Tunnel boring machine cutterhead vibration on-line remote monitoring system and method

Abstract

The application provides a tunnel boring machine cutterhead vibration online remote monitoring system and method, and belongs to the technical field of real-time monitoring of underground construction of a full-face rock tunnel boring machine. The purpose of the application is to realize a TBM cutterhead vibration long-term online monitoring and collecting system with high reliability. Firstly, a cylindrical protection device of a node is designed for the extreme environment of a tunnel, so that the vibration collecting device has the characteristics of strong impact resistance, high reliability and long service life. Meanwhile, a vibration online remote monitoring and collecting system is built, the functions of data collection, saving, display and remote transmission are realized by combining software and hardware with computer technology, the long-distance online collection of cutterhead vibration data is realized, and the automatic monitoring and early warning functions of out-of-limit vibration data can be realized by setting an alarm threshold.

Description

Technical Field

[0001] This invention relates to an online remote monitoring system and method for the vibration of a tunnel boring machine cutterhead, belonging to the field of real-time monitoring technology for underground construction of full-face rock tunnel boring machines. Background Technology

[0002] Tunnel boring machines (TBMs) are essential equipment for tunnel boring, offering advantages such as high excavation speed and overall efficiency, and are widely used. TBMs operate in complex and variable environments, and the cutterhead system, located at the front of the TBM, is responsible for the main excavation work; nearly 70% of vibration-related safety issues are directly related to the cutterhead system. Because the cutters on the cutterhead perform multi-point impact rock breaking, this causes relatively strong vibrations in the TBM, potentially leading to damage and fracture. Therefore, vibration monitoring of the TBM cutterhead system is crucial.

[0003] The TBM main system mainly includes key components such as the cutterhead system, support shield, main beam, and support shoes. Harsh load conditions cause severe cutterhead vibration, making the vibration sensors installed on the cutterhead prone to damage. This can easily lead to incorrect TBM operating parameter settings and mismatches with the tunneling geology, resulting in severe TBM vibration, construction accidents, and delays in construction progress. To ensure stable and efficient TBM tunneling, it is urgent to establish an online remote monitoring system for cutterhead vibration. This system would provide data reference for on-site construction personnel, facilitate data aggregation from multiple sections and equipment, and enable technical experts to remotely analyze the cutterhead's health status.

[0004] Due to the extremely harsh working conditions of TBMs, monitoring the vibration of the cutterhead system is extremely difficult. Although some scholars have proposed vibration monitoring technologies for key locations of the cutterhead system, these are limited to underground monitoring and do not involve remote online monitoring. A complete online remote monitoring scheme for TBM cutterhead vibration is still lacking. To reduce the difficulty of acquiring and transmitting cutterhead vibration data in TBM systems and to alleviate the problems of low efficiency and unreasonable monitoring of cutterhead vibration systems, it is necessary to propose an online remote monitoring system and method for tunnel boring machine cutterhead vibration. Summary of the Invention

[0005] The purpose of this invention is to provide an online remote monitoring system and method for tunnel boring machine (TBM) cutterhead vibration. In order to gain a more comprehensive understanding of the vibration status of the TBM during construction, an online remote monitoring and acquisition system for TBM cutterhead vibration was built based on wireless transmission technology to perform remote online monitoring of vibration.

[0006] The technical solution of the present invention is as follows:

[0007] A remote online monitoring system for the vibration of a tunnel boring machine cutterhead includes a vibration acquisition device, a gateway device, an industrial computer, a ground server, and a remote server.

[0008] The vibration acquisition device is arranged on the back of the chute of the cutterhead of the tunnel boring machine. The vibration acquisition device includes a ZigBee wireless sensor node with a built-in battery, a spherical antenna for transmitting signals, and a cylindrical protective device. The ZigBee wireless sensor node is connected to the spherical antenna for transmitting signals.

[0009] The ZigBee wireless sensor node includes an accelerometer for measuring vibration, a CC2530 data processing and transmission module, and a wireless communication module. The data obtained by the accelerometer is processed by the CC2530 data processing and transmission module and then transmitted to the wireless communication module using ZigBee transmission technology. The wireless communication module is connected to a spherical antenna for transmitting signals, and the signals are transmitted to the gateway device via the spherical antenna.

