Automatic Transport System for Replacing Disc Cutters in Tunnel Boring Machine

ABSTRACT This paper presents a novel multilayer cutter transport system for automated disc cutter replacement in slurry‐shield tunnel boring machines (TBMs) under hyperbaric conditions. The system addresses the critical challenge of transporting heavy () cutters through confined chambers and introduces three key innovations, a problem previously unsolved in robotic TBM maintenance. Our contributions include: (1) a compact two‐layer conveyor‐lifter mechanism optimized for narrow‐space operation, (2) a breadth‐first search‐based topology optimization framework that maximizes storage capacity while minimizing transition steps, and (3) a comprehensive workflow analysis enabling fully automated cutter exchange. Experimental validations demonstrate reliable transport of three cutters per cycle with 2.4× efficiency improvement over manual methods, representing a significant advancement in TBM automation and worker safety.