EBZ160紧凑型掘进机行走部和液压系统设计【含9张CAD图纸】

资源目录里展示的全都有，所见即所得。下载后全都有,请放心下载。原稿可自行编辑修改=【QQ：401339828 或11970985 有疑问可加】 英文原文 Abstract The factors affecting the performance of 90 kW-shielded roadheader is investigated in detail in a tunnel excavated for NuhCement Factory. The first part of the tunnel is horizontal and the second part is inclined with 9_ and excavated uphill. Tunnel passes through a formation of the Upper Cretaceous age with nodular marl, carbonated claystone, thin and thick laminated limestone. Water ingress changes from 0 to 11 l/min. In six different zones it is found that the rock compressive strength changed from 20 to 45 MPa, tensile strength from 1 to 4 MPa, specific energy from 11 to 16 MJ/m3, plastic limit from 15% to 29%, liquid limit from 27% to 43% and water absorption from 4% to 18% in volume. Detailed in situ observations show that in dry zones for the same rock strength the inclination of the tunnel and the strata help to increase the instantaneous cutting rate from 10 to 25 solid bank m3/cutting hour. The effect of water on cutting rate is dramatic. In the zones where the plastic limit and the amount of Al2O3 is low, instantaneous cutting rate increases from 34 to 50 solid bank m3/ cutting hour with increasing water content from 3.5 to 11 l/min. However, in the strata having high water absorption characteristic and high amount of Al2O3, cutting rate decreases considerably due to the sticky mud, causing problem to the cutterhead. Excavation, muck loading and support works are performed separately due to safety concerns in the wet and inclined sections which reduced the machine utilization time from 38% to 8%. The information gathered is believed to form a sound basis in contributing the performance prediction of roadheaders in difficult ground conditions. _ 2004 Elsevier Ltd. All rights reserved. Keywords: Tunnel excavation; Roadheader performance prediction; Core cutting test; Specific energy 1. Introduction The application of roadheaders in difficult ground conditions, in recent years, has increased considerably in both civil and mining engineering fields. The prediction of instantaneous (net) cutting rate and machine utilization time, determining daily advance rates, plays an important role in the time scheduling of the tunneling projects, hence, in determining the economy of tunnel excavation. Although many roadheader performance prediction models were published in the past, the published data on difficult ground conditions such as the effects of tunnel inclination, water ingress, excessive fracture zones, etc. on daily advance rates were quite scarce. Sandbak (1985) and Douglas (1985) used a rock classification system to explain the changes of roadheader advance rates at San Manuel Copper Mine in an inclined drift at an 11% grade. They concluded that for a performance prediction model, engineering aspects of the roadheaders had to be also incorporated with the geomechanical factors. Field data on roadheader machine performance in inclined tunnels were also published by Unrug and Whitsell (1984) for a 14_ slope in Pyro Coal Mine, by Navin et al. (1985) at 13_ and 15_ inclines in oil shale mine and by Livingstone and Dorricott (1995) in Ballarat East Gold Mine. The majority of performance prediction models were developed for horizontal tunnels. Bilgin (1983) developed a model based on specific energy obtained from drilling rate of a percussive drill. Models for widely jointed rock formations were described by Schneider (1988), Thuro and Plinninger (1998, 1999), Gehring (1989, 1997), Dun et al. (1997) and Uehigashi et al. (1987). They reported that for a given cutting power, cutting rates of roadheaders decreased dramatically with increasing values of rock compressive strength. Copur et al. (1997, 1998) stated that if the power and the weight of the roadheaders were considered together, in addition to rock compressive strength, the cutting rate predictions were more realistic. Another concept of predicting machine instantaneous cutting rate was to use specific energy described as the energy spent to excavate a unit volume of rock material. Farmer and Garrity (1987) and Poole (1987) showed that for a given power of roadheader, excavation rate in solid bank m3/cutting hour might be predicted using specific energy values given as in the following equation, where SE is the specific energy, rc is the rock compressive strength and E is the rock elastic modulus. Widely accepted rock classification and assessment for the performance estimation of roadheaders is based on the specific energy found from core cutting tests (McFeat-Smith and Fowell, 1977, 1979; Fowell and Johnson, 1982; Fowell et al., 1994). Detailed laboratory and in situ investigations carried out by McFeat-Smith and Fowell (1977, 1979) showed that there was a close relationship between specific energy values obtained from core cutting tests and cutting rates for medium and heavy weight roadheaders separately. They reported