Design and kinematic analysis of special scabbling device for operational railway tunnel maintenance

doi:10.3785/j.issn.1006-754X.2025.05.117

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (5): 708-719 DOI: 10.3785/j.issn.1006-754X.2025.05.117

Mechanical parts and equipment design

Design and kinematic analysis of special scabbling device for operational railway tunnel maintenance

Yang ZHOU¹(

),Yong YI²,Zhou LUO²,Zhi NING¹,Lairong YIN¹(

)

^1.College of Mechanical and Vehicle Engineering, Changsha University of Science & Technology, Changsha 410114, China
^2.China Railway No. 5 Engineering Group Co. , Ltd. , Changsha 410000, China

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Abstract

In response to the issues of the short window period for tunnel maintenance in operational railway, the low efficiency of manual scabbling, and the lack of directional specialized equipment, a dedicated scabbling device for tunnel maintenance has been developed based on the construction requirements of tunnel renovation. Firstly, according to the scabbling operation requirements, the structure of the scabbling device was determined as a robotic arm combined with a scissor lift frame, and the fixed-connection and articulated scabbling mechanisms were designed. Then, the kinematic model of the scabbling device was established by improved D-H (Denavit-Hartenberg) parameter method for forward and inverse kinematic analyses, and the workspace of the scabbling device was solved by using the Monte Carlo method. Finally, the motion trajectory planning analysis for the scabbling device operation process was performed. The fifth-degree polynomial interpolation method was applied for the point-to-point trajectory planning in joint space, and the planar circular interpolation method based on the S-curve acceleration and deceleration control algorithm was used for the designated path planning in Cartesian space. The results showed that the overall structure and workspace of the designed scabbling device met the design requirements, and this device performed well in terms of motion. Through the motion trajectory planning analysis, the motion impact and vibration during the scabbling device operation process were effectively reduced, which ensured the safety of the scabbling operation. The research results provide a theoretical foundation for the subsequent physical scabbling device prototype manufacturing and scabbling operation testing.

Key words： railway tunnel scabbling device S-curve acceleration and deceleration control algorithm kinematic analysis motion trajectory planning

Received: 28 February 2025 Published: 31 October 2025

CLC:

U 457.2

Corresponding Authors: Lairong YIN E-mail: zhou_yang0412@163.com;yinlairong@hotmail.com

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Cite this article:

Yang ZHOU,Yong YI,Zhou LUO,Zhi NING,Lairong YIN. Design and kinematic analysis of special scabbling device for operational railway tunnel maintenance. Chinese Journal of Engineering Design, 2025, 32(5): 708-719.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.05.117 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I5/708

运营铁路隧道治理专用凿毛装置的设计与运动学分析

针对运营铁路隧道治理天窗期短、人工凿毛效率低及定向专用设备缺乏等问题，基于隧道整治施工需求开发了一种隧道治理专用的凿毛装置。首先，根据凿毛作业要求确定了凿毛装置的结构为机械臂结合剪叉式提升架，并适配设计了固定连接型与铰接型凿毛机构。然后，通过改进D-H（Denavit-Hartenberg）参数法建立了凿毛装置运动学模型，开展了正、逆运动学分析，并采用蒙特卡洛法求解了凿毛装置的工作空间。最后，对凿毛装置的作业过程进行了运动轨迹规划分析，利用五次多项式插值法进行关节空间点到点轨迹规划，并利用基于S形加减速控制算法的平面圆弧插补方法进行笛卡儿空间指定路径规划。结果表明，所设计的凿毛装置的整体结构及工作空间符合设计要求，且运动性能良好；通过运动轨迹规划分析有效地减少了凿毛装置作业过程中的运动冲击与振动，保证了凿毛作业的安全性。研究结果为后续的凿毛装置实物样机制造与凿毛作业试验提供了理论基础。

