Automatic control system and method for super-high pressure water jet of shield tunneling machine

Abstract

This invention belongs to the field of tunneling equipment and provides an automatic control system and method for ultra-high pressure water jet in tunnel boring machines (TBMs). The automatic control system includes a control system, a cutterhead pressure sensor, a cutterhead rotation sensor, and water jet switches. The cutterhead rotation sensor detects the cutterhead rotation angle in real time and feeds it back to the control system. The control system determines the geological structure of the TBM based on the rock-breaking force of the cutterhead and, combined with pre-acquired geological information, comprehensively identifies and selects the operating mode. When the installation radius control mode is selected, the system controls the opening and closing of the water jet switches at the corresponding installation radius position based on the comparison between the rock-breaking force of the cutterhead and the set pressure. When the cutterhead zone operating mode is selected, the system determines the cutterhead area where the water jet system needs to be activated based on the comparison between the rock-breaking force of the cutterhead and the set pressure, as well as the cutterhead rotation angle information, and controls the opening and closing of the water jet switches in the corresponding cutterhead area.

Description

Technical Field

[0001] This invention belongs to the field of tunneling equipment, and particularly relates to an automatic control system and method for ultra-high pressure water jet in tunnel boring machines. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] When tunnel boring machines (TBMs) are in the reinforced areas at the entrance and exit of the construction section (e.g., areas with underground reinforced concrete structures, highly abrasive extremely hard rock, and complex strata), traditional purely mechanical tunneling methods are prone to engineering problems such as rebar entanglement on the cutterhead, abnormal cutter damage, or machine jamming, leading to low construction efficiency and increased cutter consumption costs. To solve these problems, abrasive water jet-assisted TBM tunneling is typically used to improve excavation efficiency and reduce construction costs.

[0004] The inventors discovered that, in the current process of using abrasive water jet to assist in tunnel boring machine excavation, on the one hand, the demand for abrasive water jet cutting focus in complex construction environments such as composite strata and underground reinforced concrete piles is not considered, resulting in high energy consumption and poor cutting effect; on the other hand, the difference in linear velocity caused by different installation radii of the same nozzle on the tunnel boring machine cutterhead is not considered, resulting in the problem of "the outer ring not breaking and the inner ring wasting water". Summary of the Invention

[0005] To address the technical problems of water waste, high energy consumption, and poor cutting effect caused by the failure to consider differences in nozzle linear velocity and the varying cutting effects of the same nozzle at different installation radii on the tunnel boring machine cutterhead, as described in the background art, this invention provides an automatic control system and method for ultra-high pressure water jets in tunnel boring machines. By dividing the cutterhead into sections and using pressure sensor feedback values ​​to identify the water jet usage requirements, this system can not only balance the cutting effect of water jets at different installation radii but also reduce energy consumption and save water.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] The first aspect of the present invention provides an automatic control system for ultra-high pressure water jets in a tunnel boring machine, comprising:

[0008] The control system and the roller pressure sensor, cutter head rotation sensor and water jet switch that communicate with it respectively;

[0009] The roller cutter pressure sensor is installed on the roller cutter and is used to detect the rock-breaking force of the roller cutter in real time and feed it back to the control system; the cutter head rotation sensor is used to detect the cutter head rotation angle information in real time and feed it back to the control system.

[0010] The control system is used for:

[0011] The working mode is selected based on the rock-breaking force of the cutter head and the rock structure of the strata where the tunnel boring machine is located, combined with the pre-acquired geological information.

[0012] When the installation radius control mode is selected, the opening and closing of the water jet switch at the corresponding installation radius position is controlled based on the comparison between the rock-breaking force of the roller cutter and the set pressure.

[0013] When the cutterhead zone working mode is selected, the cutterhead area that needs to be activated by the water jet system is determined based on the comparison between the rock-breaking force of the roller cutter and the set pressure, as well as the cutterhead rotation angle information. The opening and closing of the water jet switch in the corresponding cutterhead area is then controlled.

[0014] In one implementation, the control system also communicates with the high-pressure pump set, and the control system is used to control the speed of the high-pressure pump set and the number of booster pumps according to a specified pump pressure and the number of nozzles opened.

[0015] In one implementation, in the control system, when the installation radius control mode is selected, if the rock-breaking force of the cutter is greater than the set pressure, the nozzles near the installation radius are automatically controlled to open.