also that tool consumption might be predicted from weight loss of cutter used in core cutting test. Rock cuttability classification based on core cutting test is usually criticized as that the effect of rock discontinuities are not reflected in performance prediction. Bilgin et al. (1988, 1990, 1996, 1997) developed a performance equation based on rock compressive strength and rock quality designation as given below where ICR is the instantaneous cutting rate in solid bank m3/cutting hour, P is the power of cutting head in hp, RMCI is the rock mass cuttability index, rc is the uniaxial compressive strength in MPa and RQD is the rock quality designation in percent. Dun et al. (1997) compared the models described by Bilgin et al. (1988, 1990) and McFeat-Smith and Fowell (1977, 1979) in a research work carried out at Kumbalda Mine where a Voest Alpine AM75 roadheader was utilized. Two distinct groups of data were evident. The data grouped around Bilgin line was strongly influenced by the jointing and weakness zones present in rock mass. The other group of data on the line produced by McFeat-Smith and Fowell corresponded to areas where less jointing and fewer weakness zones were present. One of the most accepted method to predict the cutting rate of any excavating machine is to use, cutting power, specific energy obtained from full scale cutting tests and energy transfer ratio from the cutting head to the rock formation as in the following equation (Rostami et al., 1994; Rostami and Ozdemir, 1996) where ICR is th instantaneous production rate in solid bank m3/cutting hour, P is the cutting power of themechanical miner in kW, SEopt is the optimum specific energy in kWh/m3 and k is energy transfer coefficient depending on the mechanical miner utilized. Rostami et al. (1994) strongly emphasized that the predicted value of cutting rate was more realistic if specific energy value in equation was obtained from full-scale linear cutting tests in optimum conditions using real life cutters. Rostami et al. (1994) pointed out that k changed between 0.45 and 0.55 for roadheaders and from 0.85 to 0.90 for TBMs. Bilgin et al. (2000) showed in their experimental and numerical studies that performance of mechanical miners was affected upto a certain degree by the earth and/or overburden pressure and stress. Copur et al. (2001) showed that specific energy obtained from full-scale linear cutting tests in optimum cutting conditions was highly correlated to rock uniaxial compressive strength and Brazilian tensile strength. The effect of tunnel inclination, water ingress and the presence of clay on roadheader performance was not clearly shown in the above-mentioned works. The main objective of the research study described in this paper is to contribute the performance prediction models in difficult ground conditions. Hereke tunnel is chosen for this purpose. The first 50 m of the tunnel is horizontal. Later 225 m is inclined with 9_ and excavated uphill.There is excessive water ingress and clay in some sections. Detailed in situ observations are made during the tunnel excavation and rock samples are collected for testing in the laboratories of the Mining Engineering Department of Istanbul Technical University for ground characterization. antaneous cutting rate of the roadheader used in the project is explained by some geological and geotechnical factors. Factors affecting machine utilization time is also explained in detail. 2. Description of the tunnel project The Hereke Tunnel, located in Turkey in the city of Kocaeli next to Istanbul, was constructed for material transportation between the Nuh Cement Dock and Nuh Cement Plant. Tunneling was the best choice to avoid traffic disruption, since there was a railway, highway and freeway on the surface. The contractor firm STFA Co. was awarded the tunneling project. The tunnel included 50 m of horizontal section (chainage 0–50 m), where excavation started up, and 225 m of 9_ inclined section (chainage 50–275 m). The excavation was performed in a horizontally straight alignment through sedimentary formations including dry (chainage 0–50 and 150–275 m) and wet sections (chainage 50–150). Excavation was performed by using a shielded roadheader, Herrenknecht-SM1 with 90 kW of cutter head power, in the excavation diameter of 3.48 m. Two shafts were sunk in the plant side of the tunnel. The first shaft was planned to be used for cement transportation from the plant to the dock via steel pipe line and the second shaft for coal transportation to the plant via a belt conveyor and skip haulage system. 