長期整機進口國外掘進機，任由國外掘進機制造商來瓜分我國的市場。因而，“十一五”期間，我們必須掌握全斷面掘進機的核心技術及集成技術，建立我國自己的全斷面掘進機產(chǎn)業(yè)。
全斷面掘進機發(fā)展現(xiàn)狀
全斷面掘進機始于19世紀初的英國，發(fā)展于德、日等國，適用于地鐵隧道、鐵路隧道、公路隧道、引水隧道、礦山巷道、城市市政隧道等各種隧道工程。我國全斷面掘進機的研制、開發(fā)始于20世紀60年代，發(fā)展于90年代，其中地鐵使用的數(shù)量最多，約占80%?，F(xiàn)代全斷面掘進機已演變成為一種高度智能化，集機、電、液、光、計算機技術為一體的大型地下工程機械裝備。
1、 國外發(fā)展狀況
國際上，掘進機的發(fā)展經(jīng)歷了一個較漫長的過程。掘進機的雛形可上溯到19世紀。1876年，英國人John Dickinson Brunton和George Brunton申請了第一個機械化盾構專利，該盾構有一個由幾塊板構成的半球形的旋轉刀盤，開挖的土料落入徑向裝在刀盤上的料斗中，料斗將渣料轉運至膠帶輸送機上，再將它轉到后面從盾構中運出，這一構想后來被用于修建地鐵隧道。但由于技術和戰(zhàn)爭的緣故，掘進機的發(fā)展一直停滯不前。直到1959年，用液體支撐隧道工作面的想法由Elmer C．Gardner成功地試用于一條直徑為3.35m的排污隧道。1960 年，Schneidereit提出了用膨潤土懸浮液的活動工作面支撐。在這之后，H．Lorenz申請了用加壓膨潤土漿來穩(wěn)定隧道工作面的專利。
至此，為現(xiàn)代盾構的設計制造奠定了技術基礎。1963年，日本Sato Kogy0公司首先開發(fā)出了土壓平衡盾構機，1967年，第一臺用切削輪和水力出土的泥水盾構機在日本投入使用，其直徑為3.1m。同年，德國第一臺用膨潤土液支撐隧道工作面的盾構機由Wayss&Freytag開發(fā)并應用。至此，具有工程實用的兩類盾構機均已出現(xiàn)，為現(xiàn)代盾構機及其工法的發(fā)展和應用奠定了基礎。
從1845年開始的100多年的時間里，全世界的發(fā)明家都在尋找實現(xiàn)巖石隧道掘進機械化的方法。直到1952年，美國羅賓斯公司的創(chuàng)始人—吉姆斯·羅賓斯先生開發(fā)了第一臺具有實用性的、開掘巖石隧道的巖石掘進機，找到了巖石隧道掘進機械化的方法。
此后至今的40年來，無論是巖石掘進機還是盾構掘進機都得到了突飛猛進的發(fā)展。使用巖石掘進機掘進的隧道已超過10000km，盾構機掘進的隧道更多。目前，在國際上掘進機技術已經(jīng)成熟，已達到工作可靠性高，定向精度高，自動化水平高，適應能力強，掘進速度快，使用壽命長。掘進機的技術發(fā)展一直在圍繞地層穩(wěn)定和地面沉降控制、自動化掘進和提高掘進速度、襯砌和隧道質量三個要素進行盾構機的改進和施工方法的革命。主要技術有：1）地層穩(wěn)定和地面沉降控制技術；2）結構設計技術；3）刀具刀盤技術；4）導向及姿態(tài)控制技術；5）襯砌技術；6）防水和同步注漿技術。國際上目前掘進機技術有以下特點：
（1）高度自動化
對掘進機全部作業(yè)進行制導和監(jiān)控，使掘進過程始終處于最佳狀態(tài)，向著機械、電氣、液壓自動化控制一體化、智能化方向發(fā)展，采用了類似機器人的技術，計算機控制、遙控、傳感器、激光導向、超前地質探測、通訊技術等已普遍應用。隨著計算機技術的快速發(fā)展，掘進機的自動化程度越來越高，具有施工數(shù)據(jù)采集功能，掘進姿態(tài)管理功能，施工數(shù)據(jù)管理功能，設備管理功能，施工數(shù)據(jù)實時遠傳功能?？勺詣訖z測掘進機的位置和姿態(tài)，并利用模糊理論自動進行調整，可自動實現(xiàn)平衡壓力的控制，可自動實現(xiàn)管片的拼裝等等。在有些掘進機上，還采用了GPS地面衛(wèi)星定向系統(tǒng)以及超遠程監(jiān)控等技術。
（2）大型、超大型化和長壽命
對于巖石掘進機，其最大規(guī)格直徑已達到12m，大功率、大推力、大行程、大刀具是主要特點，其單臺使用壽命最長已達50Km，平均壽命約為15km，平均月進尺已超過1000m，盤形刀具直徑達19″，可適應抗壓強度高達450MPa的巖層，刀盤回轉功率已超過3500kW，最大推進行程已達2.45m，最大推進力達到35MN。盾構掘進機最大規(guī)格直徑已達到15,44m，并且可適應軟硬不同的復雜地質情況，壽命可達到掘進7km，最高日進尺達到30m。
（3）形式多樣化
從斷面形狀方面出現(xiàn)了矩形，馬蹄形、橢圓形、MF形（雙圓搭接、三圓搭接）等多種異圓斷面盾構。其中雙圓、三圓盾構掘進機已在上海地鐵施工中成功應用；從功能上講出現(xiàn)了球體盾構、母子盾構、擴徑盾構、變徑盾構、分岔盾構、途中更換刀具（無需豎井）盾構、障礙物直接切除盾構等特種盾構；從盾構機的掘削方式上看出現(xiàn)了搖動、擺動掘削方式的盾構。全斷面巖石掘進機出現(xiàn)了擴孔、斜井和馬蹄形等形式掘進機。
（4）高適應性
