WO2020087679A1 - 全断面岩石掘进机主机系统的减振优化方法 - Google Patents

全断面岩石掘进机主机系统的减振优化方法 Download PDF

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WO2020087679A1
WO2020087679A1 PCT/CN2018/121013 CN2018121013W WO2020087679A1 WO 2020087679 A1 WO2020087679 A1 WO 2020087679A1 CN 2018121013 W CN2018121013 W CN 2018121013W WO 2020087679 A1 WO2020087679 A1 WO 2020087679A1
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area
damping
replacement
vibration
hob
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English (en)
French (fr)
Inventor
霍军周
徐兆辉
张占葛
孙德滨
孟智超
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Dalian University of Technology
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Dalian University of Technology
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Priority claimed from CN201811281683.7A external-priority patent/CN109268434B/zh
Priority claimed from CN201811295375.XA external-priority patent/CN109522626B/zh
Priority claimed from CN201811290783.6A external-priority patent/CN109344540B/zh
Priority claimed from CN201811305468.6A external-priority patent/CN109281683B/zh
Priority claimed from CN201811325115.2A external-priority patent/CN109558648B/zh
Priority claimed from CN201811329963.0A external-priority patent/CN109594998B/zh
Application filed by Dalian University of Technology filed Critical Dalian University of Technology
Priority to US16/469,112 priority Critical patent/US20200285787A1/en
Publication of WO2020087679A1 publication Critical patent/WO2020087679A1/zh
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F9/00—Springs, vibration-dampers, shock-absorbers, or similarly-constructed movement-dampers using a fluid or the equivalent as damping medium
    • F16F9/32—Details
    • F16F9/53—Means for adjusting damping characteristics by varying fluid viscosity, e.g. electromagnetically
    • F16F9/535—Magnetorheological [MR] fluid dampers
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
    • E21D9/10—Making by using boring or cutting machines
    • E21D9/106—Making by using boring or cutting machines with percussive tools, e.g. pick-hammers
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
    • E21D9/10—Making by using boring or cutting machines
    • E21D9/1093—Devices for supporting, advancing or orientating the machine or the tool-carrier
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F9/00—Springs, vibration-dampers, shock-absorbers, or similarly-constructed movement-dampers using a fluid or the equivalent as damping medium
    • F16F9/10—Springs, vibration-dampers, shock-absorbers, or similarly-constructed movement-dampers using a fluid or the equivalent as damping medium using liquid only; using a fluid of which the nature is immaterial
    • F16F9/14—Devices with one or more members, e.g. pistons, vanes, moving to and fro in chambers and using throttling effect
    • F16F9/16—Devices with one or more members, e.g. pistons, vanes, moving to and fro in chambers and using throttling effect involving only straight-line movement of the effective parts
    • F16F9/18—Devices with one or more members, e.g. pistons, vanes, moving to and fro in chambers and using throttling effect involving only straight-line movement of the effective parts with a closed cylinder and a piston separating two or more working spaces therein
    • F16F9/19—Devices with one or more members, e.g. pistons, vanes, moving to and fro in chambers and using throttling effect involving only straight-line movement of the effective parts with a closed cylinder and a piston separating two or more working spaces therein with a single cylinder and of single-tube type
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2111/00—Details relating to CAD techniques
    • G06F2111/10—Numerical modelling
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]

Definitions

  • the invention relates to a vibration reduction optimization method for a host system of a full-section rock tunneling machine, which belongs to the technical field of vibration reduction design of a full-section rock tunneling machine.
  • Full-section tunneling equipment is an industrial assembly line tunnel construction equipment integrated with machinery, electricity, liquid, light, gas and other systems. It has the advantages of fast driving speed and high comprehensive benefits. It is widely used in engineering. Due to the complex TBM tunneling environment, coupled with the multi-point rock breaking characteristics of the TBM hob, a strong impact load will be generated during the rock cutting process of the hob, which will cause violent vibration of the TBM host and eventually cause certain key parts of the TBM to occur Wear and even break, so how to optimize the vibration reduction of the host system is particularly important.
  • the main system of TBM host (as shown in Figure 1) is mainly composed of cutter head system, support system, propulsion system and main beam.
  • the main system of TBM host is mainly composed of cutter head system, support system, propulsion system and main beam.
  • TBM host system vibration reduction optimization methods can not only reduce the incidence of failures, reduce the number of repairs by engineering construction personnel, but also ensure the safe and reliable operation of TBM.
  • the present invention uses a material replacement and a reasonable arrangement of magnetorheological dampers (as shown in Figure 2) to optimize the vibration design of the TBM host system.
  • the material replacement model of the cutter head rib plate (see Figure 3) and the wedge block damping material replacement model of the TBM hob-tool holder connection structure (shown in Figure 4) are proposed; for the support and propulsion system , The corresponding addition scheme of the magnetorheological damper is proposed; for the connection flange, a material replacement method for the flange and the connection bolt is proposed.