3. Geology of the project site The Hereke Tunnel passes through a formation of the Upper Cretaceous age. The formation exhibits fractured and folded structure with the direction of 48–52_N and the dip of 30_NE. The strata types encountered in this relatively shallow tunnel (3–21 m of overburden) are nodular marl and thin and thick laminated clayey limestone, carbonated claystone and thin laminated silisified limestone. Some levels of laminated limestone (chainage from 50 to 150 m) form a fractured aquifer causing water ingress in the tunnel. The tunnel is divided into six sections according to their structural and geotechnical differences. Fig. 1 presents the general layout of the tunnel and shafts and the geological cross-section along the tunnel route. The results of geotechnical tests are presented in Table 2. 6. Roadheader performance analysis in different zones Excavation of the Hereke Tunnel was completed in 2 months with an average daily advance rate of 4.6 m. During this period, related field data, including machineperformance and geotechnical parameters, were recorded by the authors of this paper. Performance of the roadheader was continuously recorded, including instantaneous cutting rate, machine utilization time and all stoppages for the different zones in the tunnel route. Instantaneous (or net) cutting rate (ICR) is defined as is the production rate for the actual (net) cutting time of the machine (ton or solid bank m3/cutting hour). Machine utilization time (MUT) is the net excavation time as a percentage (%) of the total working time, excluding all the stoppages. Advance rate (AR) is the linear advance rate of the tunnel or drift excavation (m/shift, m/ day, m/week and m/month) and is a function of ICR, MUT and cross-section area of the excavated face. Water ingress and geological discontinuities in the tunnel face were also recorded. The recorded instantaneous cutting rate, water ingress, RQD values of the face and machine utilization time values are tabulated for different tunnel zones in Table 3. Machine utilization, percentages of stoppages and other planned jobs such as ring montage, site surveying, etc. are presented in Fig. 3. 7 .The effect of strata inclination One of the most accepted methods for determining the roadheader cutting rate in horizontal and widely jointed rock formation is to use laboratory cutting specific energy obtained from instrumented core cutting test (McFeat-Smith and Fowell, 1979). As seen from Table 2, the samples taken from nodular marl, zone 1, have the specific energy value of 11 MJ/m3, which corresponds to an instantaneous cutting rate of 8 solid bank m3/cutting hour for non-inclined strata and medium weight roadheaders in the McFeat-Smith and Fowell’s model. However, it is observed in the site that the inclination of the strata is in favor of the cutting action and the muck is easily coming out from the excavated area. The instantaneous cutting rate in this area (zone 1) is recorded to be 10 solid bank m3/cutting hour. 7.2. The effect of tunnel inclination In zone 5, having the same compressive strength and specific energy values as in zone 1, the instantaneous cutting rate is more than double being 25 solid bank m3/ cutting hour. The inclination of the tunnel, hence, the gravity forces help the muck being loaded easily and coming quickly on the cut face preventing the muck recirculation within the cutting head and the face. 7.3. The effect of rock strength and specific energy values Samples taken from zone 5 have compressive strength of 210 kg/cm2 and specific energy of 11.2 MJ/m3, and samples taken from zone 6 have compressive strength values of 450 kg/cm2 and specific energy values of 16.3 MJ/m3. This is reflected in instantaneous cutting rate values being 25 solid bank m3/cutting hour in zone 5 and 20 solid bank m3/cutting hour in zone 6. 7.4. The effect of water The effect of water on the instantaneous cutting rate is dramatic. The water ingress in zone 2 is 11 l/min and zone 5 is dry, the samples taken from these two zones have the same compressive strength. However, the instantaneous cutting rate in the wet zone (50 solid bank m3/cutting hour) is twice (double) more than in the dry zone (25 solid bank m3/cutting hour). This might be due to the fact that the water reduces the strength of the strata and helps the muck coming easily from the tunnel face. 7.5. The effect of wet sticky zone Water ingress in zone 3 is the same as in zone 2, being 11 l/min. The samples taken from zone 3 have the same strength as zone 2. However, it is observed in the site that the muck in zone 3 is sticky (muddy) and sticks the cutting head, hence, decreases the instantaneous cutting rate from 50 to 20 solid bank m3/cutting hour. The samples taken from zone 3 have Al2O3 content of 15.1%, water absorption of 18.1%, plastic limit of 29% and liquid limit of 43%. XRD analysis show that the clay in zone 3 consists of nontronite and kaolinite. The pictures of the original (new, unused) cutting head (on top) and the mud on the cutting head after utilizing in the wet sticky zone (at the bottom) are seen in Fig. 4. Zones 2 and 4 have similar geotechnical properties, although the water ingress in zone 4 is 3.5 l/min being one-third of the water ingress in zone 2. This is reflected dramatically on the instantaneous cutting rate value, which is 31 solid bank m3/cutting hour in zone 4 and 50 solid bank m3/cutting hour in zone 2. 