CN102267034B - Opening repairing method of large-gear-ring gear teeth of main bearing of tunnel tunnelling machine - Google Patents
Opening repairing method of large-gear-ring gear teeth of main bearing of tunnel tunnelling machine Download PDFInfo
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Abstract
The invention discloses an opening repairing method of large-gear-ring gear teeth of a main bearing of a tunnel boring machine. The method comprises the following steps of: firstly, disassembling main bearing driving pinions, wherein two symmetric main bearing driving pinions are left; and then constructing an operation platform at a driving pinion hole at the left lower corner of the main bearing, wherein the operation platform is lower than the driving pinion hole; cutting a welding operation hole at the internal diameter part of the main bearing, corresponding to the non-disassembled main bearing driving pinion; carrying out welding treatment by using three welding materials for repairing and welding of the large-gear-ring gear teeth: selecting the welding materials with the corresponding performances according to the performances of a large-gear-ring gear teeth base coat, a gear teeth core part and gear teeth surfaces so that the performance of the repaired gear teeth is close to that of the original gear teeth; and detecting the teeth shape by using a three-connecting-tooth rubbing mould as a standard so as to ensure the repairing accuracy. By using the method, the large gear ring of the main bearing of the tunnel boring machine can be repaired in the hole without replacing the main bearing in the hole and disassembling the main bearing out of the hole for factory repair, and can obtain the working performance of the original teeth after being repaired.
Description
Technical field
The present invention relates to the restorative procedure of tunnel piercing main bearing bull gear, especially tunnel piercing main bearing bull gear restorative procedure in the hole in work progress.
Background technology
The rock tunnel(ling) machine English name is Tunnel Boring Machine, is called for short TBM; It is more suitable for the needs of long tunnel construction, and the general speed that adopts development machine to carry out constructing tunnel is 3～10 times of conventional drilling and blasting method.The specific aim of TBM is very strong, and different geological conditions needs different development machines, has also just produced different development machines; What have is applicable to weak soil, is called again shield machine; What have is applicable to rock, and rock ripper can be divided into open type, single shield formula and two shield formula.
Base bearing is the core component of development machine, long-term dependence on import, and only American-European, several Japanese producers can produce in the world, are worth height, and the production cycle is long.Its effect is the supporting cutterhead, and to the power of cutterhead transmission rotation, owing to limited by tunnel space, base bearing is difficult to change., base bearing lost efficacy then whole equipment paralysis, the consequence that causes unit in charge of construction to be difficult to bear if damaging.For the unit that adopts the development machine construction, base bearing service life, reliability and security requirement are very high, guarantee that the base bearing good operation is the assurance of the normal driving of development machine.
If base bearing damages, from the time that base bearing is changed, then buy the new base bearing production cycle more than half a year, add the time of external transportation and declaration, at least seven months, for unit in charge of construction, this was the loss that is difficult to bear.
The duration of changing in the base bearing hole, the base bearing diameter is large, the position that how base bearing is transported between shield and the cutterhead is a difficult problem, in the Dahuofang diversion works hole of domestic certain company's construction, change the base bearing example, the said firm from development machine next door hand excavation one detour base bearing transported to and change the position, spent six months time just complete the replacing of the base bearing of development machine, this time fault has caused very serious loss to the said firm.
Bull gear is the critical component that main shaft of boring machine holds, if bull gear breaks down, heavy wear occurs or collapse the phenomenon that tooth falls tooth, then can't continue driving, how can in the hole main shaft of boring machine be held bull gear reparation, for unit in charge of construction, be a very valuable problem.
The reparation of common gear is that successful case is arranged at home, and the gear renovation technique has welding method, laser cladding or inserted etc.Because main shaft of boring machine is housed on the equipment, the working space of reparation is limited, and laser cladding and inserted gear restorative procedure are difficult to realize that therefore on-the-spot gear reparation can only be adopted welding method.And the bull gear of base bearing and base bearing raceway are one, and the material of employing is medium carbon heat treated high strength steel, and solderability is relatively poor.Because phosphorus content is high in the base metals, in welding process, the part of base metals will be melted in the weld metal and go, and causes the layer carbon amount contained in the metals to increase, during the weld seam solidification and crystallization, crystallization temperature is interval large, the segregation tendency is also larger, and the in addition impact of sulfur-containing impurities and pore causes fire check easily in the layer metal, particularly at the ending place, crackle is more responsive.One-tenth in these gear reparations is attacked case, all need adopt the method for gear preheating to realize, but because main shaft of boring machine holds the bull gear both sides critical sealing is arranged, the method for preheating is difficult to realize.
