Research On The Getting-out-of-jam Ability Of TBM Based On Hydro-viscous Clutch

Tunnel Boring Machine(referred to as TBM) is a complete set of equipment for tunnel construction, a combination of electricity, hydraulic technology, sensors and information technology. It is mainly composed of a propulsion system, cutter system, support and change mechanism, auxiliary support equipment, hydraulic system, electrical system, guidance system, backup system and auxiliary equipment etc. Due to the characteristics change of surrounding rock, TBM often get trapped in the tunneling process, which is a serious impact on the construction progress and waste a lot of manpower and material resources. If the thrust mechanism can provide enough torque to make sure the TBM can move forward fast before the surrounding rock gets broken, it can greatly improve the construction efficiency. So it is necessary to do research on the thrust system.A new collaboration control method using variable-frequency motor, flywheel and Hydro-viscous clutch (referred to as HVC) was designed in order to improve the getting-out-of jam torque without any installed power increase in TBM cutter head driving system, improve the driving performance and the efficiency of energy. The key point is the effective use and reasonable control of the HVC. Therefore, to establish the collaboration control method by doing research on the HVC, studying the viscosity transmission mechanism and improving the Torque capacity is the main problem that needs to be solved.The main research contents of this paper are as follows:In the first chapter, the background and significance of the research on the HVC was elaborated, the general situation of the HVC technology was introduced and a new collaborative control method was designed. Because HVC is very important in this method, the development of related technology was studied. The research status of HVC、fluid flow of friction pair and the starting engagement control was summarized and the shortcomings of previous studies and the necessity of this research was analyzed. Finally the main research contents of this subject were put forward.In the second chapter, the basic research work was done. The principle of HVC was described and the piston force and the oil film bearing capacity were derived in detail. The oil film force was analyzed because it directly determines the film thickness and clutch transmission torque value. That is the foundation of chapter 4 to analyze the getting-out-of-jam ability of TBM and establish the AMESim simulation model.In the third chapter, the distribution of oil film thickness of HVC was analyzed. The analysis has proved that the oil film thickness distribution is non-uniform, which often causes the clutch friction pair gets the eccentric wear in the working process, reducing the transmission torque value and the lifespan of the clutch. Because little improvement can be made based on the traditional HVC, so a structure optimization design was carried out, and the oil film thickness uniformity and the ability to transfer torque of two type of HVC were compared in theory and simulation.In the fourth chapter, the TBM energy transfer AMESim model based on the real characteristic of electric motor, load and HVC was established. TBM successfully got out of trap using this new model. This has proved the characteristics of high power density, strong disbursement capability and small impact of the model. The model mainly includes the various energy transfer model building components and control components. The degree of impact of the clutch engagement was calculated quantitatively. The factors of moment of inertia of the flywheel and different Oil film thickness changes on the getting-out-of-jam torque, the rotational speed change and the impact degree were studied. A pressure curve of the overflow valve was designed to ensure the TBM successfully get out of jam when load torque is twice the motor torque and the time of clutch torque higher than the load torque maintained for 71.7 s.In the fifth chapter, the composition of the test rig and the various parts were designed, mainly including the mechanical structure, the structure of HVC and the hydraulic system, the hardware and software selection and design of the electric control system. In addition, the carriable test was introduced in detail, and the specific test methods were described.In the sixth chapter, the full text of the work was summarized, and the following research work was prospected.