[0016] In one implementation, in the control system, when the installation radius control mode is selected, if the rock-breaking force of some roller cutters is less than the set pressure, the water jet at the corresponding installation radius position is controlled to close, and the high-pressure pump group is controlled to adjust to the matching speed and number of booster pumps.

[0017] In one implementation, in the control system, when the cutterhead zone working mode is selected, if the rock-breaking force of the cutterhead is greater than the set pressure, it is determined that the rock-breaking force of the cutterhead in the corresponding cutterhead area is abnormal, and then it is determined that the cutterhead area where the water jet system needs to be activated is identified.

[0018] In one implementation, in the control system, when the cutterhead partitioning mode is selected, the nozzle opens when passing through the cutterhead area where the rock-breaking force of the roller cutter is abnormal, and automatically closes after the nozzle leaves the cutterhead area where the rock-breaking force of the roller cutter is abnormal. The nozzle automatically opens when entering a new cutterhead area where the rock-breaking force of the roller cutter is abnormal.

[0019] A second aspect of the present invention provides an automatic control method for ultra-high pressure water jets in tunnel boring machines, comprising:

[0020] Real-time reception of rock-breaking force and cutterhead rotation angle information of the roller cutter;

[0021] The working mode is selected based on the rock-breaking force of the cutter head and the rock structure of the strata where the tunnel boring machine is located, combined with the pre-acquired geological information.

[0022] When the installation radius control mode is selected, the opening and closing of the water jet switch at the corresponding installation radius position is controlled based on the comparison between the rock-breaking force of the roller cutter and the set pressure.

[0023] When the cutterhead zone working mode is selected, the cutterhead area that needs to be activated by the water jet system is determined based on the comparison between the rock-breaking force of the roller cutter and the set pressure, as well as the cutterhead rotation angle information. The opening and closing of the water jet switch in the corresponding cutterhead area is then controlled.

[0024] In one implementation, the speed of the high-pressure pump set and the number of booster pumps are controlled according to the specified pump pressure and the number of nozzles opened.

[0025] As one implementation method, when the installation radius control mode is selected, if the rock-breaking force of the cutter is greater than the set pressure, the nozzles near the installation radius will be automatically opened.

[0026] Or / when the installation radius control mode is selected, if the rock-breaking force of some cutters is less than the set pressure, the water jet at the corresponding installation radius position is controlled to close, and the high-pressure pump set is adjusted to match the speed and number of booster pumps.

[0027] As one implementation method, when the cutterhead partition working mode is selected, if the rock-breaking force of the roller cutter is greater than the set pressure, it is determined that the rock-breaking force of the roller cutter in the corresponding cutterhead area is abnormal, and then it is determined that the cutterhead area where the water jet system needs to be activated is identified.

[0028] The nozzle opens when passing through the cutterhead area where abnormal rock-breaking force of the roller cutter occurs, and automatically closes when the nozzle rotates out of the cutterhead area where abnormal rock-breaking force of the roller cutter occurs. The nozzle automatically opens when it rotates into the cutterhead area where abnormal rock-breaking force of the roller cutter occurs.

[0029] The beneficial effects of this invention are:

[0030] The automatic control system of the ultra-high pressure water jet system of this invention can be divided into cutterhead zone control mode and installation radius control mode according to different information of the rock mass in front of the tunnel face. The system first classifies the control mode by identifying the stress state of the tunnel boring machine cutters, and then, after comprehensively identifying the collected cutterhead rotation information, cutter cutting load information, and high-pressure water pump information, controls the opening and closing of the water jet and the operation of the high-pressure pump. This enables precise and effective cutting of the rock mass at the tunnel face, not only reducing water consumption but also effectively alleviating the problem of "outer ring not breaking, inner ring wasting water" caused by differences in nozzle linear velocity.

