US20240076983A1

US20240076983A1 - Tunnel Extraction Machine (TEM)

Info

Publication number: US20240076983A1
Application number: US18/386,989
Authority: US
Inventors: Behzad Khorshidi
Original assignee: Topeng Inc
Current assignee: Topeng Inc
Priority date: 2022-05-03
Filing date: 2023-11-03
Publication date: 2024-03-07

Abstract

A Tunnel Extraction Machine (TEM) and its alternatives is a sustainable machine to excavate the tunnel or mine or dredge seabed in a rapid, efficient and cost-effective way as it allows large parts of the rock (or soil) to be extracted and pulled out of the tunnel or mine without necessity of digging or crushing them and with significantly reduced amount of the energy. Basically, it can excavate (cut) perimeter of the tunnel section in different shapes and sizes along with some other required longitudinal and transversal cuts and then extract and pull out the untouched and undug large portions of the rock or soil out of the tunnel.

Description

FIELD OF THE INVENTION

This invention is generally related to introduction and basics of a new shield machine named Tunnel Extraction Machine (TEM) to excavate the tunnels by faster, efficient and more economic system and can be used widely in tunneling and mining industries and their variations specially in rock tunnels.

BACKGROUND AND SUMMARY OF THE INVENTION

A Tunnel Extraction Machine (TEM) is a machine to excavate the tunnels or mines in a rapid, efficient and cost-effective method as it allows large parts of the rock (or soil) to be extracted and pulled out of the tunnel or mine without necessity of digging or crushing them and with significantly reduced amount of the energy.
Basically it will excavate (cut) perimeter of the tunnel section along with some other required longitudinal and transversal cuts and then extract and pull out the untouched and undug large portions of the rock or soil mechanically out of the tunnel.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention is described by way of examples and not by way of limitations in the accompanying drawings including:

FIG. 1A. General TEM 3d Front view

FIG. 1B. General TEM 3d Rear view

FIG. 1 . General TEM longitudinal section A-A

FIG. 2 . Cross section 1-1 of FIG. 1

FIG. 3 . Cross section 2-2 of FIG. 1

FIG. 4 . Cross section 3-3 of FIG. 1

FIG. 5 . Cross section 4-4 of FIG. 1

FIG. 5A. Option showing the rotator of central drum cutter holder

FIG. 5B. Drum cutter by rotating shaft option

FIG. 6 . Cross section 6-6 of FIG. 1

FIG. 7 . Cross section 7-7 of FIG. 1

FIG. 8 . Cross section 8-8 of FIG. 1

FIG. 9 . Cross section 9-9 of FIG. 1

FIG. 10 . General TEM Longitudinal section B-B

FIG. 11 . Longitudinal TEM section A3-A3 with segmental lining

FIG. 12 . Cross section 9-9 of FIG. 11

FIG. 13 . Cross section 10-10 of FIG. 11

FIG. 14 . Longitudinal section A1-A1

FIG. 14A. Longitudinal section B1-B1

FIG. 14B. Cross section 4A-4A of FIG. 14

FIG. 15 . Cross section of TEM at middle shield

FIG. 16 . Longitudinal section A2-A2

FIG. 17A. Cross section 5A-5A of FIG. 16 —close gate

FIG. 17B. Cross section 5A-5A of FIG. 16 —open gate

FIG. 18 . Longitudinal section A4-A4

FIG. 18A. Cross section 4B-4B of FIG. 18

FIG. 19 . Longitudinal section A5-A5

FIG. 19A. Cross section 4C-4C of FIG. 19

FIG. 20 . TEM longitudinal section B2-B2

FIG. 21 . Cross section 1-1 of FIG. 20

FIG. 22 . Cross section 4-4 of FIG. 20

FIG. 23 . Cross section 6-6 of FIG. 20

FIG. 24 . Cross section of Extraction area—by Plasma torch/water jet

FIG. 25 . Cross section 8-8 of FIG. 20

FIG. 26 . Cross section 9-9 of FIG. 20

FIG. 27 . Longitudinal section B2-B2

FIG. 27A. Cross section 1A-1A of FIG. 27

FIG. 28 . Lifting switch example

FIG. 28A. Cross section of Extraction area—by Mechanical excavation

FIG. 29 . Cross section of a rectangular TEM

FIG. 30 . Sample of building walls by extracted rocks

FIG. 31A. Alternative for front cap—close gate

FIG. 31B. Alternative for front cap—open gate

FIG. 32 . Alternative for axial cutters instead of cutter drums

FIG. 33 . Rotated axial cutters for transversal cut

FIG. 34 . Example of using Cutter chains in a TEM

FIG. 35 . Example of extracting combined rocks

FIG. 36 . Example of multi-shield TEM

FIG. 37 . Extracted rocks by multi-shield TEM

FIG. 38 . Example of horseshoe TEM

FIG. 38A. Extracted rocks by horseshoe TEM

FIG. 39 . Rotatable plasma torches

FIG. 40 . Example of dredging TEM

FIG. 40A. Cross section D1-D1 of dredging TEM with plasma torches

FIG. 40B. Cross section D2-D2 of dredging TEM with plasma torches

FIG. 40C. Cross section D1-D1 of dredging TEM with drum cutters

FIG. 40D. Cross section D2-D2 of dredging TEM with drum cutters

FIG. 41 . Door caps for TEM

FIG. 42 . TEM with single drum cutter

FIG. 43 . Arc shape bridge by extracted rocks

FIG. 43A. Cross section of arc bridge by extracted rocks

DETAILED DESCRIPTION

Advantages, objects and novel features of this invention will become apparent from the following detailed description when considered along with the accompanying drawings. One skilled in the art understands that other embodiments may be utilized and other structural, mechanical, electrical and logical changes may be made without departing from the scope of the present invention. So, the following detailed illustration to not be taken in limiting sense as scope of the present invention are defined in the relevant claims.
FIG. 1A, 18 are respectively the schematic 3 d front and rear views of a TEM 5 and FIG. 1 is a longitudinal sectional view of a TEM 5 showing relation of the main parts including a hollow ring cutter head 10 which is excavating (cutting) a thin circumferential slot in the face of the tunnel (rock/soil) by rotating around the central axis of the TEM 5 and plurality of drum cutters 25 (4 nos. at this embodiment) which are excavating (cutting) slots in the rock as shown at FIG. 2 . The drum cutters 25 are mounted to a central drum cutter holder 95. As the TEM 5 is moving forward the large parts of unexcavated and untouched muck rock 81 in almost pie shape section will be entered into the space between the hollow ring cutter head 10 and drum cutters 25 and will go inside of the plurality of muck boxes 80 (4 nos. at this embodiment) which are located just behind the drum cutters 25 and within the Muck frame 21.
Whenever the muck boxes 80 are filled with rock 81, then cutter drums 25 will be rotated around the central axis of the TEM 5 while they are actively working and turning in order to cut the rock transversally. At this stage the trapped large portions of the untouched muck rocks 81 within the muck boxes 80 would be free to be extracted and pulled out of the tunnel. In some cases in soft soils, transversal cut may not be necessary. The muck boxes 80 sides may include openable connections e.g. bolted, hinged etc. between each others and may include attachable lifting eyes to be handled on the ground and to discharge its carrying rock 81.
At the illustrated embodiment, 4 sections of the Muck boxes have been considered as example. The lowest muck box 80 and its muck rock 81 may be pulled out by any pulling/pushing means such as Locomotive 99, rubber wheel truck or winches. The extracted muck box 80 to be placed on any means of transporting device such as shown muck box dollies 85 as it is being pulled out from the muck frame 21. If necessary a front cap 83 may be added as shown at FIG. 10 to avoid debris or pieces of rock/soil falling out of the muck boxes 80. Also for ease of pulling the much box 80 out of the muck frame 21, plurality of rollers may be added on the muck external frame 90.
The muck frame 21 is comprising cylindrical muck external frame 90 and muck internal frame 91 and muck central frame 92 and muck boxes 80 are being pushed/pulled into the muck frame 21. The muck frame 21 is rotatable as it is located within plurality of the rollers 39 which may be powered themselves and therefore muck boxes 80 can be positioned at lower part of the TEM 5 to be entered into the muck frame 21 or to be extracted from the muck frame 21. If necessary racks/gears may be used to be engaged with pinion/sprocket of the rollers 39 (See FIGS. 6 and 18 and 1 ). The central drum holder 95 is rotatably mounted on central frame 92 by a bearing.
As shown at FIGS. 6 and 18 the powered rollers 39 are fixed at inner face of the middle section 36 from their bases and holding the muck frame 21 on their rollers. To ease rotation of the muck frame 21, the rollers and muck external frame 90 may be engaged by gears/racks. In one embodiment the muck external frame 90 may be a can/barrel instead of framing (See FIG. 1B). Each muck boxe 80 can be rotated 360 degrees around central axis of the TEM 5 by rotation of the muck frame 21 to be positioned at lowest part of the TEM 5 in order to be pulled out of muck frame 21.
As shown at FIGS. 1, 2, 3 and 4 the ring cutter head 10 may comprise cutting tools 15 and openings 20 and is turning by engaged gears/racks with pinion/sprocket of Cutter head drives 40.
