行星齒輪減速器、回轉(zhuǎn)支承在盾構(gòu)掘進機中的應(yīng)用及維護保養(yǎng)上海市機械工程學會

趙治軍日期：10/15/2019一、盾構(gòu)掘進機簡介盾構(gòu)機始于英國，發(fā)展于日本、德國，盾構(gòu)、大直徑頂管掘進機是專門用于開挖地下隧道工程的技術(shù)密集型重大工程裝備。隨著地下空間的開發(fā)、利用，常用的鉆爆法在掘進速度、工程質(zhì)量、安全可靠、環(huán)境保護等方面已顯得落后，盾構(gòu)法施工隧道已經(jīng)運用到了各國的城市建設(shè)及其它地下工程施工中，如越江跨海隧道、煤礦巷道等，因此盾構(gòu)、大直徑頂管掘進機需求量會不斷加大。二、中國盾構(gòu)、大直徑頂管掘進機整體概況在中國盾構(gòu)、大直徑頂管掘進機市場上國外掘進機的占有率曾經(jīng)高達95%以上，目前盾構(gòu)、大直徑頂管掘進機中國市場保有量約600臺，近年來，國產(chǎn)盾構(gòu)、大直徑頂管掘進機有了長足的發(fā)展，有些品牌已經(jīng)可以與國際品牌抗衡，目前我國國產(chǎn)盾構(gòu)掘進機市場（新建造部分）占有率達60%。三、盾構(gòu)掘進機國產(chǎn)化現(xiàn)狀■■為了增強與國際品牌盾構(gòu)掘進機的競爭能力，中國盾構(gòu)機制造廠家必須制造出符合中國國情的產(chǎn)品，這是我國施工裝備領(lǐng)域不可回避的重要課題。目前盾構(gòu)機國產(chǎn)化接近80%，國產(chǎn)化盾構(gòu)掘進機的核心部分：刀盤驅(qū)動回轉(zhuǎn)支承、刀盤驅(qū)動減速器、關(guān)鍵液壓件及電氣等元部件仍依靠進口產(chǎn)品。四、盾構(gòu)掘進機國內(nèi)主要生產(chǎn)廠家

目前國內(nèi)盾構(gòu)機生產(chǎn)廠家主要有：中鐵裝備（河南）、中鐵重工（湖南）、海瑞

克（廣州、大連）、上海隧道、小松中國、石川島（常熟、無錫）、三菱重工（武漢

天地）、法麥特（遼寧沈陽北方重工）、卡特彼勒（遼寧遼陽）、秦皇島天業(yè)通聯(lián)（日立電機）、川崎重工（杭鍋、青島）、羅賓斯（武漢）、奧村（上海力行）等大

約16家。年生產(chǎn)量約100臺，每臺盾構(gòu)掘

進機配備行星齒輪減速器8~10臺。五、盾構(gòu)掘進機外觀照片六、盾構(gòu)掘進機刀盤驅(qū)動單元六、盾構(gòu)掘進機刀盤驅(qū)動單元七、盾構(gòu)掘進機刀盤驅(qū)動單元驅(qū)動單元組成：1、齒輪減速器+馬達（電動機或液壓）+回轉(zhuǎn)支承；2、低速大轉(zhuǎn)矩液壓馬達+回轉(zhuǎn)支承。八、盾構(gòu)機用行星齒輪減速器的特點

1、行星減速器體積小、重量輕，適合于盾構(gòu)機的總體布置；2、承載能力大，效率高；

3、運轉(zhuǎn)平穩(wěn)，噪聲低，可靠性高，使用壽命長。九、刀盤驅(qū)動減速器應(yīng)用現(xiàn)狀■■由于行星減速器具有以上優(yōu)點，盾構(gòu)機刀盤驅(qū)動通常采用該類齒輪減速器，作為盾構(gòu)掘進機的關(guān)鍵部件之一，其性能好壞直接影響盾構(gòu)機核心部件回轉(zhuǎn)支承與切削刀盤的工作性能。該類減速器目前以日本、德國、法國產(chǎn)為主，目前90%以上依靠進口產(chǎn)品。隨

著我國齒輪制造與研發(fā)水平的提升，已具

備該類減速器的研制能力，為降低整機成

本，目前“盾構(gòu)掘進機主驅(qū)動行星齒輪減

速器國產(chǎn)化研制”已被多家廠家提上日程。十、驅(qū)動減速器及回轉(zhuǎn)支承研制的經(jīng)濟性■雖然目前制造業(yè)市場較為低迷，但盾構(gòu)掘進機仍屬于較好行業(yè)，根據(jù)國家發(fā)改委規(guī)劃，預計該行業(yè)能持續(xù)發(fā)展到2025年，隨著市場競爭加劇，盾構(gòu)掘進機用行星齒輪減速器及回轉(zhuǎn)支承國產(chǎn)化是大勢所趨，國內(nèi)年市場需求量約120臺套，年潛市場約2.5億元，利潤5000萬元。建議專業(yè)廠家應(yīng)針對國內(nèi)高端客戶如：中鐵裝備、中鐵重工等進行配套研制。十一、刀盤驅(qū)動裝置的維護保養(yǎng)

上世紀八十年代后期上海就已引進盾構(gòu)掘進機，2004年以來我國更是大批量建造了（863盾構(gòu)掘進機為首）及引進了近600臺盾

構(gòu)掘進機，目前大多數(shù)盾構(gòu)掘進機進入服役后期，部分設(shè)備帶病工作，亟需維護保養(yǎng)，該行業(yè)除了可進行國產(chǎn)化研制外，年總需求維護行星減速器量約1000臺左右，回轉(zhuǎn)支承維護保

養(yǎng)約100套，潛在的市場同樣比較客觀。優(yōu)化設(shè)備壽命周期成本■■■■更長的服務(wù)壽命縮短交貨周期比新驅(qū)動更便宜的價格客戶定制產(chǎn)品節(jié)約能源，減少消耗節(jié)能環(huán)保節(jié)能&節(jié)約材料對環(huán)境和可持續(xù)的貢獻為什么要維護保養(yǎng)、修復驅(qū)動裝置?盾構(gòu)掘進機驅(qū)動裝置進入服役后期盾構(gòu)驅(qū)動裝置維護保養(yǎng)及修復在今天已成為客戶亟需的服務(wù)誰是一站式服務(wù)的合作伙伴？齒輪減速器維護保養(yǎng)及修復內(nèi)容1、檢查所有齒輪及傳動零部件；2、更換所有密封件及接近預期壽命軸承；3、損壞齒輪及軸更換。4、空載試驗后進行加載試驗；5、空載及加載試驗達到出廠要求后進行外觀處理。行星齒輪減速器維護保養(yǎng)實例保養(yǎng)前保養(yǎng)后行星齒輪減速器維護保養(yǎng)實例保養(yǎng)前行星齒輪減速器維護保養(yǎng)實例保養(yǎng)前保養(yǎng)后部分行星齒輪減速器損壞實例部分行星齒輪減速器損壞實例驅(qū)動減速器維保后加載試驗Section

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