行星齿轮减速器 - Ringier Events(PPT-50)

行星齿轮减速器、回转支承在盾构掘进机中的应用及维护保养上海市机械工程学会

赵治军日期：10/15/2019一、盾构掘进机简介盾构机始于英国，发展于日本、德国，盾构、大直径顶管掘进机是专门用于开挖地下隧道工程的技术密集型重大工程装备。随着地下空间的开发、利用，常用的钻爆法在掘进速度、工程质量、安全可靠、环境保护等方面已显得落后，盾构法施工隧道已经运用到了各国的城市建设及其它地下工程施工中，如越江跨海隧道、煤矿巷道等，因此盾构、大直径顶管掘进机需求量会不断加大。二、中国盾构、大直径顶管掘进机整体概况在中国盾构、大直径顶管掘进机市场上国外掘进机的占有率曾经高达95%以上，目前盾构、大直径顶管掘进机中国市场保有量约600台，近年来，国产盾构、大直径顶管掘进机有了长足的发展，有些品牌已经可以与国际品牌抗衡，目前我国国产盾构掘进机市场（新建造部分）占有率达60%。三、盾构掘进机国产化现状■■为了增强与国际品牌盾构掘进机的竞争能力，中国盾构机制造厂家必须制造出符合中国国情的产品，这是我国施工装备领域不可回避的重要课题。目前盾构机国产化接近80%，国产化盾构掘进机的核心部分：刀盘驱动回转支承、刀盘驱动减速器、关键液压件及电气等元部件仍依靠进口产品。四、盾构掘进机国内主要生产厂家

目前国内盾构机生产厂家主要有：中铁装备（河南）、中铁重工（湖南）、海瑞

克（广州、大连）、上海隧道、小松中国、石川岛（常熟、无锡）、三菱重工（武汉

天地）、法麦特（辽宁沈阳北方重工）、卡特彼勒（辽宁辽阳）、秦皇岛天业通联（日立电机）、川崎重工（杭锅、青岛）、罗宾斯（武汉）、奥村（上海力行）等大

约16家。年生产量约100台，每台盾构掘

进机配备行星齿轮减速器8~10台。五、盾构掘进机外观照片六、盾构掘进机刀盘驱动单元六、盾构掘进机刀盘驱动单元七、盾构掘进机刀盘驱动单元驱动单元组成：1、齿轮减速器+马达（电动机或液压）+回转支承；2、低速大转矩液压马达+回转支承。八、盾构机用行星齿轮减速器的特点

1、行星减速器体积小、重量轻，适合于盾构机的总体布置；2、承载能力大，效率高；

3、运转平稳，噪声低，可靠性高，使用寿命长。九、刀盘驱动减速器应用现状■■由于行星减速器具有以上优点，盾构机刀盘驱动通常采用该类齿轮减速器，作为盾构掘进机的关键部件之一，其性能好坏直接影响盾构机核心部件回转支承与切削刀盘的工作性能。该类减速器目前以日本、德国、法国产为主，目前90%以上依靠进口产品。随

着我国齿轮制造与研发水平的提升，已具

备该类减速器的研制能力，为降低整机成

本，目前“盾构掘进机主驱动行星齿轮减

速器国产化研制”已被多家厂家提上日程。十、驱动减速器及回转支承研制的经济性■虽然目前制造业市场较为低迷，但盾构掘进机仍属于较好行业，根据国家发改委规划，预计该行业能持续发展到2025年，随着市场竞争加剧，盾构掘进机用行星齿轮减速器及回转支承国产化是大势所趋，国内年市场需求量约120台套，年潜市场约2.5亿元，利润5000万元。建议专业厂家应针对国内高端客户如：中铁装备、中铁重工等进行配套研制。十一、刀盘驱动装置的维护保养

上世纪八十年代后期上海就已引进盾构掘进机，2004年以来我国更是大批量建造了（863盾构掘进机为首）及引进了近600台盾

构掘进机，目前大多数盾构掘进机进入服役后期，部分设备带病工作，亟需维护保养，该行业除了可进行国产化研制外，年总需求维护行星减速器量约1000台左右，回转支承维护保

养约100套，潜在的市场同样比较客观。优化设备寿命周期成本■■■■更长的服务寿命缩短交货周期比新驱动更便宜的价格客户定制产品节约能源，减少消耗节能环保节能&节约材料对环境和可持续的贡献为什么要维护保养、修复驱动装置?盾构掘进机驱动装置进入服役后期盾构驱动装置维护保养及修复在今天已成为客户亟需的服务谁是一站式服务的合作伙伴？齿轮减速器维护保养及修复内容1、检查所有齿轮及传动零部件；2、更换所有密封件及接近预期寿命轴承；3、损坏齿轮及轴更换。4、空载试验后进行加载试验；5、空载及加载试验达到出厂要求后进行外观处理。行星齿轮减速器维护保养实例保养前保养后行星齿轮减速器维护保养实例保养前行星齿轮减速器维护保养实例保养前保养后部分行星齿轮减速器损坏实例部分行星齿轮减速器损坏实例驱动减速器维保后加载试验Section

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