As shown at FIG. 4 the cutter head drives 40 is fixed on the cylindrical forward shield 35 and is protected by cutter head cover 45. Excavated rock which are being crushed by the ring cutter head 10 will be mucked out by any means such as conveyor belt, vacuum or cutter head screw conveyor 50 located at bottom of this embodiment in space between cylindrical muck external frame 90 and cylindrical middle shield 36. At another embodiment the cutter head screw conveyor 50 may be located at upper parts of the TEM 5 which at this case extra guided plates may be added inside the ring cutter head 10 to lift the excavated and crushed materials to upper parts during turning the ring cutter head 10. In one embodiment cutter head drives may be located within muck internal frame 91.
The cutter head screw conveyor 50 may be extended into the ring cutter head 10 as shown at FIG. 10 for better mucking out the crushed rock. The ring cutter head 10 has generally a “U” shape and the rear face of the Ring cutter head 16 is enclosed by perpendicular extension of the forward shield 35 (Fixed on the forward shield 35) which has a hole at the cutter head screw conveyor 50 location as shown at FIG. 10 and the cross section at FIG. 4 .
As shown at FIGS. 5 and 1 the drum cutter 25 may include the drum axial drive 57 that are mounted on the central drum cutter holder 95 and/or drum axial end drive 58 mounted on drum cutter base 59 including drum roller 55 positioned on the forward shield 35 inner face. The central drum cutter holder 95 is connected by a bearing to the Muck central frame 92 to be rotatable. The drum cutters 25 will be able to excavate rock or soil longitudinally by their axial rotation and excavation means e.g. bits, reamer, cutter discs (cutting tools on drum cutter not shown for clarity).
Whenever it is necessary or whenever the muck box 80 are full for excavation of the rock transversally, the drum cutters 25 can be rotated around central axis of the TEM 5 by the drum radial drives 60 which are mounted on the drum cutter 25 within space behind the ring cutter head 10 and can make rotation of the drum cutters 25 transversely by engaging its gears (pinion/sprocket) to the fixed drum radial ring gear 63 (rack) on the forward shield 35.
The said drum roller 55 may be powered itself alternatively to make perimeter rotation of the drum cutters 25 on the forward shield 35. Also due to lateral loading on the drum rollers 55 during the excavation, extra lateral supports on the drum cutters 25 within spaces behind the cutter head ring 10 may be needed.
As an alternative as shown at FIG. 5A, a central drum cutter holder rotator 56 may be mounted within the muck central frame 92 in order to rotate the drum cutters 25 transversely around central axis of the TEM 5.
The center axial cutter 30 may be added optionally on central drum cutter holder 95 and the central axial cutter drive 31 may be mounted within the central drum cutter holder 9 (See FIGS. 1,2 and 10 ).
As an alternative as shown at FIG. 5B, the drum cutter 25 may be rotated axially by a central shaft 161 connected by bearings 165 and 166 to be rotatable on central drum cutter holder 95 and drum cutter base 59 and is driven by a plurality of shaft drives 163 by engaging its sprocket and shaft sprocket by belt/chain 164. The drum cutter 25 shell may be connected by plurality of brackets 162 to the central shaft 161.
As shown at FIGS. 6, 7 and 1 the excavated and crushed mucks by cutter drums 25 can be mucket out by any means such as muck box screw conveyors 51 located in space between cylindrical muck external frame 90 and cylindrical middle shield 36 along and align with drum cutters 25 and their muck box screw conveyors extension 52. The cutter head screw conveyor extension (Removable) 53 may be added to muck out the excavated mucks by the ring cutter head 10.
The excavated and crushed materials will be discharged into a separate muck box(es)—mostly in cube shape with an open area at top to be filled by extension of cutter head screw conveyor 50 and muck box screw conveyor 51 at this example and then transported to out of the tunnel. (not shown for clarity).
Generally at some mines or tunnels, stabilizing the face of the cut areas may be required by using similar technologies of EPB or slurry TBMs.
The cutter head screw conveyor extension 53 would need to be removed/rotated/lifted to be out of way of pulling/pushing of the muck boxes 80 at invert of the TEM 5 whenever needed. Alternatively the extension may be rerouted directly to a location out of the lowest muck box 80 path.
Several types of the thruster system may be used to move the TEM 5 forward. As shown at FIGS. 8, 9, 1 and 10 the gripper 70, gripper shoes 72, gripper cylinders 73 may be used for thrusting of the machine by pushing against the gripper ring 75 which is fixed at cylindrical rear shield 37. (Partially not shown for clarity). A support structure 93 is mounted on the rear shield 37 and connected to central frame 92 by bearing to hold the muck frame 21 in place during the TEM 5 operation and prevent the muck frame 21 to move forward or backward.
For the tunnels with the segmental lining moving of the TEM 5 forward may be done by using thrust cylinders 136 thrusting against the segmental ring 135 (conventional ring/Helical course) within the tail shield 38 as shown at FIGS. 11, 12 and 13 . The segment erector 130 can be mounted on segment erector axle 131 on the additional tail frame 137 in order to install the segments 134.
In one embodiment crawlers may be used to walk the TEM 5 forward (or backward).
Due to expected high speed of TEM excavation and its advancement, it is recommended to utilize either Thrust Shell System (TSS)—WO 2020/172195 or Helical Segmental lining (HSL)—WO 2019/160638, both invented and patented by TopEng Inc.—for simultaneous/continuous excavation and segment erection to significantly increase rate of the segmental lining erections.
In one embodiment, the drum cutters 25 may be fit at shorter diameter just behind the ring cutter head 10 as shown at FIGS. 14, 14A and 14B. At this case drum cutters 25 can be rotated 360 degrees without obstruction whenever needed to make transvers cuttings. The drum radial ring 61 and drum radial ring drive 62 may be added for transversal rotation of the drum cutters 25 as as many as necessary (8 nos, of drum radial drive 62 at this example). They can be mounted on the brockets of forward shield 35. If necessary rack/gear may be provided on outer surface of the drum radial ring 61 to be engaged with pinion/sprocket of the drum radial ring drive 62. Also, generally the cutter head drives 40 can be used as many as necessary.
At this case additional muck frame conveyors 52 or 54 may be added if necessary within the muck internal frames 91 as shown at FIG. 15 .