隨著現(xiàn)代掘進機技術的發(fā)展，硬巖掘進機與軟土盾構技術相互滲透、相互融合，使其地質適應能力大大增強。目前，正在朝著將硬巖和軟巖掘進機合二為一的適應性更強的復合型掘進機方向發(fā)展，這種掘進機在有高壓水及斷層情況下，能全封閉按泥漿加壓盾構原理工作，在無水時，可很快轉換為敞開式掘進。此外，還增加高壓水輔助破巖，可提高50%左右的掘進速度。降低成本25%，傳動功率消耗減少25%左右。圍巖無側限抗壓強度（UCS）適應范圍可達3～385MPa（常見范圍為50~180MPa）。
當然，掘進機技術也像其它技術一樣，也會隨著實際隧道工程的新的要求以及科技水平的發(fā)展而不斷發(fā)展，也不斷有新問題需要解決。如將要建設的成都地鐵地質情況，目前，在世界其它地方都還未遇到過，這對于盾構掘進機的設計來說，是一個新的挑戰(zhàn)；再如南水北調西線工程，所有的隧洞工程都在海拔4000m以上，且單條洞線長度長，這在全世界已有的工程中也是從未遇到過的。所以，不管對于哪一家公司來說，都要進行新的探索和研究。
目前，國際上生產(chǎn)盾構掘進機著名的廠商有：日本的三菱重工、川崎重工、石川島播磨重工、日立建機和小松制作所，德國的海瑞克（Herrenknecht）公司、維爾特（Wirth）公司所屬的NFM公司，加拿大的羅瓦特（Lovat）公司，法國的FCB公司。生產(chǎn)巖石掘進機著名的廠商有：美國的羅賓斯（Robbins）公司，德國的維爾特公司、海瑞克公司，加拿大的羅瓦特公司。這些公司已基本上將自己的掘進機產(chǎn)品系列化。
2.英文技術資料
Roadheader cabinet and combination machine tools
Whole section tunneler is set for the mechanical, electrical, hydraulic and automatic control in the integration of the world recognized rapid underground excavation engineering the most effective large high technology, is complete construction equipment will be heading, mobile, out of ballastless and lining etc multifunctional organic combination together of the joint unit, blend the new materials, new technology, hydraulic, automatic control, information, electronic, electric power, environmental protection, artificial intelligence, laser-guided, remote measure, remote sensing such high-tech. Due to the whole section roadheader construction method is fast, high quality, safety, to rock destruction to environment protection, small, the reduction of labor intensity and improve the working environment, are widely used in characteristics such as water, water and electricity, railways, highways, mines, urban subway and network and military facilities underground engineering construction. At present, the whole section roadheader has become a large-scale tunnel construction engineering device of choice. It is to achieve heading, rock slag sensitisity bracing shipment, the holes once excavation construction equipment, is the high-tech world most advanced tunnel construction machinery.
From the practical concept of tunnel construction, to distinguish themselves from other excavation tunnel machinery, we can usually defined as the tunnel boring with crushing or cutting tunnel influence mechanical energy, then will break or cutting material output and obtain continuous backward expected hole type, tunnel line machine.
