CUTTER ASSEMBLY WITH INLINE MOUNTING

Abstract

An inline mounting assembly for a TBM cutter assembly includes first and second housing mounts, having upper and lower ear portions, and an inline channel sized to receive an end of the cutter assembly. The housing mounts include a first guide and a second guide defining forward and rearward abutment faces. A wedge assembly includes a bolt that extends through the first guide and engages a wedge configured to clamp the cutter shaft to the housing mount. A back support assembly includes a clamp block that abuts the rearward abutment face, a bridge block that abuts the forward abutment face, and a bolt that extends through the blocks. The bridge block abuts the shaft to provide support.

Claims

1. An inline mounting assembly for mounting a cutter disc assembly onto a tunnel boring machine, the mounting assembly comprising a first mounting subassembly and a second mounting subassembly that is similar to the first mounting subassembly, wherein the first mounting subassembly comprises: a housing mount having a body portion and a front end with inwardly extending first and second ears, the housing mount having a channel extending from a back end of the housing mount to the front end, a first guide disposed on one side of the channel, and a second guide disposed on the other side of the channel, wherein the first guide and the second guide define a back abutment surface and a front abutment surface; a wedge assembly comprising a first elongate attachment member that extends through an aperture in the first guide and a wedge that engages a distal end of the first elongate attachment member; a back support assembly comprising a clamp block that abuts the back abutment surface, a bridge block that abuts the front abutment surface, and a second elongate attachment member that extends through an aperture in the clamp block and an aligned aperture in the bridge block; wherein a front end of the bridge block is configured to abut a shaft of the cutter disc assembly, and the wedge is configured to slideably engage the first ear of the housing and to slideably engage the shaft such that the shaft is clamped between the wedge and the second ear of the housing mount.

2. The mounting assembly of claim 1, wherein the second mounting subassembly is substantially identical to the first mounting subassembly in mirror image.

3. The mounting assembly of claim 1, wherein the first elongate member comprises a first bolt, and the first bolt threadably engages the wedge and is configured to apply an adjustable rearward force on the wedge.

4. The mounting assembly of claim 1, wherein the first guide comprises a substantially uniform rectangular protrusion.

5. The mounting assembly of claim 1, wherein a back end of the first guide defines a first recess and a back end of the second guide defines a second recess, wherein the first and second recesses are configured to cooperatively receive the clamp block.

6. The mounting assembly of claim 1, wherein the bridge block comprises a relatively wide back face that abuts the front abutment surface and a relatively narrow front face that is configured to abut the shaft.

7. The mounting assembly of claim 1, wherein the second elongate attachment member comprises a bolt.

8. The mounting assembly of claim 7, wherein the bolt is configured to threadably engage the shaft of the cutter disc assembly.

9. The mounting assembly of claim 1, wherein the housing mount is formed as a single-piece unitary mount.

10. The mounting assembly of claim 1, wherein at least one of the first guide and the second guide are removably attached to the body portion of the housing mount.

11. The mounting assembly of claim 1, wherein the second elongate attachment member is configured to threadably engage the shaft of the cutter assembly and to preload the shaft of the cutter assembly against the bridge block.

12. A cutter assembly and inline mount for a tunnel boring machine comprising: a cutter assembly comprising a shaft and a cutter ring disposed on a hub that is rotatably mounted to the shaft; an inline mounting assembly for mounting the cutter assembly onto the tunnel boring machine, the mounting assembly comprising a first mounting subassembly and a second mounting subassembly that is similar to the first mounting subassembly, wherein the first mounting subassembly comprises: a mounting plate having a body portion and a front end with inwardly extending first and second shaft supporting portions, the mounting plate having a channel extending from a back end of the mounting plate to the front end and sized to receive an end of the shaft, a first guide disposed on one side of the channel, and a second guide disposed on the other side of the channel, wherein the first guide and the second guide cooperatively define a back abutment surface and a front abutment surface; a wedge assembly comprising a first elongate attachment member that extends through an aperture in the first guide and a wedge that engages a distal end of the first elongate attachment member; a back support assembly comprising a clamp block that abuts the back abutment surface, a bridge block that abuts the front abutment surface, and a second elongate attachment member that extends through an aperture in the clamp block and an aperture in the bridge block; wherein a front end of the bridge block is configured to abut the shaft, and wherein the wedge is configured to slideably engage the first inwardly extending shaft supporting portion, and to slideably engage the shaft such that the shaft is clamped between the wedge and the second inwardly extending shaft supporting portion of the mounting plate.

