Abstract: A housing mount assembly for a TBM disc cutter assembly having a shaft and cutter wheel assembly includes a housing half with a body and opposite edge portions extending away from the body. A removable seat block is fixed to the housing half in a space between the edge portions, and is configured to transmit forces received from the cutter shaft to the housing half in shear. A first face of the seat block is pressed against a face of one of the edge portions, and second face is pressed against the housing half body. The seat block may be preloaded against the housing half with first and second pluralities of bolts arranged perpendicularly. The seat block is configured to be removable in the field without removing the housing half from the TBM. The seat block may be hardened to a Rockwell C hardness in the range of Rc 58 to 60.

Abstract: A cutter assembly for a tunnel boring machine includes first and second housing mounts each having a plate portion, an abutment flange, and a plurality of spaced seats. A cutter ring assembly is mountable in the housings and includes two or more bridging supports that include a shaft mounting portion and two end portions that abut respective housing mount flanges. The cutter ring axis of rotation is between and parallel to the housing mounts. Separate wedge members are attachable to the housing mounts, and are configured to clamp the end portions of the bridging supports against the associated flanges. In some embodiments removable seat members are provided between the housing mount seats and the wedge members. The housing mounts and removable seats are configured to permit the cutter ring assembly to be inserted inline to the housing mounts.

Abstract: A cutter disc for a tunnel boring machine includes a middle disc portion defining a radially outer surface or edge for engaging a surface, a left toothed portion defining a first set of teeth set back from the outer edge, and a right toothed portion defining a second set of teeth set back from the outer edge. In an embodiment, a central bore through the cutter disc is configured to attach the cutter disc to a hub for rotatably mounting the cutter disc on a shaft. In an embodiment, the hub is formed integrally with the cutter disc. The left and right toothed portions provide structural support to the middle portion and facilitate rotation of the cutter disc when boring in soft or mixed conditions, but do not interfere with boring in hard rock conditions.

Abstract: A cutter assembly for a tunnel boring machine includes first and second housing mounts each having a plate portion, an abutment flange, and a plurality of spaced seats. A cutter ring assembly is mountable in the housings and includes two or more bridging supports that include a shaft mounting portion and two end portions that abut respective housing mount flanges. The cutter ring axis of rotation is between and parallel to the housing mounts. Separate wedge members are attachable to the housing mounts, and are configured to clamp the end portions of the bridging supports against the associated flanges. In some embodiments removable seat members are provided between the housing mount seats and the wedge members. The housing mounts and removable seats are configured to permit the cutter ring assembly to be inserted inline to the housing mounts.

Abstract: A housing mount assembly for a TBM disc cutter assembly having a shaft and cutter wheel assembly includes a housing half with a body and opposite edge portions extending away from the body. A removable seat block is fixed to the housing half in a space between the edge portions, and is configured to transmit forces received from the cutter shaft to the housing half in shear. A first face of the seat block is pressed against a face of one of the edge portions, and second face is pressed against the housing half body. The seat block may be preloaded against the housing half with first and second pluralities of bolts arranged perpendicularly. The seat block is configured to be removable in the field without removing the housing half from the TBM. The seat block may be hardened to a Rockwell C hardness in the range of Rc 58 to 60.

Abstract: A cutter assembly includes a disc subassembly rotatably mounted on a shaft with bearing assemblies, and end retainers. The disc subassembly includes a first hub member having a tubular portion that houses the bearing assemblies and an outer flange portion, a second hub member that slidably engages the tubular portion, and an annular cutter ring, preferably formed from a tool steel, and optionally formed in a plurality of segments. The first and second hub members define a channel that receives and clampingly engages a rectangular inner base portion of the cutter ring. The clamping force is provided by a plurality of bolts that join the first and second hub members, while the flange portion of the first hub member remains separated from the second hub member by a gap (S). In an embodiment the cutter ring includes a carbide core.

Abstract: An inline mounting assembly for a TBM cutter assembly includes first and second housing mounts, having upper and lower ear portions, and an inline channel sized to receive an end of the cutter assembly. The housing mounts include a first guide and a second guide defining forward and rearward abutment faces. A wedge assembly includes a bolt that extends through the first guide and engages a wedge configured to clamp the cutter shaft to the housing mount. A back support assembly includes a clamp block that abuts the rearward abutment face, a bridge block that abuts the forward abutment face, and a bolt that extends through the blocks. The bridge block abuts the shaft to provide support.