According to a cross section of tunnel boring excavation of all sections of proportion is divided into whole section roadheader and part two roadheader cross-section. Whole section tunneler is mainly including whole section rock tunneler (also called TBM) and whole section shield machine (commonly referred to as the shield). Whole section rock tunneler is mainly used to have certain ability of rock strata since the instability in the wild, more for tunneling of long tunnel (such as diversion tunnel, railway tunnel, etc.). And a shield machine is mainly used for water strata, weak instability surrounding rock, there is strict settlement control on the surface of the city underground engineering or request tunnel across the excavation engineering.
Whole section rock tunneler (TBM) mainly divided into open wide type, single shield, double shield to wait for a few kinds; Shield machine is mainly divided into earth pressure balance, slurry balance to wait for a few kinds. Have some difference between working principle. Whole section rock tunneler nose and influence the enclosed space between not formed according to its use,, without the need to control the surface subsidence. The technical key in high-speed, high reliability of long distance dug broken high strength rocks, geological adaptiveness, accurate orientation, transmission and ventilation dust removal, etc. And nose and environmental constraints shield between formed an airtight room to balance the formation pressure, the control of the ground surface settlement is the key. Overall, whole section rock tunneler is greater than the technical difficulties shield machine.
Whole section roadheader as the underground space development in the most modern large-scale construction equipment for underground space development, is undoubtedly the main equipment. But from the current domestic all adopt in the construction of perspective, se se but used by foreign manufacturers are almost occupied, mostly the machine imported, and a small amount of domestic enterprise production is in part, the others all import of mechanical parts in domestic assembly. As the development of its this phenomenon, the result is China's investment, but the economy, boosting others enable foreigners earn all his money away.
On the other hand, because foreign companies control the core technology and integrated technology, make the price of TBM, in a great extent high, restricted the roadheader wide application in tunnel construction. Therefore, the domestic construction enterprises with independent intellectual property rights expect local equipment will soon come out.
Whole section tunneler is with high technical content and added value high products, reflect a nation's comprehensive national strength and scientific and technological level, the equipment manufacturing industry innovation system is the important component. So whole section roadheader industry development, for the readjustment of industrial structure of our country, driving the development of relevant industries, improve the level of the equipment manufacturing industry in China will play an important role.
From a long-term strategic development, China can't always view on foreign equipment and talents to develop underground space. Our country has such a great roadheader market, and as the power equipment manufacturing, can never long-term machine imported foreign roadheader, allow foreign roadheader manufacturers to carve up China's market. Therefore, "11th five-year plan" period, we must grasp the core technology of the whole section roadheader, establish and integration technology in their whole section roadheader industry.
Whole section roadheader development situation
Whole section roadheader began in the early 19th century Britain, development, and Japanese ought to apply to the subway tunnel, railway tunnel, road tunnels, water diversion tunnel, mine laneway, city municipal tunnel, etc. Various kinds of tunnel engineering. Our whole section roadheader in the research and development began in 1960s, development in 1990's, including the largest number of subway use, accounting for approximately 80%. Modern whole section roadheader has evolved into a highly intelligent, the collecting machine, electricity, liquid, light, computer technology as one of the major underground construction machinery and equipment.
1, overseas development situation
The development of international, roadheader experienced a relatively long process. The prototype of the roadheader can be traced back to the 19th century. In 1876, British John Dickinson Brunton and George Brunton apply for the first mechanization shield patent, this shield a composed of several pieces of plate by the rotation of the hemispherical knife dish, excavation of earth material fall into radial installed in the knife dish in the hopper, hopper will slag on feeding transship to belt conveyor, it can be turned to shield out from behind in, the idea later be used to build subway tunnel. But because technology and war's sake, roadheader in development has remained stagnant. Until 1959, supported by liquid by the idea Elmer tunnel C.G ardner successfully trial on a diameter for 335 m drainage tunnel. In 1960, proposed Schneidereit with bentonite suspension of mining the activities support. After this, the orenz application with pressurized H.L bentonite pulp to stabilize the patent tunnel.
So far, the design of shield for modern manufacturing established. In 1963, Japan Sato Kogy0 company first developed soil pressure balance shield machine, in 1967, the first with a cutting wheel and realize hydraulic shield unearthed in Japan put into use, its diameter is 3.1 m. That same year, Germany with bentonite liquid support the shield tunnel work face by Wayss&Freytag develop and apply. So far, the two kinds of engineering practical shield machine were already appear, for modern shield construction machine and its development and application of methods to lay the foundation.
