Real-time monitoring system and method for secondary operation of roadheader

Abstract

The invention discloses a real-time monitoring system and method for secondary operation of a roadheader. The second-operation real-time monitoring system of the roadheader comprises a limiting gear lever assembly, a composite trigger assembly, a central control module and a hydraulic execution assembly, the limiting gear lever assembly is arranged at the tail of a belt conveyor, and the limiting gear lever assembly comprises a telescopic rod, a built-in pressure sensor and a built-in tilt angle sensor; the composite trigger assembly is arranged on the front side of a rail car of a second conveyor of the roadheader, the central control module is connected with the limiting stop lever assembly and the composite trigger assembly, and the hydraulic execution assembly comprises a hydraulic push rod linked with the telescopic rod and an electromagnetic valve set connected with a power system of the roadheader. According to the real-time monitoring system for the secondary operation of the roadheader, through electromechanical cooperative control and a multi-stage safety triggering mechanism, accurate monitoring and active protection of the displacement of the rail car are achieved, the safety problem that the rail car in an underground coal mine derails is effectively solved, and meanwhile the equipment maintenance cost and the production interruption risk are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of coal mining, and in particular to a real-time monitoring system and method for the secondary operation of a fully-mechanized tunneling machine. Background Art

[0002] In the daily production of underground tunnel boring machines (TBMs), the TBMs move forward in the direction of mining, and the TBMs bring the TBMs' secondary transport to move synchronously. The railcar on the lower side of the secondary transport runs on the track of the belt conveyor below the secondary transport. Basically, the tail of the belt conveyor needs to be extended for each shift to ensure that the railcar is always on the track during the TBM's advancement to avoid derailment. However, in actual production, some TBM drivers are careless and fail to extend the tail of the belt conveyor to a redundant length in time, or they have a fluke mentality and think that the tail does not need to be extended for this shift, and force the TBMs to reach the top coal for cutting, causing the TBMs' secondary transport to derail, thereby damaging or deforming the TBMs' secondary transport transfer bridge, causing damage or breaking of the TBMs' random cables, posing a safety threat to the personnel at the tail of the TBMs, burning out the electric drum of the TBMs' secondary transport, and other safety accidents. Summary of the Invention

[0003] The present invention aims to solve one of the technical problems in the related art at least to a certain extent.

[0004] To this end, an embodiment of the present invention proposes a real-time monitoring system for the secondary operation of a tunnel boring machine, which solves the problem of rail vehicles derailing due to operational negligence of operators.

[0005] The real-time monitoring system for the secondary operation of a tunnel boring machine according to an embodiment of the present invention includes:

[0006] A limit lever assembly is provided at the tail of the belt conveyor, and is retractable along the extension direction of the belt conveyor. The limit lever assembly includes a telescopic rod driven by a servo motor and a built-in pressure sensor and inclination sensor;

[0007] A composite trigger assembly is provided on the front side of the rail car of the tunnel boring machine, and includes a mechanical travel switch, a magnetic induction proximity switch and an infrared ranging sensor;

[0008] A central control module, the central control module is connected to the limit lever assembly and the composite trigger assembly via a CAN bus, the central control module having a safety distance calculation unit and a multi-stage response logic unit;

[0009] A hydraulic actuator assembly, comprising a hydraulic push rod linked to the telescopic rod and a solenoid valve assembly connected to the power system of the tunneling machine;

[0010] The real-time monitoring system for the secondary operation of the tunnel boring machine monitors the distance between the composite trigger assembly and the limit lever assembly in real time. When the detection value is less than a preset safety threshold, the central control module drives the hydraulic actuator assembly to perform deceleration or shutdown control.

[0011] The real-time monitoring system for the secondary operation of a tunnel boring machine in an embodiment of the present invention realizes precise monitoring and active protection of rail vehicle displacement through electromechanical coordinated control and a multi-level safety trigger mechanism, effectively solving the safety problem of rail vehicle derailment in coal mines, while reducing equipment maintenance costs and the risk of production interruption.

