A monitoring system for wear of a cutting head of a tunnel boring machine

Abstract

The application provides a shield machine cutter wear monitoring system and relates to the technical field of tunneling.The monitoring system comprises a detection module, a first excitation magnet and a second excitation magnet which are sequentially and interval arranged, the magnetic field of the first excitation magnet and the second excitation magnet is superposed, the magnetic sensitive element detects the change of the magnetic field between the first excitation magnet and the second excitation magnet and outputs a detection signal, and an acquisition module which is electrically connected with the magnetic sensitive element and receives the detection signal of the magnetic sensitive element.The shield machine cutter wear monitoring system increases the detection range, improves the reliability and consistency of detection.

Description

Technical Field

[0001] This invention relates to the field of tunnel boring technology, and in particular to a monitoring system for cutterhead wear of a tunnel boring machine. Background Technology

[0002] A tunnel boring machine (TBM) is a specialized engineering machine for tunnel excavation. The cutter head is the component most prone to wear and failure during the TBM excavation process. If worn cutter heads are not detected and replaced in a timely manner, they will become severely worn, making it difficult for the TBM to excavate and affecting construction efficiency. In some cases, it may even cause severe wear of the cutterhead, requiring the excavation of a vertical shaft to replace the cutterhead. Furthermore, manual pressurized entry into the shaft poses a significant health hazard and presents substantial economic and safety risks.

[0003] Existing technologies typically employ eddy current sensors for wear detection. However, the measuring range of currently used eddy current sensors is relatively small, generally only around 20mm. This limitation restricts their mounting on the tool holder, requiring them to protrude from the holder and be close to the hob, making them susceptible to damage from debris. Furthermore, eddy current sensors consume significant power. In addition, existing hob wear detection devices suffer from poor consistency and low sensitivity, requiring individual calibration, which is cumbersome.

[0004] In view of this, based on years of experience in production and design in this and related fields, the inventor has designed a monitoring system for the wear of tunnel boring machine cutters through repeated experiments, in order to solve the problems existing in the prior art. Summary of the Invention

[0005] The purpose of this invention is to provide a monitoring system for cutter wear in tunnel boring machines, which increases the detection range and improves the reliability and consistency of the detection.

[0006] To achieve the above objectives, this invention proposes a monitoring system for cutterhead wear in tunnel boring machines, wherein the monitoring system includes:

[0007] The detection module includes a magnetic sensitive element, a first excitation magnet, and a second excitation magnet arranged sequentially at intervals. The magnetic fields of the first excitation magnet and the second excitation magnet are superimposed. The magnetic sensitive element detects the change in the magnetic field between the first excitation magnet, the second excitation magnet, and the hobbing cutter and outputs a detection signal.

[0008] The acquisition module is electrically connected to the magnetic sensing element and receives the detection signal from the magnetic sensing element.

[0009] The tunnel boring machine cutterhead wear monitoring system described above further includes a data processing module, which is electrically connected to the acquisition module and analyzes and displays the detection signals transmitted by the acquisition module.

[0010] In the tunnel boring machine cutter wear monitoring system described above, the data processing module has a built-in detection signal-wear curve, and the data processing module determines the wear amount of the cutter's cutting edge based on the detection signal-wear curve.

[0011] In the tunnel boring machine cutter wear monitoring system described above, the magnetic sensitive element, the first excitation magnet, and the second excitation magnet are arranged sequentially along the radial direction of the cutter and in a direction away from the cutting edge.

[0012] In the tunnel boring machine cutterhead wear monitoring system described above, the outer diameter of the first excitation magnet is smaller than the outer diameter of the second excitation magnet.

[0013] In the tunnel boring machine cutterhead wear monitoring system described above, the detection signal output by the acquisition module is a voltage signal.

[0014] The tunnel boring machine cutterhead wear monitoring system described above further includes a magnet spacing adjustment module, which comprises:

[0015] The second excitation magnet bracket is used to mount the second excitation magnet;

[0016] A first excitation magnet bracket is used to mount the first excitation magnet, and the first excitation magnet bracket is mounted on the second excitation magnet bracket;

[0017] A magnetic element bracket is used to mount the magnetic element, and the magnetic element bracket is mounted on the second excitation magnet bracket.