[0010] The gateway device includes a ZigBee gateway and a gateway antenna. The ZigBee gateway is installed on the outer side of the middle section of the main beam of the tunnel boring machine, and the gateway antenna is arranged on the inner side of the middle section of the main beam to achieve signal transmission without metal obstruction.

[0011] The vibration acquisition device is wirelessly connected to the gateway device; the industrial computer is connected to the gateway device; the industrial computer is wirelessly connected to the ground server; and the ground server communicates wirelessly with the remote server.

[0012] The vibration data collected by the vibration acquisition device is transmitted through an antenna. The gateway device receives the vibration data collected by the acquisition device through a wireless receiving module and transmits the vibration data to the industrial computer. The ground server reads and controls the wireless signal transmitted by the industrial computer through the local area network, and at the same time interacts with the remote server of the monitoring center through the wide area network. The ground server is equipped with data acquisition software to collect and process the vibration data.

[0013] The specific structure of the vibration acquisition device is as follows:

[0014] The outer shell of the ZigBee wireless sensor node consists of a cylindrical segment and an octagonal segment. The accelerometer, CC2530 data processing and transmission module, and wireless communication module are all fixed inside the outer shell.

[0015] The cylindrical protective device consists of a top cover, a top locking ring, and a protective cover base;

[0016] The protective cover base includes a base and a cylindrical structure located on the base. The vibration acquisition device is fixed in the installation position by the base. One end of the cylindrical structure is open, and the inner wall of the other end is provided with an octagonal groove that matches the octagonal segment of the ZigBee wireless sensor node shell, so that the octagonal segment of the ZigBee wireless sensor node can be inserted into the cylindrical structure to achieve plug-in installation.

[0017] The top locking ring comprises a cylindrical part and a disc part, which are integral structures. The cylindrical part is inserted into the open end of the cylindrical structure of the protective cover base, and the inner wall of the cylindrical part matches the outer wall of the cylindrical section of the ZigBee wireless sensor node shell to further fix the ZigBee wireless sensor node. The disc part has screw holes along the circumference and is fixed to the outside of the top end of the open end of the cylindrical structure of the protective cover base with bolts, thereby fixing the top locking ring to the protective cover base.

[0018] The upper cover comprises two circular structures, upper and lower, connected and fixed by multiple cylinders. The upper disk is smaller than the lower disk, and both have through holes in their centers. The bottom of the spherical antenna is installed in the central through hole of the lower disk, located between the two disks and the cylinders, providing external protection for the spherical antenna. The central through hole of the upper disk is used for signal transmission by the spherical antenna. The lower disk has screw holes along its circumference, corresponding to the screw holes on the disk portion of the top retaining ring. Through the cooperation of the screw holes and bolts, the upper cover and the top retaining ring are fixed together to the protective cover base.

[0019] The gateway device also includes a shock-absorbing pad, a protective cover, and a network cable.

[0020] The data acquisition software includes data analysis and processing software, protocol configuration software, communication software, and receiving software.

[0021] A method for online remote monitoring of tunnel boring machine vibration based on the above detection system includes the following steps:

[0022] (1) Device layout and software installation: The vibration acquisition device is placed on the back of the chute of the tunnel boring machine cutterhead. Vibration acquisition devices can be installed on the back of multiple chutes that do not interfere with the cutter replacement space; the ZigBee gateway is installed on the outer side of the middle section of the main beam of the tunnel boring machine, and the gateway antenna is arranged on the inner side of the middle section of the main beam; data acquisition software is installed on the ground server.

[0023] (2) Vibration monitoring: Vibration information around the ZigBee wireless sensor nodes is collected by an accelerometer. The analog variables are then processed by the CC2530 data processing and transmission module. The data is then wirelessly transmitted to the ZigBee gateway device via a spherical antenna and connected to the network port (industrial computer) in the TBM control room for data storage and analysis. The industrial computer data is transmitted to the ground server via LoRa wireless bridging technology. At the same time, data acquisition software is installed on the ground server to display and store the vibration data collected by the ZigBee wireless sensor nodes in real time. The remote server (local server) and the ground server transmit data over long distances via GPRS wireless wide area network. The receiving end parses the database and saves it to the remote server database to realize online remote monitoring of the data. At the same time, alarm thresholds are set to realize the automatic monitoring and early warning function for excessive vibration data.