13. The cutter assembly and inline mount of claim 12, wherein the second mounting subassembly is substantially identical to the first mounting subassembly in mirror image.

14. The cutter assembly and inline mount of claim 12, wherein the first elongate member comprises a first bolt, and the first bolt threadably engages the wedge and is configured to apply an adjustable rearward force on the wedge.

15. The cutter assembly and inline mount of claim 12, wherein the first guide comprises a substantially uniform rectangular protrusion.

16. The cutter assembly and inline mount of claim 12, wherein a back end of the first guide defines a first recess and a back end of the second guide defines a second recess, wherein the first and second recesses are configured to cooperatively receive the clamp block.

17. The cutter assembly and inline mount of claim 12, wherein the bridge block comprises a relatively wide back face that abuts the front abutment surface and a relatively narrow front face that is configured to abut the shaft.

18. The cutter assembly and inline mount of claim 12, wherein the second elongate attachment member comprises a bolt.

19. The cutter assembly and inline mount of claim 18, wherein the bolt is configured to threadably engage the shaft of the cutter disc assembly.

20. The cutter assembly and inline mount of claim 12, wherein the mounting plate is formed as a single-piece unitary mount.

21. The cutter assembly and inline mount of claim 12, wherein at least one of the first guide and the second guide are removably attached to the body portion of the mounting plate.

Description

DESCRIPTION OF THE DRAWINGS

[0037] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0038] FIG. 1 is a perspective, partially exploded view of a prior art cutter assembly and mounting system;

[0039] FIG. 2 is a perspective view of a cutter assembly mounted in a cutter attachment and housing assembly, in accordance with the present invention;

[0040] FIG. 3 is a perspective view of the left housing mount shown in FIG. 2, with the wedge assembly installed, wherein the right housing mount and related components are omitted for clarity;

[0041] FIG. 4 is a perspective view of the left housing mount shown in FIG. 2, with the cutter assembly shaft inserted, wherein the body of the cutter assembly is omitted for clarity;

[0042] FIG. 5 is a perspective view of the left housing mount shown in FIG. 2, with the back support assembly also shown installed; and

[0043] FIG. 6 is a partially exploded view illustrating insertion of the cutter ring assembly into the housing assembly shown in FIG. 2.

DETAILED DESCRIPTION

[0044] A TBM cutter attachment and housing assembly in accordance with the present invention overcomes the disadvantages described above. An exemplary embodiment of the cutter attachment and housing assembly 100 is shown in a right-rear perspective view in FIG. 2, with a cutter assembly 115 installed. In this embodiment, a pair of housing mounts 120, which are configured to be attached to the main cutterhead assembly (not shown), are each provided with a wedge assembly 130 and a back support assembly 140. The wedge assembly 130 and back support assembly 140 cooperate to secure the cutter assembly 115 in the housing 120 such that the cutter assembly 115 is rotatable on a shaft 117 (see FIG. 3), with a portion of the cutter assembly 115 extending forwardly from the housing 120. Importantly, the shaft 117 is inserted along a straight-line channel 123 without requiring any shift away from the channel, and is supported inline.

[0045] FIG. 3 shows the left housing mount 120 with the wedge assembly 130 installed to the mount 120. In order to show other aspects of the assembly, the right housing mount 120 and other components are not shown. Refer also to FIG. 6, which shows an exploded view of one side of the housing assembly 100.

[0046] In a current embodiment the right housing mount 120 is substantially similar in mirror symmetry to the left housing mount 120. In some embodiments there may be advantages or reasons for various differences between the left and right housing mounts and related components, for example, to accommodate mounting on a particular cutterwheel design or to simplify the assembly. The housing mount 120 includes upper and lower protrusions or ears 121 that extend inwardly from the body of the housing mount 120. The ears 121 reduce the exposed cutter opening, serve to spread the wedge and cutter tangential loads to the cutterhead structure, and provide surfaces for reacting clamping forces supporting and securing the cutter assembly shaft 117.