[0018] In the tunnel boring machine cutterhead wear monitoring system described above, the first excitation magnet bracket is mounted on the second excitation magnet bracket via a spacing adjustment mechanism, which can adjust the spacing between the first excitation magnet and the second excitation magnet.

[0019] The tunnel boring machine cutterhead wear monitoring system described above further includes a protection module, wherein the magnet spacing adjustment module is fixed inside the protection module, and the protection module is fixedly installed on the cutterhead end cover of the tunnel boring machine.

[0020] In the tunnel boring machine cutterhead wear monitoring system described above, the magnetic sensing element detects signals and transmits them to the acquisition module via a wired or wireless means through the end cover.

[0021] Compared with the prior art, the present invention has the following features and advantages:

[0022] The shield machine cutter wear monitoring system proposed in this invention has a detection module set up directly opposite the cutter edge. A first excitation magnet and a second excitation magnet generate a magnetic field. When the cutter edge wears, the distance between the cutter edge and the wear detection sensor changes, resulting in a change in the magnetic field. The magnetic sensitive element senses the change in magnetic field strength caused by the cutter wear and further outputs a detection signal.

[0023] The magnetic field at the magnetic sensing element is the superposition of the magnetic fields of multiple excitation magnets and the magnetization magnetic field of the blade. By adjusting the relative positions of the multiple excitation magnets and the magnetic sensing element, the sensitivity of wear detection can be improved, and the consistency among multiple wear sensors can be ensured.

[0024] The shield machine cutter wear monitoring system proposed in this invention can accurately and reliably detect changes in cutter wear, monitor changes in cutter wear in real time, and provide reliable data support for shield machine cutter replacement. Attached Figure Description

[0025] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. Those skilled in the art, guided by the teachings of this invention, can select various possible shapes and proportions to implement the invention according to specific circumstances.

[0026] Figure 1 This is a schematic diagram of the overall system for monitoring cutter wear of tunnel boring machines proposed in this invention;

[0027] Figure 2 This is a schematic diagram of the connection of the tunnel boring machine cutter wear monitoring system proposed in this invention;

[0028] Figure 3 This is a schematic diagram of the structure of the device for adjusting the distance between the first excitation magnet and the second excitation magnet in this invention.

[0029] Figure 4 This is a schematic diagram of one embodiment of the present invention.

[0030] Explanation of reference numerals in the attached figures:

[0031] 100. Monitoring system; 10. Detection module;

[0032] 11. Magnetic sensitive element; 12. First excitation magnet;

[0033] 13. Second excitation magnet; 20. Acquisition module;

[0034] 30. Data processing module; 40. Magnet spacing adjustment module;

[0035] 41. Second excitation magnet support; 42. First excitation magnet support;

[0036] 43. Magnetic Sensitive Element Support; 50. Protection Module;

[0037] 60. Data receiving module;

[0038] 200, hobbing cutter; 300, end cap. Detailed Implementation

[0039] The details of the present invention can be more clearly understood by referring to the accompanying drawings and the description of specific embodiments. However, the specific embodiments of the present invention described herein are for illustrative purposes only and should not be construed as limiting the invention in any way. Under the teachings of this invention, those skilled in the art can conceive of any possible modifications based on the invention, and these should all be considered to fall within the scope of the invention.

[0040] like Figures 1 to 3 As shown, the present invention proposes a monitoring system 100 for the wear of the cutter head of a tunnel boring machine. The monitoring system includes at least a detection module 10 and a data acquisition module 20. The detection module 10 includes a magnetic sensitive element 11, a first excitation magnet 12 and a second excitation magnet 13 arranged sequentially at intervals. The magnetic fields of the first excitation magnet 12 and the second excitation magnet 13 are superimposed. The magnetic sensitive element 11 detects the change in the magnetic field between the first excitation magnet 12, the second excitation magnet 13 and the cutter head 200 and outputs a detection signal. The data acquisition module 20 is electrically connected to the magnetic sensitive element 11 and receives the detection signal from the magnetic sensitive element 11.