[0024] The beneficial effects of this invention are:

[0025] (1) The designed integrated vibration acquisition device can improve the stability of underground monitoring devices and wirelessly transmit vibration information to the ZigBee gateway. It has the characteristics of strong impact resistance, high reliability and long service life. The designed cylindrical protective device and ZigBee wireless sensor node are used together to achieve plug-in installation. The integrated design saves space. At the same time, the protective cover base keeps the node in a good relative position to prevent movement and rotation. It has the advantages of simple installation and removal and easy replacement in harsh construction environments.

[0026] (2) The monitoring system can display and store the vibration data collected by the vibration acquisition device in real time, and send the data to the remote server for storage in real time, realizing the wireless nature of the online remote monitoring system;

[0027] (3) The application direction of online remote monitoring of tunnel boring equipment data was proposed, and real-time remote online monitoring of cutterhead vibration during TBM tunneling was realized. Attached Figure Description

[0028] Figure 1 This is the overall architecture of the tunnel boring machine cutterhead vibration online remote monitoring system of the present invention.

[0029] Figure 2 This is an underground layout diagram of the tunnel boring machine cutterhead vibration online remote monitoring system of the present invention.

[0030] Figure 3 This is a magnified view of the installation location of the vibration acquisition device.

[0031] Figure 4 This is a schematic diagram of the overall structure of the vibration acquisition device.

[0032] Figure 5 This is a schematic diagram of the structure of the protective cover base.

[0033] Figure 6 This is a schematic diagram of the structure of the shell of a ZigBee wireless sensor node.

[0034] Figure 7 This is a schematic diagram of the top retaining ring.

[0035] Figure 8 This is a schematic diagram of the upper cover.

[0036] Figure 9 This is a schematic diagram of a spherical antenna.

[0037] In the diagram: 1a Vibration acquisition device; 1b Signal transmission path; 1c ZigBee gateway; 1d Gateway antenna;

[0038] 2a Spherical antenna; 2b Top cover; 2c Top retaining ring; 2d Protective cover base; 2e ZigBee wireless sensor node. Detailed Implementation

[0039] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings and technical solutions.

[0040] The overall architecture of the tunnel boring machine vibration online remote monitoring system of the present invention is as follows: Figure 1 As shown, it includes a vibration acquisition device, a gateway device, an industrial computer, a ground server, and a remote server.

[0041] The TBM main system includes major components such as the cutterhead, support shield, main beam, and support shoes. During the rock breaking process, the cutterhead vibrates due to the impact of the rock.

[0042] Since the vibration acquisition device 1a is a vulnerable component, to reduce the probability of impact during tunneling and to prevent sensor failure due to the damp underground environment, this invention designs a cylindrical protective device to protect the ZigBee wireless sensor node 2e (with built-in battery), thus achieving waterproofing, moisture resistance, and impact resistance for the vibration acquisition device. Figure 4-9As shown, the cylindrical protective device consists of an upper cover 2b, a top locking ring 2c, and a protective cover base 2d. A spherical antenna 2a for transmitting signals is fixed at the center of the upper cover 2b, protecting it from damage caused by impacts from broken rocks. The top locking ring 2c is connected to both the upper cover 2b and the protective cover base 2d. The ZigBee wireless sensor node 2e is fixed to an octagonal groove within the protective cover base 2d to ensure it does not deflect during detection. The ZigBee wireless sensor node 2e is used to detect the vibration state of the cutterhead during operation. To ensure stable operation and greatly reduce the possibility of rock impacts, it is positioned on the back of the chute plate. The specific location and number of nodes can be set according to actual measurement requirements.

[0043] Figure 2 This is an underground layout diagram of the tunnel boring machine vibration online remote monitoring system of the present invention. The gateway device consists of a ZigBee gateway 1c for receiving wireless signals, a shock-absorbing pad, a protective cover, a gateway antenna 1d, and a network cable. During TBM tunneling, the vibration acquisition device 1a transmits the vibration data measured by the accelerometer to the ZigBee gateway 1c at the rear end of the main beam after the signal is amplified by the spherical antenna 2a. To ensure that the transmission path is unobstructed by metal, the gateway antenna 1d is placed inside the main beam.