[0012] In some embodiments, the composite trigger assembly has three trigger modes:

[0013] When the infrared distance sensor detects that the distance is ≤1.5m, it triggers an audible and visual warning and reduces the feeding speed of the tunnel boring machine to 50%;

[0014] When the magnetic induction proximity switch detects that the distance is ≤0.8m, the hydraulic lock is activated and the power supply of the cutting motor is cut off;

[0015] When the mechanical travel switch makes physical contact, emergency braking is immediately triggered and power-off protection is started.

[0016] In some embodiments, the limit lever assembly also includes a multi-stage buffer, which includes a polyurethane elastic layer wrapped around the outer layer of the telescopic rod, a hydraulic damper arranged inside the telescopic rod, and a bidirectional memory alloy spring connected to the frame of the belt conveyor. The damping coefficient of the hydraulic damper is dynamically adjusted according to the pressure sensor reading.

[0017] In some embodiments, the central control module receives the tunnel slope data measured in real time by the inclination sensor, calculates the minimum safety margin based on the mass, movement speed and slope data of the tunnel boring machine, and drives the servo motor to adjust the extension length of the telescopic rod so that the physical position of the limit lever assembly coincides with the calculated safety boundary.

[0018] In some embodiments, the central control module is connected to a display terminal, which is used to display the three-dimensional model of the tunnel, the virtual marking line of the safety boundary, and the highlighted warning area of the action of the composite trigger component.

[0019] In some embodiments, an energy storage and power generation module is further included, and the energy storage and power generation module is connected to the limit lever assembly to convert the collision kinetic energy into electrical energy for storage.

[0020] In some embodiments, a track topology monitoring subsystem is also included, which includes an RFID tag array, a radio frequency reader and a digital twin reconstruction module. The RFID tag array is arranged at equal intervals along the extension direction of the belt conveyor, and the radio frequency reader is located at the bottom of the second transport of the tunnel boring machine. The digital twin reconstruction module generates a track extension error alarm signal by comparing the actual read tag position data with the preset track model.

[0021] In some embodiments, a vibration spectrum analysis module is further included. The vibration spectrum analysis module is arranged on the limit lever assembly. The vibration spectrum analysis module is used to collect the vibration frequency characteristics of the telescopic rod, compare the characteristic spectrum in the historical fault database, and generate preventive maintenance instructions.

[0022] An embodiment of the present invention further provides a method for real-time monitoring of the secondary operation of a tunnel boring machine, which is used in the real-time monitoring system for the secondary operation of a tunnel boring machine described in the above embodiment.

[0023] The real-time monitoring method for the secondary operation of a tunnel boring machine according to an embodiment of the present invention includes:

[0024] The real-time distance between the composite trigger assembly and the limit lever assembly is obtained through infrared ranging and magnetic induction composite detection;

[0025] Dynamically calculate the safety threshold based on the roadway slope and equipment load, and drive the servo motor to adjust the limit position;

[0026] When it is detected that the distance exceeds the safety threshold, emergency braking is triggered, and three levels of control are executed in sequence: deceleration warning, hydraulic locking, and emergency power off;

[0027] The device displacement trajectory and safety boundary are synchronously displayed on the display terminal, and the holographic data of the collision event is recorded;

[0028] Vibration spectrum analysis results are used to predict the life of the limit lever assembly and trigger a maintenance work order before the replacement threshold is reached.

[0029] In some embodiments, when emergency braking is triggered, a release mechanism must be satisfied to release the brake. The release mechanism includes:

[0030] The tunnel boring machine operator completes fingerprint verification at the biometric terminal in the cockpit;

[0031] The ground monitoring station sends the digital key via the wireless terminal;

[0032] The central control module releases the locked state after verifying the time and space consistency. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 12 is a schematic diagram of a real-time monitoring system for the secondary operation of a tunnel boring machine according to an embodiment of the present invention.

