TECHNICAL FIELD
[0001] The present invention relates to a cutter head and a rock excavator provided therewith
suitable for excavating base rocks in free section to proceed excavating a mine gallery,
a tunnel, a shaft and the like.
BACKGROUND
[0002] As a rock excavator for excavating base rocks in free section to proceed excavating
a mine gallery, a tunnel and the like, there has been heretofore known a rock excavator
in which a cutter head having a plurality of bits arranged or a cutter head having
a plurality of roller cutters arranged is mounted on the extreme end of an excavating
boom.
[0003] As shown in FIG. 19, a rock excavator 201, on which is mounted the aforesaid cutter
head having the bits arranged, excavates by rotating a cutter head 202 while pressing
it against the base rock and crushing the base rock against the compression strength
of rocks by the bits. When the compression strength of the rocks increases, it is
difficult to excavate the base rock and the bits are severely worn out, resulting
in uneconomical.
[0004] Rock excavators 301 and 401, on which is mounted the aforesaid cutter head having
the roller cutters arranged, excavates by rotating cutter heads 302 and 402 while
pressing them against the base rocks and crushing the base rocks against the compression
strength of rocks by a disk roller cutter, a button roller cutter or the like as shown
in FIGS. 20 and 21, or excavates by cutting off, or so-called "undercutting," the
base rocks against the tensile strength of rocks by a disk roller cutter as shown
in FIGS. 22 and 23.
[0005] However, in the case where the base rocks are crushed by the disk roller cutter or
the button roller cutter, it is necessary to strengthen the pressure of the cutter
head against the base rock, thus requiring a machine of large size and great weight,
but the excavating ability is not so large as to correspond thereto, so that the efficiency
is poor.
[0006] Further, in the case where the base rocks are cut off by the disk roller cutter,
a relatively small pressure is used, the roller cutter is less worn out to make it
possible to carry out a large amount of cutting, and the base rocks in which the compression
strength of rocks is great can be excavated. As shown in FIG. 23, however, in the
vicinity of the point of the disk roller cutter in contact with the base rock, the
base rock is hard to be cut in deeply, so that leftover L is apt to occur in a curve-like
fashion along the force-exerting line.
[0007] Therefore, the disk roller cutter successively in contact with the base rock cannot
cut into the base rock sufficiently so that the disk roller cutter floats from the
base rock along the leftover-curve L, or the base rock is scrubbed by the disk roller
cutter to produce dust.
[0008] Further, portions except an edge of the disk roller cutter of the cutter head 402
come in contact with the base rock to impair cutting of the disk roller cutter into
the base rock, and sometimes, the whole cutter head 402 receives reaction from the
base rock to be pushed back, and greatly vibrates to make the cut-off difficult.
DISCLOSURE OF THE INVENTION
[0009] It is an object of the present invention to provide a cutter head and a rock excavator
on which is mounted the cutter head, wherein the base rock can be excavated easily
even if the compression strength of the rocks is great, the wear of the roller cutter
is relatively small, the roller cutter does not float from the base rock, the base
rock is not scrubbed to produce dust, the cutting of the roller cutter into the rock
is not impaired, and the whole cutter head is not pushed back from the base rock.
[0010] A cutter head according to the present invention is characterized in structure that
two kinds of disk roller cutters having different cutting lines with a direction of
a support shaft and a position of a disk edge differentiated are arranged on a cutter
head drum, and one is a disk roller cutter for undercut to cut off the base rock,
whereas the other is a disk roller cutter for scraper to crush the base rock.
[0011] In a preferred embodiment, the two kinds of disk roller cutters are arranged in many
rows front and rear, and in the vertical direction, in order to make the cut-in depth
of the base rock large, and in order that a plurality of disk roller cutters are placed
in contact with rocks to effectively cut into the base rock and cut the leftover Further,
the disk roller cutter may include a both-side-type disk roller cutter having disks
disposed on both sides so as not to occupy space in the arrangement of the disk roller
cutter. Further, for scraper a button roller cutter, a rotating-type round pick, a
fixed bit or a buried-type tip for cutting may be mounted in place of the disk roller
cutter for scraper. There may be equipped with a mucking vane in order to efficiently
remove the muck.