[0041] The shield machine cutter wear monitoring system 100 proposed in this invention has a detection module 10 positioned directly opposite the cutter edge of the cutter 200. A first excitation magnet 12 and a second excitation magnet 13 generate a magnetic field. When the cutter edge of the cutter 200 wears, the distance between the cutter edge and the first excitation magnet 12 and the second excitation magnet 13 changes, thereby causing a change in the magnetic field. The magnetic sensitive element 11 senses the change in magnetic field strength caused by the cutter wear and further outputs a detection signal.

[0042] The shield machine cutter wear monitoring system 100 proposed in this invention can accurately and reliably detect changes in cutter wear, monitor changes in cutter wear in real time, and provide reliable data support for shield machine cutter replacement.

[0043] In this invention, the magnetic field generated by the first excitation magnet 12 and the second excitation magnet 13 forms a closed magnetic circuit after passing through the cutting edge of the hob. Therefore, when the cutting edge wears down, the distance between the cutting edge and the excitation magnet will also increase. As reflected in the detection signal, the detected signal changes as the cutting edge wears down.

[0044] In an optional embodiment of the present invention, the magnetic sensitive element 11, the first excitation magnet 12, and the second excitation magnet 13 are arranged sequentially in a direction opposite to the cutting edge of the hob. This ensures that the magnetic field formed between the first excitation magnet 12 and the second excitation magnet 13 changes more sensitively and accurately as the cutting edge wears.

[0045] In an optional example of this embodiment, the outer diameter of the first excitation magnet 12 is smaller than the outer diameter of the second excitation magnet 13. With this structure, the second excitation magnet 13 generates the main excitation signal, and the first excitation magnet 12 eliminates the inconsistencies of the second excitation magnet 13, while simultaneously reducing the magnetic field strength at the location of the magnetic sensing element 11 (detection chip) without affecting the magnetic field at the cutting edge of the hobbing cutter. This allows for the selection of a magnetic sensing element 11 with a small range and high sensitivity, while simultaneously allowing for the selection of a second excitation magnet 13 with a large magnetic field strength, thereby increasing the sensor's range. Furthermore, due to the poor consistency of the magnets, adjusting the position of the first excitation magnet 12 enables unified calibration of the detection module 10, improving the consistency of the detection module 10.

[0046] In an optional embodiment of the present invention, the first excitation magnet 12 and the second excitation magnet 13 can each be composed of one or more magnets, and the first excitation magnet 12 and the second excitation magnet 13 can be hollow magnets (hollow cylindrical type) or other shapes.

[0047] Furthermore, taking the first excitation magnet 12 as an example, the first excitation magnet 12 can be composed of one or more magnets. The first excitation magnet 12 can also use multiple magnets. When multiple magnets are used, the magnetic field generated by the first excitation magnet 12 itself can be adjusted by adjusting the spacing between the magnets.

[0048] In this invention, the selection of the first excitation magnet 12 and the second excitation magnet 13 is determined based on the required range and space. The specific selection method is as follows: a. First, select a large magnet (second excitation magnet 13) according to the range to ensure that a relatively clear magnetic field strength can still be detected at the blade edge within the maximum range; b. Plot the curve of the change of magnetic field strength at the blade edge as the distance from the blade changes when only the large magnet is used. Then, perform the same test with several small magnets and plot the test curves of the large and small magnets on the same coordinate system; c. The intersection point represents the position where the magnetic field strength of the small magnet and the large magnet can cancel each other out to 0. Then, select a suitable small magnet (first excitation magnet 12) according to the spatial requirements and magnet volume to avoid interference.

[0049] In an optional embodiment of the present invention, the monitoring system 100 further includes a magnet spacing adjustment module 40. The magnet spacing adjustment module 40 includes a second excitation magnet bracket 41, a first excitation magnet bracket 42, and a magnetic sensitive element bracket 43. The second excitation magnet bracket 41 is used to mount the second excitation magnet 13; the first excitation magnet bracket 42 is used to mount the first excitation magnet 12; and the magnetic sensitive element bracket 43 is used to mount the magnetic sensitive element 11. The first excitation magnet bracket 42 and the magnetic sensitive element bracket 43 are respectively mounted on the second excitation magnet bracket 41. Using the above structure, the detection module 10 is installed and adjusted via the magnet spacing adjustment module 40.

