Intelligent shield cutter with integrated energy self-provision and working state self-test and monitoring method

Abstract

This invention belongs to the field of tunnel boring machine (TBM) cutters and provides an intelligent TBM cutter and monitoring method integrating energy self-sufficiency and working status self-monitoring. The intelligent TBM cutter integrating energy self-sufficiency and working status self-monitoring includes a cutter sensing system, a data transmission system, an energy supply system, and an anomaly early warning system. The energy supply system provides electrical energy to the cutter sensing system, data transmission system, and anomaly early warning system. The cutter sensing system senses the TBM cutter interface information, rotational speed, and operating temperature. The data transmission system is connected to both the cutter sensing system and the anomaly early warning system, transmitting all information sensed by the cutter sensing system to the anomaly early warning system. The anomaly early warning system, based on the TBM cutter interface information, rotational speed, and operating temperature, determines the geological changes at the tunnel face and the cutter's working status, thereby determining the timing for opening the cutterhead and changing the cutterhead, and guiding the TBM tunneling parameters.

Description

Technical Field

[0001] This invention belongs to the field of tunnel boring machine (TBM) cutters, and particularly relates to an intelligent TBM cutter and monitoring method that integrates energy self-sufficiency and working status self-testing. 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] The wear and tear of tunnel boring machine (TBM) cutters directly impacts project progress and construction costs. Traditional TBM cutters suffer from high energy consumption, easy wear and tear, and difficulty in real-time monitoring of their working status. Delayed cutter replacement can slow tunneling speed and affect project schedule. However, frequent opening of the tunnel boring machine to inspect cutter condition can also hinder construction progress and increase costs. Summary of the Invention

[0004] To address the challenges in the prior art regarding the real-time monitoring of shield tunneling cutters' working status and the inability to rationally determine the timing for cutter replacement, this invention provides an intelligent shield tunneling cutter and monitoring method integrating energy self-sufficiency and working status self-monitoring. This method enables real-time monitoring and analysis of cutter wear status, automatically adjusts working parameters, and improves cutter utilization and work efficiency. Simultaneously, by utilizing the cutter's own power system, it achieves energy self-sufficiency, reducing dependence on external energy sources and lowering operating costs, demonstrating significant potential for engineering applications.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] The first aspect of the present invention provides an intelligent tunnel boring machine cutter that integrates energy self-sufficiency and working status self-testing.

[0007] A smart tunnel boring machine cutter integrating energy self-sufficiency and working status self-testing, comprising:

[0008] Tool sensing system, data transmission system, energy supply system, and anomaly early warning system;

[0009] The energy supply system is used to provide electrical energy for the tool sensing system, data transmission system, and anomaly early warning system.

[0010] The tool sensing system is used to sense the shield tunneling tool interface information, rotation speed, and operating temperature.

[0011] The data transmission system is connected to the tool sensing system and the anomaly warning system respectively, and is used to transmit all the information sensed by the tool sensing system to the anomaly warning system.

[0012] The anomaly early warning system is used to determine the geological changes and working status of the cutter face based on the cutter interface information, rotation speed and working temperature, and then determine the timing of opening the cutter head and changing the cutter head, as well as to guide the tunneling parameters.

[0013] In one embodiment, the tool sensing system includes an acoustic emission device; the acoustic emission device includes a signal excitation component and an interface sensing component;

[0014] When the cutting tool is in working condition, the signal excitation component is in non-working condition, and the interface sensing component is used to collect the cutting tool rock-breaking noise.

[0015] When the hob is not in operation, the signal excitation component is used to hammer the tool to generate vibration, and the interface sensing component is used to collect reflected sound wave information.

[0016] In one embodiment, the tool sensing system further includes a speed sensor and a temperature sensor; the speed sensor is used to sense the rotation information of the tool; and the temperature sensor is used to sense the operating temperature of the tool.

[0017] In one implementation, the data transmission system is installed on the upper part of the tunnel boring machine cutterhead and is equipped with an external charging cable.