[0044] Figure 1 This invention presents the overall architecture of the tunnel boring machine (TBM) vibration online remote monitoring system. Multiple vibration acquisition devices are arranged at the cutterhead, forming a star network topology to monitor vibration levels across 12 channels at multiple nodes. Vibration information around the nodes is collected via accelerometers. The analog variables are then processed by the CC2530 data processing and transmission module, and wirelessly transmitted via a spherical antenna 2a and a ZigBee gateway 1c. The signals received by the ZigBee gateway 1c are connected to the TBM control room's network port (industrial computer) for data storage and analysis. The industrial computer can control the nodes' built-in batteries to enter sleep mode when the machine is stopped, ensuring low power consumption.

[0045] Data is transmitted to a ground server via a wireless LAN. Simultaneously, data acquisition software is installed on the ground server to display and store the vibration data collected by the ZigBee wireless sensor node 2e in real time. The wireless LAN transmits industrial computer data to the ground server via LoRa wireless bridging technology. Utilizing LoRa wireless RF transmission technology, which offers longer transmission distances and low power consumption, increases the transmission distance of a single repeater. This allows the wireless LAN to cover the same area with fewer repeaters, reducing deployment costs.

[0046] The remote server (local server) and the ground server transmit data over long distances via a GPRS wireless wide area network. The receiving end parses the database and saves it to the remote server's database. The GPRS wireless modem on the ground server stores the received IP address in the data terminal, which then sends a configured data frame to the remote server. After identifying the IP address, the data is transmitted to the remote server, thus achieving remote data transmission.

[0047] During monitoring, ZigBee wireless sensor node 2e is installed on the back of the slag chute of the TBM cutterhead, and ZigBee gateway 1c is installed at the front end of the main beam to receive signals from the vibration acquisition device. Based on ZigBee short-range wireless communication technology, the vibration data collected by vibration acquisition device 1a is transmitted to the gateway device and connected to an industrial computer via a network cable. Then, LoRa wireless bridging technology is used to transmit the data to a ground server through a local area network. At the same time, data acquisition software is installed on the ground server to display and store the vibration data collected by vibration acquisition device 1a in real time. The remote server and the field server communicate with each other via GPRS wireless wide area network. The ground server transmits data signals to the remote server acquisition software receiver through the data acquisition software transmitter, realizing online remote detection of data. At the same time, alarm thresholds can be set to realize the automatic monitoring and early warning function for excessive vibration data.

[0048] The tunnel boring machine vibration online remote monitoring system and method of the present invention combines software and hardware with computer technology to realize the functions of collecting, storing, displaying and remotely transmitting tunnel boring machine vibration data.