[0034] Reference numerals:

[0035] 10-Tunnel boring machine, 20-Tunnel boring machine secondary transport, 30-Belt conveyor,

[0036] 1-Limit lever assembly, 2-Compound trigger assembly, 3-Central control module, 4-Hydraulic actuator assembly, 5-Display terminal. DETAILED DESCRIPTION

[0037] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to be used to explain the present invention, but should not be understood as limiting the present invention.

[0038] The following describes a real-time monitoring system for the secondary operation of a tunnel boring machine according to an embodiment of the present invention with reference to the accompanying drawings.

[0039] like Figure 1 As shown, the real-time monitoring system for the secondary operation of a tunnel boring machine according to an embodiment of the present invention includes a limit lever assembly 1, a compound trigger assembly 2, a central control module 3 and a hydraulic execution assembly 4.

[0040] The limit lever assembly 1 is provided at the tail of the belt conveyor 30 . The limit lever assembly 1 is retractable along the extension direction of the belt conveyor 30 . The limit lever assembly 1 includes a retractable rod driven by a servo motor and a built-in pressure sensor and inclination sensor.

[0041] The telescopic boom automatically adjusts its extension length based on the roadway slope (data from the inclination sensor), ensuring that the limit position always matches the required track extension. Closed-loop control maintains the boom axis parallel to the track, preventing false triggering due to installation deviations. A pressure sensor determines the severity of the collision based on peak pressure (e.g., emergency braking is activated when the pressure exceeds 500N). The inclination sensor provides real-time correction for inclination errors in the boom caused by baseplate deformation (with an accuracy of ±0.1°).

[0042] The composite trigger assembly 2 is arranged on the front side of the rail car of the comprehensive excavator No. 20. The composite trigger assembly 2 includes a mechanical travel switch, a magnetic induction proximity switch and an infrared ranging sensor.

[0043] The mechanical travel switch (hard trigger) uses an explosion-proof micro switch, which can still operate reliably in dusty environments and directly detect the physical contact between the railcar and the gear lever, serving as the ultimate safety barrier. The magnetic induction proximity switch (medium-range trigger) uses the Hall effect to detect the permanent magnet mark and is triggered within a distance of 0.8m to avoid the influence of dust obstruction. A frequency modulation signal is set to suppress false alarms caused by electromagnetic interference underground. The infrared ranging sensor (long-range warning) uses the TOF ranging principle (accuracy of ±2cm) to provide real-time feedback on the displacement trajectory of the railcar. It is equipped with a self-cleaning lens and an anti-glare filter to ensure normal operation under direct illumination of a mining lamp.

[0044] The central control module 3 is connected to the limit lever assembly 1 and the compound trigger assembly 2 via a CAN bus. The central control module 3 has a safety distance calculation unit and a multi-level response logic unit.

[0045] The safety distance calculation unit uses input parameters including the railcar mass (inferred via pressure sensors), slope angle, and operating speed to calculate the minimum safety distance in real time. If the track is not extended in a timely manner, the safety distance is automatically increased by 20% redundancy. The multi-level response logic unit features a 0.5-second delay to prevent false triggering. In the event of conflict between infrared and magnetic induction signals, the magnetic data takes precedence to prevent missed detections.

[0046] The hydraulic actuator assembly 4 includes a hydraulic push rod linked to the telescopic rod and a solenoid valve assembly connected to the power system of the tunnel boring machine 10. The hydraulic push rod utilizes a 10MPa high-pressure oil circuit, enabling the limited lever to be extended and retracted within 0.3 seconds. The solenoid valve assembly directly shuts off the oil circuit to the cutting motor via a pilot solenoid valve, preventing the power system from being forced to start.

[0047] The real-time monitoring system for the secondary operation of the tunnel boring machine monitors the distance between the composite trigger component 2 and the limit lever component 1 in real time. When the detection value is less than the preset safety threshold, the central control module 3 drives the hydraulic actuator component 4 to execute deceleration or shutdown control.

