中英文翻译盾构机螺旋输送机抱死的疏通方法.doc

XXXX毕业设计（论文）
盾构机螺旋输送机抱死的疏通方法
摘 要：对螺旋输送机出料管和螺杆中间被砂浆填充抱死的疏通方法进行详细介绍，并对疏通时 出现的问题及解决方法进行总结，为今后同类问题的解决提供借鉴经验。
关键词：螺旋输送机；抱死；疏通
1 引言
海瑞克盾构机配置的螺旋输送机的叶片为有轴式叶片，能把渣土从盾构机土仓底部运动到皮带输送机进料端，比配置无轴式叶片的螺旋输送机更能控制喷涌。但当螺栓输送机堵塞时，疏通就有很大的难度。
2 工程概况
海瑞克S436盾构机正在进行深圳地铁二号线2202标科沙区间左线的盾构施工任务。在处理地质问题时进行土仓填充砂浆，但因经验不足，导致砂浆存留在螺旋输送机里面并凝固，使得螺旋输送机出料管与螺杆抱死，不能转动和伸缩，无法工作。为了恢复螺旋输送机功能，使其能正常工作，就必须对其进行疏通。
螺旋输送机是把碴土从盾构机土仓底部运送到皮带输送机进料端的装置，它安装在土仓壁的连接法兰上，与隔板到拖车沿中心线上的仰角为22°。螺旋输送机主要部件包括：
（1）安装法兰（焊接在仓壁上，伸往土仓的一段为可更换的耐磨管）
（2）出料管（出料管总长8215mm，内径950mm，壁厚30mm）
（3）螺杆（螺杆总长10100mm，外径900mm，螺距630mm，叶片厚度50mm，共有13.5个螺距，其中在从出料口往内第四个螺距处空余一螺距距离）
（4）驱动装置，包括：离合器座、离合器、带有行星齿轮的液压马达、卸料闸门。
（5）螺旋输送机出料管有八个R2”螺纹接头型的物料注射孔，利用已连管道可以注射泡沫和膨润土。
（6）螺旋输送机下部和中部分别有一个800mm×600mm的观察窗。
（7）螺旋输送机内径和轴径决定了能通过的碴土的最大尺寸为520 X 340mm，最大出土能力为430 m3/h，最大工作扭矩为200kNm。
（8）螺旋输送机出料口可用滑动闸门关上。滑动闸门靠液压油缸操纵，具备在停电时自动关闭的紧急功能。

作者简介：李剑祥，中铁六局集团有限公司
1

（9）螺旋输送机中部是两个160/90-1000wr的油缸，使其具有伸缩功能，伸缩距离为1000mm。详情见下图：

3 初步疏通措施与难点
在砂浆初凝期间，我们对其进行了清洗。通过两个观察窗，我们把底部每个观察窗附近的螺距清理干净，共4个螺距；然后拆除中部四个R2”螺纹接头型的物料注射管道清洗，因孔小，只清洗了很小的洞；最后从出料口往里清洗，因空间大，螺杆与内壁间隙大，人可以往里面钻一个螺距，所以在这里清洗了2个螺距。我们清洗的工具是高压清洗机和高压水枪，高压水枪的出口压力高达400bar，但是水枪长度达1000mm，只能利用外壁的孔洞往内清洗孔洞附近的砂浆，几乎就是孔洞在哪个螺距，那么只能清洗该螺距，叶片挡住了枪头，不能清洗其他螺距。
随着时间的推移，砂浆越来越硬，经高压水枪冲洗，可以验证砂浆硬度已经高达200bar。我们只清洗了6个螺距，还剩7.5个螺距。我们可以验算一下螺旋输送机此时的旋转阻力和伸缩阻力。
旋转阻力计算：砂浆填充了螺杆与出料管之间的缝隙，并将螺杆与出料管内壁粘结在一起，要使螺旋输送机旋转，必须破坏砂浆，那么沿缝隙一周处的砂浆剪切力就是旋转阻力。
为了使螺旋输送机的清洗工作继续，我们尝试了两个办法：一是使用更高压力的高压清洗机清理，二是请小个子工人钻进螺旋输送机里用手电钻清理。在使用更高压力的清洗机时，枪头的出口压力高达500bar，在用水枪把那些能看到的砂浆清理后，再往里清理只能取掉枪头，使用软管往里面清理，但是螺杆是螺旋叶片式，高压水管不能继续往里面清理。此方法是用一段时间之后，就不能再用。我们请过小个子工人，从出料口钻进螺旋输送机里清洗，当他往里进来2个螺距后，就再也进不去了，里面碰到伸缩内套，此段空间更加狭小；而且工作条件更加恶劣，人往里面钻了2个螺距，与外面的联系就很不方便，而且通风条件非常差，这样人在里面非常容易遇到危险，而且无法与外界联系。这样，该方法我们也取消使用。