[0012] A rock excavator according to the present invention is characterized in structure
that the cutter head constituted as described above is mounted on an excavating boom.
[0013] In a preferred embodiment, a shaft of the cutter head constituted as described above
is mounted nearly parallel to a shaft of an excavating boom. Further, there is constituted
a road-header-type rock excavator wherein a shaft of the cutter head constituted as
described above is mounted nearly vertical to a shaft of an excavating boom. Further,
there is constituted a shovel-type rock excavator wherein the cutter head constituted
as mentioned above is mounted as an attachment. Furthermore, there is constituted
a surface-miner-type rock excavator wherein the cutter head constituted as mentioned
above is mounted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014]
FIG. 1 is a side sectional view of a cutter head according to the present invention.
FIG. 2 is a front view of the cutter head of FIG. 1.
FIG. 3 is an explanatory view showing a positional relation of disk roller cutters
in a state that the cutter head of FIG. 1 is rotated.
FIG. 4 is an explanatory view showing the function of a disk roller cutter for undercut
and a disk roller cutter for scraper.
FIG. 5 is an explanatory view showing the case where a disk roller cutter for undercut
and a disk roller cutter for scraper are arranged in many stages particularly in order
to make the cut-in depth great.
FIG. 6 is an explanatory view showing the case where, in the case that a cutting face
of the base rock has no free section, a cutter head is mounted so that a rotating
shaft thereof is nearly parallel to a boom, and particularly, a cutter head having
disk roller cutters arranged in many stages for back cutting is thrust into the base
rock for cutting.
FIG. 7 is an explanatory view showing, in the case shown in FIG. 6, a cutting track
by each roller cutter traced on the base rock.
FIG. 8 is an explanatory view showing the case where two cutter heads are mounted
so that their rotating shafts are nearly vertical to a boom, and the cutter head is
thrust into the base rock for cutting.
FIG. 9 shows one embodiment of a cutter head in which the cutter head is arranged
nearly parallel to a cutting face of the base rock, (A) being a front view of the
cutter head, and (B) being a side sectional view showing a positional relation of
a roller cutter.
FIG. 10 shows another embodiment of a cutter head in which the cutter head is arranged
nearly parallel to a cutting face of the base rock, (A) being a front view of the
cutter head, and (B) being a side sectional view showing a positional relation of
a roller cutter.
FIG. 11 shows one embodiment of a cutter head in which the cutter head is arranged
nearly vertical to a cutting face of the base rock, (A) being a front view of the
cutter head, and (B) being a side sectional view showing a positional relation of
a roller cutter.
FIG. 12 is a front view of another embodiment of a cutter head in which the cutter
head is arranged nearly vertical to a cutting face of the base rock.
FIG. 13 is a side view of a road-header-type rock excavator on which is mounted the
cutter head shown in FIG. 9.
FIG. 14 is a plan view of the rock excavator shown in FIG. 13.
FIG. 15 is a side view of a road-header-type rock excavator on which is mounted the
cutter head shown in FIG. 11.
FIG. 16 is a plan view of the rock excavator of FIG. 15.
FIG. 17 is an external view of a shovel-type rock excavator in which the cutter head
of FIG. 9 is mounted as an attachment.
FIG. 18 is a side view of a surface-miner-type rock excavator in which the cutter
head of FIG. 9 is mounted.
FIG. 19 is a side view of a rock excavator in which a cutter head having a bit arranged
is mounted.
FIG. 20 is a side view of a rock excavator in which the cutter head shown in FIG.
21 having a roller cutter arranged is mounted.
FIG. 21 is an explanatory view showing the case where the base rock is crushed by
a disk roller cutter.
FIG. 22 is a side view of a rock excavator in which the cutter head shown in FIG.
23 having a roller cutter arranged is mounted.
FIG. 23 is an explanatory view showing the case where the rock is cut off by a disk
roller cutter.