  • the purpose of the present invention is to provide a complete set of vibration damping optimization solutions for the TBM host system.
  • the vibration reduction optimization plan of the host system of the full-section rock tunneling machine is as follows:
  • Vibration damping optimization plan of the host system of the full full section rock tunneling machine including damping alloy for material replacement, magnetorheological damper, cutter disc rib plate material replacement model, hob wedge block damping material replacement model, support cylinder and propulsion Adding scheme of magnetorheological damper at the oil cylinder, replacing material of flange and connecting bolt.
  • the characteristic is that the vibration damping optimization design of the TBM host system is realized by replacing the material of the cutter head system and the connecting flange and adding magnetorheological dampers to the support cylinder and the propulsion cylinder.
  • the specific system is divided into the following two aspects: cutter head system material optimization replacement model; support and propulsion system magnetorheological damper addition scheme; connection flange material replacement scheme.
  • Model 1 replacement model of cutter bar rib plate material
  • the purpose of this model is to propose a damping alloy to replace the cutter plate rib plate material vibration optimization program, to achieve the optimal replacement of the rib plate material, from the transmission process to reduce the overall vibration of the cutter plate, thereby reducing the vibration of TBM and preventing TBM
  • Partial replacement of damping alloy materials is used to minimize the vibration of ribs to reduce the vibration of TBM, and then an optimized layout model of damping alloy replacement ribs is proposed (Figure 5).
  • the optimal layout model formula is as follows:
  • a and b are coefficients of exponential terms, and their values range from -6.1 to -4.3 and 0.11 to 0.150, respectively.
  • the above parameters decrease with the increase of the block area
  • c and d are cosine coefficients, and their values range from 0.7 to 0.93 and 1.3 to 2.5 and above.
  • the parameters increase with the increase of the block area
  • e, f, and g are the main coefficients, and their values range from 2.6 to 5.2, -4.4 to -4.1, and -1.2 to -0.9, respectively.
  • the above parameters increase with the increase of the divided area
  • ⁇ is the area division coefficient, 1.1 ⁇ 1.72, which increases with the increase of the block area
  • x and y are the area number and replacement area number respectively, and the range is 1 ⁇ n;
  • This optimized layout model uses the area where the cutter head is located as the divided area, with the center of the cutter head as the center O, and the 4 central hobs surrounding the center O are symmetrical laterally and longitudinally, forming the first center with O as the center Circle ellipse; the positive hobs arranged on the long and short axes of the first circle ellipse form multiple concentric ellipses; the outermost circle ellipse and the edge ribs serve as the last layer, (the small circle in the model picture 5 is the horizontal Vertical hob position); divide the area according to ⁇ ° equally divided circles, turn the horizontal center hob direction as the center line, and rotate ( ⁇ / 2) ° upward and downward respectively, and define it as the number 1 replacement number (such as (Shaded part in Figure 5), continue to number in a counter-clockwise direction, replace numbers in order from inside to outside, and directly replace the number n to end the number; if the rib is located between the two areas of replacement and non-replacement, the
  • ⁇ is the division angle coefficient, its value range is 0.95 ⁇ 1.12, the smaller the unit angle value divided in the circumferential direction of the cutter head, the smaller the value;
  • R 1 and R 2 are the diameter coefficients of the positive hob area and the side hob area respectively, and their values range from 2.603 to 3.535 and 0.346 to 1.705 respectively. The larger the diameter of the circumference, the larger the value;
  • a, b, c, and d are binomial coefficient, exponential coefficient, sine coefficient and initial phase coefficient, respectively, their value ranges are 0.415 ⁇ 0.487, 2.92 ⁇ 6.99, 3.209 ⁇ 8.063 and 3.224 ⁇ 3.649, the above coefficients are The unit angle value of the cutter head divided in the circumferential direction decreases and increases;
  • x and y are the area number and replacement area number respectively, and the range is 1 ⁇ n;
  • step (2) in the positive hob area 6b, from the left, the number of the area located above the first sheet is marked as 1, after programming the positive hob area 6b, write the edge hob area 6c in the same way ; Now bring the serial number written in step (2) into the material optimization model, and solve for the f (x) value. If the value is a non-integer, take the integer part; the value obtained is the need to connect the hob Replace the material of the wedge block with the serial number of the damping alloy area (shaded area in the figure) ; Until f (x) ⁇ x stops bringing in, the result is all the areas that need to be replaced.
  • the newly added magnetorheological damper includes the right magnetorheological damper 2 and the upper right oblique upper magnetorheological damper 5.
