{"id":2707,"date":"2011-08-25T11:52:30","date_gmt":"2011-08-25T11:52:30","guid":{"rendered":"\/?p=2707"},"modified":"2017-06-01T03:51:59","modified_gmt":"2017-06-01T03:51:59","slug":"research-and-development","status":"publish","type":"post","link":"https:\/\/www.robbinstbm.com\/zh-hans\/research-and-development\/","title":{"rendered":"Research and Development: A Sneak Peek at the Next Generation of Disc Cutters"},"content":{"rendered":"<p><!--:en--><\/p>\n<div id=\"attachment_2714\" style=\"width: 645px\" class=\"wp-caption aligncenter\"><a href=\"\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cutters_2010_pic1.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2714\" class=\"size-full wp-image-2714\" title=\"MB_344_PahangSelangor_cutters_2010_pic1\" src=\"\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cutters_2010_pic1.jpg\" alt=\"Cutter Changing in Malaysia\" width=\"635\" height=\"400\" \/><\/a><p id=\"caption-attachment-2714\" class=\"wp-caption-text\">Cutter Changing at Malaysia&#8217;s Pahang Selangor Raw Water Tunnel<\/p><\/div>\n<p>R &amp; D is important in any industry, and it is no less true for the tunneling industry.\u00a0 Evolution, even if it is incremental, is where most research and development successes are made.\u00a0 Such improvement forms part of the competitiveness among manufacturers and thus begets further improvements.\u00a0 I also believe it is our obligation, as equipment manufacturers, to assist the market in driving down the costs of tunneling in general by improved product performance and product life.<\/p>\n<p>Take, for example the research and development going on with our disc cutters: Robbins disc cutters have improved dramatically since the 1950s when they achieved their first success at 11 inches in diameter in crystalline limestone of 190 MPa (28,000 psi) UCS.\u00a0 Today\u2019s disc cutters do reach 20 inches in diameter and cost-effectively excavate rock strengths of 400 MPa (60,000 psi) UCS, all while lasting much longer than their predecessors.<\/p>\n<div id=\"attachment_2715\" style=\"width: 645px\" class=\"wp-caption aligncenter\"><a href=\"\/wp-content\/uploads\/2011\/08\/SingleDiscCutter_pic1.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2715\" class=\"size-full wp-image-2715\" title=\"SingleDiscCutter_pic1\" src=\"\/wp-content\/uploads\/2011\/08\/SingleDiscCutter_pic1.jpg\" alt=\"Single Disc Cutter in a workshop.\" width=\"635\" height=\"400\" \/><\/a><p id=\"caption-attachment-2715\" class=\"wp-caption-text\">Today&#8217;s disc cutters are capable of excavating 400 MPa (60,000 psi) UCS rock.<\/p><\/div>\n<p>That being said, we believe there is always room for improvement.\u00a0 We are working hard right now to develop customized cutters for EPB tunneling in soft and mixed ground, and to optimize those designs so they can excavate under high pressure.\u00a0 In hard rock, we are researching and testing new steels, and developing monitoring systems to allow contractors to plan cutter changes.<\/p>\n<p>Here\u2019s a snapshot of what research and development is going on in the cutter department, both in the lab and in the field:<\/p>\n<h3><strong>Improved Metallurgy<\/strong><\/h3>\n<p>Working with the University of Trondheim and the Norwegian government, we are commencing a program of laboratory and field testing to improve the materials making up the disc ring itself.\u00a0 We are always testing new materials in order to find the most durable materials based on the ground conditions. An example of past cutter research in the lab can be seen below:<\/p>\n<p><iframe loading=\"lazy\" src=\"http:\/\/www.youtube.com\/embed\/rjj481bsifk\" width=\"420\" height=\"345\" frameborder=\"0\"><\/iframe><\/p>\n<h3><strong><br \/>\nPressure Compensated Disc Cutters<\/strong><\/h3>\n<p>We are currently developing improved disc cutters specifically for use on EPB and Slurry TBMs at high pressures of plus 10 bars, using a testing module in our Kent, Washington facility.\u00a0 The module duplicates a pressurized operational environment so that we can analyze how the cutter seals perform under pressure\u2014the design is in its 3<sup>rd<\/sup> or 4<sup>th<\/sup> generation with continuous improvements being made.<\/p>\n<div id=\"attachment_2716\" style=\"width: 645px\" class=\"wp-caption aligncenter\"><a href=\"\/wp-content\/uploads\/2011\/08\/PressureCompensatedCutters_PressureVessel_pic1.