Main shaft of boring machine holds and repairs the requirement height in the bull gear gear hole, difficulty is large: owing to do not remove welding in the hole, working space is very limited, need to find out the position that reasonably opens a position and weld, and this is unexampled; The development machine that is used in addition the hard rock driving, the main gear ring that drives need bear large moment of torsion and thrust, and needing after the gear teeth reparation has suitable hardness and wearability.Hold the case that breaks down from domestic and international main shaft of boring machine, also do not have in the world main shaft of boring machine to hold the precedent of repairing in the bull gear gear hole.
Summary of the invention
Technical problem to be solved by this invention is to propose a kind of when main shaft of boring machine holds bull gear and breaks down, not be used in and change base bearing in the hole, need not also base bearing split out that to advance repair in shop outside the hole multiple, can in the hole, hold the method that bull gear is repaired to main shaft of boring machine, and the base bearing bull gear after repairing can reach the service behaviour of original tooth.
The measure that realizes objects of the present invention is:
The restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth of the present invention, the working space that relates to field repair is selected, welding procedure and the profile of tooth restorative procedure of field repair,
When the working space of described field repair is selected, at first remove the base bearing driving pinion, stay two base bearing driving pinions not remove in the mode of symmetry, make bull gear energy turned position in the repair process; Then take job platform at the place, driving pinion hole in the base bearing lower left corner, job platform is lower than the driving pinion hole; Cut the weld job hole at base bearing internal diameter position corresponding to the base bearing driving pinion place of not removing;
The welding procedure of described field repair, the reparation welding of the bull gear gear teeth adopts three kinds of wldings to carry out soldering: bull gear gear teeth prime coat good welding performance, the wlding that tensile strength is high, bull gear gear teeth core is used without heat treatment, hardness and the intensity wlding close to bull gear gear teeth core, bull gear tooth surface layer is with the approaching wlding of hardness after hardness and the heat treatment of the bull gear gear teeth, makes gear teeth performance after the reparation close to the original gear teeth;
Described profile of tooth restorative procedure adopts three company's teeth to open up mould and carries out carrying out the profile of tooth detection for standard, guarantees to repair precision.
For better implementing the invention, also relate to when the bull gear gear teeth are carried out an acceptance inspection, adopt the developer of dye penetrant inspection agent to spray, the engagement inspection of the bull gear gear teeth is carried out in test running, the part that impression is arranged is polished, guarantee to repair the accuracy of mesh of the rear bull gear gear teeth.
For better implementing the invention, before dismounting base bearing driving pinion, need put the gear oil in the clean base bearing, and the iron filings foreign material of cleaning base bearing gear-box inside, and indicate the gear teeth that need reparation.
For better implementing the invention, after definite base bearing internal diameter parts cut the position in weld job hole, need the in-site modeling by operating personnel's operation, satisfy the operation hole width greater than operating personnel's shoulder breadth, the operation hole length should satisfy the operating personnel when wearing welding mask, and hand and head can stretch in the operation hole simultaneously; Carry out the repair of tooth with the size of determining the operation hole.
For better implementing the invention, the welding procedure of described field repair is at first carried out material analysis by hardness tester test bull gear Teeth Hardness and to the bull gear gear teeth, to confirm choosing of welding material and welding method.
For better implementing the invention, the welding procedure of described field repair before the reparation welding of the bull gear gear teeth, installs the required illuminating lamp of repair at the scene, is ready to the required ventilation blower of repair.
Be the better the invention of implementing, the welding procedure of described field repair, before the reparation welding of the bull gear gear teeth, the gear teeth of the need reparation that need indicate are polished, and the face rounding off that requirement polishes out can not have the right angle; Detect a flaw with the mode of magnetic powder inspection or dye penetrant inspection after the polishing, be polished to till all crackles eliminations; Clear away at last surface and oil contaminant to be welded, and clean the buffed surface that needs to repair the gear teeth.
Be better enforcement the invention, the welding procedure of described field repair, every weldering one deck all need carry out welding stress to be eliminated, and adopts hammering method to carry out the elimination of welding stress, and polishing is detected a flaw with the mode of dye penetrant inspection again.