  • a left top oil cylinder 14 and a right top oil cylinder 3 Located between the top shield 1 and the main drive 16, there are a left top oil cylinder 14 and a right top oil cylinder 3 respectively, and a left magnetorheological damper is added within a range of 90 to 600 mm from the left side top oil cylinder 14 in the direction of the main machine's digging direction 15. Add the right side magnetorheological damper 2 within 90 ⁇ 600mm from the right side of the right top oil cylinder 3 in the driving direction of the main machine.
  • the angle range between the axis of this group of magnetorheological dampers and the vertical direction of the main machine is 0 ⁇ 60 ° , Its function is mainly to reduce the longitudinal vibration of the host system.
  • an upper left oblique upper cylinder 19 Located between the upper left shield 13 and the main drive 16, there is an upper left oblique upper cylinder 19, and an upper left oblique upper magnetorheological damper 18 is added within a range of 0 to 500 mm from the left side of the upper left oblique upper cylinder 19, obliquely from the upper left side
  • the upper left oblique upper magnetorheological damper 12 is added within the range of 0 to 400mm on the right side of the upper oil cylinder 19; there is an upper right oblique upper oil cylinder 20 between the upper right shield 4 and the main drive 16, which is left from the upper right oblique upper oil cylinder 20
  • Add the upper right oblique upper magnetorheological damper 5 within the range of 0 to 400mm on the side, and add the upper right oblique upper magnetorheological damper 21 within the range of 0 to 500mm from the right side of the upper right oblique upper cylinder 20; these two sets of magnetorhe
  • the left lower cylinder 9 is located between the left shield 11 and the main drive 16, and the left lower magnetorheological damper 10 is added within 300 to 600 mm from the main driving direction of the lower left cylinder 9; the right shield 6 and There is a lower right side oil cylinder 8 between the main drives 16, and a lower right side magnetorheological damper 7 is added within a range of 300 to 600 mm from the lower right side oil cylinder 8 side of the main machine in the driving direction; the installation axis of this group of magnetorheological dampers
  • the angle range with the vertical direction of the host is -10 ⁇ 90 °, its added function is mainly to reduce the longitudinal vibration of the host system, but also to a certain extent to reduce the lateral vibration of the host system.
  • add magneto-rheological dampers to the propulsion cylinders at both ends of the TBM see Figure 8).
  • the method of polymer sandwich damping and damping steel plates (as shown in Figure 9) is adopted.
  • the polymer sandwich damping and damping steel plates are divided into three layers, the upper and lower layers are steel plates, and the inner layer is damping and damping sandwich layers ( Take the circular connecting flange of cutter head as an example).
  • the model results are analyzed and compared to determine the damping damping sandwich thickness t1 of the damping steel plate and the thickness t2 of the steel plate; for the replacement of bolt materials, bolts in the flange bolt structure
  • Bolt material transformation is carried out every interval of a group of bolt groups.
  • the present invention proposes a vibration reduction optimization method for the host system of the full-section rock tunneling machine to reduce the vibration of the host and prevent fatigue damage at key weak positions of the TBM host system.
  • the damping alloy material is used to replace the material of the cutter head system and the connecting flange, and the method of adding a magnetorheological damper at the support cylinder and the propulsion cylinder is used to realize the vibration damping optimization of the TBM host system, which also reduces the difficulty of TBM structure optimization.
  • FIG. 1 is a general view of TBM.
  • Fig. 2 is a diagram of a magnetorheological damper.
  • Figure 3 is a cutter plate rib.
  • Figure 4 is the connection structure of TBM hob and tool holder.
  • Fig. 5 is a material replacement model of cutter plate rib plate.
  • Figure 6 is a replacement model of hob wedge block damping material.
  • Fig. 7 is the adding scheme of the support system magnetorheological damper.
  • Figure 8 is the addition scheme of the magneto-rheological damper of the propulsion system.
  • Figure 9 is a polymer sandwich damping damping steel plate.
  • FIG. 1 is a schematic diagram of the TBM host system of a project, including the main components such as the cutter head, support shield, main beam and support boots.
  • the hob has the characteristics of multi-point impact rock breaking. During the rock cutting process, the hob will generate a strong impact load, which will cause the TBM to violently vibrate, and eventually cause some key parts of the TBM to wear or even break.
  • the wedge shape in the cutter head rib plate and the tool holder-hob connection structure is mainly used for material replacement to achieve the purpose of vibration damping optimization.
  • the cutter head rib plate material replacement model and hob wedge block damping material are mainly used Replace the model to complete the replacement of the material of the cutter plate rib plate and wedge block to achieve the vibration reduction of the cutter plate system.
  • the support and propulsion system the support and propulsion system magnetorheological damper addition scheme is adopted to perform the corresponding addition of the magnetorheological damper to realize the optimization of the vibration damping of the support and thrust system.