在经过以上的方法尝试后，取得的效果不大，而且时间浪费严重，必须重新制定有效方案清洗螺旋输送机。
4 进一步的措施和步骤
如果要继续疏通螺旋输送机，那么只有一个螺距一个螺距的对砂浆进行清理了。目前可以肯定的是，在螺旋输送机的下半部出料管还有4个螺距，其中两个在螺杆的前端，另外两个在中观察孔到内套中间位置。螺杆前端两个螺距的砂浆可以从土仓里面进行清洗，当时工程实际具备这样的条件，因为刀盘正在换刀；中间两个螺距需要在出料管相应位置割孔，内套内的两个螺距和一个空螺距也需要割孔清理。我们制定了以下的措施；
（1）从土仓里面清理螺杆前端两个螺距的砂浆，第一个螺距使用风稿清理，第二个使用高压水枪通过缝隙进行清洗，要求把螺杆与出料管内壁缝隙处的砂浆清理干净。
（2）在中观察孔与内套之间位置对螺距进行定位，并割孔，在每个螺距的右侧割孔，再在两螺距中间的左侧割孔，这样可以通过三个孔，使用风稿和高压清洗机完全清理该处砂浆。
（3）分离出料管下半部分和内套，使出料管和螺杆整体与下部分裂开500mm距离，从该处可以对上半部分和下半部分露出来的螺距进行清理。
（4）在内套上割孔孔。其中靠近空螺距的螺距处割除的孔尺寸为400mm×300mm，小个子工人可以从这里进去，清理空螺距处的砂浆。另一个螺距也割除一孔进行清理。
（5）对割除的五个孔进行焊接恢复。对出料管下部分与内套裂缝进行恢复。
至此可以将剩下7.5个螺距和一个空螺距的砂浆清理干净。但是要实现上面四个步骤，都有相当的难度。我们是这样做的；
首先从土仓里面对螺杆前端清理时，正是盾构工区组织刀盘换刀的时间，刚好让他们清理该处砂浆；
然后在中观察孔与内套之间使用气割割除两个孔。考虑到割孔会对出料管结构产生影响，但是又要利于清理，所以孔的尺寸定为直径200mm的圆孔。孔的位置在螺距处，不能定在叶片处，而且两个孔位于两螺距一侧，那另一孔必须在两孔中间另一侧，这样才能完全清理该处砂浆。
其次，分离出料管下部分和内套，并使其裂缝达到500mm左右，为的是清理该处砂浆和清理内套时产生的砂浆能从这里排出来。分离出料管下部分和内套，并使其裂缝达到500mm左右，我们必须先对出料管后部分进行加固。因为出料管后部分和驱动装置都是靠下部分与内套法兰连接紧固固定的，当他们与下部分分开后，后部分的重量就全部被螺杆承受力，为减轻螺杆的承重，在螺旋输送机后部分出土口位置与连接桥使用两个10吨葫芦拉接。我们先使用液压扳手拆除出料管下部分与内套连接法兰的螺栓，然后使用左右两边的伸缩油缸的缩功能，希望能拉开缝隙，但是没有裂开缝隙，所以考虑到加力，我们在内套的上下两处各加100吨的液压油缸进行加力，最终裂开了缝隙，并进行了清理。
其次是在内套上割孔。考虑到割孔与焊接恢复对内套产生的变形，会对内套与外套的配合，和内套与螺杆的配合产生影响，我们必须严格控制割孔和焊接时产生的变形。我们使用了电弧气刨进行割孔操作，使用了二氧化碳保护焊进行焊接操作，有效的控制了内变形。
最后是恢复工作。对于内套上个两个孔，我们采用二氧化碳保护焊焊接。对于出料管上个三个孔，我们加工法兰焊接在孔上，并在法兰上加装盖板，使其具备观察孔的功能，弥补了盾构机螺旋输送机观察孔少和位置不好的缺陷。接下来的工作就是恢复出料管下部分与内套的裂缝。我们先使用伸缩油缸把内套缩回外套500mm，再在内套和出料管下部分之间焊接拉板使其固定，然后使用伸缩油缸把出料管后部分往回拉，再割除拉板，最后使用伸缩油缸把内套拉回至出料管下部分法兰位置。做到这步，出现了问题，内套法兰与出料管下部分法兰错位，我们采取的措施是使用钢丝绳，一端固定在内套上，一段固定在并装机夹持头上，利用拼装机的红蓝油缸移动，使内套法兰与出料管下部分法兰对位。
至此工作全部完成，我们转动螺旋输送机时，螺旋输送机液压泵的工作压力为20bar ，伸缩螺杆时，一切正常。这两项操作说明，经过疏通，螺旋输送机的旋转出土功能和伸缩功能已完全恢复。