[0018] In one embodiment, the energy supply system includes a self-generating device and an energy storage device, wherein the self-generating device generates current during the operation of the cutting tool and transmits it to the energy storage device for storage.

[0019] In one embodiment, the self-generating device includes a micro-magnet, a micro-damping coil, and wires. The micro-magnet is fixed at the rotating position of the outer ring of the cutter during operation, while the micro-damping coil is located at the center of the cutter and never rotates. When the cutter is working, the micro-magnet cuts the micro-damping coil to generate current.

[0020] As one implementation method, in the anomaly early warning system:

[0021] The boundary between soft and hard geology on the tunnel face is determined by the rolling cutter rock-breaking vibration information in the shield cutter interface information.

[0022] Determine whether to replace the hob based on the hob wear monitoring information in the tool interface;

[0023] The rotational speed and operating temperature can be used to help determine whether the hob is working properly.

[0024] As one implementation method, the working process of the hob is determined by using the rotational speed and operating temperature as an aid:

[0025] When the rotation speed is 0 and the operating temperature is less than the preset temperature threshold, it is considered a normal phenomenon.

[0026] When the rotational speed is not 0 and the temperature is less than the preset temperature threshold, it is determined that the hob is not in saturation and the spindle thrust can be increased.

[0027] When the rotational speed is not 0 and the temperature is greater than or equal to the set temperature threshold, it is determined that the hob is in an oversaturated working state, and the spindle thrust can be reduced.

[0028] In one implementation, the anomaly early warning system includes a data processing module and an early warning decision module; the data processing module is used to analyze tool interface information, tool rotation speed information, and tool temperature information; the early warning decision module provides early warnings for abnormal data, offers tool changing schemes, and can guide the selection of tunnel boring machine parameters.

[0029] A second aspect of the present invention provides a monitoring method for intelligent tunnel boring machine cutters that integrates energy self-sufficiency and working status self-testing.

[0030] A monitoring method for intelligent tunnel boring machine cutters that integrates energy self-sufficiency and working status self-testing, comprising:

[0031] Sensing shield cutter interface information, rotation speed, and operating temperature;

[0032] Based on the information of the shield cutter interface, rotation speed and working temperature, the geological changes on the tunnel face and the working status of the cutter are judged, thereby determining the timing of opening the tunnel and changing the cutter and guiding the shield tunneling parameters.

[0033] The beneficial effects of this invention are:

[0034] To address the challenge of real-time monitoring of the working status of tunnel boring machine (TBM) cutters and the inability to rationally determine the timing of cutterhead opening and replacement, this invention proposes an intelligent TBM cutter with self-sufficient energy and self-monitoring capabilities. It utilizes a cutter sensing system to detect the cutter interface information, rotational speed, and operating temperature. An anomaly warning system then uses this information to assess geological changes at the tunnel face and the cutter's working status, thereby determining the timing of cutterhead opening and replacement and guiding TBM tunneling parameters. This achieves real-time monitoring and analysis of cutter wear, automatically adjusting operating parameters and improving cutter utilization and work efficiency. Furthermore, by utilizing the cutter's own power system, it achieves energy self-sufficiency, reducing dependence on external energy sources and lowering operating costs, demonstrating significant engineering application potential.

[0035] This invention enables real-time monitoring and damage warning of the cutting tools during shield tunneling. It also features energy self-sufficiency, ensuring long-term real-time monitoring. Its ability to accurately detect tool damage and determine the appropriate timing for tool replacement is crucial for safe and efficient shield tunneling.

[0036] 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

[0037] 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.

[0038] Figure 1 This is a schematic diagram of the intelligent shield tunneling cutter structure integrating energy self-sufficiency and working status self-testing according to an embodiment of the present invention;

[0039] Figure 2 This is a schematic diagram illustrating the monitoring principle of an intelligent shield tunneling cutter that integrates energy self-sufficiency and working status self-testing according to an embodiment of the invention.