[0050] In an optional example of this implementation, the monitoring system 100 further includes a protection module 50, with a magnet spacing adjustment module 40 fixed inside the protection module 50, and the protection module 50 is fixedly installed on the cutterhead end cover 300 of the tunnel boring machine.

[0051] In an optional example, the protective module 50 is welded to the end cap 300 of the cutter barrel.

[0052] Preferably, the protective module 50 is located on the end cap directly opposite the blade, and this installation position is about 8mm away from the blade surface, so as not to affect the normal rotation of the roller to break rocks, and not to affect the normal replacement of the blade.

[0053] In an optional example of this embodiment, the first excitation magnet support 42 is mounted on the second excitation magnet support 41 by a spacing adjustment mechanism, which can adjust the spacing between the first excitation magnet 12 and the second excitation magnet 13.

[0054] The initial spacing range of the first excitation magnet 12 and the second excitation magnet 13 is determined according to the zeroing state. Due to the differences in actual specifications of different magnets, plus assembly errors, the initial detection value of the detection module 10 is made the same by adjusting the spacing, so as to ensure the consistency of the detection module 10 (sensor).

[0055] In an optional example, by adjusting the spacing between the first excitation magnet 12 and the second excitation magnet 13 through the spacing adjustment mechanism, the magnetic field strength of the second excitation magnet 13 at the magnetic sensitive element 11 can be reduced, making it easier to select a high-sensitivity magnetic sensitive element 11. Furthermore, by adjusting the first excitation magnet 12, the initial state of different detection modules 10 (sensors) can be adjusted to be the same, improving the consistency of the sensors and avoiding the need for individual calibration after installation.

[0056] In an optional example, the spacing adjustment mechanism includes two adjusting bolts, each of which passes through the first excitation magnet bracket 42 and is threadedly engaged with the first excitation magnet 42. The second excitation magnet bracket 41 has a mounting threaded hole for the adjusting bolts to align with it. The position of the first excitation magnet bracket 42 can be adjusted by rotating the adjusting bolts.

[0057] In an optional example, the range of the measurement module 10 is adjusted by a spacing adjustment mechanism, which facilitates the selection of a high-sensitivity detection module. Furthermore, by adjusting the position of the first excitation magnet 12, the initial state of different detection modules 10 can be made the same, avoiding the need for individual calibration after installation and improving the consistency of the detection modules 10 (sensors).

[0058] In an optional example of this embodiment, the protective module 50 is made in the shape of a club by means of the cable outlet of the cutter barrel end cap 300, while avoiding interference from other components. The protective module 50 includes a base and a cover plate; it is made of non-magnetic, highly wear-resistant metal material to avoid damage from the slag inside the cutter barrel and improve the stability of the sensor.

[0059] In an optional embodiment of the present invention, the monitoring system further includes a data processing module 30, which is electrically connected to the acquisition module 20. The data processing module 30 analyzes, processes, and displays the detection signals.

[0060] In an optional example of this implementation, the data processing module 30 is located in the host computer and electrically connected to the acquisition module 20 through the data receiving module, and is used to analyze and confirm the amount of wear.

[0061] Furthermore, such as Figure 4 As shown, a monitoring module 10 (cutter monitoring sensor) is set at the position of each cutter 200 on the shield machine. The monitoring module 10 is electrically connected to the acquisition module 20 (data acquisition module). The acquisition module 20 is electrically connected to the data processing module 30 through the data collection module.

[0062] In an optional embodiment of the present invention, the detection signal output by the acquisition module 20 is a voltage signal.

[0063] In an optional example of this implementation, the data processing module 30 has a built-in detection signal-wear curve, and the data processing module 30 determines the wear amount of the hob 200 based on the detection signal-wear curve.