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2716\" class=\"size-full wp-image-2716\" title=\"PressureCompensatedCutters_PressureVessel_pic1\" src=\"\/wp-content\/uploads\/2011\/08\/PressureCompensatedCutters_PressureVessel_pic1.jpg\" alt=\"Testing module for pressure compensated disc cutters.\" width=\"635\" height=\"400\" \/><\/a><p id=\"caption-attachment-2716\" class=\"wp-caption-text\">Pressure vessel testing module for pressure compensated disc cutters.<\/p><\/div>\n<h3><strong><br \/>\nRemote Cutter Monitoring<\/strong><\/h3>\n<p>Our remote cutter monitoring system is a breakthrough that we have been field testing for four years.\u00a0 The system is now undergoing full scale testing on three Main Beam TBMs at Malaysia\u2019s Pahang Selangor Raw Water Tunnel.\u00a0 The setup allows crews to more closely monitor the actual working conditions and cutter wear.\u00a0 We project, through this system, to increase the TBM utilization of each machine by 3 to 4% and to reduce cutter cost by 10%.<\/p>\n<p>We\u2019re also working on expanding this wireless system to EPB and Slurry machines, so that monitoring of cutter wear and rotation can be used while those machines are in closed mode.\u00a0 This would be a highly beneficial development, because under pressure the detection of tool wear is difficult.\u00a0 Our goal here is to reduce or better plan interventions because of tool wear.<\/p>\n<div id=\"attachment_2717\" style=\"width: 645px\" class=\"wp-caption aligncenter\"><a href=\"\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cuttermonitoring_pic1.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2717\" class=\"size-full wp-image-2717\" title=\"MB_344_PahangSelangor_cuttermonitoring_pic1\" src=\"\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cuttermonitoring_pic1.jpg\" alt=\"Robbins remote cutter monitoring system.\" width=\"635\" height=\"400\" \/><\/a><p id=\"caption-attachment-2717\" class=\"wp-caption-text\">Sample screenshot of the Robbins remote cutter monitoring systems. Failed cutters are highlighted by a color on the screen.<\/p><\/div>\n<h3><strong><br \/>\nRobbins Atmospheric Cutter Change System (RACCS)<\/strong><\/h3>\n<p>Finally, we are developing a system to allow cutter changes at atmospheric pressure on large diameter EPBs. \u00a0This atmospheric cutter change system is superior to other systems on the market because it allows muck to flow through.\u00a0 Other systems on the market are very prone to clogging. Each spoke of an EPB cutterhead will contain a chamber at atmospheric pressure.\u00a0\u00a0 Cutters can be rotated from the pressure zone into the chamber to allow for efficient and relatively fast cutter changes.<\/p>\n<p>The development is also significant because a huge cost of operating large diameter EPBs is associated with intervention for cutter inspection and change.\u00a0 We are currently building a large test fixture for this system, which will analyze how RACCS reacts in sand, gravel, boulders, clay, and mud conditions under pressure.<\/p>\n<p>&nbsp;<\/p>\n<h3>Conclusions<\/h3>\n<p>These research and development projects are all aimed at solving a particular problem or shortfall\u2014with the objective to bore more meters per month.\u00a0 It is not the only area where we have research and development underway, as we have similar programs to investigate improvements of the probe drilling and lube systems on our TBMs.\u00a0 The process is usually rigorous, as designs need to be tested and re-tested in both the lab and the field.<\/p>\n<p>I am not a big believer in \u201cBig Step\u201d research and development as was tried in earlier days at Robbins with the Mobile Miner and the Bore Pack.\u00a0 Such \u201cBig Step\u201d research and development usually leads to disappointment and heavy cost for the client and the company.<\/p>\n<p>However, improvements like the 19\u201d cutters and the cutter monitoring systems are and will be big wins for the contractors and for Robbins.<!--:--><!--:zh--><\/p>\n<div id=\"attachment_2714\" style=\"width: 645px\" class=\"wp-caption alignleft\"><a href=\"\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cutters_2010_pic1.jpg\"><img loading=\"lazy\" decoding=\"async\" aria-describedby=\"caption-attachment-2714\" class=\"size-full wp-image-2714\" title=\"MB_344_PahangSelangor_cutters_2010_pic1\" src=\"\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cutters_2010_pic1.jpg\" alt=\"Cutter Changing in Malaysia\" width=\"635\" height=\"400\" \/><\/a><p id=\"caption-attachment-2714\" class=\"wp-caption-text\">Cutter Changing at Malaysia&#8217;s Pahang Selangor Raw Water Tunnel<\/p><\/div>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>R &amp; D is important in any industry, and it is no less true for the tunneling industry.