BEST MODE FOR CARRYING OUT THE INVENTION
[0015] FIG. 1 is a side sectional view of a curter head according to the present invention,
FIG. 2 is a front view thereof, and FIG. 3 is an explanatory view showing a positional
relation of each disk roller cutter in a state that the cutter head is rotated. As
seen in these drawings, two kinds of disk roller cutters having different cutting
lines with a direction of a support shaft and a position of a disk edge differentiated
are arranged on a cutter head drum.
[0016] In a cutter head 1, as shown in FIGS. 1 and 2, two kinds of disk roller cutters 3,
4 are arranged at predetermined spaces in a circumferential direction on a cutter
head drum 2 mounted on a excavating boom through a drive shaft, and the same kind
of disk roller cutters 3, 3, 3 and 4, 4, 4 are also arranged at predetermined spaces
in a circumferential direction.
[0017] Two kinds of the disk roller cutters 3, 4 are arranged with a direction of the support
shaft and a position of the disk edge differentiated, and one is a disk roller cutter
for undercut and the other is a disk roller cutter for scraper corresponding to a
moving direction of the cutter head 1, that is, a main cutting direction.
[0018] The support shafts of the disk roller cutters 3, 4 are that one is nearly parallel
to a rotating shaft of the cutter head 1 and the other is nearly vertical thereto.
Angles α 3 and α 4 formed between the support shafts of the disk roller cutters 3,
4 and the rotating shaft of the cutter head 1 can be suitably set so that the circular
plane portion of the disk roller cutter is hard to come in contact with the rock,
and a cutting angle of the disk roller cutter into the base rock is selected adjusting
to properties of the base rock or the pressure of the head against the base rock.
[0019] As shown in FIG. 3, where the cutter head 1 moves in the X direction along the cutting
face of the base rock I to cut a free section 5, the disk roller cutter 3 works as
a disk roller cutter for undercut, the disk roller cutter 4 works as a disk roller
cutter for scraper, X3 is a main base-rock cutting-line and X4 is a scraper cutting-line.
[0020] On the other hand, where the cutter head 1 moves in the Y direction along the cutting
face of the base rock I to cut a free section 6, the disk roller cutter 4 works as
a disk roller cutter for undercut, the disk roller cutter 3 works as a disk roller
cutter for scraper, Y4 is a main base-rock cutting-line and Y3 is a scraper cutting-line.
[0021] A positional relation in all directions of the edges of the disk roller cutters 3,
4 or the spacing of the cutting lines X3/X4, Y3/Y4 can be suitably set in consideration
of the properties of base rocks, the rotational frequency of the cutter head 1, the
turning speed of a excavating boom, and angles α 3, α 4 formed between the support
shafts of the disk roller cutters 3, 4 and the rotating shaft of the cutter head 1.
[0022] FIG. 4 is an explanatory view showing the function of a disk roller cutter for undercut
and a disk roller cutter for scraper. When the cutter head 1 moves in the X direction
while rotating, a disk roller cutter 3A for undercut first cuts in a free section
5 formed in the base rock I to cut it along a main base-rock-cutting-line X3, but
the free section 5 traces a crushing curve 7 which starts from the vicinity of a cutter
edge. At this time, a succeeding disk roller cutter for scraper is at a position of
4A0 in the X direction.
[0023] When the cutter head 1 further moves in the X direction while rotating, the succeeding
disk roller cutter for scraper comes to the position of 4A in the X direction to crush
the base rock along the scraper-cutting-line X4 to form a free section 8 having a
shape similar to the original free section 5.
[0024] Thereby, a succeeding disk roller cutter 3B for undercut deeply cuts in the free
section 8 similar to the preceding disk roller cutter 3A for undercut to cut it along
a main base-rock cutting-line X3. Thereafter, in the similar procedure, the base rock
I is cut by disk roller cutters for scraper 4B, 4C, 4D, ... and disk roller cutters
for undercut 3C, 3D,
[0025] FIG. 5 is an explanatory view showing one example where the disk roller cutters for
undercut and the disk roller cutters for scraper are arranged in many stages so that
a deep cut-in in the base rock I can be formed. When a cutter head 11 moves in the
X direction, the disk roller cutters for undercut 3, 13 cut the base rock along the
main base-rock-cutting-lines X3, X13, while forming two stages of the free sections
5, 15 in the base rock I. Further, the disk roller cutters for scraper 4, 14 crush
the base rock I along the scraper-cutting-lines X4, X14 to form free sections having
a shape similar to the original free sections 5, 15.