[0031] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0032] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0033] Figure 1 This is a schematic diagram of the automatic control system structure of the ultra-high pressure water jet system according to an embodiment of the present invention;

[0034] Figure 2 This is a flowchart of the automatic control method for the ultra-high pressure water jet system according to an embodiment of the present invention;

[0035] Figure 3(a) is a schematic diagram of the nozzle installation radius according to an embodiment of the present invention;

[0036] Figure 3(b) is a schematic diagram of the blade disk partitioning according to an embodiment of the present invention. Detailed Implementation

[0037] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0038] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0039] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0040] according to Figure 1An automatic control system for ultra-high pressure water jet in a tunnel boring machine (TBM) is provided, comprising: a control system 1 and a cutterhead pressure sensor 3, a cutterhead rotation sensor 2, and a water jet switch 4, which communicate with the control system respectively; the cutterhead pressure sensor is installed on the cutterhead and is used to detect the rock-breaking force of the cutterhead in real time and feed it back to the control system; the cutterhead rotation sensor is used to detect the rotation angle information of the cutterhead in real time and feed it back to the control system; the control system is used to: determine the geological structure of the TBM based on the rock-breaking force of the cutterhead, and comprehensively identify and select the working mode in combination with the pre-acquired geological exploration information; when the installation radius control mode is selected, the control system controls the opening and closing of the water jet switch at the corresponding installation radius position based on the comparison result of the rock-breaking force of the cutterhead and the set pressure; when the cutterhead zone working mode is selected, the control system determines the cutterhead area where the water jet system needs to be activated based on the comparison result of the rock-breaking force of the cutterhead and the set pressure, as well as the cutterhead rotation angle information, and controls the opening and closing of the water jet switch in the corresponding cutterhead area.

[0041] according to Figure 1 The control system 1 also communicates with the high-pressure pump group 5. The control system 1 is used to control the speed of the high-pressure pump group and the number of booster pumps according to the specified pump pressure and the number of nozzles opened.

[0042] When the high-pressure pump set 5 maintains a specified pump pressure, there is a corresponding relationship between its speed, the number of booster pumps and the number of nozzles opened (i.e. flow rate). The control system 1 can adjust the parameters of the high-pressure pump set by using this relationship when some nozzles are open or closed, so as to maximize the pressure stability of the pump set.

[0043] It should be noted that the correspondence between the high-pressure pump set speed, the number of booster pumps, and the number of nozzles opened can be found in a table constructed based on the actual test results.

[0044] In the specific implementation process, in the control system, when the installation radius control mode is selected, if the rock-breaking force of the cutter is greater than the set pressure, the nozzles on the adjacent installation radius will be automatically opened.

[0045] In the control system, when the installation radius control mode is selected, if the rock-breaking force of some cutters is less than the set pressure, the water jet at the corresponding installation radius position is controlled to close, and the high-pressure pump group is controlled to adjust to the matching speed and number of booster pumps.

[0046] like Figure 2As shown in Figure 3(a), when the rock at the working face is homogeneous (i.e., the physical and mechanical parameters of the rock in front of the working face are similar, and the rock strength is basically the same), the control system enters the installation radius control mode. A pressure sensor is installed on one side of the cutter head. By judging the signal fed back by this pressure sensor, when the feedback signal is greater than the pressure set value (wherein, this set value is determined by the combined rock-breaking equipment before operation based on the site's geological conditions, equipment parameters, construction parameters, etc.), the cutter head is under excessive force. After receiving the signal feedback, the control system automatically opens the nozzles near the installation radius. After the nozzles open, the nozzle opening signal is transmitted to the back-end control system. The system turns on the water pump and sets the motor speed, the number of booster pumps, and other information according to the number of nozzles opened. The high-pressure water jet system begins to work. When the jet system starts, as cutting progresses, the cutter head load signal fed back by the pressure sensor gradually decreases. When the rock-breaking load of some cutters is less than the pressure set value, the control system obtains the information and shuts off the water jets at the corresponding installation radius position. At the same time, it controls the high-pressure pump group to adjust to an appropriate speed and the number of booster pumps.

[0047] When encountering reinforced concrete piles or composite strata, the control system enters the cutterhead zone control mode. The cutterhead is divided into four zones, as shown in Figure 3(b). When the rock-breaking force of a cutter exceeds the pressure setpoint, the control system analyzes the information from the cutterhead rotation monitoring system to determine the zone where the water jet system needs to be activated. It also identifies the angle of the cutter with the abnormal pressure sensor reading. If the abnormal cutter is located in zone A, the jet equipment needs to be activated in zone A. The nozzle opens when passing through this zone and automatically closes after rotating out of the zone. New nozzles entering the zone automatically open. After these steps are completed, the automatic control system of the high-pressure water jet system completes its operation, and the tunneling work proceeds smoothly.