\u00a0 Evolution, even if it is incremental, is where most research and development successes are made.\u00a0 Such improvement forms part of the competitiveness among manufacturers and thus begets further improvements.\u00a0 I also believe it is our obligation, as equipment manufacturers, to assist the market in driving down the costs of tunneling in general by improved product performance and product life.<\/p>\n<p>Take, for example the research and development going on with our disc cutters: Robbins disc cutters have improved dramatically since the 1950s when they achieved their first success at 11 inches in diameter in crystalline limestone of 190 MPa (28,000 psi) UCS.\u00a0 Today\u2019s disc cutters do reach 20 inches in diameter and cost-effectively excavate rock strengths of 400 MPa (60,000 psi) UCS, all while lasting much longer than their predecessors.<\/p>\n<p>[Photo of a disc cutter]<\/p>\n<p>That being said, we believe there is always room for improvement.\u00a0 We are working hard right now to develop customized cutters for EPB tunneling in soft and mixed ground, and to optimize those designs so they can excavate under high pressure.\u00a0 In hard rock, we are researching and testing new steels, and developing monitoring systems to allow contractors to plan cutter changes.<\/p>\n<p>Here\u2019s a snapshot of what research and development is going on in the cutter department, both in the lab and in the field:<\/p>\n<h3><strong>Improved Metallurgy<\/strong><\/h3>\n<p>Working with the University of Trondheim and the Norwegian government, we are commencing a program of laboratory and field testing to improve the materials making up the disc ring itself.\u00a0 We are always testing new materials in order to find the most durable materials based on the ground conditions. An example of past cutter research in the lab can be seen below:<\/p>\n<p><iframe loading=\"lazy\" src=\"http:\/\/www.youtube.com\/embed\/rjj481bsifk\" width=\"420\" height=\"345\" frameborder=\"0\"><\/iframe><\/p>\n<h3><strong>Pressure Compensated Disc Cutters<\/strong><\/h3>\n<p>We are currently developing improved disc cutters specifically for use on EPB and Slurry TBMs at high pressures of plus 10 bars, using a testing module in our Kent, Washington facility.\u00a0 The module duplicates a pressurized operational environment so that we can analyze how the cutter seals perform under pressure\u2014the design is in its 3<sup>rd<\/sup> or 4<sup>th<\/sup> generation with continuous improvements being made.\u00a0 [Photo of testing facility?]<\/p>\n<p>&nbsp;<\/p>\n<h3><strong>Remote Cutter Monitoring<\/strong><\/h3>\n<p>Our remote cutter monitoring system is a breakthrough that we have been field testing for four years.\u00a0 The system is now undergoing full scale testing on three Main Beam TBMs at Malaysia\u2019s Pahang Selangor Raw Water Tunnel.\u00a0 The setup allows crews to more closely monitor the actual working conditions and cutter wear.\u00a0 We project, through this system, to increase the TBM utilization of each machine by 3 to 4% and to reduce cutter cost by 10%.<\/p>\n<p>We\u2019re also working on expanding this wireless system to EPB and Slurry machines, so that monitoring of cutter wear and rotation can be used while those machines are in closed mode.\u00a0 This would be a highly beneficial development, because under pressure the detection of tool wear is difficult.\u00a0 Our goal here is to reduce or better plan interventions because of tool wear.<\/p>\n<p>[Show screen shot of monitoring system]<\/p>\n<h3><strong><br \/>\nRobbins Atmospheric Cutter Change System (RACCS)<\/strong><\/h3>\n<p>Finally, we are developing a system to allow cutter changes at atmospheric pressure on large diameter EPBs. \u00a0This atmospheric cutter change system is superior to other systems on the market because it allows muck to flow through.\u00a0 Other systems on the market are very prone to clogging. Each spoke of an EPB cutterhead will contain a chamber at atmospheric pressure.\u00a0\u00a0 Cutters can be rotated from the pressure zone into the chamber to allow for efficient and relatively fast cutter changes.