Design and Applications of Disc Cutter Changing Robots for Shield Machines

doi:10.3969/j.issn.1004-132X.2026.05.003

Abstract

Abstract:

To address the problems of high labor intensity， high operational risk， and low operational efficiency in manual disc cutter changing during shield tunneling machine construction， a changing operation plan using robot instead of humans was proposed. A new type of tool system suitable for robot operation and a high-power density redundant degree of freedom robot mechanisms were designed.The D-H parameter method was used for kinematic modeling， the robot pose calculation was achieved. The rapidly-exploring random tree（RRT） algorithm was used for robot tool change path planning， the obstacle avoidance path calculation was achieved during the motion processes. Based on the B-spline curves， the robot joint motion trajectory calculation was achieved. A simulation analysis platform was built for robot tool changing， and the effectiveness of the proposed solution was verified. Finally， a tool changing robot test bench was built， and a tool changing robot control system was constructed based on the operation layer， control layer， and execution layer. The feasibility of the tool changing robot system design scheme was verified through parameter calibration， laboratory and engineering testing.

Key words: shield machine, disc cutter changing robot, structure design, simulation analysis

摘要：

针对盾构机施工过程中人工换刀劳动强度大、作业风险高、操作效率低等问题，提出了一种采用机器代人的换刀作业方案。设计了一种适于机器人操作的新型滚刀系统与高功率密度冗余自由度机器人机构；采用D-H参数法进行运动学建模，实现机器人位姿计算，通过快速扩展随机树（RRT）算法进行机器人换刀路径规划，实现运动过程避障路径计算，基于B样条曲线实现机器人关节运动轨迹计算；搭建了机器人换刀仿真分析平台，验证了所提方案的有效性；最后，搭建了换刀机器人试验台，构建了基于操作层、控制层、执行层的换刀机器人控制系统，通过参数标定、实验室和工程测试验证了换刀机器人系统设计方案的可行性。

关键词: 盾构机, 换刀机器人, 结构设计, 仿真分析

CLC Number:

TP24

JIANG Lijie, YANG Hang, HAN Dong, SUN Yanming, WANG Yixin, WU Qiankun, JIA Lianhui. Design and Applications of Disc Cutter Changing Robots for Shield Machines[J]. China Mechanical Engineering, 2026, 37(5): 1037-1044.

姜礼杰, 杨航, 韩冬, 孙颜明, 王一新, 吴乾坤, 贾连辉. 盾构换刀机器人设计与应用[J]. 中国机械工程, 2026, 37(5): 1037-1044.

Figures/Tables 22

Fig.1 Structural diagram of traditional disccutter system

Fig.2 Design diagram of new disc cutter system

Fig.3 Schematic diagram of the structure and disassembly steps of new disc cutter system

Fig.4 Installation and workspace extraction of disc cutter changing robot

Fig.5 Diagram of requirement analysis for robot disc cutter changing action

Fig.6 Schematic diagram of the final configuration of the disc cutter changing robot

Fig.7 Sketch of disc cutter changing robot

Fig.8 Link coordinate system of disc cutter changing robot

Fig.9 Flow chart of path planning algorithm

Fig.10 Simulation motion sequence diagram of disc cutter changing robot

Fig.11 Change in position coordinates of prismatic joints

Fig.12 Change in position coordinates of rotary joints

Fig.13 Prototype of disc cutter changing robot

Fig.14 Diagram of cutterhead movement

Fig.15 Disc cutter syster simulation test bench

Fig.16 Schematic diagram of disc cutter changing robot control system

Tab.1 Parameter table for prototype of disc cutter changing robot and cutter posture simulation test bench

序号	参数	数值
1	机器人臂展范围/m	0~3.5
2	机器人最大负载能力/kg	500
3	机器人自由度	8
4	模拟试验台自由度	5
5	可模拟刀盘直径/m	8~15
6	机器人存储空间截面尺寸/（m×m）	0.9×0.9

Fig.17 Parameter calibration of disc cutter changing robot

Fig.18 Motion Sequence diagram of the disc cutter changing robot during indoor experiment

Fig.19 Engineering assembly of the disc cutter changing robot

Fig.20 Schematic diagram of the tool changing area of the disc cutter changing robot

Fig.21 Disc cutter changing test of disc cutter changing robot in a real project

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