Start from 1845 100 years, the world's inventors were looking for realizing method of rock tunnel heading machine. In 1952, founder of the American Robbins company -- James Robbins sir developed the first practical, the rock tunneler dig rock tunnel excavation, found a method of rock tunnels. Mechanized
Since then the 40 years since, whether rock tunneler or shield tunnelling machine have been improved by leaps and bounds development. Use the tunneling of rock tunneler is already more than 10000km tunnel shield tunneling, the tunnel more. At present, in international roadheader technology has matured, has reached work high reliability, high precision, automatic horizontal directional high, adaptable, heading speed and long service life. The technical development has been especial around stratigraphic stability and land subsidence control, automation heading and improve speed and lining and tunnel excavation quality three factors of shield machine improvement and construction method of the revolution. Main technology are: 1) formation stability and land subsidence control technology; 2) structure design technology; 3) tool knife plate technology; 4) orientation and the attitude control technology; 5) lining technology; 6) waterproof and synchronization grouting technology. International currently roadheader technology has the following features:
(1) high automation
All of roadheader operations in guidance and the monitoring, make the tunneling process always at its best, toward the mechanical, electrical, hydraulic automation control integration, intelligent direction, using a similar robot technology, computer control, remote control, sensors, laser guidance, early geological exploration, communication technology etc have applies generally. Along with the rapid development of computer technology, automation degree of roadheader in more and more high, high construction data acquisition function, heading stance management features, construction data management function, equipment management function, construction data real-time remote transmission function. Can the automatic detection roadheader position and posture, and by using fuzzy theory, it can automatic automatically adjust the control, balanced pressure can be automatically realize segment of the assembly, etc. In some roadheader, has also used the GPS ground satellite directional system and super remote monitoring techniques.
(2) exist large change and long life
For rock tunneler is, its biggest diameter specification has reached 12m, high power, big thrust, big trip, big knives are the main character, its single platform use the longest life expectancy has amounted to about 50Km, average life expectancy 15km, average monthly footage has more than 1000m, disk cutter diameter of 19 ", can be used as the compressive strength of 450MPa layers, the knife dish already more than 3500kW, turn power maximizes trip has reached 245 m, 35MN maximizes force to achieve. Maximum diameter of shield tunnelling machine has reached 15,44 m specifications, and can adapt to soft different complex geologic conditions, life can reach the highest 7km tunneling, as well, to the footage.
(3) various form
From the rectangular cross-section shape, have followed, oval, MF shape (double circular lap, three round lap) etc. Various different circular cross-section shield. Double round, three circles of shield tunnelling machine in subway construction in Shanghai has been successfully applied; Tell from the function appeared sphere mother shield, shield, the hole diameter diameter changes of shield, shield, bifurcation shield, exchanging cutting tool (without shaft on shield, obstacles) shield etc special directly resection of shield; The shield machine from dig cut way see appeared shaken, the swinging the dig cut way of shield. Whole section rock tunneler appeared reaming, slope and the form such as roadheader followed.
(4) high adaptability
With modern roadheader technology development, the hard-rock roadheader shield technology with soft soil infiltration, and mutual confluence, make its geological adaptability greatly enhanced. At present, is moving will hard-rock and soft rock tunneler is incorporated in the adaptability stronger composite roadheader direction, this kind of roadheader in a high-pressure water and fault cases, according to the slurry pressurized can fully enclosed shield principle work, in anhydrous, can quickly converted to open wide type heading. In addition, also increases high-pressure water auxiliary broken rock, can raise around 50% of tunneling speed. Reduce costs by 25%, transmission power consumption reduce about 25%. Rock the unconfined compressive strength (UCS) range up to 3 ~ 385MPa (common area for 50 ~ 180MPa).
Of course, also like other technology se technology, as well as the actual tunnel project with the new requirements and scientific and technological level of continuous development and development, also unceasingly have new problems to solve. As the construction of chengdu subway to geologic condition, at present, in other parts of the world are not met, this for the design of shield tunnelling machine, it is a new challenge; Be like again, all the west-line project of south-to-north water transfer project is at an altitude of tunnel engineering 4000m above, and a single hole line long length, the existing engineering in the world is never met. So, no matter for which a company, it must make new exploration and research.
Now, the production of shield tunnelling machine for famous manufacturer has: Japan's mitsubishi heavy industries, kawasaki heavy, ishikawa island, Hitachi built dhi broadcast grinding machine and komatsu making, German Herrenknecht (Herrenknecht) company, Nashville Wirth) company, (subordinate to the (NFM) company, Canada's ROM watt (Lovat) company, French FCB company. Production rock tunneler is famous manufacturer has: American Robbins (Robbins) company, Germany's vale, herrenknecht ag, Canada's ROM watt company. The companies have basic admiral own roadheader series of products.
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