As shown at FIG. 28A, relatively large part of the tunnel of the rock (more than 60% at this example) will be extracted in almost untouched condition without necessity of digging/crushing them which will be increasing speed of tunneling and reduce required energy and budget considerably. The percentage of the untouched areas may be increased by using thinner ring cutter head 10 and thinner cutter drums 25 and smaller diameter of the cutter head drive 40 and powered rollers 39.
In one embodiment, the muck box dollies 85 may be powered and make them mechanically movable platforms for the muck boxes 80 that may enter or exit inside of the muck frame 21 without necessity to any other device such as locomotive 99 or rubber wheel truck.
The muck box 80 may have removable muck box rear cap 82 as shown in FIGS. 1 and 10 . The muck box front cap 84 may be also added to the muck box 80 if necessary, as shown at FIGS. 16, 17A and 17B. The FIG. 17 a is showing muck box front cap 83 at close gate mode comprising front cap segments 101-106 that are continuously and slidably connected to each other. At this example the front cap segment 106 has a gate opening hole 112 that would be engaged with the gate rod 111 of the gate drive 110. The gate drive 110 can be moving on the gate rail 108 inward and outward which is mounted on the muck frame 21. By moving the gate drive 110 outward the front segments 101-106 will be moved and collected within the space between muck external frame 90 and forward shield 35 that is shown at FIG. 17B as muck box front gate 84 in open gate mode. At this example the provided gate space 115 may be used to place the cutter head drive 40 or cutter head screw conveyor 50.
Then after filling the muck boxes 80 and transversal cut of the rock by drum cutters 25, the muck box front gate 84 may be closed before extracting of the muck boxes 90 by moving the gate driver 110 inward direction.
The articulation jacks may be added between forward shield 35 and cylindrical middle shield 36 and cylindrical rear shield 37 for making turns by the TEM 5. These articulations have not been shown for the clarity but basically they would be similar to articulation of the conventional TBMs.
In one embodiment as alternative a plurality of axial drum cutters 325 or similar to roadheader attachments will be driven by axial drum drives 350 through the axial shafts 351 which are mounted and rotatable within the muck internal frame 91 as shown at FIGS. 18 and 18A. At this case drum cutters 325 may be rotated 360 degrees to perform the transversal cutting of the rock. Further circumferential rotation of the muck frame 21 by rollers 39 at this case will help completing of the rock transversal cut.
FIGS. 19 and 19A has almost same set up however the drum drive axle 361 are not at the center and positioned closed to the outer shields in such a way that majority of the rock transversal cut will be done only by rotation of the drum cutters 335.
The muck frame 21 may include some means and devices to keep the muck boxes 80 during the mining/tunneling operation in their places within the muck frame 21 and avoid sliding them while TEM 5 is moving forward and rock 81 is moving into the muck box 80. (not shown for clarity)
Generally any means of excavation/cutting/crushing/melting/rock weakening tools 15 may be used as cutting and excavation devises either on the external face of ring cutter head 10 or on external face (or instead) of drum cutter 25 such as cutter discs, bits, reamers, waterjet, wave, plasma thermal torches, ultrasonic, laser, chain cutters, trenching devices and etc. or combination of them.
FIGS. 20, 21 and 22 are showing how considering plasma torches for the TEM 5 may look like. At this embodiment, the ring cutter head 210 is fixed to the forward shield 235 (doesn't rotate) and instead, plurality of the cutter head plasma torch pan 215 including the plasma torches 216 will be moved within the ring cutter head 210 by cutter head plasma torch pan drives 245 in order to melt/evaporate the rock/soil in perimeter of the tunnel section. Indeed all components at this case exposed to the ultra high temperature must be coated or fabricated by resisting materials to ultra high heats.
The plurality of sliding rails 228 mounted on the central rail holder 295 will be utilized as guide rail for the sliding plasma torch pans 225 which have front plasma torches 226 to melt/evaporate front of the sliding rails 228 as well as muck boxes 280 edges. The sliding plasma torch pans 225 also have side plasma torch 227 that will be utilized for transversal cutting of the rock whenever the muck boxes 280 are full. Alternatively the sliding rail 228 may be rotatable (90 degrees) to position the front plasma torches 226 for transversal cutting.
Optional center plasma torch pan 230 may be added to the central rail holder 295 if necessary.
FIG. 23 is showing how the cross section at cylindrical middle shield 236 may look like showing plurality of muck boxes 280, muck external frame 290, muck internal frame 291 and muck central frame 292. The powered rollers 239 will be rotating the muck frame 221 along with the muck boxes 280 and cutter head screw conveyor 250 and muck box screw conveyors 251 (or vacuum, etc.) will be mucking out the excavated or melted materials at this case.
FIG. 24 is showing that relatively very large parts of the rock (more than 80% of the cross section at this example) can be extracted without necessity of digging/crushing/melting them which will be increasing speed of tunneling and reduce required energy and budget significantly.
The TEM 5 is being thrusted by gripper system as mentioned before and FIGS. 25 and 26 are displaying how the rear parts of the TEM 5 will look like for the TEM 5 with plasma torches 216 and 226 cutting system.
FIGS. 27 and 27A are displaying an alternative for the TEM 5 with thermal plasma torch technology that have ring cutter head 310 with mounted cutter head plasma torches 316 and openings 320 that can be rotated by plasma torch cutter head drive 240 with engaging its pinion gears with the gears/racks on the ring cutter head 210.
As mentioned any other excavation tools on the ring cutter head or instead of drums such as Waterjet or microwaves or cutter chains will be working in TEM well.
At FIGS. 20, 21, 22, 27 and 27A it would be imaginable to assume that shown plasma torches 216, 226 and 227 are waterjet nozzles or microwave antennas for excavation, or combination of them.
For transporting the large parts of the muck boxes 80 out or into the tunnel, it may be necessary to have a liftable platform to work as switch inside the tunnel. An example has been shown at FIG. 28 that has a switch frame 120 and lifting winches 122 which can lift the liftable floor 121.
At this example it might be better to have 12 muck boxes 80, 4 within the TEM 5 that are being filled and 4 muck boxes 80 that are being transported to be dumped on the ground and 4 other muck boxes 80 that are empty and returning or waiting at the switch lift to be entered into the TEM 5.
