Design method for test bed of on-line monitoring system of normal-pressure cutter cylinder

Abstract

The invention discloses a design method for a test bed of an on-line monitoring system of a normal-pressure cutter cylinder, and belongs to the technical field of shield construction. The hobbing cutter cylinder system comprises a cylinder body supporting frame, a first cutter cylinder arranged on the cylinder body supporting frame, a second cutter cylinder arranged on one side of the first cutter cylinder, hobbing cutters arranged in the first cutter cylinder and the second cutter cylinder, and a sensor integration module connected to the hobbing cutters; the power driving system is connected to the hobbing cutter cylinder system and comprises a motor supporting frame, a variable-frequency and variable-speed motor arranged on the motor supporting frame, a spline shaft in transmission connection with the variable-frequency and variable-speed motor and the outward extending shaft, and a transmission V belt in transmission connection with the spline shaft; the environment pressure regulating system is connected to the hobbing cutter cylinder system and comprises a pressure release valve arranged on the second cutter cylinder, an air compressor arranged on one side of the hobbing cutter cylinder system, a pressure regulating valve arranged on the air compressor and an air inflation pipeline connected to the pressure regulating valve and the pressure release valve. According to the invention, a reliable test platform is provided for performance test and online monitoring of the hob.

Description

Technical Field

[0001] The invention belongs to the technical field of shield construction, and in particular relates to a design method for a test bench of a normal pressure cutter cylinder online monitoring system. Background Art

[0002] Shield machine construction is widely used in many fields such as traffic tunnels and pipeline transportation. It is an indispensable construction equipment in the construction of subways and cross-sea and cross-river tunnels. During the tunneling process of the shield machine, the cutter in the cutter barrel is in direct contact with the rock and soil outside. The cutter and the rock are squeezed and broken. The actual wear process of the cutter ring is related to many factors such as the geological conditions and tunneling parameters during the tunneling of the shield machine. In the service project of the cutter, the difference in the state of soil and rock in the geological environment will affect the wear rate of the cutter to varying degrees. The cutter barrel, as a fixed part of the cutter, often has mud residue accumulated inside. The increase and hardening of the accumulated residue inside the cutter barrel leads to increased wear of the cutter, which seriously affects the normal service life of the cutter. The types of mud residue in different geological environments vary greatly, and the internal environment of the cutter barrel will also change. In the process of tunneling at the same geographical location, the working conditions of the cutter barrels at different cutterhead positions are also different. Therefore, the design of the atmospheric pressure cutter barrel online monitoring system test bench is to accurately monitor the internal state of the cutter barrel, timely change the cutter, and timely and rationally clean up the accumulated residue in the cutter barrel to ensure efficient and stable tunneling of the shield machine. Summary of the invention

[0003] In order to solve the technical problems existing in the above-mentioned background technology, the present invention provides a design method of a test bench for an online monitoring system of a normal pressure knife cylinder. The present invention adopts the following technical scheme: a design method of a test bench for a normal pressure cutter drum online monitoring system, comprising: a hob cutter drum system, a power drive system, and an environmental pressure regulating system; The roller cutter drum system at least comprises: a drum support frame, a first cutter drum arranged on the drum support frame, a second cutter drum arranged on one side of the first cutter drum, roller cutters arranged inside the first cutter drum and the second cutter drum, and a sensor integrated module connected to the roller cutters; The power drive system is connected to the hob cutter drum system, and includes: a motor support frame arranged on one side of the hob cutter drum system, a variable frequency speed regulating motor arranged on the motor support frame, a spline shaft connected to the variable frequency speed regulating motor and the outward extension shaft, and a transmission V-belt connected to the spline shaft; The environmental pressure regulating system is connected to the hob cutter drum system, and includes: a pressure relief valve arranged on the second cutter drum, an air compressor arranged on one side of the hob cutter drum system, a pressure regulating valve arranged on the air compressor, and an air charging pipe connected to the pressure regulating valve and the pressure relief valve.

[0004] Preferably, the first knife cylinder includes: a first cylinder body, a battery single chip structure arranged inside the first cylinder body, a knife cylinder end cover arranged at the end of the first cylinder body, a peep hole sealing structure arranged on the first cylinder body, and an extended shaft connecting the roller cutter and the power drive system.

[0005] Preferably, the second knife cylinder includes: a second cylinder body, a mud flushing interface opened at the upper part of the second cylinder body, a mud discharge port opened at the bottom of the second cylinder body, a mud discharge valve connected to the mud discharge port, and a mud discharge pipe connected to the mud discharge valve.