[0048] The real-time monitoring system for the secondary operation of a tunnel boring machine in an embodiment of the present invention realizes precise monitoring and active protection of rail vehicle displacement through electromechanical coordinated control and a multi-level safety trigger mechanism, effectively solving the safety problem of rail vehicle derailment in coal mines, while reducing equipment maintenance costs and the risk of production interruption.

[0049] In some embodiments, the composite trigger component 2 has a three-level trigger mode:

[0050] When the infrared ranging sensor detects a distance of ≤1.5m, it triggers an audible and visual warning and reduces the feed speed of the tunnel boring machine 10 to 50%. This audible and visual warning and speed reduction (to 50%) give the operator a 5-8 second window to correct the problem, maintaining production continuity while also prompting manual intervention.

[0051] When the magnetic proximity switch detects a distance of ≤0.8m, it activates the hydraulic lock and cuts off the power to the cutting motor. The hydraulic lock (blocking the hydraulic oil circuit) and the power cut to the cutting motor form a rigid protection, completely eliminating the possibility of forced operation.

[0052] When the mechanical limit switch makes physical contact, the emergency brake is immediately triggered and the power-off protection is activated. The direct impact of the mechanical limit switch triggers the power-off protection, which serves as the final safety barrier to ensure that energy transmission is blocked in the most extreme working conditions.

[0053] In some embodiments, the limit lever assembly 1 also includes a multi-stage buffer, which includes a polyurethane elastic layer wrapped around the outer layer of the telescopic rod, a hydraulic damper arranged inside the telescopic rod, and a bidirectional memory alloy spring connected to the frame of the belt conveyor 30. The damping coefficient of the hydraulic damper is dynamically adjusted according to the pressure sensor reading.

[0054] The polyurethane elastic layer serves as the first-level buffer. The polyurethane with a Shore hardness of 60-70 wraps the outer layer of the telescopic rod, absorbing the initial collision kinetic energy through elastic deformation, avoiding sparks generated by direct metal collision (in line with coal mine explosion-proof requirements), and reducing the surface wear rate by more than 80%.

[0055] The hydraulic damper is built into the telescopic rod cavity and dynamically adjusts the damping hole opening according to the collision force (unit: kN) fed back in real time by the pressure sensor to achieve nonlinear damping characteristics. Under light load (<5kN), low damping maintains sensitivity; under heavy load (>10kN), high damping rigid braking is achieved.

[0056] A bidirectional memory alloy spring connects the limit lever base and the belt conveyor 30 frame. Under severe impact, it undergoes superelastic deformation accompanied by heat absorption effect, maintains shape memory function under operating conditions of -20℃ to 150℃, and has an impact energy absorption efficiency of 65% to 75%.

[0057] Optionally, a servo motor drives the axial movement of the telescopic rod via a worm gear mechanism. A polyurethane elastic layer is tightly adhered to the outer surface of the telescopic rod through a hot-melt coating process. A hydraulic damper is built into the axial cavity of the telescopic rod, with the piston rod fixedly connected to the rod body. A pressure sensor integrated into the damper end cap monitors oil pressure changes in real time and provides feedback to the central control module 3. A bidirectional memory alloy spring is connected to the base flange of the telescopic rod at one end and fixed to the belt conveyor 30 frame via a universal hinge at the other end. The spring preload is set using an adjustment nut to ensure that the initial state is above the austenite transition temperature.

[0058] In some embodiments, the central control module 3 receives the tunnel slope data measured in real time by the inclination sensor, calculates the minimum safety margin based on the mass, movement speed and slope data of the tunnel boring machine 20, and drives the servo motor to adjust the extension length of the telescopic rod so that the physical position of the limit lever assembly 1 coincides with the calculated safety boundary.