7.6. The effect of lamination It is considered that lamination affects the instantaneous cutting rate. Thin laminated limestone (zone 2) has a thickness varying between 2 and 0.6 cm. The instantaneous cutting rate in zone 2 reaches at an average of 50 solid bank m3/cutting hour, which is the maximum rate among all of the zones, as seen in Table 3. On the other hand, the chemical composition of the excavated formations affects the instantaneous cutting rate, as well. Although the thin laminated limestone (zone 2) and thin laminated silisified limestone (zone 5) have similar thicknesses, the instantaneous cutting rate is lower in zone 5, being 25 solid bank m3/cutting hour, which might be due to silisification, as well as being dry. The thickness of thick laminated clayey limestone (zone 6) is greater than 60 cm. Therefore, it can be concluded that, based on previous researches (Bilgin et al., 1988, 1990, 1996, 1997), lamination does not increase the instantaneous cutting rate in zone 6. It is a known fact that discontinuity spacing smaller than around 10 cm increases the instantaneous cutting rate. Joint type discontinuities affect similarly the all of the zones in the region. Since the RQD values are similar in all of the zones, Table 3, the effect of joints on the roadheader performance cannot be deduced. 7.7. The factors affecting machine utilization time Machine utilization time is as important as instantaneous cutting rate, since daily advance rates are directly related to machine utilization time, daily working hours, tunnel cross-section area and instantaneous cutting rates. The machine utilization time is 38% in the horizontal section of the tunnel (zone 1). Tunnel excavation and ring montage are executed simultaneously in zone 1. However, the machine utilization time decreases to 8% in the inclined zones 2, 3, 4 and 5 due to the difficulties related to the tunnel inclination, which is reflected in job organization. Tunnel excavation and ring montage are executed separately, which reduces the machine utilization time, in the inclined section of the tunnel due to the safety concerns. In other words, excavation stops during the ring montage. The ring montage takes 13% of the total working time in the dry-inclined section, while it takes 20% in the wet-inclined section. In addition to the ring montage stoppages, some other stoppages coming from the job organization are encountered in the inclined wet and dry zones: 9–13% of the total time is spent to waiting for material and muck trucks. The cutting head sticks in the sticky zone due to the sticky mud, causing a delay of 5%. About 15–17% of the total working time is spent to machine breakdown and maintenance in the entire tunnel. 8. Conclusions The prediction of instantaneous (net) cutting rate and machine utilization time, determining daily advance rates, play an important role in the time scheduling of the tunneling projects, hence, in determining the economy of tunnel excavation. The majority of the performance prediction models developed by different research workers were for non-inclined tunnels. The effects of strata inclination, tunnel inclination, water ingress and the presence of clay on roadheader performance were not clearly shown in those models. Detailed in situ investigations during Hereke Tunnel excavation show that strata and tunnel inclination, water ingress to a certain extend increase the instantaneous cutting rate up to 2–5 times compared to a noninclined tunnel. The inclination of the tunnel, hence, gravity forces help the muck being loaded easily and coming quickly on the cut face preventing the muck recirculation within the cutting head and the face. However, material cut in the wet zones containing nontronite and kaolinite sticks the cutting head and decreases the instantaneous cutting rate considerably. Machine utilization time which is a very important parameter in determining daily advance rate is much effected by the tunnel inclination, decreasing from 38% to 8%. In Hereke Tunnel, in the inclined zone tunnel excavation and ring montage were executed separately due to safety reasons which reduced the machine utilization time. 中文译文 影响倾斜隧道中掘进机的工作的一些地质和岩土性能 摘要 在一次为Nuh水泥厂开凿隧道的工程中，对90kW巷道掘进机的工作进行仔细的研究. 第一部分的隧道是水平的，但第二部分是向上倾斜9挖掘的. 隧道穿过形成于晚白垩世年代，由散碎的泥灰土,碳酸泥岩,薄厚不一的层灰岩组成. 渗水量在0到11升/分钟的范围中. 在6个不同地区被发现的岩石抗压强度在20到45 MPa之间, 抗拉强度在1到4MPa之间,比热容的范围是11到16MJ/m， 塑料极限的范围是15%到29% , 液态极限从27%到43% ,吸水率从4%到18%. 详细的实地观测表明,在干旱区,对于同样硬度的岩石，隧道的倾角与岩石的层理有助于增加切割速度. 水对切割速度的影响效果是惊人. 在某些塑性极限与数量很低的地方, 瞬时切割速度增加,34-50立方米/小时，伴随着3.50-11升/分钟的涌水量. 但是,在地层具有高吸水特性和大量的氧化铝时, 由于粘泥的影响，切割速度将大大降低. 开挖，铲装和支护工程分开进行,由于安全上的顾虑,潮湿和倾斜路段将降低机器利用率的8%至38% . 所收集的资料源于一个健全系统，对掘进机工作条件进行预测. 关键词: 隧洞开挖; 掘进机性能预测; 核心切削试验; 具体能源 1、绪论 近年来，在民事和采矿工程等领域，复杂地质条件下掘进机的应用大大增加了. 预计切削速率和机器工作时间,决定着每天的工作量,并且在掘进工程的时间安排中起着重要的作用,因此, 也决定着隧道开挖的经济性. 虽然过去刊登过许多掘进机性能预测模型, 根据公布的数据,在复杂的地质条件下（倾斜的隧道,涌水量的增加,过断层破碎带等）,它们每天的工作量是很少的. Sandbak ( 1985年)和Douglas(