[0040] Among them, 1 is a temperature sensor, 2 is an energy storage device, 3 is an integrated cutter ring, 4 is an acoustic emission device, 5 is a data relay system, 6 is a tunnel boring machine, 7 is an anomaly early warning system, 8 is a cutter box, 9 is a self-generating device, 10 is a micro magnetic block, 11 is a speed sensor, 12 is a sensing information transmission system, and 13 is a sensing information transmission line. Detailed Implementation

[0041] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0042] 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.

[0043] 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.

[0044] according to Figure 1 This embodiment provides an intelligent shield cutter that integrates energy self-sufficiency and working status self-testing, which includes: a cutter sensing system, a data transmission system, an energy supply system, and an anomaly early warning system;

[0045] The energy supply system provides power to the cutter sensing system, data transmission system, and anomaly early warning system. The cutter sensing system senses the shield cutter interface information, rotational speed, and operating temperature. The data transmission system is connected to both the cutter sensing system and the anomaly early warning system, transmitting all information sensed by the cutter sensing system to the anomaly early warning system. The anomaly early warning system determines the geological changes at the tunnel face and the working status of the cutter based on the shield cutter interface information, rotational speed, and operating temperature, thereby determining the timing for opening the cutterhead and changing the cutterhead, and guiding the shield tunneling parameters.

[0046] In practical implementation, the tool sensing system includes an acoustic emission device; the acoustic emission device includes a signal excitation component and an interface sensing component;

[0047] When the cutting tool is in working condition, the signal excitation component is in non-working condition, and the interface sensing component is used to collect the cutting tool rock-breaking noise.

[0048] When the hob is not in operation, the signal excitation component is used to hammer the tool to generate vibration, and the interface sensing component is used to collect reflected sound wave information.

[0049] When the cutting tool is in operation, the sound frequency generated by the tool varies depending on the geological strata, requiring a high-precision database. When the hob is not in operation, the monitoring effect is more accurate due to the regular vibration source sound waves it provides.

[0050] In one or more embodiments, the tool sensing system further includes a speed sensor and a temperature sensor; the speed sensor is used to sense the rotation information of the tool; and the temperature sensor is used to sense the operating temperature of the tool.

[0051] In some specific implementations, the data transmission system is installed on the upper part of the tunnel boring machine cutterhead and is equipped with an external charging cable. The data transmission system mainly serves to transmit information, which is the monitoring information from the cutterhead sensing system, including information monitored by the acoustic emission device, speed sensor, and temperature sensor.

[0052] In practice, the energy supply system includes a self-generating device and an energy storage device. The self-generating device generates current when the cutting tool is working and transmits it to the energy storage device for storage.

[0053] The self-generating device includes a micro-magnet, a micro-damping coil, and wires. The micro-magnet is fixed at the rotating position of the outer ring of the cutter during operation, while the micro-damping coil is located at the center of the cutter and never rotates. When the cutter is working, the micro-magnet cuts the micro-damping coil, generating current.

[0054] The energy storage device consists of a miniature super battery capable of storing the electrical energy generated by the cutting tool itself. Secondly, an external charging cable is provided, ensuring that the tool sensing system operates normally when the tool is taken offline for operation, as it already has a large amount of stored energy.

[0055] The energy storage device is equipped with an external charging cable. When the tool is offline, it has already stored a large amount of electrical energy, thus ensuring the normal operation of the tool sensing system.

[0056] according to Figure 2 The shield cutter interface information includes cutter rock-breaking vibration information and cutter wear monitoring information.

[0057] In the anomaly early warning system:

[0058] The boundary between soft and hard geology on the tunnel face is determined by the rolling cutter rock-breaking vibration information in the shield cutter interface information.

[0059] Determine whether to replace the hob based on the hob wear monitoring information in the tool interface;

[0060] The rotational speed and operating temperature can be used to help determine whether the hob is working properly.

[0061] In the specific implementation process, the steps for determining the soft and hard geological boundary points on the tunnel face based on the rock-breaking vibration information of the cutterhead in the shield cutter interface information are as follows:

[0062] When the hob transitions from one homogeneous layer to the next, if the amplitude of the vibration information change exceeds a set threshold, the abnormality warning system will mark this point as a soft-hard boundary point.