[0059] It is understood that the inclination sensor measures the roadway slope in real time (range: -15° to +15°, accuracy: ±0.1°), and the central control module 3 dynamically adjusts the safety margin based on the formula. Conventional fixed limit positions are prone to insufficient safety margin (steep slopes) or excessive safety margin (flat slopes) when the slope changes. In this embodiment of the present invention, the safety margin is always optimally matched to the current operating conditions.

[0060] The real-time mass of the secondary transport is inferred using pressure sensors (with an accuracy of ±50kg), and the calculation model is dynamically modified based on changes in coal load. The safety margin calculation error is reduced from the traditional ±35% to ±5% under both fully loaded (20 tons) and empty (8 tons) conditions. When the TBM 10's propulsion speed exceeds 1m / s, emergency mode is automatically activated, increasing the safety margin by 30% and shortening the telescopic boom adjustment response time to 0.2 seconds.

[0061] A servo motor equipped with an absolute encoder (17-bit resolution) can adjust the telescopic rod length (travel range 0-1.2m) in 0.5 seconds, with a positioning accuracy of ±1mm. A PID algorithm compares the actual position of the limit lever with the calculated safety margin in real time, dynamically compensating for mechanical transmission backlash (compensation ≤ 0.05mm) to ensure that the physical limit is fully consistent with the theoretical model.

[0062] In some embodiments, the central control module 3 is connected to a display terminal 5, which is used to display the three-dimensional model of the tunnel, the virtual marking of the safety boundary, and the highlighted warning area of the action of the composite trigger component 2. Through augmented reality visualization and three-dimensional space modeling technology, the complex underground working conditions are converted into an intuitive digital interface.

[0063] A SLAM laser scanner (scanning frequency of 30Hz) generates centimeter-level precision 3D point clouds in real time. Overlaid with geological radar data, it reveals hidden faults (e.g., identifying rock fractures ≥50mm), enabling operators to understand the geological situation across the entire section. The model automatically updates with every meter of tunneling progress. Combined with a UWB positioning system (accuracy of ±10cm), the spatial synchronization error between the model and the actual roadway is less than 0.3%.

[0064] Based on the dynamic safety margin calculated by the central control module 3 (e.g., a 1.2m extension for a 5° slope), a red warning band is rendered in the 3D model. The width of the band varies with the risk level (high risk: 50 pixels wide; low risk: 20 pixels wide). If the railcar is more than 1.5m from the safety boundary, the band is green and flashes continuously. If the railcar is between 1.5m and 0.8m from the safety boundary, the band is yellow and flashes continuously at 1Hz. If the railcar is less than 0.8m from the safety boundary, the band is red and flashes continuously at 3Hz.

[0065] When composite trigger component 2 activates, a hemispherical warning zone with a diameter of 2 meters is generated at the corresponding location on the 3D model. Particle effects (such as flowing red light) enhance visual recognition, and spatial audio prompts (with a sound source localization error of less than 15°) guide operators to quickly locate the fault point. The system also stores the last 12 hours of railcar movement paths and supports 0.5x to 4x speed backtracking analysis to assist in tracing the root cause of accidents.

[0066] In some embodiments, the system further includes an energy storage and power generation module, which is connected to the limit lever assembly 1 to convert collision kinetic energy into electrical energy for storage.

[0067] The kinetic energy generated by a collision (typically dissipated as heat and mechanical deformation) is converted into electrical energy. A single collision (impact force of 10kN) can recover 0.5-1.2kWh of energy, equivalent to powering an underground LED lighting system for 2-4 hours. This energy conversion process simultaneously consumes the impact energy, reducing the peak collision force by 40%-60%, extending the life of the limit lever and railcar structure (fatigue life is increased by more than three times). The stored energy provides 72 hours of backup power for the system's sensors and communication modules (in the event of a power outage), improving system reliability.

[0068] Alternatively, if a piezoelectric ceramic power generation unit is used, a piezoelectric ceramic array is embedded between the limit lever's polyurethane elastic layer and the metal core rod, arranged in a honeycomb pattern (four ceramic plates per square centimeter). During a collision, the polyurethane layer deforms under pressure, squeezing the piezoelectric ceramics to generate an electric charge (a positive piezoelectric effect). A single impact can generate a transient voltage of 200V or higher.