[0006] Preferably, a plurality of lifting ears are provided on the first knife cylinder and the second knife cylinder, and the support frame is provided with a clamp to fix the first knife cylinder and the second knife cylinder.

[0007] Preferably, a support platform is provided inside the first knife cylinder, and the roller cutter is arranged on the support platform.

[0008] Preferably, the method comprises the following steps: Step 1: The variable frequency speed regulating motor provides power, which is driven by the transmission V-belt and connected to the roller cutter in cooperation with the spline shaft, driving the roller cutter to rotate, simulating different rotation speeds of the roller cutter during the operation of the shield machine, and replacing the cutter rings with different wear forms to simulate abnormal wear occurring during rock breaking; Step 2: The environmental pressure regulating system is connected to the second knife barrel through the inflation pipe, and the pressure regulating valve controls the air pressure inside the knife barrel, and verifies the accuracy of the sensor detection; the mud outlet is opened to add mud, and the pressurization is carried out at the same time to simulate the mud slag formation process when the shield machine is running; Step 3: After the test bench completes the simulation of the slag accumulation inside the cutter barrel and the operation of the hob, the sensor integration module obtains the state information of each physical quantity, providing a basis for the next step of data processing; Step 4: adjust the pressure relief valve to relieve the pressure inside the knife barrel; stop the frequency conversion speed regulating motor, and after the entire system stops, connect an external high-pressure water gun to the mud flushing interface to clean the internal slag and discharge the sewage through the mud discharge pipe.

[0009] The beneficial effects of the present invention are as follows: a design method for a test bench for an online monitoring system for a normal pressure cutter barrel is provided. By replacing cutter rings with different wear forms in the cutter barrel system to simulate abnormal wear that occurs when breaking rocks, the cutter barrel system in an actual working environment can be simulated. The working status and performance of the cutter are monitored in real time through a multi-sensor integrated module to ensure the accuracy and reliability of the experimental data. The power drive system provides power to the cutter barrel system, adjusts the rotation speed of the cutter, simulates the different rotation speeds of the cutter at different positions on the cutter disc during actual working, and ensures the stability of the power transmission. The environmental pressure regulating system simulates different pressure environments, and achieves precise control of the internal pressure of the cutter barrel through a pressure regulating valve and a pressure relief valve to ensure the consistency and repeatability of the experimental environment.

[0010] According to the environmental characteristics inside the cutter barrel when the shield machine is working, a test bench for the normal pressure cutter barrel online monitoring system is designed. According to the comprehensive state of the cutter and the internal state of the cutter, which is related to the cutter rotation speed, wear amount, temperature and pressure of the internal environment, the abnormal state of the cutter barrel and the cutter that cannot be directly monitored is comprehensively analyzed using the monitorable physical quantities. This provides a certain reference for timely cutter replacement and timely and reasonable cleaning of cutter barrel slag, ensuring efficient and stable excavation of the shield machine and reducing construction costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a structural schematic diagram of the present invention.

[0012] Figure 2 It is a structural diagram of the hob cutter drum system.

[0013] Figure 3 Schematic diagram of the exploded structure of the hob cutter drum system.

[0014] In the accompanying drawings, the list of components represented by each reference numeral is as follows: battery single-chip microcomputer structure 1, knife barrel end cover 2, peep mud injection hole sealing structure 3, sensor integrated module 4, hob 5, support platform 6, lifting ear 7, clamp 8, mud discharge valve 9, mud discharge pipe 10, cylinder support frame 11, variable frequency speed regulation motor 12, transmission V-belt 13, spline shaft 14, motor support frame 15, air compressor 16, inflation pipe 17, pressure regulating valve 18, pressure relief valve 19, first cylinder 20, extended shaft 21, second cylinder 22, mud flushing interface 23, mud discharge port 24. DETAILED DESCRIPTION

[0015] The present invention will be further described below in conjunction with the embodiments.

[0016] A design method for a test bench for an atmospheric pressure knife barrel online monitoring system. Figures 1 to 3As shown, it includes: a roller cutter 5 barrel system, a power drive system, and an environmental pressure regulating system; the roller cutter 5 barrel system at least includes: a barrel support frame 11, a first barrel set on the barrel support frame 11, a second barrel set on one side of the first barrel, a roller cutter 5 set inside the first barrel and the second barrel, and a sensor integrated module 4 connected to the roller cutter 5; the barrel support frame 11 fixes and supports the roller cutter 5 barrel system to ensure its stability and safety during the experiment. The first barrel is used to accommodate the roller cutter 5 and the multi-sensor integrated module 4. Through the roller cutter 5 and the sensor set inside, the working state and performance of the roller cutter 5 can be monitored in real time. The second barrel is connected to the environmental pressure regulating system for pressure regulation; through the sensor integrated module 4, the working state and performance of the roller cutter 5 are monitored in real time, and multi-dimensional data such as the rotation speed, temperature, and vibration of the roller cutter 5 can be obtained to ensure the accuracy and reliability of the experimental data.