For better implementing the invention, after the bull gear gear teeth carried out an acceptance inspection, the steel plate that the base bearing perforate is cut off welded the original situation that reverts to again, remove each operation platform, clean the base bearing gearbox system, recover each driving pinion, the filling gear oil recovers driving.
Because adopt aforesaid technical scheme, the invention has following superiority:
1, the present invention need not change base bearing when main shaft of boring machine holds the bull gear gear teeth and breaks down, and can carry out field repair in the hole.Implementation method is to choose suitable job position, adopts rational welding procedure and profile of tooth restorative procedure, selects the test stone of science to check and accept the repairing quality of the gear teeth.Saved the cost of purchasing a new base bearing.
,The present invention is when main shaft of boring machine holds the bull gear gear teeth and breaks down, can about one month, keep in repair complete, can make the development machine applying unit within the shortest time, recover driving, than about five months the time of method saving of changing base bearing, successful aspect duration and economy.
Description of drawings
Accompanying drawing 1 is base bearing weld job perforate master TV structure schematic diagram in the embodiment of the invention;
Among the figure: the 1-1# driving pinion; The 2-2# driving pinion; The 3-3# driving pinion; The 4-4# driving pinion; The 5-5# driving pinion; The 6-6# driving pinion; The 7-7# driving pinion; The 8-8# driving pinion; The 9-base bearing is repaired perforate; The 10-shield; 11-base bearing external diameter; 12-base bearing internal diameter; The 13-job platform; The 14-pinion; The 15-bull gear; The 16-pinion gear aperture; The 17-sealing.
The specific embodiment
TBM880E development machine in certain Tunnel Engineering broke down in February, 2011, and base bearing bull gear gear heavy wear, impression occur and collapses the tooth fault, shuts down it is repaired, and the method for enforcement is:
1, puts the gear oil in the clean base bearing after development machine is shut down;
2, the foreign material such as iron filings of cleaning base bearing gear-box inside;
3, check out the gear of need repairing, and all teeth of base bearing bull gear (totally 174 teeth) be numbered and take pictures that record needs gear numbering and the damaged condition of repairing;
4, in conjunction with Fig. 1, stay the 4# driving pinion 4 in the upper left corner and the 8# driving pinion 8 in the lower right corner, all the other complete removals; Make that driving pinion can drive the bull gear turned position in the repair process;
5, in conjunction with Fig. 2, the place takes job platform 13 in the 1# of base bearing lower left quarter driving pinion 1 hole, and job platform has ladder to climb on the platform from tunnel bottom, and job platform 13 is lower than about 1 meter of 1# driving pinion 1 hole;
6, by checking the base bearing structural drawings of development machine manufacturer, external diameter 11 Φ 4800mm cooperate with development machine shield 10, do not have the repair space; Internal diameter 12 Φ 2750mm are the passage of development machine tool changing, can be used as the operation place of REPAIR WELDING, and therefore choosing base bearing internal diameter position cuts the weld job hole;
7, pass through the in-site modeling of operating personnel's operation, determine that it is the size in operation hole that base bearing is repaired perforate 9: Main Basis is the distance of bull gear and base bearing internal diameter, if bull gear from internal diameter away from, owing to need head to stretch into the operation hole during welding, electric welding mask, both hands carry out the REPAIR WELDING operation, and the operation hole width is at least greater than operating personnel's shoulder breadth, operating personnel's shoulder breadth 400mm, the wide 430mm that is decided to be of operation hole dimension; The operation hole length should satisfy the operating personnel when wearing welding mask, and hand and head can stretch in the operation hole simultaneously, determine the long 600mm in operation hole; The operating personnel needs all to be polished in the flank of tooth both sides of repairing rear tooth, and the operation hole is determined above base bearing 1# driving pinion 1;
8, the base bearing bull gear gear teeth are carried out material analysis and test base bearing bull gear Teeth Hardness by hardness tester;
Material from bull gear to Wei Erte company of development machine manufacturer that understand is 42CrMo4, and chemical analysis is:
Carbon C: 0.38～0.45, silicon Si:0.17～0.37, manganese Mn:0.50～0.80, sulphur S: allow residual content≤0.035, phosphorus P: allow residual content≤0.035, chromium Cr:0.90～1.20, nickel: allow residual content≤0.030, copper Cu: allow residual content≤0.030, molybdenum Mo:0.15～0.25
Falling outside the piece committee of base bearing bull gear gear carried out material analysis, and the content of its metallic element and 42CrMo4 coincide;
" the TH110 Leeb Hardness Tester " that adopt the Beijing Time Zhifeng Science Co., Ltd to produce tested the case hardness of tooth, and test result is that the tooth surface hardness of bull gear is HRC45～50, and the core hardness of damaging tooth is HRC30～31;
9, install the required illuminating lamp of repair;
10, be ready to the required ventilation blower of repair;