关键词： 铁路隧道, 凿毛装置, S形加减速控制算法, 运动学分析, 运动轨迹规划

Fig.1 Internal profile structures of various tunnel linings

Fig.2 Overall structural dimensions of scabbling device

Fig.3 Workspace division of scabbling device

Fig.4 Three-dimensional model of scabbling device

Fig.5 Linkage coordinate systems of scabbling device

连杆i	$α i - 1 j$ /(°)	$a i - 1 j$ /mm	$d i j$ /mm	$θ i j$ /(°)
1	-90	0	$d 1 j$	$θ 1 j$ （-110.95~-15.75）
2	0	$a 1 j$	0	$θ 2 j$ （0~88.25）
3	0	$a 2 j$	0	$θ 3 j$ （-30~11）
4	0	$a 3 j$	0	0

Table 1 D-H parameters of articulated scabbling device

连杆i	$α i - 1 g$ /(°)	$a i - 1 g$ /mm	$d i g$ /mm	$θ i g$ /(°)
1	0	0	$d 1 g$ （1 300~3 730）	0
2	-90	0	0	$θ 2 g$ （-110.95~-15.75）
3	0	$a 2 g$	0	$θ 3 g$ （0~88.25）
4	0	$a 3 g$	0	0

Table 2 D-H parameters of fixed-connection scabbling device

Fig.6 Geometric relationships of each linkage of scabbling device

Fig.7 Solution process for workspace of scabbling device based on Monte Carlo method

Fig.8 Workspace of scabbling device

Fig.9 Internal profile structure dimensions of single-track tunnel lining for 250 km/h

Fig.10 Key postures of scabbling operation

运动阶段	轨迹点	关节位置/(°)或mm			关节速度/[(°)/s]或(mm/s)			关节加速度/[(°)/s²]或(mm/s²)			对应时刻/s
运动阶段	轨迹点	$θ 1 j$ （ $d 1 g$ ）	$θ 2 j$ （ $θ 2 g$ ）	$θ 3 j$ （ $θ 3 g$ ）	$θ ˙ 1 j$ （ $d ˙ 1 g$ ）	$θ ˙ 2 j$ （ $θ ˙ 2 g$ ）	$θ ˙ 3 j$ （ $θ ˙ 3 g$ ）	$θ ¨ 1 j$ （ $d ¨ 1 g$ ）	$θ ¨ 2 j$ （ $θ ¨ 2 g$ ）	$θ ¨ 3 j$ （ $θ ¨ 3 g$ ）	对应时刻/s
第1阶段	1	-45	85	11	0	0	0	0	0	0	0
	2	-24.18	52.73	11	3	1	0	-1	1	0	10
	3	-19.49	53.94	-14.47	0	0	0	0	0	0	15
第3阶段	1	-24.02	18.20	10.13	0	0	0	0	0	0	49.61
	2	-26.09	21.35	11	-2	4	0	-0.8	2.5	0	55
	3	-45	85	11	0	0	0	0	0	0	65
第5阶段^①	1	1 300	-45	85	0	0	0	0	0	0	75
第5阶段^①	2	1 300	-46.27	50.57	0	0	0	0	0	0	90

Table 3 Motion information for point-to-point trajectory planning in joint space

Fig.11 Planar circular interpolation diagram

Fig.12 S-shaped acceleration and deceleration curve

运动阶段

最大加加速度

j m

/[(°)/s³]

最大加速度a_m/

[(°)/s²]

最大速度v_m/

[(°)/s]

圆弧起始角度

α

/(°)

圆弧圆心角

β

/(°)

第2阶段

0.2

0.25

0.5

-19.99

15.68

第6阶段

0.2

0.25

1.0

-4.31

24.31

0.2

0.40

1.0

20.00

50.53

Table 4 Motion information for specified path planning in Cartesian space

Fig.13 Variation curves of kinematic parameters of each joint in scabbling device

Fig.14 Motion trajectory at the end of scabbling device


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