[0063] The hard-soft boundary point can be identified by rotating the hob once. By installing the sensor on all the hobs on a line, the hard-soft boundary point of the entire working face can be obtained.

[0064] By connecting the soft and hard boundary points in sequence, the soft and hard interface of the formation can be obtained.

[0065] In the specific implementation process, the steps to determine whether to replace the hob based on the hob wear monitoring information in the tool interface information are as follows:

[0066] When the hob is not working, the acoustic emission device strikes the cutter ring, and the interface sensing component senses the acoustic wave information.

[0067] The abnormality warning system can calculate the real-time thickness of the hob using the formula d = 0.5 × v × t. When the thickness of the hob is less than the thickness threshold, an alarm is triggered to guide the staff to open the chamber and replace the hob in a timely manner.

[0068] Where v is the speed at which sound travels in the cutter ring, t is the time from the emission of the sound wave to its rebound and reception, and d is the thickness of the hob.

[0069] Specifically, the working process of the hob is determined by its rotational speed and operating temperature as follows:

[0070] When the rotation speed is 0 and the operating temperature is less than the preset temperature threshold, it is considered a normal phenomenon; at this time, the stratum is most likely a soft soil stratum.

[0071] When the rotational speed is not 0 and the temperature is less than the preset temperature threshold, it is determined that the hob is not in saturation. The spindle thrust can be increased to improve the working efficiency.

[0072] When the rotational speed is not 0 and the temperature is greater than or equal to the set temperature threshold, it indicates that the stratum is too hard. It is judged that the working state of the cutter head is oversaturated. The main shaft thrust can be reduced to reduce the damage to the cutter head. This can be used to judge and guide the selection of tunnel boring machine parameters.

[0073] In one or more embodiments, the anomaly early warning system includes a data processing module and an early warning decision module; the data processing module is used to analyze tool interface information, tool rotation speed information and tool temperature information; the early warning decision module provides early warning of abnormal data and provides tool changing schemes, and can also guide the selection of shield tunneling parameters.

[0074] In other embodiments, the anomaly warning system further includes a data display module, a database, and a data push module; the data display module intuitively projects decision data onto a screen. The database gradually accumulates data, providing data support for accurate tool analysis. The data push module can push data to mobile devices and PCs, allowing multiple people to view and obtain tool status in a timely manner.

[0075] The monitoring method for intelligent shield tunneling cutters based on the above-mentioned integrated energy self-sufficiency and working status self-testing includes:

[0076] Sensing shield cutter interface information, rotation speed, and operating temperature;

[0077] Based on the information of the shield cutter interface, rotation speed and working temperature, the geological changes on the tunnel face and the working status of the cutter are judged, thereby determining the timing of opening the tunnel and changing the cutter and guiding the shield tunneling parameters.

[0078] This invention enables real-time monitoring and analysis of tool wear conditions, and can automatically adjust working parameters, thereby improving tool utilization and work efficiency. Simultaneously, it utilizes the tool's own power system to achieve energy self-sufficiency, reducing dependence on external energy sources, lowering operating costs, and possessing significant engineering application potential.