[0047] The housing mount 120 includes a bolt guide 122 as shown in FIG. 3 having a through-hole 137 configured to slideably receive an attachment member, for example, a bolt 131 for the wedge assembly 130. The bolt 131 extends through the through-hole 137 in the bolt guide 122 and engages a wedge 132. For example, the wedge 132 may be threadably attached to the bolt 131. An upper face 133 of the wedge 132 is configured to slideably engage a lower face of the associated ear 121 of the housing mount 120. An angled lower face 134 is configured to slideably engage a corresponding face of the shaft 117 end (FIG. 6).

[0048] FIG. 4 shows the subassembly of FIG. 3, with the cutter assembly shaft 117 positioned to engage the wedge 132. It will be appreciated that as the bolt 132 is tightened the wedge is pulled rearwardly by the bolt 132. Therefore, the cutter assembly shaft 117 is clampingly engaged between the wedge 132 and the lower ear portion 121 of the housing 120 to secure the cutter assembly 115 in the housing. The wedge 132, which engages a face on the shaft 117, is angled such that tightening the bolt 132 also causes the wedge 132 to also apply a rearward force on the shaft 117 end. The opposite end of the shaft 117 is similarly clamped by the other housing mount 120.

[0049] The housing mount 120 in this embodiment further defines a channel 123 that extends along the length of the housing mount 120. The channel 123 is sized to receive an end of the cutter assembly shaft 117. The left and right housing mounts 120 will therefore receive opposite ends of the shaft 117, allowing the cutter assembly to be positioned in the mount by sliding the cutter assembly from the back end of the mounts 120 to the front end. The corresponding wedges 132 may be prepositioned to prevent the cutter assembly 115 from traveling too far along the channel 123.

[0050] Referring still to FIGS. 3 and 4, the housing mounts 120 (one shown) further include a second guide or abutment member 124 that is generally parallel to, and spaced apart from, the bolt guide 122. The second guide 124 is located on the opposite side of the channel 123 as the bolt guide 122. The bolt guide 122 and the second guide 124 each include corresponding recesses 125 at the back end of the housing mount 120. The recesses 125 are sized and positioned to cooperatively receive and abut a clamp block 142 as shown in FIG. 5, and discussed below.

[0051] The bolt guide 122 and the second guide 124 extend only part way towards a front end of the housing mount 120, thereby cooperatively defining a gap 126, for the back support assembly 140.

[0052] FIG. 5 is similar to FIG. 4, with the back support assembly 140 also installed in the housing mount 120. Refer also to the exploded view in FIG. 6. The back support assembly 140 includes an attachment member, for example, a bolt 141 that extends through the clamp block 142 and to or through a bridge block 143. In this embodiment the bolt 141 threadably engages the cutter assembly shaft 117 through the threaded aperture 118. Other attachment mechanisms may alternatively be used. In an alternative embodiment the bolt 141 is configured to attach directly to the bridge block 143, and the bridge block 143 abuts the shaft 117. The clamp block 142 is sized to engage and abut the recesses 125 in the bolt guide 122 and the second guide 124, as discussed above.

[0053] The bridge block 143 abuts forward ends of the bolt guide 122 and the second guide 124. The bridge block 143 may be suitably positioned by sliding the bridge block 143 through the gap 126 between the second guide 124 and the lower ear portion 121 (e.g., moving upwardly in FIG. 6), before inserting the bolt 141. The bridge block 143 therefore bridges the ends of the bolt guide 122 and the second guide 124 nearest the shaft 117.

[0054] Tightening the bolt 141 to a design torque securely seats the cutter assembly shaft 117 against the bridge block 143. The wedge assembly bolt 131 is tightened to secure the cutter assembly 115 in the housing mounts 120. The wedge assembly 130 securely clamps the shaft 117 between the wedge 132 and the upper face of the lower ear portion 121 of the housing mount 120.

[0055] In contrast to prior art cutter assembly mounting assemblies, the cutter assembly 115 is mounted inline, slideably inserting the ends of the cutter assembly shaft 117 into the opposed channels 123 of the housing mounts 120, and sliding the cutter assembly 115 forward, without requiring the wedge drop-down or lateral shift discussed above. Thus the wedge 132 may be optimized for providing the maintaining lateral clamping of the cutter assembly 115 via the mechanical advantage provided by the wedge.