  • the polymer sandwich damping damping steel plate and the method of partially replacing the bolt material are used to achieve the optimization of vibration damping at the joint.
  • the vibration damping optimization of the cutter head system, support and propulsion system and connection position can be achieved.
  • the overall TBM host system is implemented from the corresponding vibration reduction measures of the four parts of the nugget position, support position, propulsion position and connection position. Damping requirements.
  • the present invention proposes a vibration reduction optimization method for the host system of a full-section rock tunneling machine to reduce the vibration of the host and prevent fatigue damage at key weak positions of the TBM host system.
  • the damping alloy material is used to replace the material of the cutter head system and the connecting flange, and the magneto-rheological damper is added at the support cylinder and the propulsion cylinder to realize the vibration damping optimization of the TBM host system to prevent the accident of the TBM cutter system. Generated to ensure that the TBM works safely and reliably.

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Abstract

本发明提出了一种全断面岩石掘进机主机系统的减振优化方法，来减少主机的振动，防止TBM主机系统关键薄弱位置发生疲劳破坏。采用阻尼合金材料对刀盘系统和连接法兰处进行材料替换，并在支撑油缸与推进油缸处添加磁流变阻尼器来实现TBM主机系统的减振优化，防止TBM刀盘系统突发事故的产生，确保TBM安全可靠地工作，从而构建了一整套TBM主机系统的主机系统减振优化方法。

Description

全断面岩石掘进机主机系统的减振优化方法 技术领域
本发明涉及一种全断面岩石掘进机主机系统减振优化方法，属于全断面岩石掘进机减振设计技术领域。
背景技术
全断面掘进装备(简称TBM)，是机、电、液、光、气等系统集成的工厂化流水线隧道施工装备，具有掘进速度快、综合效益高等优点，在铁道、水电、交通、矿山等隧洞工程中得到广泛应用。由于TBM掘进环境复杂，再加上TBM滚刀多点冲击破岩的特点，滚刀切削岩石过程中将产生强冲击载荷，这就会造成TBM主机剧烈的振动，最终造成TBM某些关键部位发生磨损甚至断裂，因此如何实现主机系统的减振优化显得尤为重要。
TBM主机(如图1)系统主要由刀盘系统、支撑系统、推进系统和主梁等组成，恶劣的载荷条件是造成TBM主机系统剧烈的振动，进而造成主机系统的故障，影响TBM正常的运行，为了保证TBM安全可靠的运行和减少故障的发生，必须降低TBM主机掘进时的剧烈振动。建立一套TBM主机系统减振动优化方法，既可以降低故障的发生率，减少工程施工人员检修次数，同时又能保证TBM安全可靠地运行。