The present invention may be generalized to non-circular sections as rectangular, horseshoe, etc. FIG. 29 is showing a rectangular section with plurality of rectangular shape muck boxes 181 that are located within drum cutters 125. The horseshoe shape tunnel sections have been illustrated in the Tunnel Digging Machine (TDM)—USPTO 17/476399-Invented and patented by TopEng Inc.
The extracted rocks 81 by muck boxes 80 may be used in various construction sectors such as armors in water breaks, retaining walls etc. FIG. 30 shows their use for building the rock walls.
FIGS. 31A and 31B are showing an alternative concept for open and close gate of the muck box front cap 83 including segmented caps that are being collected within the muck internal frames 91 by jacks. As shown at FIG. 31A embodiment, the front cap segments 201-204 that are continuously and slidably connected to each other (almost similar to a handheld folding fan) as well as front cap segments 301-304 from its neighbor muck box 80 have been pushed by gate rods 212 of the gate drive jack (not shown for clarity) by engaging a gate opening hole 211 on the front cap segment 201 and 304. At the open mode the front cap segments 201-204 and 301-304 can be pulled by the same rod 212 and keep all the mentioned front segment caps 201-204 and 301-304 within the space of the muck internal frame 91. The same concept can be used symmetrically at other muck box 80 locations.
During pulling the muckboxes 80 out of the muck frame 21, the face of the excavated rock will be partially supported by drum cutters 25 which may be sufficient in most of the cases. If there is concern that this support is not sufficient, similar gate concepts shown at FIGS. 31A-31B or 17A-17B may be added to open/close gates on front of the muck frame 21 to fully support the face.
As an alternative instead of drum cutters 25 plurality of axial cutters 395 in serios may be utilized as shown at FIG. 32 for the longitudinal excavation of the rock or soil. The axial cutters 395 are mounted on the rotatable frames 396 that are hold by central holder 394 at one side and on the forward shield 35 or drum radial ring 61 at the other side. For the transversal excavation, the axial cutters 395 may be rotated 90 degrees as shown at FIG. 33 to be positioned for transversal excavation whenever needed. In one embodiment the axial cutters 395 may be slidable on the frame 396.
FIG. 34 shows an example of using circumferential cutter chains 380 and longitudinal cutter chains 381 in a TEM 5 with 3 pie shape muck rocks. The rotatable frames and muck boxes have not been shown for clarity.
As an alternative method the rotating of the drum cutters 25 around the central axis of the TEM 5 during rock transversal cutting may be done by utilizing wireropes and mounted winches within the space between front shield 35 and Muck external frame 90. At this case the wirerope that have been connected to the drum cutter 25 frame at their outer point can be pulled at both clockwise and counter-clockwise directions to make necessary rotations around the central axis of the TEM 5 (e.g. 90 degrees at this example) by engaging 2 winches for each drum cutters 25.
As an alternative for cutting the rocks transversally, instead of rotatable drum cutters 25, a similar system of expandable rings described in Thrust Shell system patent (TSS) may be utilized that waterjet nozzles or plasma torches or any other cutting tools will be mounted on inner face of the expandable rings which will cut the rock whenever it collapses by its circumferential cylinders/jacks to reduce its diameter.
In one embodiment, transversal cut of rock may not be done at the face of the tunnel and the cutter drums 25 may only be used for longitudinal excavation. However other means of transversal cut may be provided with offset from the face of the tunnel in order to cut the extracted rock in desired length.
In one embodiment, the muck frame 21 may be not rotatable and discharging of the extracted rock 81 or muck boxes 80 may be done by other means from their position without rotating them to lowest part of the TEM 5.
In one embodiment the drum cutters 25 may be hollow and have openings on their face (similar to hollow ring cutter head 10) that excavated material may enters into the cutter drums 25 and carried to either muck box screw conveyors 51/52/54 or into a central screw conveyor placed within the central muck frame 92.
In one embodiment the extracted muckboxes 80 may be combined and connected by necessary devices to be extracted out of tunnel together on dollies or other means like shown example at FIG. 35 .
This system may be used for construction of the shafts as well by utilizing it in vertical position with some modifications. At this case front cap closing system may be necessary.
In soft soils transversal cut of the soil by rotation of the drum cutters 25 may not be necessary as soft soil may be transversally separated itself from the face of the tunnel while pulling the muck boxes 80 out.
For larger diameter TEM 500, a plurality of shields and a plurality of cutter drums 425 between the shields may be added to a single shield TEM 5 as shown example at FIG. 36 to cut the rock longitudinally including offset ring cutter head 410 with its cutter tools 415 and openings 420. Then cutter drums 425 and 25 will be rotated around central axis of the TEM 500 to transversally cut the rock. FIG. 37 shows how extracted rocks 81 and 281 may look like at the multi-shield TEM 500.
In hard rocks using muck boxes 80 may not be necessary as rock may be stable enough to be handled within muck frame 21. In some cases, only bottom curved side of the muck boxes 80 may be sufficient which can hold the extracted rock 81 while being pulled out of the muck frame 21 or while it is being transported on the dollies 85.
In one embodiment, a plurality of plasma torches 216 will be fixed on the fixed cutter ring to cover full perimeter of the cutter drum without necessity to rotate. Similarly a plurality of front plasma torches 226 may be fixed on the sliding rail 228 to cover full length of the sliding rail 228 to avoid necessity to slide.