[0064] In an optional example, the process of plotting the detection signal-wear curve is as follows: By controlling the change of the distance D between the detection surface of the detection module 10 and the blade, the voltage signal output by the detection module is recorded. The distance D changes from near to far. When the distance is near, a smaller amount is adjusted each time, and when the distance is far, a slightly larger amount is adjusted each time to ensure the continuity of the detection signal.

[0065] When the detection module 10 is close to the blade, a smaller distance is adjusted for each measurement. When the distance is greater, the adjustment distance can be appropriately increased for each measurement. Then, a curve is fitted based on the distance and the output voltage signal, which serves as the sensor's calibration curve. Multiple sets of tests are performed, and the final average fitted curve is obtained. Then, in actual measurements, the corresponding wear amount can be obtained based on the output voltage signal.

[0066] In an optional embodiment of the present invention, the magnetic sensing element 11 and the acquisition module 20 can be connected by wired or wireless means.

[0067] Compared with the prior art, the shield machine cutter wear monitoring system 100 proposed in this invention adopts a monitoring module 10 (sensor) including an excitation magnet placed in the opposite direction. This solves the problems of small detection range, easy damage by slag and soil, poor sensor consistency and difficult calibration in the prior art. Therefore, the shield machine cutter wear monitoring system 100 proposed in this invention can realize real-time, simple and accurate measurement of cutter wear without affecting the normal operation of the cutter, providing reliable data support for cutter replacement and improving the safety factor in the construction process.

[0068] The detailed explanations of the above embodiments are intended only to explain the present invention so as to facilitate a better understanding of the present invention. However, these descriptions should not be construed as limiting the present invention for any reason. In particular, the various features described in different embodiments can be arbitrarily combined with each other to form other embodiments. Unless there is an explicit description to the contrary, these features should be understood to be applicable to any embodiment, and not limited to the described embodiments.

Claims

1. A monitoring system for cutterhead wear in a tunnel boring machine, characterized in that, The monitoring system includes: The detection module includes a magnetic sensitive element, a first excitation magnet, and a second excitation magnet arranged sequentially at intervals. The magnetic fields of the first excitation magnet and the second excitation magnet are superimposed. The magnetic sensitive element detects the change in the magnetic field between the first excitation magnet, the second excitation magnet, and the hobbing cutter and outputs a detection signal. The acquisition module is electrically connected to the magnetic sensing element and receives the detection signal from the magnetic sensing element; Magnet spacing adjustment module, the magnet spacing adjustment module includes: The second excitation magnet bracket is used to mount the second excitation magnet; A first excitation magnet bracket is used to mount the first excitation magnet, and the first excitation magnet bracket is mounted on the second excitation magnet bracket; A magnetic element bracket is used to mount the magnetic element, and the magnetic element bracket is mounted on the second excitation magnet bracket.

2. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 1, characterized in that, The monitoring system also includes a data processing module, which is electrically connected to the acquisition module and analyzes and displays the detection signals transmitted by the acquisition module.

3. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 2, characterized in that, The data processing module has a built-in detection signal-wear curve, and the data processing module determines the wear amount of the cutting edge of the hob based on the detection signal-wear curve.

4. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 1, characterized in that, The magnetic sensitive element, the first excitation magnet, and the second excitation magnet are arranged sequentially along the radial direction of the hob and in a direction away from the cutting edge.

5. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 4, characterized in that, The outer diameter of the first excitation magnet is smaller than the outer diameter of the second excitation magnet.

6. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 1, characterized in that, The detection signal output by the acquisition module is a voltage signal.

7. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 1, characterized in that, The first excitation magnet bracket is mounted on the second excitation magnet bracket via a spacing adjustment mechanism, which can adjust the spacing between the first excitation magnet and the second excitation magnet.

8. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 1, characterized in that, The monitoring system also includes a protection module, the magnet spacing adjustment module is fixed inside the protection module, and the protection module is fixedly installed on the cutterhead end cover of the tunnel boring machine.

9. The monitoring system for cutterhead wear of a tunnel boring machine as described in claim 1, characterized in that, The detection signal from the magnetic sensing element is transmitted to the acquisition module via a wired or wireless means through the end cover.

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