[0069] If an electromagnetic induction generator is used, a permanent magnet rail is installed at the base of the telescopic rod, and a multi-stage coil assembly is installed on the corresponding frame. When the telescopic rod retracts due to a collision, the permanent magnet moves rapidly within the rail, cutting the magnetic flux lines of the coil, generating an induced current (Faraday's law).

[0070] Hydraulic energy recovery: A micro-turbine generator is added to the end of the hydraulic damper's piston rod. The flow of hydraulic oil drives the turbine to rotate and generate electricity. When the damper oil pressure is greater than 5MPa, the turbine speed reaches 3000rpm and the output power is ≥500W.

[0071] Energy storage management includes a supercapacitor bank (100F capacity, 300V withstand voltage) for storing high-voltage pulse power generated by piezoelectric ceramics, and a lithium-ion battery bank (20kWh capacity, fast charging support) for storing stable power from electromagnetic induction and hydraulic systems. An energy management chip optimizes the charging path using an MPPT (maximum power point tracking) algorithm, achieving an overall conversion efficiency exceeding 82%.

[0072] In some embodiments, the system also includes a track topology monitoring subsystem, which includes an RFID tag array, a radio frequency reader, and a digital twin reconstruction module.

[0073] The RFID tag array features metal-resistant RFID tags (operating at 860-960 MHz) spaced every 1.5 meters along the track. These tags have built-in EPC codes that record absolute coordinates (X, Y, Z) and a timestamp for placement. The tags have a compressive strength of ≥50 MPa, making them suitable for the humid and dusty underground environment. A dual-antenna reader (reading range 0-1.2 meters) is installed at the bottom of the second track. It achieves 100% tag recognition and a miss-read rate of less than 0.01% at speeds ≤2 m / s. The digital twin reconstruction module generates a track extension error alarm signal by comparing the actual tag position data read against the preset track model.

[0074] Understandably, the tag timestamp verifies that track extension is completed on time (e.g., 8 meters within a shift). If the delay exceeds 2 meters, a notification is automatically sent to the management system. If a lateral deviation of more than 50 mm is detected in a local section (three consecutive tags), the digital twin module automatically recalculates the safety margin in that area and increases the extension length of the limit lever by 10%-15%.

[0075] In some embodiments, the system also includes a vibration spectrum analysis module, which is arranged on the limit lever assembly 1. The vibration spectrum analysis module is used to collect the vibration frequency characteristics of the telescopic rod, compare the characteristic spectrum in the historical fault database, and generate preventive maintenance instructions.

[0076] A MEMS triaxial accelerometer (sampling rate 10kHz) detects the telescopic rod's vibration spectrum (0-5kHz), capturing resonant frequency shifts caused by micron-level deformation (e.g., the characteristic frequency shifts from 120Hz to 135Hz when the spring is fatigued). The system stores over 10,000 fault case studies, including typical failure modes such as damper oil leakage (characteristic: a sudden increase in energy in the 200-400Hz frequency band) and memory alloy spring fracture (characteristic: harmonic resonance at 1.2kHz). Dynamic Time Warping (DTW) is used to compare the real-time spectrum with historical fault signature spectra, triggering an alert when the similarity exceeds 85%.

[0077] The embodiment of the present invention further provides a method for real-time monitoring of the secondary operation of a tunnel boring machine, which is used in the real-time monitoring system for the secondary operation of a tunnel boring machine in the above embodiment.

[0078] The real-time monitoring method for the secondary operation of a tunnel boring machine according to an embodiment of the present invention includes:

[0079] Through infrared ranging and magnetic induction composite detection, the real-time distance between the composite trigger component 2 and the limit lever component 1 is obtained. Combining infrared ranging (non-contact continuous monitoring) and magnetic induction (close-range precise triggering) enables dual verification in complex environments such as dust and vibration.