<\/p>\n<p>The development is also significant because a huge cost of operating large diameter EPBs is associated with intervention for cutter inspection and change.\u00a0 We are currently building a large test fixture for this system, which will analyze how RACCS reacts in sand, gravel, boulders, clay, and mud conditions under pressure.<\/p>\n<p>&nbsp;<\/p>\n<h3>Conclusions<\/h3>\n<p>These research and development projects are all aimed at solving a particular problem or shortfall\u2014with the objective to bore more meters per month.\u00a0 It is not the only area where we have research and development underway, as we have similar programs to investigate improvements of the probe drilling and lube systems on our TBMs.\u00a0 The process is usually rigorous, as designs need to be tested and re-tested in both the lab and the field.<\/p>\n<p>I am not a big believer in \u201cBig Step\u201d research and development as was tried in earlier days at Robbins with the Mobile Miner and the Bore Pack.\u00a0 Such \u201cBig Step\u201d research and development usually leads to disappointment and heavy cost for the client and the company.<\/p>\n<p>However, improvements like the 19\u201d cutters and the cutter monitoring systems are and will be big wins for the contractors and for Robbins.<!--:--><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Robbins disc cutter advancements are accelerating, from pressure compensated disc cutters for soft ground TBMs to remote cutter monitoring.  Read on for a snapshot of our latest R&#038;D projects. <\/p>\n","protected":false},"author":14,"featured_media":8343,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":"","_links_to":"","_links_to_target":""},"categories":[1,35],"tags":[],"class_list":["post-2707","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","category-redefining-the-industry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Research and Development: A Sneak Peek at the Next Generation of Disc Cutters - Robbins<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.robbinstbm.com\/research-and-development\/\" \/>\n<meta property=\"og:locale\" content=\"zh_CN\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Research and Development: A Sneak Peek at the Next Generation of Disc Cutters - Robbins\" \/>\n<meta property=\"og:description\" content=\"Robbins disc cutter advancements are accelerating, from pressure compensated disc cutters for soft ground TBMs to remote cutter monitoring. Read on for a snapshot of our latest R&amp;D projects.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.robbinstbm.com\/research-and-development\/\" \/>\n<meta property=\"og:site_name\" content=\"Robbins\" \/>\n<meta property=\"article:published_time\" content=\"2011-08-25T11:52:30+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2017-06-01T03:51:59+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.robbinstbm.com\/wp-content\/uploads\/2011\/08\/MB_344_PahangSelangor_cutters_2010_pic1-1.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"635\" \/>\n\t<meta property=\"og:image:height\" content=\"400\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"author\" content=\"Lok Home\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:creator\" content=\"@Robbins_Co\" \/>\n<meta name=\"twitter:site\" content=\"@Robbins_Co\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Lok Home\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"8 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/\"},\"author\":{\"name\":\"Lok Home\",\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/#\\\/schema\\\/person\\\/883e60fc8af203750dbac4d4eb2f695c\"},\"headline\":\"Research and Development: A Sneak Peek at the Next Generation of Disc Cutters\",\"datePublished\":\"2011-08-25T11:52:30+00:00\",\"dateModified\":\"2017-06-01T03:51:59+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/\"},\"wordCount\":1700,\"commentCount\":4,\"publisher\":{\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/#organization\"},\"image\":{\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/www.robbinstbm.com\\\/wp-content\\\/uploads\\\/2011\\\/08\\\/MB_344_PahangSelangor_cutters_2010_pic1-1.jpg\",\"articleSection\":[\"Blog\",\"Redefining the Industry\"],\"inLanguage\":\"zh-CN\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/\",\"url\":\"https:\\\/\\\/www.robbinstbm.com\\\/research-and-development\\\/\",\"name\":\"Research and Development: A Sneak Peek at the Next Generation of Disc Cutters - 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