[0017] The power drive system is connected to the cutter drum system of the hob 5, and includes: a motor support frame 15 arranged on one side of the cutter drum system of the hob 5, a variable frequency speed regulating motor 12 arranged on the motor support frame 15, a spline shaft 14 connected to the variable frequency speed regulating motor 12 and the extension shaft 21, and a transmission V-belt 13 connected to the spline shaft 14; the power drive system provides stable power output, and realizes precise control of the rotation speed of the hob 5 through the variable frequency speed regulating motor 12 to meet different experimental requirements. The spline shaft 14 is connected to the variable frequency speed regulating motor 12 and the extension shaft 21 for transmitting power and torque, and the transmission V-belt 13 further transmits power and torque.

[0018] The environmental pressure regulating system is connected to the knife barrel system of the hob 5, and includes: a pressure relief valve 19 arranged on the second knife barrel, an air compressor 16 arranged on one side of the knife barrel system of the hob 5, a pressure regulating valve 18 arranged on the air compressor 16, and an air charging pipe 17 connected to the pressure regulating valve 18 and the pressure relief valve 19. The environmental pressure regulating system simulates different pressure environments, and realizes precise control of the internal pressure of the knife barrel through the pressure regulating valve 18 and the pressure relief valve 19 to ensure the consistency and repeatability of the experimental environment. The pressure relief valve 19 adjusts the pressure inside the knife barrel. The air compressor 16 is used to provide compressed air, and the inside of the knife barrel is inflated through the pressure regulating valve 18 and the air charging pipe 17. The design of the air compressor 16 can simulate different pressure environments and improve the comprehensiveness and authenticity of the experiment. The pressure regulating valve 18 adjusts the pressure of the compressed air. The air charging pipe 17 is connected to the pressure regulating valve 18 and the pressure relief valve 19 to inflate the inside of the knife barrel.

[0019] In a further embodiment, the first knife barrel includes: a first barrel 20, a battery single chip microcomputer structure 1 disposed inside the first barrel 20, a barrel end cover 2 disposed at the end of the first barrel 20, a peep hole sealing structure 3 disposed on the first barrel 20, and an extended shaft 21 connecting the roller 5 and the power drive system. The first barrel 20 is used to accommodate the roller 5 and the multi-sensor integrated module 4 to ensure the sealing and stability inside the barrel. The battery single chip microcomputer structure 1 monitors and controls the roller 5 in real time to improve the degree of automation of the experiment and the accuracy of data collection. The peep hole sealing structure 3 is used to observe and inject mud. The extended shaft 21 is connected to the roller 5 and the power drive system to transmit power and torque.

[0020] In a further embodiment, the second knife cylinder includes: a second cylinder 22, a mud flushing interface 23 opened at the upper part of the second cylinder 22, a mud discharge port 24 opened at the bottom of the second cylinder 22, a mud discharge valve 9 connected to the mud discharge port 24, and a mud discharge pipe 10 connected to the mud discharge valve 9, which is used to regulate the entry and discharge of mud.

[0021] In a further embodiment, a plurality of lifting ears 7 are provided on the first knife cylinder and the second knife cylinder for easy lifting, and the cylinder support frame 11 is provided with a clamp 8 to fix the first knife cylinder and the second knife cylinder to ensure the stability and safety of the knife cylinder during the experiment and prevent the knife cylinder from being displaced or tilted during the experiment.

[0022] In a further embodiment, a support platform 6 is provided inside the first knife barrel, and the hob 5 is provided on the support platform 6. The support platform 6 is used to fix and support the hob 5 to ensure the stability and positioning accuracy of the hob 5 inside the knife barrel. In a further embodiment, the steps include: Step 1: The variable frequency speed regulating motor 12 provides power, which is transmitted through the transmission V-belt 13 and connected to the hob 5 in conjunction with the spline shaft 14, driving the hob 5 to rotate, simulating the different speeds of the hob 5 when the shield machine is running, and replacing the cutter rings with different wear forms to simulate the abnormal wear that occurs when breaking rocks; Step 2: The environmental pressure regulating system is connected to the second knife barrel through the air charging pipe 17, and the pressure regulating valve 18 controls the air pressure inside the knife barrel, and verifies the accuracy of the sensor detection; the mud outlet 24 is opened to add mud, and the pressurization is carried out at the same time to simulate the mud slag formation process when the shield machine is running; Step 3: After the test bench completes the simulation of the slag accumulation inside the cutter barrel and the operation of the hob 5, the sensor integration module 4 obtains the state information of each physical quantity, providing a basis for the next step of data processing; Step 4: adjust the pressure relief valve 19 to relieve the pressure inside the knife barrel; stop the variable frequency speed regulating motor 12, and after the entire system stops, connect the external high-pressure water gun to the mud flushing interface 23 to clean the internal slag and discharge the sewage through the mud discharge pipe 10.