A sample of horseshoe shape TEM 550 by using plasma torches 216 on the perimeter to cut circumference of the section and internal front or side plasma torches 226 or 227 may look like FIG. 38 . In this example sliding or rotating rails 328 comprising a plurality of perimeter members matching with horseshoe shape of TEM 550 for holding perimeter plasma torches 216 and internal vertical and horizontal members that are holding the front or side plasma torches 226 or 227. Also vertical or horizontal members of rails 328 may be axially rotatable as well which at this case using side plasma torches 227 won't be necessary. A separate fixed frame (not shown) will be positioned exactly behind the rails 328 inside the TEM 550 at FIG. 38 with longitudinally offset from the rails 328 to hold perimeter, vertical or horizontal members of the rails 328, and members of rails 328 can have slidable connections to the fixed frame at their both ends to enable them to move left or right, or up and down over the fixed frame or just rotate radially around one point of the fixed frame with pivot connection to the fixed frame (not shown). For example at FIG. 38 case, horizontal members of rails 328 are able to move up and down as well as rotate around center point (intersection of vertical and horizontal members) radially whenever necessary for transversal cuts of the ground. Also generally at the horseshoe shape TEM 550 pulling the extracted rocks out of the machine can be done without necessity of rotation of the muck frame since rectangular shape rocks 481 at bottom will be pulled out directly and sector shape rocks 482 at top will be lowered on its horizontal platform to the ground by winches or hydraulic jacks within the internal or external muckframe 321 and then pulled out of the machine without rotating them, as shown at FIG. 38A.
In order to reduce nos. of required plasma torches 216 to decrease amount of required energy either sliding systems may be utilized as explained or alternatively rotatable plasma torches 216 can be mounted on two frames 218 and 219 by pivot connections as shown at FIG. 39 that by moving the frames 218 and 219 relative to each other plasma torches can be rotated to cover larger portions at their front.
The TEM concept may be used for dredging purposes as well with different cutting tools. FIG. 40 is showing and example of a trapezoid or rectangular TEM 501 with Plasma torches 216 and dredge barge or dredge ship 601 which has been connected to a TEM 501 at the seabed 610 by adjustable and telescopic framing or spuds 603 to main U shape shield 502 of TEM 501 in order to push or drag the TEM 501. Extra bracings may be needed between spuds 603 structurally. The upper side of dredging TEM 501 is uncovered at the dredging operation so extracted rocks or soil 581 can be lifted up by a crane 602 or gantry crane from opening inside the dredge ship 601. The Plasma torches 216 are mounted on the U shape frame 510 for longitudinal cut and a separate sliding frame 511 at the top over the seabed 610 including vertical positioned plasma torches 217 will cut the extracted rock transversally whenever needed when extracted rock 581 has entered into the dredge boxes 512 and will be ready to be lifted up by crane 602. FIG. 40A is showing D1-D1 view and FIG. 40B is showing a plan view at section D2-D2 of the dredging TEM 501. A closing gate 514 and its additional upper framing 515 may be also added to the upper sliding frame 511 to move down and cover the face of the dredging till receiving next empty dredge box 512 is lowered and positioned to resume dredging. Similarly closing gates may be added to the front side of dredge box 512 as well. Broken, excavated, melted or spalled rock at the dredging may be either removed by similar explained systems in TEM 5 or may be left at the seabed level formed after dredging 611.
Alternatively axial cutters 395 in series may be used instead of described plasma torches 216, drum cutters 325 in a dredging TEM 501. Also drum cutters 325 may be utilized as well for cutting the rock or soil longitudinally and transversally. At this case section D1-D1 in a dredging TEM 501 may look like to FIG. 40C and section D2-D2 may look like to FIG. 40D. As shown, a plurality of drum cutters 325 and their drum drives 350 are utilized on within the side walls and base for longitudinal cutting of the rock and vertical positioned drum cutters 326 and their drum cutter drives 355 on a sliding frame may be used only for the transversal cut of the rock. The excavated and broken rocks can be discharged by a plurality of screw conveyor 51 within side wall and base of the dredging TEM 501 at this example.
As An alternative for the front cap 83, pairs of door caps 183 and 184 may be utilized as shown in an example at FIG. 41 . The right side of the FIG. 41 shows pairs of door caps 183 and 184 in close mode and left side shows them at open mode that have been rotated like French doors, and overlapped on the inner faces of the TEM 5. Hydraulic systems may be utilized within muck frame 21 or forward shield 35 to open or close the pairs of the door caps 183 and 184. A similar method may be used to provide closing caps on the muck boxes as well.
FIG. 42 shows a sample of a TEM 5 with a single drum cutter 25 which is able to rotate 360 degrees around the central axis of the TEM 5 during transversal cut of the rock in order to extract a full circle shape rock 483, assuming equipment located at the back of the TEM 5 may be adjusted to allow extraction of full circle rock 483.
Available technologies for drum roller compactors that their motors are inside the drums may be used for detailed design of the drum cutters 25. As an example refer to U.S. Pat. No. 3,814,531 which describes such roller assembly, however electric motors may be used for the drum cutters 25 of a TEM 5.
In case of using plasma torches for the TEM, a similar methods for closing front face of Tunnel Digging Machine (TDM)—USPTO 17/476399 may be utilized with adding cutting tools (e.g. plasma torches) on the front edge of the closing gates in order to transversally cut front face of the rock.
Extracted rocks 81 may be used to make arc shapes storage, shelters or arc bridges 87 as shown in an example at FIG. 43 and its cross section E1-E1 is shown at FIG. 43A. At this example filler concrete 88 is used to fill the gaps between extracted rocks 81. For assembly of the rocks 81, an adjustable and movable arc shape framing may be used under the arc bridge 87 to temporarily support the extracted rocks 81 till setting the filler concrete 88 to make stable rock arc bridge 87.
Smaller versions of the TEM 5 may be used in other industries for core drilling of anything that can be dug, such as wood industry to dig out inside the trunks without affecting entire face.
In one embodiment, thrusting the TEM 5 forward may be done by using crawler or rubber wheels similar to the Continuous miner or cranes, which in this case thrusting against erected segmental lining or rib and lagging or moving TEM 5 by grippers may not be necessary.
In one embodiment of horseshoe shape tunnel TEM 550, plasma torches 216 on perimeter of horseshoe section may be used for transversal cut as well either by making them axially rotatable (e.g. 90 degrees in this example) and then sliding them to complete the transversal cut, or by adding extra side plasma torches on the perimeter of the horseshoe shape section mounted on frame 328 and then slide them to make the transversal cut.