由于TBM的掘进环境十分恶劣，虽然目前学者们对TBM的减振优化已经做了一些研究，但国内外对TBM主机系统的减振优化尚没有一套完整的方案。并且由于TBM主机系统结构复杂且需要考虑的耦合因素较多，目前虽也有一些学者也做过一定的理论研究来进行减振优化，但往往存在模型简化严重、分析不全面、工程应用性不强等问题，具有一定的局限性。
基于以上情况，本发明采用材料替换和合理布置磁流变阻尼器(如图2)的 方式对TBM主机系统进行了减振优化设计。对于刀盘系统，提出了刀盘筋板(如图3)的材料替换模型和TBM滚刀-刀座的连接结构(如图4所示)的楔形块阻尼材料替换模型；对于支撑和推进系统，提出了相应的磁流变阻尼器添加方案；对于连接法兰，提出了一种法兰和连接螺栓的材料替换方法。通过制定以上方案，构建了套用于TBM主机系统的减振优化方案。
发明内容
本发明的目的在于提供一套完整的TBM主机系统的减振优化方案。
本发明的技术方案：
全断面岩石掘进机主机系统的减振优化方案，步骤如下：
全全断面岩石掘进机主机系统的减振优化方案，包含用于材料替换的阻尼合金、磁流变阻尼器、刀盘筋板材料替换模型、滚刀楔形块阻尼材料替换模型、支撑油缸和推进油缸处磁流变阻尼器添加方案、法兰和连接螺栓的材料替换方案。其特征在于，通过对刀盘系统和连接法兰处进行材料替换以及对支撑油缸和推进油缸处添加磁流变阻尼器来实现TBM主机系统的减振优化设计。具体的系统分为以下两个方面：刀盘系统材料优化替换模型；支撑和推进系统磁流变阻尼器添加方案；连接法兰材料替换方案。
Ⅰ、刀盘系统材料优化替换模型
模型1，刀盘筋板材料替换模型
本模型的目的在于提出一种阻尼合金替换刀盘筋板材料的减振优化方案，实现对筋板材料的优化替换，从传递过程方面减少刀盘整体的振动，进而减少TBM的振动，防止TBM突发事故的产生，确保TBM安全可靠地工作。采用部分替换阻尼合金材料来实现最大限度的减少筋板的振动，来减少TBM的振动，进而提出阻尼合金替换筋板材料的优化布局模型(如图5)，优化布局模型公式 如下：
Figure PCTCN2018121013-appb-000001
式中：a和b为指数项系数，它们的取值范围分别为-6.1～-4.3和0.11～0.150，以上参数随分块区域的增多而减小；
c和d为余弦系数，它们的取值范围分别为0.7～0.93和1.3～2.5以上参数随所分块区域的增多而增大；
e、f和g为主项系数，它们的取值范围分别为2.6～5.2,-4.4～-4.1和-1.2～-0.9，以上参数随所分块区域的增多而增大；
α为区域划分系数，1.1～1.72，随着分块区域的增多而增大；
x和y分别为区域编号和替换区域编号，其范围为1～n；
模型说明：本优化布局模型以刀盘所在的区域为划分区域，以刀盘的中心为圆心O，围绕着圆心O的4把中心滚刀分别横向和纵向对称，形成以O为圆心的第一圈椭圆；在第一圈椭圆的长、短轴上布置的正滚刀，形成多个同心椭圆；最外圈椭圆与边缘筋板作为最后一层，(模型图5中小圆圈为所述的横纵滚刀位置)；按照θ°等分圆周划分区域，以横向中心滚刀的方向为中心线，向上和向下各转动(θ/2)°，并将其定义为1号替换编号(如图5阴影部分)，以逆时针方向继续编号，依次从内向外进行替换编号，直接替换编号n结束编号；如果筋板位于替换和不替换两个区域之间，则采用混合替换方法，一部分替换一部分保留；当计算的替换区域编号非整时做近位处理；当最后计算替换区域编号超出了替换编号的区域则舍掉即可。
模型2，滚刀楔形块阻尼材料替换模型
本模型将刀盘振动剧烈区域内的滚刀连接楔形块材料更换为阻尼合金，来降低了减振刀盘滚刀造成的振动，将部分滚刀连接楔形块材料更换为阻尼合金来减振的目的，滚刀楔形块阻尼材料替换模型(如图6)，具体材料优化模型公 式如下：
Figure PCTCN2018121013-appb-000002
式中：δ为划分角度系数，其取值范围为0.95～1.12，在刀盘的圆周方向上划分的单位角度值越小，其值越小；
Figure PCTCN2018121013-appb-000003
为刀盘结构系数，其取值范围为0.91～1.04，刀盘本体分块越多，
Figure PCTCN2018121013-appb-000004
值越大；
R 1和R 2分别为正滚刀区域和边滚刀区域的直径系数，其取值范围分别为2.603～3.535和0.346～1.705，圆周直径越大，其取值越大；
a,b,c,d分别为二项系数,指数系数,正弦系数和初相系数，它们的取值范围分别为0.415～0.487，2.92～6.99，3.209～8.063和3.224～3.649，以上系数均随刀盘在圆周方向上划分的单位角度值的减小而增大；