[0048] Specifically, in the control system, when the cutterhead partition working mode is selected, if the rock-breaking force of the cutterhead is greater than the set pressure, the cutterhead in the corresponding cutterhead area is determined to be abnormal, and then the cutterhead area where the water jet system needs to be activated is determined.

[0049] In the control system, when the cutterhead partition working mode is selected, the nozzle opens when passing through the cutterhead area where the rock-breaking force of the roller cutter is abnormal, and automatically closes after the nozzle rotates out of the cutterhead area where the rock-breaking force of the roller cutter is abnormal. The nozzle automatically opens when it enters a new cutterhead area where the rock-breaking force of the roller cutter is abnormal.

[0050] The automatic control method for ultra-high pressure water jet of the tunnel boring machine in this embodiment includes:

[0051] Step 1: Receive real-time information on the rock-breaking force of the roller cutter and the rotation angle of the cutterhead;

[0052] Step 2: Determine the geological structure of the tunnel boring machine based on the rock-breaking force of the cutter head, and select the working mode by combining the pre-acquired geological exploration information.

[0053] When the installation radius control mode is selected, the opening and closing of the water jet switch at the corresponding installation radius position is controlled based on the comparison between the rock-breaking force of the roller cutter and the set pressure.

[0054] When the cutterhead zone working mode is selected, the cutterhead area that needs to be activated by the water jet system is determined based on the comparison between the rock-breaking force of the roller cutter and the set pressure, as well as the cutterhead rotation angle information. The opening and closing of the water jet switch in the corresponding cutterhead area is then controlled.

[0055] The speed of the high-pressure pump set and the number of booster pumps are controlled according to the specified pump pressure and the number of nozzles opened.

[0056] When the installation radius control mode is selected, if the rock-breaking force of the cutter is greater than the set pressure, the nozzles near the installation radius will be automatically opened.

[0057] When the installation radius control mode is selected, if the rock-breaking force of some roller cutters is less than the set pressure, the water jet at the corresponding installation radius position is controlled to close, and the high-pressure pump set is adjusted to match the speed and number of booster pumps.

[0058] When the cutterhead partition working mode is selected, if the rock-breaking force of the roller cutter is greater than the set pressure, it is determined that the rock-breaking force of the roller cutter in the corresponding cutterhead area is abnormal, and then it is determined that the cutterhead area where the water jet system needs to be activated is determined.

[0059] The nozzle opens when passing through the cutterhead area where abnormal rock-breaking force of the roller cutter occurs, and automatically closes when the nozzle rotates out of the cutterhead area where abnormal rock-breaking force of the roller cutter occurs. The nozzle automatically opens when it rotates into the cutterhead area where abnormal rock-breaking force of the roller cutter occurs.

[0060] Based on the different rock mass information in front of the tunnel face, this embodiment divides the system control mode into cutterhead zone control mode and installation radius control mode. The system first classifies the control mode by identifying the stress state of the tunnel boring machine cutters. Then, combining collected cutterhead rotation information, cutter cutting load information, and high-pressure water pump information, it comprehensively identifies and controls the opening and closing of the water jets and the operation of the high-pressure pump. This enables precise and effective cutting of the rock mass at the tunnel face, reducing water consumption and effectively alleviating the problem of "outer ring not breaking, inner ring wasting water" caused by differences in nozzle linear velocity.

[0061] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automatic control system for ultra-high pressure water jet in a tunnel boring machine, characterized in that, include: The control system and the roller pressure sensor, cutter head rotation sensor and water jet switch that communicate with it respectively; The roller cutter pressure sensor is installed on the rear side of the roller cutter to detect the rock-breaking force of the roller cutter in real time and feed it back to the control system; the cutter head rotation sensor is used to detect the cutter head rotation angle information in real time and feed it back to the control system. The control system is used for: The working mode is selected based on the rock-breaking force of the cutter head and the rock structure of the strata where the tunnel boring machine is located, combined with the pre-acquired geological information. When the installation radius control mode is selected, the opening and closing of the water jet switch at the corresponding installation radius position is controlled based on the comparison between the rock-breaking force of the roller cutter and the set pressure. When the cutterhead zone working mode is selected, the cutterhead area that needs to be activated by the water jet system is determined based on the comparison between the rock-breaking force of the roller cutter and the set pressure, as well as the cutterhead rotation angle information. The opening and closing of the water jet switch in the corresponding cutterhead area is then controlled.