[0056] The disclosed system 100 simplifies mounting and removing cutter assemblies 115 from the cutterhead.

[0057] For example, in some instances to install the cutter assembly 115 the left and right wedge assemblies 130 are installed and the cutter assembly 115 is then positioned to slideably engage the opposed channels 123 from the back and slide forward until the shaft 117 ends engage the wedges 132. For each housing mount 120 the clamp block 142 is positioned in the recesses 125, the bridge block 143 is inserted through the gap 126 between the shaft 117 and the bolt guide 122 second guide 124, and the second bolt 141 is inserted through both blocks 142, 143 and threadably engages the corresponding aperture 118 in the shaft 117. In embodiments wherein the second bolt 141 threadably engages the shaft 117, tightening the second bolt 141 preloads the shaft 117 securely against the bridge block 143.

[0058] Tightening the second bolt to a first design torque secures the shaft 117 to the bridge block 143, and tightening the bolt 131 secures the shaft 117 laterally in the housing mount 120. In some cases the cutter assembly 117 may alternatively be positioned in the channels 123 from the front end of the housing mounts 120, prior to installing the wedge assemblies 130, and the wedge assembly 130 and back support assembly 140 installed in situ.

[0059] Removal of the cutter assembly 117, for example, for replacement or maintenance in the field, is simplified because the cutter assembly 115 does not have to be shifted laterally to be in a position for removal. After removal of the back support assembly 140 and loosening the wedge assembly 130, the cutter assembly 115 may be simply pulled rearwardly along the channels 123.

[0060] In the disclosed inline loading system, the cutter assembly 115 slides directly into the mounted position. The bridge block 143 is located directly behind the cutter assembly shaft 117, which is clamped initially against the bridge block 143 to fully position the cutter assembly 115. The wedge 132 is then drawn into position to lock the cutter assembly 115 in place. In prior art systems the position of the cutter in the housing is not established prior to the wedge being engaged, and the cutter assembly change personnel cannot see if the housing seats are cleaned properly or even see if the cutter is positioned properly.

[0061] The housing assemblies such as the housing assembly 100 of FIG. 2 may also be smaller than conventional housing systems (for example, the prior art system shown in FIG. 1) because the housing mounts use an inline mounting channel, and do not require prior art L-shaped channels 21.

[0062] Although the bolt guide 122 and the abutment guide 124 in the current embodiment are generally rectangular and unitary protrusions from the body portion of the housing mount 120, it is contemplated that these members may be formed as multiple short protrusions. For example, the bolt guide 122 may be formed as two or more aligned lugs, for example, a first lug located at or near a back end of the housing mount 120 and providing an abutment for the clamp block 142, and a second lug located at or near the front end of the bolt guide 122 shown in FIG. 3, providing an abutment for the bridge block 143.

[0063] Although in the currently current embodiment shown in FIG. 2 each of the housing mounts 120 are formed as an unitary construction, it is contemplated that the housing mounts 120 may alternatively be formed as an assembly or modularly, to improve maintainability of the assembly 100, and/or to improve manufacturability. In particular, in another embodiment the first and second guides 122, 124 may be formed as separable portions of the housing mount 120. The guides 122, 124 experience higher cyclical loadings than other portions of the housing mount 120, and therefore may be more susceptible to damage. It is contemplated that the first guide 122 and/or the second guide 124 may be formed separately, and assembled to the back portion to form the housing mount 120, for example with bolts or other attachment means as are known in the art. In an exemplary embodiment the back plate portion of the housing mount 120 includes recesses for slideably receiving and securing such modular guides 122, 124. An assembled housing mount 120 would facilitate repair and/or maintenance of the assembly 100, allowing users to replace the guides 122, 124 if they become worn or damaged without removing the entire mount 120 from the cutterwheel. Separable guides 122, 124 would also allow the guides 122, 124 to be formed from a different material than the rest of the housing mount 120. Separable guides 122, 124 would also allow the assembly 100 to be customized or modified, for example to accommodate different cutter assemblies 115.

[0064] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.