5 总结与思考
经过对螺旋输送机的疏通，使我们对螺旋输送机的性能有了更加充分的认识，同时也认识到了HRK盾构机配置的螺旋输送机的功能不足之处。比如螺旋输送机出料管的观察孔少，而且位置也不好，特别是后部分，没有观察孔，当类似砂浆填充到出料管的情况发生时，我们没有孔洞进行清理。螺旋输送机的前仓门关闭的力量小，要是在仓门位置有稍硬碴土，就会发生仓门关不了的情况。经过这次清理，我们在出料管下部分留下来三个直径200mm的观察孔。
同时，当盾构机开挖面的地质不好，需要超前注浆或者水平注浆时，避免发生砂浆填充螺旋送机的情况，我们可以采取一些保护措施，比如关闭前仓门，如果前仓门关不了，可以利用螺旋输送机出料管上的八个R2螺纹接头型的物料注射孔注射盾尾油脂等材料。
参考文献
[1]海瑞克.S436 S437技术说明，2008.
[2]成大先.机械设计手册[M].北京:化学工业出版社，2002.

Shield machine of screw conveyor, holding in death of the dredge method
Abstract: the screw conveyor discharge tube and the screw in the middle is filled with mortar, holding in death of the dredge method is introduced in detail, and when it comes to dredge
Summarized the problems and solutions of now, provide reference experience for future similar problem.
Keywords: screw; conveyor; lock open
1.the introduction
Herrenknecht shield machine configuration of screw conveyor of the leaf blade for axis, can the residue from the soil at the bottom of the chamber of shield machine motion to the belt conveyor feed side, than configuration without shaft blade screw conveyor can control Wells. But when bolt conveyor jams, dredge will have great difficulty.
2.project summary
Herrenknecht S436 shield machine is on shenzhen metro line 2, 2202 the task division between the left line of shield construction in sandy. In processing geological problems when the soil bin filled with mortar, but due to the inadequate experience, lead to mortar remaining inside the screw conveyor and solidified, made with screw lock screw conveyor discharge tube, not rotation and scaling, losing itself functions. In order to restore the function of screw conveyor, presently to unblock it.