Claims

What is claimed is:

1. A tunnel extraction machine 5 to extract and excavate material from ground, the machine 5 comprising:

a hollow ring cutter head 10 with a plurality of openings 20 and a plurality of cutting tools 15 on its external face that is rotated around central axis of said machine 5 for excavation,

a cylindrical forward shield 35 which said ring cutter head 10 is rotatably mounted,

a plurality of drum cutters 25 with a plurality of cutting tools on their external faces that are rotated axially for excavation,

a central drum cutter holder 95 positioned at axial center of said machine 5 which said drum cutters 25 are rotatably mounted,

wherein tunnel face is only excavated at location of said ring cutter head 10 circumferentially and at location of said drum cutters 25 longitudinally while said machine 5 moves forward and concurrently unexcavated and untouched parts of tunnel 81 enter into spaces between said ring cutter head 10 and said drum cutters 25,

whereby said drum cutters 25 will be rotated around central axis of said machine 5 for transversal excavation at their location as needed,

wherein unexcavated parts of tunnel 81 are extracted without necessity of digging them.

2. The tunnel extraction machine 5 according to claim 1, further comprising a plurality of cutter head drivers 40 mounted inside said forward shield 35 for rotating said ring cutter head 10 for excavation.

3. The tunnel extraction machine 5 according to claim 1, further comprising a center cutter 30 and a center cutter drive 31 that is mounted within said central drum cutter holder 95 to excavate at central axis location of said machine 5.

4. The tunnel extraction machine 5 according to claim 1, further comprising a plurality of drum radial drive 60 that are mounted on said drum cutter 25 in the space behind said ring cutter head 10 to rotate drum cutters 25 around central axis of said machine 5 and within said forward shield 35 whenever needed for transversal excavation.

5. The tunnel extraction machine 5 according to claim 1, further comprising a cylindrical middle shield 36 at extension of said cylindrical forward shield 35, a muck frame 21 comprising a central frame 92 located at central axis of said machine 5 which said drum cutter holder 95 is rotatably mounted, a cylindrical muck external frame 90 and a plurality of muck internal frame 91 that is connecting said central frame 92 and said external frame 90, wherein said muck internal frame 91 are located behind said drum cutters 25 during moving forward of said machine 5, wherein said external frame 90 is rotatably hold by a plurality of rollers 39 that are mounted on said middle shield 36.

6. The tunnel extraction machine 5 according to claim 5, further comprising a plurality of muck boxes 80, wherein said muck boxes 80 are slidably located within said muck internal frame 91 and said cylindrical muck external frame 90, wherein untouched muck rock 81 or soil within said ring cutter head 10 and said drum cutters 25 enters into said muck boxes 80 during moving forward of said machine 5, wherein said muck boxes 80 can be rotated around central axis of said machine 5 by rotation of said muck frame 21.

7. The tunnel extraction machine 5 according to claim 1, further comprising a cylindrical rear shield 37 at extension of said cylindrical middle shield 36, a central frame support 93 that is mounted on said rear shield 37, wherein said muck central frame 92 is rotatably mounted on said central frame support 93, wherein said central frame support 93 is preventing muck frame 21 to move backward or forward.

8. The tunnel extraction machine 5 according to claim 1, further comprising a plurality of cutter head screw conveyor 50 that are mounted at bottom of said machine 5 in space between said cylindrical muck external frame 90 and said cylindrical middle shield 36 to discharge the excavated muck from said ring cutter head 10, whereby said screw conveyor 50 may be extended inside said ring cutter head 10 for better discharge of the excavated muck.

9. The tunnel extraction machine 5 according to claim 1, further comprising a plurality of muck box screw conveyors 51 that are mounted at lower part of said machine 5 in space between said cylindrical muck external frame 90 and said cylindrical middle shield 36 align with said drum cutters 25 to discharge the excavated muck from said drum cutters 25.

10. The tunnel extraction machine 5 according to claim 1, further comprising a central drum cutter holder rotator 56 mounted within said muck central frame 92, wherein said central drum cutter holder rotator 56 rotates said central drum cutter holder 95 around central axis of said machine 5 during the transversal excavation.

11. The tunnel extraction machine 5 according to claim 1, further comprising a plurality of drum drives 57 mounted on said central drum cutter holder 95 and within said drum cutters 25 to rotate said drum cutters 25 axially for excavation.

12. The tunnel extraction machine 5 according to claim 1, further comprising a plurality of drum end drives 58 mounted within said drum cutters 25 and on a drum cutter base 59 with a plurality of drum rollers 55 sitting on said forward shield 35 to rotate said drum cutters 25 axially for excavation.