[0026] FIG. 6 is an explanatory view showing the case that, where there is no free section
in a cutting face of the base rock I, the disk roller cutters for undercut and the
disk roller cutters for scraper are arranged in many stages, and the cutter head is
thrust in the base rock I to cut it. The boom is extended or the rock excavator is
moved in the direction of the base rock I first, and a cutter head 21 is pressed against
the base rock to rotate. Then, the boom is turned in the X direction, and the cutter
head 21 is encroached into the base rock I to cut it.
[0027] At this time, a disk roller cutter for undercut 23 arranged on the front side in
the cutting direction cuts the base rock I along the main base-rock-cutting-line X23,
and a disk roller cutter for scraper 24 crushes the base rock I along the scraper-cutting-line
X24 to cut off a front cutting-face of base rock 25. Further, a disk roller cutter
for undercut 33 arranged at the rear in the cutting direction cuts the base rock I
along the main base-rock-cutting-line X33, and a disk roller cutter for scraper 34
crushes the base rock I along the scraper-cutting-line X34 to cut off a rock portion
sandwiched between the scraper-cutting-lines X24 and X33.
[0028] When the disk roller cutters 33, 34 are moved on the front side in the cutting direction
by the rotation of the cutter head 21, particularly a disk roller cutter 340 cuts
the base rock I along the cutting-line X340.
[0029] At this time, since the cutter head 21 turns in the X direction while the boom is
pressed in the direction of the rock I while rotating, as shown in FIG. 7, the disk
roller cutters 23, 24 and 33, 34 cut while tracing a cutting track of a plurality
of modification of cubic cycloid curves at the predetermined spaces on the base rock
I, in contact with rocks according to the rotational frequency of the cutter head
21, the turning speed of the boom and the pressing degree.
[0030] Here, it may happen that when the disk roller cutters 33, 34 on the rear side are
not present, portions except the edges of the disk roller cutters 23, 24, the cutter
body or the drum portion 21 of the cutter head come in contact with the base rock
I at the rear of the cutting line X24 to be pressed back. In order to avoid this,
the cutter head 21 has to be turn sideways to thrust into the base rock I by deviating
the turning center of the rock excavator or the boom, which is very inconvenient in
the excavating work.
[0031] Further, even if the cutting face is formed in the free section, the leftover of
the base rock I is sometimes produced due to vibrations of the machine, which can
be however cut off by the disk roller cutters 33, 34 on the back side (back cutting).
[0032] FIG. 8 is an explanatory view showing the case where two cutter heads 51, 52 are
mounted so that their rotating shafts are nearly vertical to the axis of the excavating
boom, and the cutter heads 51, 52 are thrust into the base rock I to cut it. Disk
roller cutters 56, 57 and 58, 59 on the excavating-boom side of the cutter heads 51,
52 perform the function similar to the function mentioned previously.
[0033] Further, in FIG. 8, when the cutter heads 51, 52 are thrust in the X direction to
cut, and on the contrary, cutting is intended in the Y direction, a difference-in-level
portion 53 of the base rock I formed between the cutter heads 51, 52 has to be cut
off. At this time, the disk roller cutter for undercut 56 and the disk roller cutter
for scraper 57 on the boom side of the cutter head 51 cut off the difference-in-level
portion 53 and the leftover. The disk roller cutter for undercut 58 and the disk roller
cutter for scraper 59 on the excavating-boom side of the cutter head 52 perform the
function similar to the former.
[0034] FIG. 9 shows one embodiment of a cutter head 61 having a cutter head nearly parallel
to the cutting face of the base rock arranged for cutting. The cutter head 61 moves
in the Y direction or in the direction opposite thereto while rotating to cut the
base rock I.