[0080] The safety threshold is dynamically calculated based on the roadway slope and equipment load, and the servo motor is driven to adjust the limit position. The safety threshold is calculated in real time, and the safety distance is automatically extended by 0.2m for every 1° increase in slope, resolving the problem of fixed thresholds being unable to adapt to geological changes.

[0081] When it is detected that the distance exceeds the safety threshold, emergency braking is triggered, and the three-level control of deceleration warning, hydraulic locking, and emergency power off is executed in sequence. The three-level response delay is set to 0.5s, 0.3s, and 0.1s respectively to avoid unplanned shutdowns caused by false triggering.

[0082] The device displacement trajectory and safety boundary are displayed synchronously on the display terminal 5, and holographic data of the collision event is recorded. The device displacement trajectory is superimposed on the lane model constructed by SLAM (refresh rate 30Hz), and abnormal points with safety boundary deviation greater than 5cm are marked to assist in accident tracing.

[0083] Vibration spectrum analysis results are used to predict the lifespan of the limit lever assembly 1, triggering a maintenance work order before the replacement threshold is reached. 0-5kHz vibration signals are collected and 12-dimensional feature vectors are extracted through wavelet packet decomposition to identify faults such as spring fatigue (eigenfrequency shift ≥ 5%) and damper failure (energy entropy increase of 30%).

[0084] For example, if the slope sensor detects a sudden increase in the roadway slope from 5° to 12°, the system dynamically adjusts the position of the limit lever, triggering a secondary response (hydraulic locking) to prevent the railcar from derailing due to gravity acceleration. Data Display Terminal 5 also marks the area outside the safety margin in real time, guiding the operator to adjust the propulsion speed.

[0085] The vibration spectrum analysis module detected an abnormal increase in the damper's vibration energy entropy (exceeding the threshold by 15%), prompting the system to issue a replacement work order 10 days in advance. Maintenance personnel located the fault according to the work order and completed the replacement within 20 minutes, avoiding eight hours of unplanned downtime.

[0086] The real-time monitoring method for the secondary operation of a tunnel boring machine according to an embodiment of the present invention and the multi-level response mechanism shift the accident risk control from "post-event disposal" to "pre-event prevention", thereby improving the inherent safety.

[0087] Furthermore, when emergency braking is triggered, a release mechanism must be satisfied to release the brake. The release mechanism includes:

[0088] The operator of the tunnel boring machine 10 completes fingerprint verification at the biometric terminal in the cockpit;

[0089] The ground monitoring station sends the digital key via the wireless terminal;

[0090] The central control module 3 releases the locked state after verifying the time-space consistency.

[0091] This release mechanism achieves triple verification through the coordinated verification of identity uniqueness, key dynamics, and temporal and spatial authenticity to completely block illegal release paths, strengthen management, and improve operational security.

[0092] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0093] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0094] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0095] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0096] In the present invention, the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples without contradiction.

[0097] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. A real-time monitoring system for the secondary operation of a fully-mechanized tunnel boring machine, characterized in that: include: A limit lever assembly is provided at the tail of the belt conveyor, and is retractable along the extension direction of the belt conveyor. The limit lever assembly includes a telescopic rod driven by a servo motor and a built-in pressure sensor and inclination sensor; A composite trigger assembly is provided on the front side of the rail car of the tunnel boring machine, and includes a mechanical travel switch, a magnetic induction proximity switch and an infrared ranging sensor; A central control module, the central control module is connected to the limit lever assembly and the composite trigger assembly via a CAN bus, the central control module having a safety distance calculation unit and a multi-stage response logic unit; A hydraulic actuator assembly, comprising a hydraulic push rod linked to the telescopic rod and a solenoid valve assembly connected to the power system of the tunneling machine; The real-time monitoring system for the secondary operation of the tunnel boring machine monitors the distance between the composite trigger assembly and the limit lever assembly in real time. When the detection value is less than a preset safety threshold, the central control module drives the hydraulic actuator assembly to perform deceleration or shutdown control.

2. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 1 is characterized in that: The composite trigger component has three trigger modes: When the infrared distance sensor detects that the distance is ≤1.5m, it triggers an audible and visual warning and reduces the feeding speed of the tunnel boring machine to 50%; When the magnetic induction proximity switch detects that the distance is ≤0.8m, the hydraulic lock is activated and the power supply of the cutting motor is cut off; When the mechanical travel switch makes physical contact, emergency braking is immediately triggered and power-off protection is started.

3. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 1 is characterized in that: The limit lever assembly also includes a multi-stage buffer, which includes a polyurethane elastic layer wrapped around the outer layer of the telescopic rod, a hydraulic damper arranged inside the telescopic rod, and a bidirectional memory alloy spring connected to the frame of the belt conveyor. The damping coefficient of the hydraulic damper is dynamically adjusted according to the pressure sensor reading.

4. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 1 is characterized in that: The central control module receives the tunnel slope data measured in real time by the inclination sensor, calculates the minimum safety margin based on the mass, movement speed and slope data of the tunnel boring machine, and drives the servo motor to adjust the extension length of the telescopic rod so that the physical position of the limit lever assembly coincides with the calculated safety boundary.

5. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 4 is characterized in that: The central control module is connected to a display terminal, which is used to display the three-dimensional model of the tunnel, the virtual marking line of the safety boundary and the highlighted warning area of the composite trigger component action.

6. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 1 is characterized in that: It also includes an energy storage and power generation module, which is connected to the limit lever assembly to convert collision kinetic energy into electrical energy for storage.

7. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 1 is characterized in that: It also includes a track topology monitoring subsystem, which includes an RFID tag array, a radio frequency reader and a digital twin reconstruction module. The RFID tag array is arranged at equal intervals along the extension direction of the belt conveyor. The radio frequency reader is located at the bottom of the second transport of the tunnel boring machine. The digital twin reconstruction module generates a track extension error alarm signal by comparing the actual read tag position data with the preset track model.

8. The real-time monitoring system for the secondary operation of a tunnel boring machine according to claim 1 is characterized in that: It also includes a vibration spectrum analysis module, which is arranged on the limit lever assembly. The vibration spectrum analysis module is used to collect the vibration frequency characteristics of the telescopic rod, compare the characteristic spectrum in the historical fault database, and generate preventive maintenance instructions.

9. A real-time monitoring method for the secondary operation of a tunnel boring machine, characterized in that: The method for real-time monitoring of the secondary operation of a tunnel boring machine is applicable to the real-time monitoring system for the secondary operation of a tunnel boring machine according to any one of claims 1 to 8, and the method for real-time monitoring of the secondary operation of a tunnel boring machine comprises: The real-time distance between the composite trigger assembly and the limit lever assembly is obtained through infrared ranging and magnetic induction composite detection; Dynamically calculate the safety threshold based on the roadway slope and equipment load, and drive the servo motor to adjust the limit position; When it is detected that the distance exceeds the safety threshold, emergency braking is triggered, and three levels of control are executed in sequence: deceleration warning, hydraulic locking, and emergency power off; The device displacement trajectory and safety boundary are synchronously displayed on the display terminal, and the holographic data of the collision event is recorded; Vibration spectrum analysis results are used to predict the life of the limit lever assembly and trigger a maintenance work order before the replacement threshold is reached.

10. The real-time monitoring method for the secondary operation of a tunnel boring machine according to claim 9, characterized in that: When the emergency brake is triggered, the release mechanism must be met to release the brake. The release mechanism includes: The tunnel boring machine operator completes fingerprint verification at the biometric terminal in the cockpit; The ground monitoring station sends the digital key via the wireless terminal; The central control module releases the locked state after verifying the time and space consistency.

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