13. The tunnel extraction machine 5 according to claim 1, further comprising a drum radial ring 61 which said drum cutters 25 are mounted, a plurality of drum radial ring drives 62 that are mounted on a plurality of brackets of said forward shield 35 and within space behind said ring cutter head 10 to rotate said drum radial ring 61 during transversal excavation of said drum cutters 25.

14. The tunnel extraction machine 5 according to claim 6, further comprising a plurality of muck box front cap 84 in open mode and 83 close mode by continuously connected front cap segments 101-106 that are engaged by a plurality of gate rod 111 that are mounted on a plurality of gate drive 110 to plurality of opening holes in the smallest said front cap segments 101-106, wherein said gate drive 110 are sliding inward and outward on a plurality of gate rail 108 which are mounted on said muck frame 21, wherein said front cap segments will close front of said muck boxes 80 by moving said gate drive 110 inward and will open front of said muck boxes 80 by moving said gate drive 110 outward, wherein said font cap segments 101-106 are located in space between said forward shield 35 and said external frame 90 and behind said ring cutter head 10 at open mode.

15. A tunnel extraction machine 5 to extract and excavate material from ground, the machine 5 comprising:

a ring cutter head 210,

a plurality of cutter head pans 215 including a plurality of plasma torches 216 or water jet nozzles or microwave antenna that are rotatably mounted on said ring cutter head 210,

a plurality of plasma torches 226 or water jet nozzles or microwave antennas mounted on a plurality of sliding pans 225 on a plurality of sliding rails 228,

a central rail holder 295 positioned at axial center of said machine 5 which said sliding rails 228 are rotatably mounted,

wherein tunnel face is only excavated at location of said ring cutter head 210 circumferentially and at location of said sliding pans 225 longitudinally while said machine 5 moves forward and concurrently unexcavated and untouched part of tunnel enters into spaces between said ring cutter head 210 and said sliding pans 225,

whereby said drum cutters 225 will be rotated around central axis of said machine 5 for transversal excavation at their location when needed,

wherein unexcavated parts of tunnel are extracted without necessity of digging them.

16. The tunnel extraction machine 5 according to claim 15, further comprising a center plasma torch pan 230 or waterjet nozzles or microwave antennas and a center plasma ring driver 231 that is mounted within said central drum cutter holder 295 to excavate at central axis of said machine 5.

17. A tunnel extraction machine 5 to extract and excavate material from ground, the machine 5 comprising:

a plurality of drum cutters 325 with a plurality of cutting tools on their external faces that are rotated axially for excavation,

a cylindrical middle shield 36 at extension of said cylindrical forward shield 35,

a muck frame 21 comprising a central frame 92 located at central axis of said machine 5, a cylindrical muck external frame 90 and a plurality of muck internal frame 91 that is connecting said central frame 92 and said external frame 90,

a plurality of axial drum drives 350 that are rotatably mounted within said internal muck frame 91, wherein said drum cutters 325 are rotated axially by axial shaft 351 connected between said drum cutters 325 and said axial drum drive 350,

wherein said muck internal frame 91 are located behind said drum cutters 325 during moving forward of said machine 5,

wherein tunnel face is only excavated at location of said ring cutter head 10 circumferentially and at location of said drum cutters 325 longitudinally while said machine 5 moves forward and concurrently unexcavated and untouched parts of tunnel 81 enter into spaces between said ring cutter head 10 and said drum cutters 325,

whereby said axial drum drive 350 will be rotated axially within said internal muck frame 91 to rotate said drum cutters 325 during transversal excavation of the rock,

18. The tunnel extraction machine 5 according to claim 1, further comprising:

a plurality of hollow offset ring cutter head 410 with a plurality of openings 420 and a plurality of cutting tools 415 on its external face that is rotated around central axis of said machine 5 for excavation,

a plurality of drum cutters 425 with a plurality of cutting tools on their external faces that are rotated axially for excavation,

wherein tunnel face is only excavated at location of said ring cutter head 10 and 410 circumferentially and at location of said drum cutters 25 and 425 longitudinally while said machine 5 moves forward and concurrently unexcavated and untouched parts of tunnel 281 and 81 enter into spaces between said ring cutter head 10 and 410 and said drum cutters 425 and 25,

whereby said drum cutters 425 and 25 will be rotated around central axis of said machine 5 for transversal excavation at their location as needed,

wherein unexcavated parts of tunnel 281 and 81 are extracted without necessity of digging them.

19. A horseshoe shape tunnel extraction machine 550 to extract and excavate material from ground, the machine 550 comprising:

a plurality of sliding or rotating rails 328 with a horseshoe shape in perimeter matching with shape of said machine 550 and a plurality of internal vertical and horizontal members,

a plurality of plasma torches 216 on perimeter of said rails 328 to cut circumferential of the horseshoe shape section,

a plurality of internal plasma torches 226 on internal members of said rails 328,

wherein tunnel face is only cut at perimeter of said machine 550 circumferentially and at location of said internal members of rails 328 longitudinally while said machine 550 moves forward and concurrently unexcavated and untouched parts of ground 481 and 482 enter into spaces within perimeter and internal members of said rails 328,

whereby horizontal or vertical members of said rails 328 are rotatable axially and radially and slidable for transversal cutting of the ground,

wherein unexcavated parts of ground 481 and 482 are extracted without necessity of digging them.

20. A horseshoe shape tunnel extraction machine 550 according to claim 19, further comprising side plasma torches 227 on side faces of internal horizontal and vertical members of said rails 328 to avoid necessity of axial rotatability of members of said rails 328.