Screw conveyor is to put the holes in the soil from the soil of shield machine to the warehouse to the belt conveyor feed at the bottom of the device, it is installed on the connecting flange of the soil bin wall, and the diaphragm to the trailer the elevation along the center line for 23 °. Screw conveyor main components include:
(1) install the flange (welding in the warehouse walls and stretched into the soil for the period of replaceable wear tube)
(2) the discharge tube ('s discharging pipe is 8215 mm, inner diameter is 950 mm, thickness of 30 mm)
(3) the screw (screw length 10100 mm, outside diameter is 10100 mm, pitch of 630 mm, 50 mm blade thickness, a total of 13.5 pitch, which from the discharging mouth to spare her fourth pitch within a pitch distance)
(4) drive, including: clutch, clutch, hydraulic motor with planet gear, discharging gate.
(5) there are eight R2 "screw conveyor discharge tube nipple material injection hole, has even pipe can be used to injection foam and bentonite.
(6) lower part of screw conveyor and central respectively has a 800 mm x 600 mm observation window.
Screw conveyor diameter and the diameter of axle (7) can determine the through holes in the soil of the biggest size is 520 X 340 mm, unearthed in the maximum capacity of 430 m3 / h, maximum torque of 200 KNM.
(8) screw conveyor discharge mouth sliding gate is closed. Slide gate by manipulation of the hydraulic oil cylinder, has shut down automatically during blackout emergency function.
(9) central screw conveyor are two 160/90-1000 - wr oil cylinder, has the scaling, telescopic distance is 1000 mm. See below for details:
3.preliminary measures and difficulty
In the slurry during the initial setting, we have to clean. Through two observation window, we see at the bottom of each window near the pitch is clean, a total of four pitch; Then removed four R2 "central nipple material injection pipe cleaning, because of small hole, cleaning only a very small hole; the last cleaning from the discharging mouth, because the space is large, the screw and the internal clearance is big, people can go to drill a pitch inside, so wash the two pitch here. Our cleaning tool is high pressure cleaner and water cannons, the outlet pressure of high pressure water gun up to 400 bar, but the nozzle length is 1000 mm, can only be used within the outer wall of the hole to cleaning hole near the mortar, which is almost a hole in the pitch, you can only wash the pitch, blade blocking the spear, not clean the other pitch.
With the passage of time, the mortar has become more and more hard, by the high-pressure spray on them, can be used for verify hardness has up to 200 bar. We only clean the six pitch, with 7.5 a pitch. We can check the rotation of the screw conveyor at this point resistance and slip resistance.
Rotational resistance calculation: mortar filling of the screw and the gaps between the discharge tube, and screw and discharge tube wall bonded together, to make the screw conveyor, must destroy mortar, so the gap week shear force is rotating resistance of mortar,
One for mortar preventing screw rotating shear force;
The allowable shear stress of cement mortar, general half as much as that of the compressive stress of cement mortar bar;
For residue slurry discharge pipe length, length of 7.5 a pitch;
For discharging tube radius.
In order to make the work of cleaning the screw conveyor to continue, we tried two ways: one is the use of higher pressure of high pressure cleaning machine to clean up, second is little workers hand electric drill in drilling screw conveyor, please clean up. In the use of higher pressure cleaning machine, point the outlet pressure of up to 500 bar, those who can see the mortar with the nozzle after cleaning, clean up can only take the spear in that, using a hose to clean up, but the screw is spiral vane, high pressure pipe can not continue to clean up. This method is to use after a period of time, can no longer use. We have please little workers, cleaning from the discharging mouth drilling screw conveyor, when he went to two in pitch, never into not to go, met telescopic inner sleeve inside, this period of space more narrow; And the working conditions worse, people to drill 2 pitch, contact with the outside is very inconvenient, and ventilation conditions are very poor, so people in there are very easy to encounter risks, and unable to make contact with the outside world. In this way, we also this method
After above method to try, the effect is not big, and the severe waste of time, have to make effective solution cleaning screw conveyor.