[0035] G1, G2 and G3 denote disk roller cutters for undercut on the front row in the cutting
direction arranged nearly at the same position with respect to the rotating shaft
of the cutter head 61; and N1, N2 and N3 denote succeeding disk roller cutters for
scraper arranged nearly at the same position with respect to the rotating shaft of
the cutter head 61. R1, R2 and R3 denote disk roller cutters for undercut on the rear
row in the cutting direction arranged nearly at the same position with respect to
the rotating shaft of the cutter head 61; and S1, S2 and S3 denote succeeding disk
roller cutters for scraper arranged nearly at the same position with respect to the
rotating shaft of the cutter head 61. The function of these disk roller cutters is
as mentioned previously.
[0036] One embodiment of a positional relation of the disk roller cutters, and an angle
formed between the support shaft and the rotating shaft are given in the following
Table.
Roller cutter symbol |
Disposition angle ψ (°) |
Radial position (mm) |
Axial position (mm) |
Angle relative to rotating shaft |
S1 |
30 |
508 |
1090 |
αS: 90° ≦ 93°≦ 96° |
R1 |
60 |
628 |
1198 |
αR: 06° ≦ 09° ≦ 12° |
N1 |
90 |
790 |
1054 |
αN: 83° ≦ 86° ≦ 89° |
G1 |
120 |
670 |
1186 |
αG: 01° ≦ 02° ≦ 05° |
S2 |
150 |
508 |
1090 |
αS: 90° ≦ 93° ≦ 96° |
R2 |
180 |
628 |
1198 |
αR: 06° ≦ 09° ≦ 12° |
N2 |
210 |
790 |
1054 |
αN: 83° ≦ 86° ≦ 89° |
G2 |
240 |
670 |
1186 |
αG: 01° ≦ 02° ≦ 05° |
S3 |
270 |
508 |
1090 |
αS: 90° ≦ 93° ≦ 96° |
R3 |
300 |
628 |
1198 |
αS: 90° ≦ 93° ≦ 97° |
N3 |
330 |
790 |
1054 |
αS: 90° ≦ 93° ≦ 98° |
G3 |
360 |
670 |
1186 |
αS: 90° ≦ 93° ≦ 99° |
[0037] FIG. 10 shows another embodiment of a cutter head 71 having a cutter head arranged
nearly parallel to the cutting face of the base rock to cut. The cutter head 71, also,
moves in the Y direction or in the direction opposite thereto while rotating to cut
the base rock I.
[0038] G1, G2 and G3 denote disk roller cutters for undercut on the front row in the cutting
direction arranged nearly at the same position with respect to the rotating shaft
of the cutter head 71; and N1, N2 and N3 denote succeeding disk roller cutters for
scraper arranged nearly at the same position with respect to the rotating shaft of
the cutter head 71. E1, E2, and up to E9 denote disk roller cutters for scraper arranged
while being deviated in order in the radial direction and in the rotating shaft direction
of the cutter head 71. The function of these disk roller cutters is also as mentioned
previously.
[0039] P denotes a disk roller cutter for undercut positioned away from the base rock more
than G1, G2 and G3 from the base rock I, and on the rear row with respect to the base
rock in which where G1, G2 and G3 produce leftover, the leftover are cut off so that
plate surfaces of N1, N2 and N3 do not come in contact of the leftover to the utmost.
[0040] E1+5 and E2+6 denote a both-side type disk roller cutter, employing a cutter arrangement
not occupying space. Others are a one-side type disk roller cutter.
[0041] FIG. 11 shows one embodiment of a cutter head 81 having a cutter head arranged nearly
vertical to the cutting face of the base rock to cut. The cutter head 81 moves in
the X direction while rotating to cut the base rock I.
[0042] GV1, GV2 and GV3 denote disk roller cutters for undercut on the front row in the
cutting direction arranged nearly at the same position with respect to the rotating
shaft of the cutter head 81; and PD1, PD2 and PD3 denote succeeding disk roller cutters
for scraper arranged nearly at the same position with respect to the rotating shaft
of the cutter head 81. GN1, GN2 and GN3 denote disk roller cutters for undercut on
the rear row in the cutting direction arranged nearly at the same position with respect
to the rotating shaft of the cutter head 81; and PD4, PD5 and PD6 denote succeeding
disk roller cutters for scraper arranged nearly at the same position with respect
to the rotating shaft of the cutter head 81. The function of these disk roller cutters
is also as mentioned previously.