[0079] 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 intelligent shield cutter integrated with energy self-sufficiency and working state self-test, characterized in that, include: Tool sensing system, data transmission system, energy supply system, and anomaly early warning system; The energy supply system is used to provide electrical energy for the tool sensing system, data transmission system, and anomaly early warning system. The tool sensing system is used to sense the shield tunneling tool interface information, rotation speed, and operating temperature. The data transmission system is connected to the tool sensing system and the anomaly warning system respectively, and is used to transmit all the information sensed by the tool sensing system to the anomaly warning system. The abnormal early warning system is used to determine the geological changes and working status of the cutter face based on the shield cutter interface information, rotation speed and working temperature, and then determine the timing of opening the cutter head and changing the cutter head and guide the shield tunneling parameters. The tool sensing system includes an acoustic emission device; the acoustic emission device includes a signal excitation component and an interface sensing component. When the cutting tool is in working condition, the signal excitation component is in non-working condition, and the interface sensing component is used to collect the cutting tool rock-breaking noise. When the hob is not in operation, the signal excitation component is used to hammer the tool to generate vibration, and the interface sensing component is used to collect reflected sound wave information. In the aforementioned anomaly warning system: The steps for determining the soft and hard geological boundary points on the tunnel face based on the rock-breaking vibration information of the cutterhead interface are as follows: When the cutter moves from one homogeneous stratum to the next, if the amplitude of the vibration information exceeds a set threshold, the anomaly warning system will mark this point as a soft-hard interface. The cutter can identify all the soft-hard interfaces in one rotation. By installing sensors on all the cutters on a single axis, the soft-hard interfaces on the entire working face can be obtained. Then, by connecting the soft-hard interfaces in sequence, the formation soft-hard interface can be obtained. Determine whether to replace the cutter based on the cutter wear monitoring information in the shield cutter interface; The process is as follows: When the hob is not working, the acoustic emission device strikes the cutter ring, and the interface sensing component senses the acoustic wave information; the abnormality early warning system calculates the real-time thickness of the hob according to the formula d=0.5×v×t, and alarms are triggered when the thickness of the hob is less than the thickness threshold, guiding the staff to open the chamber and replace the cutter in time; where v is the speed of sound transmission in the cutter ring, t is the time from the emission of the sound wave to its rebound and reception, and d is the thickness of the hob; The hob's normal operation is determined by its rotational speed and operating temperature. The process is as follows: when the rotational speed is 0 and the operating temperature is less than the preset temperature threshold, it is considered normal. When the rotational speed is not 0 and the operating temperature is less than the preset temperature threshold, the hob is considered to be under-saturated, and the spindle thrust is increased. When the rotational speed is not 0 and the operating temperature is greater than or equal to the set temperature threshold, the hob is considered to be over-saturated, and the spindle thrust is reduced.

2. The integrated energy self-sufficient and working condition self-test intelligent shield cutter of claim 1, wherein, The tool sensing system also includes a speed sensor and a temperature sensor; the speed sensor is used to sense the rotation information of the tool; the temperature sensor is used to sense the operating temperature of the tool.

3. The integrated energy self-sufficient and working condition self-test intelligent shield cutter of claim 1, wherein, The data transmission system is installed on the upper part of the shield cutterhead and is equipped with an external charging cable.

4. The intelligent shield tunneling cutterhead integrating energy self-sufficiency and working status self-testing as described in claim 1, characterized in that, The energy supply system includes a self-generating device and an energy storage device. The self-generating device generates current when the cutting tool is working and transmits it to the energy storage device for storage.

5. The integrated energy self-sufficient and working condition self-test intelligent shield cutter of claim 4, wherein, The self-generating device includes a micro-magnet, a micro-damping coil, and wires. The micro-magnet is fixed at the rotating position of the outer ring of the cutter during operation, while the micro-damping coil is located at the center of the cutter and never rotates. When the cutter is working, the micro-magnet cuts the micro-damping coil, generating current.

6. The integrated energy self-sufficient and working condition self-test intelligent shield cutter of claim 1, wherein, The anomaly early warning system includes a data processing module and an early warning decision module. The data processing module is used to analyze tool interface information, tool rotation speed information, and tool temperature information. The early warning decision module issues early warnings for abnormal data, provides tool changing schemes, and guides the selection of tunnel boring machine parameters.

7. A monitoring method for intelligent shield tunneling cutters integrating energy self-sufficiency and working status self-testing as described in any one of claims 1-6, comprising: Sensing shield cutter interface information, rotation speed, and operating temperature; Based on the information of the shield cutter interface, rotation speed and working temperature, the geological changes on the tunnel face and the working status of the cutter are judged, thereby determining the timing of opening the tunnel and changing the cutter and guiding the shield tunneling parameters.

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