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The segment handling system is a dedicated lifting solution for shield tunneling machines. It enables the gripping, rotation, and transportation of tunnel segments and box culvert components, serving as a key guarantee for safe and efficient shield tunneling construction.
The system can be custom-designed according to the cutterhead diameter and specific working conditions of the shield machine. It is capable of handling single segments, multiple segments, and box culvert components.
The segment crane features a compact overall structure, smooth and stable lifting and traveling motions, and high positioning accuracy. It is equipped with PLC control, hydraulic gripping, automatic acceleration and deceleration, safety interlocking, mechanical positioning, slope traveling capability, overwind protection, and reliable safety braking functions.
Key Features of the Segment Handling System
The segment lifting and handling system is a critical piece of equipment used in shield tunneling construction for transporting tunnel segments. Its main features include the following aspects:
Adaptability to Complex Working Conditions
- Capable of stable operation in the complex environments of tunnel construction.
- Traveling rails can accommodate gradients of 1°–10°, meeting the requirements of longitudinal tunnel slopes and curved sections.
- Able to work collaboratively with the shield machine and other equipment within confined spaces.
High-Efficiency Lifting and Handling Capability
- Typical lifting capacity ranges from 2 t to 10 t, suitable for handling tunnel segments and box culvert components of various specifications.
- Hoisting and traveling speeds are adjustable, balancing efficiency and operational safety.
- In some systems, hoisting speeds can reach 0.4–4 m/min, while light-load traveling speeds can reach 0.2–40 m/min.
Precise Positioning and Synchronized Control
- Equipped with encoders, sensors, and other monitoring devices to ensure precise control of hook positioning.
- Synchronization error can be controlled within 2 mm, ensuring accuracy during segment handling and assembly.
- Supports synchronized hoisting and traveling of multiple hoists or trolleys.
Comprehensive Safety Protection
- Fitted with multiple safety devices, including braking systems, limit switches, and buffer devices.
- Features include overload protection and light-load acceleration functions.
- Can be integrated with vacuum suction pads or grabbing devices, with status feedback to prevent segment slippage.
Modular and Scalable Design
- Adopts a modular structural design, allowing flexible configuration according to shield diameter and project requirements.
- Supports seamless integration with segment feeders, erectors, and other equipment to form a complete segment transportation and assembly system.
Intelligent and Remote Control
- Can integrate PLC control and wireless remote-control technology for remote operation and real-time status monitoring.
- Supports linkage with the shield machine control system to enable automated workflows and reduce manual intervention.
Segment Handling System Parameters
| Overall Performance of Single Segment Handling Crane | ||
| Hoisting System | Spreader Lifting Capacity | 20t (Spreader: 4t; Load: 16t) |
| Kelajuan Mengangkat | 8 m/min | |
| Mengangkat Ketinggian | 6 m | |
| Trolley Travel System | Travel Speed | 30 m/min (Slope: ±5%) |
| Rotating Spreader | Rotation Speed | 1.15 r/min |
| Sudut Putaran | ±90° | |
| Drum Hoist | Kapasiti Mengangkat | 1600 kg |
| Kelajuan Mengangkat | 4.0/1.3 m/min | |
| Overall Performance of Double Segment Handling Crane | ||
| Hoisting System | Spreader Lifting Capacity | 40t (Spreader: 8t; Load: 32t) |
| Kelajuan Mengangkat | 8 m/min | |
| Mengangkat Ketinggian | 10 m | |
| Control Mode | Remote + Wired Control | |
| Trolley Travel System | Travel Speed | 50 m/min (Slope: ±5%) |
| Translation System | Translation Distance | ±400 mm |
| Overall Performance of Box Culvert Handling Crane | ||
| Hoisting System | Spreader Lifting Capacity | 25t |
| Kelajuan Mengangkat | 5 m/min | |
| Mengangkat Ketinggian | 10 m | |
| Control Mode | Remote + Wired Control | |
| Trolley Travel System | Travel Speed | 50 m/min (Slope: ±5%) |
| Translation System | Translation Distance | ±300 mm |
DAFANG Segment Handling System – Operating Reference
The DAFANG Segment Handling System is shown operating in a TBM project environment, performing the gripping, rotation, and transportation of precast concrete tunnel segments. The system is designed to support safe, stable, and efficient segment handling under continuous shield tunneling conditions.
Lubrication and Maintenance Requirements
To ensure long-term stable operation of the system, the segment handling system requires standardized lubrication and maintenance:
- Regularly spray an appropriate amount of 220 or 320 gear oil on the surface of the electric hoist’s ring chain (the chain surface should be cleaned before spraying).
- Regularly apply an appropriate amount of grease to the walking drive chain or rack surface.
- Apply grease to the outer surface of the balance beam supports to ensure smooth and reliable movement of the gripper head.
The segment handling system integrates multiple disciplines, including mechanical, electrical, hydraulic, and automated control technologies. It features high efficiency, precision, safety, and reliability, making it an indispensable core piece of equipment for TBM (Tunnel Boring Machine) tunneling. Through customized design and intelligent control, the system can effectively improve construction efficiency, reduce operational risks, and provide solid support for the smooth advancement of TBM projects.