x和y分别为区域编号和替换区域编号，其范围为1～n；
模型说明：本模型以刀盘中心为圆心，分别以中心滚刀与刀盘圆心的最大距离、边滚刀与刀盘圆心的最小距离为半径做圆，将刀盘在径向方向上划分为三个区域，从内向外分别为中心滚刀区域6a、正滚刀区域6b和边滚刀区域6c；以通过刀盘中心的水平线作为第一块薄板，以第一块薄板为基准，按照一定的角度值(本模型以30°为例)将刀盘在圆周方向上等分为若干区域，按顺时针方向由内向外依次编写刀盘区域的序号x，x＝1、2、3、…、n；在正滚刀区域6b中，从左侧开始，将位于第一块薄板上方的区域的序号记为1，编写完正滚刀区域6b后，按照同样的方式编写边滚刀区域6c；现将步骤(2)已经编写的序号带入材料优化模型，求解f(x)值，若其值为非整数时，取整数部分即可；所求得的值便为需要将滚刀连接楔形块材料更换为阻尼合金区域的序号(图中阴影区域)；直到f(x)≥x停止带入，得到的结果即为全部需要替换的区域。
II、支撑和推进系统磁流变阻尼器添加方案
在靠近原有支撑油缸的位置并根据实际空间的可操作性添加磁流变阻尼器, 新增的磁流变阻尼器包括右侧磁流变阻尼器2、右上侧斜上磁流变阻尼器5、右下侧磁流变阻尼器7、左下侧磁流变阻尼器10、左上侧斜上磁流变阻尼器12、左侧磁流变阻尼器15、左上侧斜上磁流变阻尼器18和右上侧斜上磁流变阻尼器21,方案示意图(如图7)，具体的添加方案如下：
位于顶护盾1与主驱动16之间，分别存在左侧顶油缸14与右侧顶油缸3，距左侧顶油缸14主机掘进方向一侧90～600mm范围内添加左侧磁流变阻尼器15，距右侧顶油缸3主机掘进方向一侧90～600mm范围内添加右侧磁流变阻尼器2，此一组磁流变阻尼器轴线与主机竖直方向的角度范围为0～60°，其功能主要是降低主机系统的纵向振动。位于左上侧护盾13与主驱动16之间存在左上侧斜上油缸19，距左上侧斜上油缸19左侧0～500mm范围内添加左上侧斜上磁流变阻尼器18，距左上侧斜上油缸19右侧0～400mm范围内添加左上侧斜上磁流变阻尼器12；位于右上侧护盾4与主驱动16之间存在右上侧斜上油缸20，距右上侧斜上油缸20左侧0～400mm范围内添加右上侧斜上磁流变阻尼器5，距右上侧斜上油缸20右侧0～500mm范围内添加右上侧斜上磁流变阻尼器21；此两组磁流变阻尼器的安装轴线与原有支撑油缸轴线相平行，其添加功能主要是分别降低主机系统的纵向振动与横向振动。位于左侧护盾11与主驱动16之间存在左下侧油缸9，距左下侧油缸9主机掘进方向一侧300～600mm范围内添加左下侧磁流变阻尼器10；位于右侧护盾6与主驱动16之间存在右下侧油缸8，距离右下侧油缸8主机掘进方向一侧300～600mm范围内添加右下侧磁流变阻尼器7；此一组磁流变阻尼器的安装轴线与主机竖直方向角度范围为-10～90°，其添加功能主要是降低主机系统的纵向振动，也可一定程度上降低主机系统的横向振动。另外，在TBM两端的推进油缸处分别添加磁流变阻尼器(如图8)。
III、连接法兰材料替换方案
为了减少TBM连接处的振动采用了一种高分子夹层阻尼减振钢板以及局部替换螺栓材料的方法来实现连接处减振的目的，具体方案如下：
对于TBM连接法兰的减振优化主要采用高分子夹层阻尼减振钢板(如图9)的方法，高分子夹层阻尼减振钢板分三层，上下层为钢板，内层为阻尼减振夹层(以刀盘圆形连接法兰为例)。通过构建全断面硬岩掘进机刀盘动力学模型，对模型结果进行分析对比，确定减振钢板的阻尼减振夹层厚度t1与钢板厚度尺寸t2；对于螺栓材料的替换，法兰螺栓结构中螺栓每间隔一组螺栓组进行一次螺栓材料变换。
本发明的有益效果：本发明提出了一种全断面岩石掘进机主机系统的减振优化方法，来减少主机的振动，防止TBM主机系统关键薄弱位置发生疲劳破坏。采用阻尼合金材料对刀盘系统和连接法兰处进行材料替换和在支撑油缸与推进油缸处添加磁流变阻尼器的方式来实现TBM主机系统的减振优化，这也降低了TBM结构优化难度，防止TBM刀盘系统突发事故的产生，确保TBM安全可靠地工作。
附图说明
图1是TBM总体图。
图2是磁流变阻尼器图。
图3是刀盘筋板。
图4是TBM滚刀与刀座的连接结构。
图5是刀盘筋板材料替换模型。
图6是滚刀楔形块阻尼材料替换模型。
图7是支撑系统磁流变阻尼器添加方案。
图8是推进系统磁流变阻尼器添加方案。
图9是高分子夹层阻尼减振钢板。