Claims

1. A remote online monitoring system for the vibration of a tunnel boring machine cutterhead, characterized in that, The tunnel boring machine cutterhead vibration online remote monitoring system includes a vibration acquisition device, a gateway device, an industrial computer, a ground server, and a remote server; The vibration acquisition device is arranged on the back of the chute of the cutterhead of the tunnel boring machine. The vibration acquisition device includes a ZigBee wireless sensor node with a built-in battery, a spherical antenna for transmitting signals, and a cylindrical protective device. The ZigBee wireless sensor node is connected to the spherical antenna for transmitting signals. The ZigBee wireless sensor node includes an accelerometer for measuring vibration, a CC2530 data processing and transmission module, and a wireless communication module. The data obtained by the accelerometer is processed by the CC2530 data processing and transmission module and then transmitted to the wireless communication module using ZigBee transmission technology. The wireless communication module is connected to a spherical antenna for transmitting signals, and the signals are transmitted to the gateway device through the spherical antenna. The gateway device includes a ZigBee gateway and a gateway antenna. The ZigBee gateway is installed on the outer side of the middle section of the main beam of the tunnel boring machine, and the gateway antenna is arranged on the inner side of the middle section of the main beam to achieve signal transmission without metal obstruction. The vibration acquisition device is wirelessly connected to the gateway device; the industrial computer is connected to the gateway device; the industrial computer is wirelessly connected to the ground server; and the ground server communicates wirelessly with the remote server. The vibration data collected by the vibration acquisition device is transmitted through a spherical antenna. The gateway device receives the vibration data collected by the acquisition device through a wireless receiving module and transmits the vibration data to the industrial computer. The ground server reads and controls the wireless signal transmitted by the industrial computer through the local area network, and at the same time interacts with the remote server of the monitoring center through the wide area network. The ground server is equipped with data acquisition software to collect and process the vibration data. The specific structure of the vibration acquisition device is as follows: The outer shell of the ZigBee wireless sensor node consists of a cylindrical segment and an octagonal segment. The accelerometer, CC2530 data processing and transmission module, and wireless communication module are all fixed inside the outer shell. The cylindrical protective device consists of a top cover, a top locking ring, and a protective cover base; The protective cover base includes a base and a cylindrical structure located on the base. The vibration acquisition device is fixed in the installation position by the base. One end of the cylindrical structure is open, and the inner wall of the other end is provided with an octagonal groove that matches the octagonal segment of the ZigBee wireless sensor node shell, so that the octagonal segment of the ZigBee wireless sensor node can be inserted into the cylindrical structure to achieve plug-in installation. The top locking ring comprises a cylindrical part and a disc part, which are integral structures. The cylindrical part is inserted into the open end of the cylindrical structure of the protective cover base, and the inner wall of the cylindrical part matches the outer wall of the cylindrical section of the ZigBee wireless sensor node shell to further fix the ZigBee wireless sensor node. The disc part has screw holes along the circumference and is fixed to the outside of the top end of the open end of the cylindrical structure of the protective cover base with bolts, thereby fixing the top locking ring to the protective cover base. The upper cover comprises two circular structures, upper and lower, connected and fixed by multiple cylinders. The upper disk is smaller than the lower disk, and both have through holes in their centers. The bottom of the spherical antenna is installed in the central through hole of the lower disk, located between the two disks and the cylinders, providing external protection for the spherical antenna. The central through hole of the upper disk is used for signal transmission by the spherical antenna. The lower disk has screw holes along its circumference, corresponding to the screw holes on the disk portion of the top retaining ring. Through the cooperation of the screw holes and bolts, the upper cover and the top retaining ring are fixed together to the protective cover base.

2. The online remote monitoring system for tunnel boring machine cutterhead vibration according to claim 1, characterized in that, The gateway device also includes a shock-absorbing pad, a protective cover, and a network cable.

3. A remote online monitoring system for tunnel boring machine cutterhead vibration according to claim 1 or 2, characterized in that, The data acquisition software includes data analysis and processing software, protocol configuration software, communication software, and receiving software.

4. A method for online remote monitoring of tunnel boring machine cutterhead vibration, employing the monitoring system described in any one of claims 1-3, characterized in that, The specific steps are as follows: (1) Device layout and software installation: The vibration acquisition device is placed on the back of the chute of the cutterhead of the tunnel boring machine. Vibration acquisition devices are installed on the back of multiple chutes that do not interfere with the replacement cutter space. The ZigBee gateway is installed on the outer side of the middle section of the main beam of the tunnel boring machine, and the gateway antenna is arranged on the inner side of the middle section of the main beam. Data acquisition software is installed on the ground server. (2) Vibration monitoring: Vibration information around the ZigBee wireless sensor node is collected by an accelerometer. The analog variable is then passed to the CC2530 data processing and transmission module for analog-to-digital processing. The data is then wirelessly transmitted to the ZigBee gateway device via a spherical antenna and connected to an industrial computer for data storage and analysis. The industrial computer data is transmitted to the ground server via LoRa wireless bridging technology. At the same time, data acquisition software is installed on the ground server to display and store the vibration data collected by the ZigBee wireless sensor node in real time. The remote server and the ground server transmit data over long distances via GPRS wireless wide area network. The receiving end parses the database and saves it to the remote server database to realize online remote monitoring of the data. At the same time, alarm thresholds are set to realize the automatic monitoring and early warning function for excessive vibration data.

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