[0043] PD1+4, PD2+5 and PD3+6 denote a both-side type disk roller cutter, employing a cutter
arrangement without occupying space. Others are a one-side type disk roller cutter.
[0044] One embodiment of a positional relation of the disk roller cutters, and an angle
formed between the support shaft and the rotating shaft are given in the following
Table.
Roller cutter symbol |
Disposition angle ψ (°) |
Radial position (mm) |
Axial position (mm) |
Angle relative to rotating shaft |
GV1 |
40 |
660 |
584 |
αGV: 95°≦99° ≦ 103° |
PD1 |
80 |
582 |
672 |
αPD: 10° ≦ 12° ≦ 14° |
GN1 |
120 |
721 |
475 |
αGN: 68° ≦ 69° ≦ 79° |
GV2 |
160 |
660 |
584 |
αGV: 95°≦99°≦ 103° |
PD2 |
200 |
582 |
672 |
αPD: 10° ≦ 12° ≦ 14° |
GN2 |
240 |
721 |
475 |
αGN: 68° ≦ 69° ≦ 79° |
GV3 |
280 |
660 |
584 |
αGV: 95° ≦ 99° ≦ 103° |
PD3 |
320 |
582 |
672 |
αPD: 10° ≦ 12° ≦ 14° |
GN3 |
360 |
721 |
475 |
αGN: 68°≦ 69° ≦ 79° |
[0045] FIG. 12 shows another embodiment of a cutter head 91 having a cutter head arranged
nearly vertical to the cutting face of the base rock. The cutter head 91, also, moves
in the X direction while rotating to cut the base rock I.
[0046] In this embodiment, many disk roller cutters are arranged in a multi-stage in the
front cutting-direction, which arrangement is realized using a both-side type disk
roller cutter without occupying space.
[0047] Next, a preferred embodiment of a rock excavator having a cutter head mounted thereon
according to the present invention will be described.
[0048] FIG. 13 shows a rock excavator of a road-header type having the cutter head shown
in FIG. 9 mounted thereon.
[0049] In a rock excavator 101, a base 103 is disposed above a crawler 102, and an excavating
boom 104 is disposed before the base 103. The excavating boom 104 is expanded forward
and backward by an expanding cylinder 105, swung vertically by a swinging cylinder
106 and is also turned to left and right.
[0050] Further, the cutter head is mounted on the extreme end of the excavating boom 104,
so that the cutter head can be rotated about the rotating axis by a drive mechanism
(not shown) in both normal and reverse directions, with the desired rotational frequency
and rotational torque.
[0051] Whereby, the excavating boom 104 is expanded forward and backward, and swung up and
down to press the cutter head in the diametrical direction against the cutting face
of the base rock; and the excavating boom 104 is turned to left and right to press
the cutter head in the direction of the rotating shaft against the cutting face of
the base rock, the disk roller cutter of the cutter head comes in contact with the
base rock to cut.
[0052] FIG. 15 shows a rock excavator 114 of a road header type in which the cutter head
shown in FIG. 11 is mounted.
[0053] FIG. 17 shows a rock excavator 121 of a shovel type in which the cutter head shown
in FIG. 9 is mounted as an attachment. Alternatively, the cutter head of FIG. 11 may
be mounted in place of the cutter head shown in FIG. 9.
[0054] FIG. 18 shows a rock excavator 131 of a surface-miner type in which the cutter head
shown in FIG. 9 is mounted.
[0055] According to the rock excavator having the cutter head of the present invention mounted
thereon, the base rock can be excavated easily even if the compression strength of
the rocks is great, the wear of the roller cutter is relatively small, the roller
cutter does not float from the base rock, the base rock is not scrubbed to produce
muck, the cutting of the roller cutter into the rock is not impaired, and the whole
cutter head is not pushed back from the base rock.