图中：1a-刀盘系统；1b-支撑系统；1c-推进系统；1d-主梁；2a-耳环；2b-活塞杆；2c-缸筒；2d-活塞；2e-磁流变液体；2f-线圈；2g-阻尼通道线圈；2h-活塞；2i-线圈引线；4a-上楔形块；4b-下楔形块；6a-中心滚刀区域；6b-正滚刀区域；6c-边滚刀区域；7a-主驱动与护盾系统结构；7b-左侧磁流变阻尼器添加位置；7c-右侧磁流变阻尼器添加位置；8a-推进液压缸；8b-磁流变阻尼器；1-顶护盾；2-右侧磁流变阻尼器；3-右侧顶护盾；4-右上侧护盾；5-右上侧斜上磁流变阻尼器；6-右侧护盾；7-右下侧磁流变阻尼器；8-右下侧油缸；9-左下侧油缸；10-左下侧磁流变阻尼器；11-左侧护盾；12-左上侧斜上磁流变阻尼器；13-左上侧护盾；14-左侧顶油缸；15-左侧磁流变阻尼器；16-主驱动；17-驱动电机；18-左上侧斜上磁流变阻尼器；19-左上侧斜上油缸；20-右上侧斜上油缸；21-右上侧斜上磁流变阻尼器。
具体实施方式
下面结合附图及技术方案详细说明本发明的具体实施方式，图1为某工程的TBM主机系统示意图，包含刀盘、支撑盾体、主梁及支撑靴等主要部件，TBM在工作过程中，滚刀具有多点冲击破岩的特点，滚刀切削岩石过程中将产生强冲击载荷，这就会造成TBM剧烈的振动，最终造成TBM某些关键部位发生磨损甚至断裂。
对于刀盘系统，主要采用对刀盘筋板和刀座-滚刀连接结构中的楔形快进行材料替换达到减振优化的目的，主要采用刀盘筋板材料替换模型和滚刀楔形块阻尼材料替换模型，完成对刀盘筋板和楔形块的材料替换，来实现刀盘系统的减振。对于支撑和推进系统，采用支撑和推进系统磁流变阻尼器添加方案来进行相应的磁流变阻尼器的添加来实现支撑和推力系统的减振优化。对于各部件 之间的连接法兰处，采用高分子夹层阻尼减振钢板和局部替换螺栓材料的方法来实现连接处的减振优化。通过以上措施可以实现了刀盘系统、支撑和推进系统和连接位置的减振优化，从掘金部位、支撑部位、推进部位和连接部位四个部分的相应减振措施来实TBM主机系统的整体减振要求。
工业实用性
本发明提出了一种全断面岩石掘进机主机系统的减振优化方法，来减少主机的振动，防止TBM主机系统关键薄弱位置发生疲劳破坏。采用阻尼合金材料对刀盘系统和连接法兰处进行材料替换，并在支撑油缸与推进油缸处添加磁流变阻尼器来实现TBM主机系统的减振优化，防止TBM刀盘系统突发事故的产生，确保TBM安全可靠地工作。

Claims (1)

  1. 一种全断面岩石掘进机主机系统减振优化方法，其特征在于，所述的全断面岩石掘进机主机系统减振优化方法包括刀盘系统材料优化替换模型、支撑和推进系统磁流变阻尼器添加方案和连接法兰材料替换方案三部分，具体步骤如下：
    Ⅰ、刀盘系统材料优化替换模型
    模型1，刀盘筋板材料替换模型
    本模型采用部分替换阻尼合金材料来实现最大限度的减少筋板的振动，来减少TBM的振动，进而提出阻尼合金替换筋板材料的优化布局模型，优化布局模型公式如下：
    Figure PCTCN2018121013-appb-100001
    式中：a和b为指数项系数，它们的取值范围分别为-6.1～-4.3和0.11～0.150，以上参数随分块区域的增多而减小；c和d为余弦系数，它们的取值范围分别为0.7～0.93和1.3～2.5以上参数随所分块区域的增多而增大；e、f和g为主项系数，它们的取值范围分别为2.6～5.2,-4.4～-4.1和-1.2～-0.9，以上参数随所分块区域的增多而增大；α为区域划分系数，1.1～1.72，随着分块区域的增多而增大；x和y分别为区域编号和替换区域编号，其范围为1～n；
    模型说明：本模型以刀盘所在的区域为划分区域，以刀盘的中心为圆心O，围绕着圆心O的4把中心滚刀分别横向和纵向对称，形成以O为圆心的第一圈椭圆；在第一圈椭圆的长、短轴上布置的正滚刀，形成多个同心椭圆；最外圈椭圆与边缘筋板作为最后一层；按照θ°等分圆周划分区域，以横向中心滚刀的方向为中心线，向上和向下各转动(θ/2)°，并将其定义为1号替换编号，以逆时针方向继续编号，依次从内向外进行替换编号，直接替换编号n结束编号；如果筋板位于替换和不替换两个区域之间，则采用混合替换方法，一部分替换一部分保留；当计算的替换区域编号非整时做近位处理；当最后计算替换区域 编号超出了替换编号的区域则舍掉即可；
    模型2，滚刀楔形块阻尼材料替换模型
    本模型将刀盘振动剧烈区域内的滚刀连接楔形块材料更换为阻尼合金，来降低了减振刀盘滚刀造成的振动，将部分滚刀连接楔形块材料更换为阻尼合金来减振的目的，滚刀楔形块阻尼材料替换模型，具体材料优化模型公式如下：
    Figure PCTCN2018121013-appb-100002
    式中：δ为划分角度系数，其取值范围为0.95～1.12，在刀盘的圆周方向上划分的单位角度值越小，其值越小；