Abstract: A cutter disc for a tunnel boring machine includes a middle disc portion defining a radially outer surface or edge for engaging a surface, a left toothed portion defining a first set of teeth set back from the outer edge, and a right toothed portion defining a second set of teeth set back from the outer edge. In an embodiment, a central bore through the cutter disc is configured to attach the cutter disc to a hub for rotatably mounting the cutter disc on a shaft. In an embodiment, the hub is formed integrally with the cutter disc. The left and right toothed portions provide structural support to the middle portion and facilitate rotation of the cutter disc when boring in soft or mixed conditions, but do not interfere with boring in hard rock conditions.

Abstract: An inline mounting assembly for a TBM cutter assembly includes first and second housing mounts, having upper and lower ear portions, and an inline channel sized to receive an end of the cutter assembly. The housing mounts include a first guide and a second guide defining forward and rearward abutment faces. A wedge assembly includes a bolt that extends through the first guide and engages a wedge configured to clamp the cutter shaft to the housing mount. A back support assembly includes a clamp block that abuts the rearward abutment face, a bridge block that abuts the forward abutment face, and a bolt that extends through the blocks. The bridge block abuts the shaft to provide support.

Abstract: A cutter assembly includes a disc subassembly rotatably mounted on a shaft with bearing assemblies, and end retainers. The disc subassembly includes a first hub member having a tubular portion that houses the bearing assemblies and an outer flange portion, a second hub member that slidably engages the tubular portion, and an annular cutter ring, preferably formed from a tool steel, and optionally formed in a plurality of segments. The first and second hub members define a channel that receives and clampingly engages a rectangular inner base portion of the cutter ring. The clamping force is provided by a plurality of bolts that join the first and second hub members, while the flange portion of the first hub member remains separated from the second hub member by a gap (S). In an embodiment the cutter ring includes a carbide core.

Abstract: A tunnel boring machine (100) includes a cutterhead assembly (102) rotatably mounted to a forward shield assembly (116) through a cutterhead support assembly (110). The cutterhead support assembly is configured to receive a variable number of drive assemblies (105), such that the number of drive assemblies may be selected after fabricating the cutterhead support structure (120). The cutterhead support structure includes a housing portion (121) that houses the main bearing assembly (101) and a drive gear (104). A plurality of drive mount stations (111) provide access to the drive gear, and are provided with a pinion housing (130) for stations that receive a drive assembly, or with a cradle cover (140) for stations that do not receive a drive assembly.

Abstract: A pressure-compensated cutter assembly for a tunnel boring machine includes a shaft a cutter ring assembly rotatably mounted on the shaft, and first and second end retainers non-rotatably attached to the shaft. Rotary seal groups, immersed in lubricant, provide a moving seal between the rotating cutter ring assembly and the end retainers. A movable piston member is exposed to ambient pressures, and contacts the lubricant, such that increasing ambient pressure will increase the lubricant pressure, thereby keeping the pressure differential across the seal small. In one embodiment, the piston is a floating retainer portion. In another embodiment, the piston is an annular piston, and in another embodiment, the piston is a plurality of smaller pistons disposed in the first retainer.

Abstract: A tunnel boring machine (100) includes a cutterhead assembly (102) rotatably mounted to a forward shield assembly (116) through a cutterhead support assembly (110). The cutterhead support assembly is configured to receive a variable number of drive assemblies (105), such that the number of drive assemblies may be selected after fabricating the cutterhead support structure (120). The cutterhead support structure includes a housing portion (121) that houses the main bearing assembly (101) and a drive gear (104). A plurality of drive mount stations (111) provide access to the drive gear, and are provided with a pinion housing (130) for stations that receive a drive assembly, or with a cradle cover (140) for stations that do not receive a drive assembly.

Abstract: A pressure-compensated cutter assembly for a tunnel boring machine includes a shaft a cutter ring assembly rotatably mounted on the shaft, and first and second end retainers non-rotatably attached to the shaft. Rotary seal groups, immersed in lubricant, provide a moving seal between the rotating cutter ring assembly and the end retainers. A movable piston member is exposed to ambient pressures, and contacts the lubricant, such that increasing ambient pressure will increase the lubricant pressure, thereby keeping the pressure differential across the seal small. In one embodiment, the piston is a floating retainer portion. In another embodiment, the piston is an annular piston, and in another embodiment, the piston is a plurality of smaller pistons disposed in the first retainer.

Abstract: A roller cutter assembly comprising a cutter hub adapted for rotation with respect to a rock face and having a peripheral surface with an axially extending width. The first cutter ring is located on the cutter hub. A second cutter ring is also located on the cutter hub. Both the first cutter ring and the second cutter ring are adjustable between at least first locations and second locations along the width of the peripheral surface of the cutter hub such that reorientation of at least one of the first cutter ring and the second cutter ring on the cutter hub alters the axial spacing between the first cutter ring and the second cutter ring, resulting in alteration of the spacing of the cutters located thereon.