11, in conjunction with Fig. 3, prepare wet cotton or towel be placed on Seeding location around, protect the sealing 17 of bull gear 15 sides, and prevent that iron filings from falling into base bearing inside;
12, the base bearing bull gear gear teeth of damage are polished, the necessary rounding off of polishing face out can not have the right angle, detects a flaw with the method for dye penetrant inspection after the polishing, is polished to till all crackles eliminations;
13, clear away the surface and oil contaminant of the rear tooth to be welded of polishing with oxygen-acetylene;
14, clean the buffed surface of the need reparation of the base bearing bull gear gear teeth with acetone;
15, the mode of imitation laser weldering is adopted in the reparation of base bearing bull gear gear teeth welding, adopt the WS-02 portable multi-function imitation laser welding machine welding of Dongguan letter difficult to understand laser welder equipment Co., Ltd exploitation, adopt three kinds of wldings to carry out soldering, prime coat good welding performance, the wlding that tensile strength is high, the tooth core adopts without wlding heat treated, that hardness is approaching with the tooth core, base bearing bull gear tooth surface layer is with the wlding that hardness after hardness and the heat treatment of bull gear gear approaches, and makes tooth performance after the reparation close to original tooth;
Wlding has been selected three kinds of welding wires of the Thyssen brand of German import, and TIG-SKD888 is adopted in bottoming, and the stretching resistance that is combined is strong, and hardness can reach HRC30; Transition zone adopts TIG-SKD61, and hardness can reach HRC35; Superficial layer adopts TIG-SKD11, and hardness is higher, is equivalent to the quench layer, and hardness can reach HRC50;
16, because near the seal protection the bull gear needs, can not adopt the mode of heat tracing; Every weldering one deck all need adopt hammering method to carry out the elimination of welding stress, polishes afterwards again, and detects a flaw with painted scratch method;
17, three connect tooth and do one three and connect tooth and open up mould preferably according to situation, connect on the tooth but the plastic-steel healant that adopts the U.S. must answer the production of Kanggong department is cast in selected three, be three after doing and connect tooth and open up mould;
18, connect tooth take three and open up mould as standard, tooth after welding is carried out tooth polishing shaping, profile of tooth testing staff stands on the job platform 13 and to connect teeth with the light of flashlight take three by 1# driving pinion 1 hole and open up mould and carry out profile of tooth as standard and detect, and detects a flaw with Dye inspectiong;
19, the hardness of repairing rear tooth is carried out an acceptance inspection, " the TH110 Leeb Hardness Tester " that adopt the Beijing Time Zhifeng Science Co., Ltd to produce carries out hardness test, makes the hardness of repairing rear tooth can reach more than 95% of former hardness;
20, the tooth after repairing is adopted the developer spraying of painted scratch agent, carry out the engagement inspection of tooth, the part that is engaged with impression is polished, the tooth after guaranteeing to repair has 80% can mesh;
21, the tooth of repairing is accomplished fluently the clearly sign of Zhe, and make a record;
22, the steel plate that the weld job perforate is cut off welds by original situation;
23, remove each operation platform, clean the base bearing gearbox system, recover each driving pinion, the filling gear oil is finished the recovery driving the middle ten days in March, 2011.
The present invention not detailed descriptionthe partly is prior art.
Claims (1)
1. the restorative procedure that opens a position of tunnel piercing main bearing bull gear gear teeth relates to the working space selection of field repair, welding procedure and the profile of tooth restorative procedure of field repair, it is characterized in that:
When the working space of described field repair is selected, at first remove the base bearing driving pinion, stay two base bearing driving pinions not remove in the mode of symmetry, make bull gear energy turned position in the repair process; Then take job platform at the place, driving pinion hole in the base bearing lower left corner, job platform is lower than the driving pinion hole; Cut the weld job hole at base bearing internal diameter position corresponding to the base bearing driving pinion place of not removing;
The welding procedure of described field repair, the reparation welding of the bull gear gear teeth adopts three kinds of wldings to carry out soldering: bull gear gear teeth prime coat good welding performance, the wlding that tensile strength is high, bull gear gear teeth core is used without heat treatment, hardness and the intensity wlding close to bull gear gear teeth core, bull gear tooth surface layer is with the approaching wlding of hardness after hardness and the heat treatment of the bull gear gear teeth, makes gear teeth performance after the reparation close to the original gear teeth;
Described profile of tooth restorative procedure, adopting three company's teeth to open up mould is that standard is carried out the profile of tooth detection, guarantees to repair precision;
After the bull gear gear teeth carried out an acceptance inspection, the steel plate that the base bearing perforate is cut off welded and reverts to original situation, removes each operation platform, cleaned the base bearing gearbox system, recovered each driving pinion, and the filling gear oil recovers driving.
2, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: also relate to when the bull gear gear teeth are carried out an acceptance inspection, adopt the developer of dye penetrant inspection agent to spray, the engagement inspection of the bull gear gear teeth is carried out in test running, the part that impression is arranged is polished, guarantee to repair the accuracy of mesh of the rear bull gear gear teeth.
3, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: before removing the base bearing driving pinion, need put the gear oil in the clean base bearing, and the iron filings foreign material of cleaning base bearing gear-box inside, and indicate the gear teeth that need reparation.
4, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: after definite base bearing internal diameter parts cut the position in weld job hole, need the in-site modeling by operating personnel's operation, satisfy the operation hole width greater than operating personnel's shoulder breadth, the operation hole length should satisfy the operating personnel when wearing welding mask, and hand and head can stretch in the operation hole simultaneously; Carry out the repair of tooth with the size of determining the operation hole.
5, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: the welding procedure of described field repair, at first carry out material analysis by hardness tester test bull gear Teeth Hardness and to the bull gear gear teeth, to confirm choosing of welding material and welding method.
6, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: the welding procedure of described field repair, before the reparation welding of the bull gear gear teeth, install at the scene the required illuminating lamp of repair, be ready to the required ventilation blower of repair.
7, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: the welding procedure of described field repair, before the reparation welding of the bull gear gear teeth, the gear teeth of the need reparation that need indicate are polished, the face rounding off that requirement polishes out can not have the right angle; Detect a flaw with the mode of magnetic powder inspection or dye penetrant inspection after the polishing, be polished to till all crackles eliminations; Clear away at last surface and oil contaminant to be welded, and clean the buffed surface that needs to repair the gear teeth.
8, the restorative procedure that opens a position of the tunnel piercing main bearing bull gear gear teeth according to claim 1, it is characterized in that: the welding procedure of described field repair, every weldering one deck all need carry out welding stress to be eliminated, adopt hammering method to carry out the elimination of welding stress, polishing is detected a flaw with the mode of dye penetrant inspection again.
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| CN 201110171614 CN102267034B (en) | 2011-06-24 | 2011-06-24 | Opening repairing method of large-gear-ring gear teeth of main bearing of tunnel tunnelling machine |
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| CN 201110171614 CN102267034B (en) | 2011-06-24 | 2011-06-24 | Opening repairing method of large-gear-ring gear teeth of main bearing of tunnel tunnelling machine |
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Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102305082B (en) * | 2011-07-23 | 2013-10-23 | 中铁十二局集团第二工程有限公司 | Method for relieving and cutterhead repairing of shield machine in weathering groove |
| CN103737273B (en) * | 2013-12-31 | 2015-12-30 | 武汉团结点金激光科技有限公司 | A kind of manufacture craft of New Kind of Hob of laser melting coating WC wear-resistant coating |
| CN104314576B (en) * | 2014-08-22 | 2016-03-30 | 江苏凯宫隧道机械有限公司 | Shield machine assembling machine base bearing down-hole replacing options |
| CN108547623B (en) * | 2018-03-05 | 2019-07-16 | 广东水电二局股份有限公司 | A kind of replacing options of tunnel piercing main bearing bull gear |
| CN111203692B (en) * | 2020-01-18 | 2021-02-12 | 上海兴道锻造有限公司 | Forging process of high-low pressure partition plate |
| CN112846637A (en) * | 2021-01-15 | 2021-05-28 | 中铁工程装备集团有限公司 | In-situ repairing method for collapse of support surface of cutter shaft of heading machine and cutter shaft of heading machine |
| CN113249718B (en) * | 2021-05-13 | 2022-09-30 | 清华大学 | Laser cladding method of 42CrMo gear ring and 42CrMo gear ring |
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