[0023] A design method for a test bench for an online monitoring system for a normal pressure knife barrel is provided. It is worth noting that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical details described in the aforementioned embodiments, or to make equivalent replacements for some of the technical features therein. Any equivalent replacements, modifications, etc. made within the core ideas and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A design method for a test bench for an atmospheric pressure knife cylinder online monitoring system, characterized in that: include: Hob cutter drum system, power drive system, environmental pressure regulating system; The roller cutter drum system at least comprises: a drum support frame, a first cutter drum arranged on the drum support frame, a second cutter drum arranged on one side of the first cutter drum, roller cutters arranged inside the first cutter drum and the second cutter drum, and a sensor integrated module connected to the roller cutters; The power drive system is connected to the hob cutter drum system, and includes: a motor support frame arranged on one side of the hob cutter drum system, a variable frequency speed regulating motor arranged on the motor support frame, a spline shaft transmission-connected to the variable frequency speed regulating motor, and a transmission V-belt transmission-connected to the spline shaft; The environmental pressure regulating system is connected to the hob cutter drum system, and includes: a pressure relief valve arranged on the second cutter drum, an air compressor arranged on one side of the hob cutter drum system, a pressure regulating valve arranged on the air compressor, and an air charging pipe connected to the pressure regulating valve and the pressure relief valve.

2. The design method of a test bench for an atmospheric pressure knife cylinder online monitoring system according to claim 1 is characterized in that: The first knife cylinder includes: a first cylinder body, a battery single chip structure arranged inside the first cylinder body, a knife cylinder end cover arranged at the end of the first cylinder body, a peep hole sealing structure arranged on the first cylinder body, and an extended shaft connecting the roller cutter and the power drive system.

3. The design method of a test bench for an atmospheric pressure knife cylinder online monitoring system according to claim 2 is characterized in that: The second knife cylinder includes: a second cylinder body, a mud flushing interface opened at the upper part of the second cylinder body, a mud discharge port opened at the bottom of the second cylinder body, a mud discharge valve connected to the mud discharge port, and a mud discharge pipe connected to the mud discharge valve.

4. The design method of a test bench for an atmospheric pressure knife cylinder online monitoring system according to claim 3 is characterized in that: The first knife cylinder and the second knife cylinder are provided with a plurality of lifting ears, and the cylinder support frame is provided with a clamp to fix the first knife cylinder and the second knife cylinder.

5. The design method of a test bench for an atmospheric pressure knife cylinder online monitoring system according to claim 4 is characterized in that: A support platform is arranged inside the first knife cylinder, and the roller cutter is arranged on the support platform.

6. The method for designing a test bench for an atmospheric pressure knife cylinder online monitoring system according to claim 5 is characterized in that: The following steps are involved: Step 1: The variable frequency speed regulating motor provides power, which is driven by the transmission V-belt and connected to the roller cutter in cooperation with the spline shaft, driving the roller cutter to rotate, simulating different rotation speeds of the roller cutter during the operation of the shield machine, and replacing the cutter rings with different wear forms to simulate abnormal wear occurring during rock breaking; Step 2: The environmental pressure regulating system is connected to the second knife barrel through the inflation pipe, and the pressure regulating valve controls the air pressure inside the knife barrel, and verifies the accuracy of the sensor detection; the mud outlet is opened to add mud, and the pressurization is carried out at the same time to simulate the mud slag formation process when the shield machine is running; Step 3: After the test bench completes the simulation of the slag accumulation inside the cutter barrel and the operation of the hob, the sensor integration module obtains the state information of each physical quantity, providing a basis for the next step of data processing; Step 4: adjust the pressure relief valve to relieve the pressure inside the knife barrel; stop the frequency conversion speed regulating motor, and after the entire system stops, connect an external high-pressure water gun to the mud flushing interface to clean the internal slag and discharge the sewage through the mud discharge pipe.

Images