Three further measures and steps
If you want to continue to unclog the screw conveyor, so only a pitch a pitch for mortar to clean up. Now to be sure, in the screw conveyor of the lower discharge pipe is 4 pitch, two of which, in the front of the screw, the other two in the middle of the observation hole to the inner sleeve in place. Screw the front two pitch slurry can undertake cleaning warehouse inside in the soil, at that time, the engineering practice have such requirement, because the knife dish is tool change; Between two pitch need to cut hole in discharge tube corresponding position, both within the set of the pitch and an empty pitch need to cut hole cleaning.
4.We make such measures
(1) from the soil bin to clean up the screw inside the front two pitch of mortar, first pitch using wind clear version, the second use of water cannons cleaning through the cracks, requested the screw and discharge tube wall cracks in mortar is clean.
(2) in the observation was carried out on the pitch between hole and inner sleeve position, and cut the hole, cut holes in each of the right side of the pitch, then cut in the middle of the two pitch on the left side of the hole, so that we can through three holes, using wind and pressure washer to clean up the place completely mortar.
(3) separation of discharging tube of the lower part and the inner sleeve, do feed tube and screw the whole and the parts cracked 500 mm distance from there to the upper part and lower part exposed to pitch to clean up.
(4) sets of cut only electives. Which near the empty pitch pitch cut out hole size is 400 mm * 300 mm, and the little workers can go in from here, to clean up empty pitch of mortar. Another pitch also cut out a hole to clean up.
Five (5) to cut out the hole for welding repair. Set of cracks within the discharge pipe and a portion of the recovery.
At this point can be 7.5 pitch and left an empty pitch slurry is clean. But in order to achieve the above four steps, there is quite difficult. We are doing this;
Clear storehouse in the face of the screw in the front end in the soil above all, it is shield work area organization knife tool change time, just let them clean up the place mortar;
And then in the observation hole and inner sleeve to use gas cutting cut out between two holes. Considering the cutting hole affect discharging tube structure, but also is conducive to clean up, so the size of the hole for the circular hole with a diameter of 200 mm. Hole position on the pitch, not set in the blade, and two holes located on the two side of the pitch, then another hole must be in the middle of the two holes on the other side, in order to fully clean up in the mortar.
Secondly, separation of discharging pipe and a portion of the inner sleeve, and the fracture of 500 mm or so, in order to clean up the slurry and clean the inner sleeve there mortar can come out from here. Separate discharge pipe and a portion of the inner sleeve, and the fracture of 500 mm or so, we must first part after the discharge tube for reinforcement. Because after discharging tube parts and driving devices are lower and the fastening flange connection within fixed, when after they separated from next part, the weight of the part after all be screw tolerance, to reduce the screw bearing, unearthed some locations and the connection after the screw conveyer bridge using two 10 tons of gourd pulled through. First we use hydraulic wrench removed discharging tube with a portion of the inner sleeve connecting flange bolt, and then use the diastolic function of left and right sides of the telescopic oil cylinder, hopes to open cracks, but there is no crack aperture, so considering the strength, we set, and two put 100 tons of hydraulic oil cylinder for strength, eventually cracked gap, and cleaning up.
Again is, set cut hole. Considering the deformation of the cut hole and weld repaired internally set to produce, can coordinate internally set and coat, and inner sleeve and the screw to cooperate, we must strictly control the cut hole and the deformation occurring during welding. We use the cut hole arc gouging for operation, using the carbon dioxide protection welding for welding operation, good in deformation control.
The last is to return to work. For the set within the last two holes, we adopts carbon dioxide protection welding. For discharging tube last three holes, we are processing the flange welded on the hole, and mounted on the flange cover plate, make its have the function of the hole, make up the shield construction machine screw conveyor observation hole less bad and location of defects. The next job is to restore discharging tube with a portion of the inner sleeve of the cracks. We use telescopic oil cylinder within the first 500 mm set back coat, set again, and the discharge pipe between a portion of the welded plate so that it is fixed, and then use the telescopic oil cylinder pull back after discharging tube part, cutting board, again using a t