2. The automatic control system for ultra-high pressure water jet of a tunnel boring machine as described in claim 1, characterized in that, The control system also communicates with the high-pressure pump set, and the control system is used to control the speed of the high-pressure pump set and the number of booster pumps according to the specified pump pressure and the number of nozzles opened.

3. The automatic control system for ultra-high pressure water jet of a tunnel boring machine as described in claim 1, characterized in that, In the control system, when the installation radius control mode is selected, if the rock-breaking force of the cutter is greater than the set pressure, the nozzles near the installation radius will be automatically opened.

4. The automatic control system for ultra-high pressure water jet of a tunnel boring machine as described in claim 1, characterized in that, In the control system, when the installation radius control mode is selected, if the rock-breaking force of some roller cutters is less than the set pressure, the water jet at the corresponding installation radius position is controlled to close, and the high-pressure pump group is controlled to adjust to the matching speed and number of booster pumps.

5. The automatic control system for ultra-high pressure water jet of a tunnel boring machine as described in claim 1, characterized in that, In the control system, when the cutterhead zone working mode is selected, if the rock-breaking force of the cutterhead is greater than the set pressure, it is determined that the rock-breaking force of the cutterhead in the corresponding cutterhead area is abnormal, and then it is determined that the cutterhead area where the water jet system needs to be activated is determined.

6. The automatic control system for ultra-high pressure water jet of a tunnel boring machine as described in claim 5, characterized in that, In the control system, when the cutterhead partition working mode is selected, the nozzle opens when passing through the cutterhead area where the rock-breaking force of the roller cutter is abnormal, and automatically closes after the nozzle rotates out of the cutterhead area where the rock-breaking force of the roller cutter is abnormal. The nozzle automatically opens when it enters a new cutterhead area where the rock-breaking force of the roller cutter is abnormal.

7. An automatic control method for ultra-high pressure water jet in a tunnel boring machine, characterized in that, include: Real-time reception of rock-breaking force and cutterhead rotation angle information of the roller cutter; The working mode is selected based on the rock-breaking force of the cutter head, the geological structure of the tunnel boring machine is determined, and the rock-breaking force is determined by combining the pre-acquired geological information. When the installation radius control mode is selected, the opening and closing of the water jet switch at the corresponding installation radius position is controlled based on the comparison between the rock-breaking force of the roller cutter and the set pressure. When the cutterhead zone working mode is selected, the cutterhead area that needs to be activated by the water jet system is determined based on the comparison between the rock-breaking force of the roller cutter and the set pressure, as well as the cutterhead rotation angle information. The opening and closing of the water jet switch in the corresponding cutterhead area is then controlled.

8. The automatic control method for ultra-high pressure water jet of a tunnel boring machine as described in claim 7, characterized in that, The speed of the high-pressure pump set and the number of booster pumps are controlled according to the specified pump pressure and the number of nozzles opened.

9. The automatic control method for ultra-high pressure water jet of a tunnel boring machine as described in claim 7, characterized in that, When the installation radius control mode is selected, if the rock-breaking force of the cutter is greater than the set pressure, the nozzles on the nearest installation radius will be automatically opened. Or / when the installation radius control mode is selected, if the rock-breaking force of some cutters is less than the set pressure, the water jet at the corresponding installation radius position is controlled to close, and the high-pressure pump set is adjusted to match the speed and number of booster pumps.

10. The automatic control method for ultra-high pressure water jet of a tunnel boring machine as described in claim 7, characterized in that, When the cutterhead partition working mode is selected, if the rock-breaking force of the roller cutter is greater than the set pressure, it is determined that the rock-breaking force of the roller cutter in the corresponding cutterhead area is abnormal, and then it is determined that the cutterhead area where the water jet system needs to be activated is determined. The nozzle opens when passing through the cutterhead area where abnormal rock-breaking force of the roller cutter occurs, and automatically closes when the nozzle rotates out of the cutterhead area where abnormal rock-breaking force of the roller cutter occurs. The nozzle automatically opens when it rotates into the cutterhead area where abnormal rock-breaking force of the roller cutter occurs.

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