    Figure PCTCN2018121013-appb-100003
    为刀盘结构系数，其取值范围为0.91～1.04，刀盘本体分块越多，
    Figure PCTCN2018121013-appb-100004
    值越大；R 1和R 2分别为正滚刀区域和边滚刀区域的直径系数，其取值范围分别为2.603～3.535和0.346～1.705，圆周直径越大，其取值越大；a,b,c,d分别为二项系数、指数系数、正弦系数和初相系数，它们的取值范围分别为0.415～0.487，2.92～6.99，3.209～8.063和3.224～3.649，以上系数均随刀盘在圆周方向上划分的单位角度值的减小而增大；x和y分别为区域编号和替换区域编号，其范围为1～n；
    模型说明：本模型以刀盘中心为圆心，分别以中心滚刀与刀盘圆心的最大距离、边滚刀与刀盘圆心的最小距离为半径做圆，将刀盘在径向方向上划分为三个区域，从内向外分别为中心滚刀区域、正滚刀区域和边滚刀区域；以通过刀盘中心的水平线作为第一块薄板，以第一块薄板为基准，按照一定的角度值将刀盘在圆周方向上等分为若干区域，按顺时针方向由内向外依次编写刀盘区域的序号x，x＝1、2、3、…、n；在正滚刀区域中，从左侧开始，将位于第一块薄板上方的区域的序号记为1，编写完正滚刀区域后，按照同样的方式编写边滚刀区域；现将上一步已经编写的序号带入材料优化模型，求解f(x)值，若其值为非整数时，取整数部分即可；所求得的值便为需要将滚刀连接楔形块材料更 换为阻尼合金区域的序号；直到f(x)≥x停止带入，得到的结果即为全部需要替换的区域；
    II、支撑和推进系统磁流变阻尼器添加方案
    在靠近原有支撑油缸的位置并根据实际空间的可操作性添加磁流变阻尼器，新增的磁流变阻尼器包括右侧磁流变阻尼器(2)、右上侧斜上磁流变阻尼器(5)、右下侧磁流变阻尼器(7)、左下侧磁流变阻尼器(10)、左上侧斜上磁流变阻尼器(12)、左侧磁流变阻尼器(15)、左上侧斜上磁流变阻尼器(18)和右上侧斜上磁流变阻尼器(21)，具体的添加方案如下：
    位于顶护盾(1)与主驱动(16)之间，分别存在左侧顶油缸(14)与右侧顶油缸(3)，距左侧顶油缸(14)主机掘进方向一侧90～600mm范围内添加左侧磁流变阻尼器(15)，距右侧顶油缸(3)主机掘进方向一侧90～600mm范围内添加右侧磁流变阻尼器(2)，此一组磁流变阻尼器轴线与主机竖直方向的角度范围为0～60°，其功能主要是降低主机系统的纵向振动；位于左上侧护盾(13)与主驱动(16)之间存在左上侧斜上油缸(19)，距左上侧斜上油缸(19)左侧0～500mm范围内添加左上侧斜上磁流变阻尼器(18)，距左上侧斜上油缸(19)右侧0～400mm范围内添加左上侧斜上磁流变阻尼器(12)；位于右上侧护盾(4)与主驱动(16)之间存在右上侧斜上油缸(20)，距右上侧斜上油缸(20)左侧0～400mm范围内添加右上侧斜上磁流变阻尼器(5)，距右上侧斜上油缸(20)右侧0～500mm范围内添加右上侧斜上磁流变阻尼器(21)；此两组磁流变阻尼器的安装轴线与原有支撑油缸轴线相平行，其添加功能主要是分别降低主机系统的纵向振动与横向振动；位于左侧护盾(11)与主驱动(16)之间存在左下侧油缸(9)，距左下侧油缸(9)主机掘进方向一侧300～600mm范围内添加左下侧磁流变阻尼器(10)；位于右侧护盾(6)与主驱动(16)之间存在右下侧 油缸(8)，距离右下侧油缸(8)主机掘进方向一侧300～600mm范围内添加右下侧磁流变阻尼器(7)；此一组磁流变阻尼器的安装轴线与主机竖直方向角度范围为-10～90°，其添加功能主要是降低主机系统的纵向振动，也可一定程度上降低主机系统的横向振动；另外，在TBM两端推进油缸处分别添加磁流变阻尼器；
    III、连接法兰材料替换方案
    为了减少TBM连接处的振动采用了一种高分子夹层阻尼减振钢板以及局部替换螺栓材料的方法来实现连接处减振的目的，具体方案如下：
    对于TBM连接法兰的减振优化主要采用高分子夹层阻尼减振钢板的方法，高分子夹层阻尼减振钢板分三层，上下层为钢板，内层为阻尼减振夹层；通过构建全断面硬岩掘进机刀盘动力学模型，对模型结果进行分析对比，确定减振钢板的阻尼减振夹层厚度t1与钢板厚度尺寸t2；对于螺栓材料的替换，法兰螺栓结构中螺栓每间隔一组螺栓组进行一次螺栓材料变换。
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