Control method of shield tunneling machine cutterhead driving system

Abstract

The invention relates to the technical field of shield tunneling machines, and discloses a control method of a shield tunneling machine cutterhead driving system. According to the method, data of a cutterhead driving system are collected through a sensor, the collected data are filtered and subjected to time sequence analysis, a trend and a mean value are calculated, the working state of a cutterhead is adjusted in real time according to the calculated data, cutterhead propelling force and the cutterhead rotating speed are calculated, cutterhead temperature changes are predicted through a formula, and control errors are calculated. PID control is carried out on the error to adjust output, after the error is controlled, threshold monitoring is carried out on the rotating speed, torque and temperature parameters of the cutterhead, the abnormal condition of the cutterhead driving system is judged, and the cutterhead driving system is adjusted and optimized through the main control system when abnormity occurs. Through the application of the method, the defect of manually checking the abnormity of the cutterhead driving system is overcome, real-time monitoring and autonomous abnormity early warning are carried out on the cutterhead driving system, fault abnormity control and repair of the system are carried out in time, and the working efficiency of the shield tunneling machine is improved.

Description

Technical Field

[0001] The invention relates to the technical field of shield machines, and in particular to a control method for a cutter head drive system of a shield machine. Background Art

[0002] The main function of the cutterhead drive system of the shield machine is to provide power for the rotation and propulsion of the cutterhead. The cutterhead drive system balances the torque changes in the cutting process through reasonable power distribution and dynamic control, ensuring that the cutterhead will not become unstable during the excavation process. By controlling the speed and torque of the cutterhead to cope with different soil and rock characteristics, the adaptability and effectiveness of the shield machine are guaranteed. Precise control can monitor the working status of the cutterhead in real time, promptly detect abnormal conditions such as overload, temperature increase, etc., reduce the risk of accidents, and ensure the safety of equipment and operators.

[0003] Although the current cutterhead drive control system has basic monitoring functions, fault diagnosis relies on manual inspection and post-analysis, and is unable to achieve real-time monitoring and autonomous fault warning, which delays emergency response and reduces the working efficiency of the shield machine. Summary of the invention

[0004] 1. Technical issues to be solved

[0005] In view of the deficiencies in the prior art, the present invention provides a control method for a cutterhead drive system of a shield machine. The method comprises the following steps: collecting data of the cutterhead drive system through sensors, including cutterhead rotation speed, shield machine thrust, motor current and power, tool wear status, soil moisture, soil density, motor temperature and vibration data, filtering the collected data, performing time series analysis on the filtered data, calculating trends and means, adjusting the working status of the cutterhead in real time according to the processed and calculated data, calculating the cutterhead thrust and cutterhead rotation speed, predicting the cutterhead temperature change through a formula, calculating the control error, performing PID control adjustment output on the error, performing threshold monitoring on the cutterhead rotation speed, torque and temperature parameters after the error is controlled, judging the abnormality of the cutterhead drive system, and adjusting and optimizing the cutterhead drive system through a main control system when an abnormality occurs. The application of this method makes up for the defects of manually checking the abnormality of the cutterhead drive system, performs real-time monitoring of the cutterhead drive system and autonomously warns of abnormalities, promptly performs system fault abnormality control and repair, improves the working efficiency of the shield machine, and solves the above problems.

[0006] (II) Technical solution

[0007] To achieve the above object, the present invention provides the following technical solution: a control method for a cutter head drive system of a shield machine, comprising the following steps:

[0008] S1, collects the cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor through sensors;

[0009] S2, filtering all the data collected in S1, performing time series analysis on the filtered data and calculating the trend and mean of the processed data;

[0010] S3, adjusting the working state of the cutter disc in real time according to the above processed and calculated data, calculating the propulsion force and rotation speed of the cutter disc, and predicting the temperature change of the cutter disc;

[0011] S4, calculate the control error based on the system's desired target and the actual measured process variable, and perform PID control to adjust the error output;

[0012] S5. After the error is controlled, threshold monitoring is performed on the cutter disc speed, torque and temperature parameters to determine the abnormality of the cutter disc drive system. When an abnormality occurs, the cutter disc drive system is adjusted and optimized through the main control system.

[0013] Preferably, the formula for filtering the collected data by S2 is as follows:

[0014]

[0015] In the formula, SMA t,a represents the moving average at time t, N represents the filter window size, x t-i represents the original data, i represents the data count subscript, and subscript a refers to the collected cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor, It means that the collected data from the first data to the N-1th data are summed and divided by the selected size N of the filter window to obtain the filtered data.

[0016] Preferably, S2 performs time series analysis on the filtered data, and the formula for calculating the data mean is as follows:

[0017]

[0018] In the formula, Jx represents the data mean, M represents the total number of data points, and Kc i represents the i-th data point, i represents the data count subscript, It means that the filtered data from the first data to the Mth data are summed and divided by the total number of data points M to obtain the mean of the required data. d represents the cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor.

[0019] Preferably, S2 performs trend analysis on the filtered data, and the formula is as follows:

[0020] ya=m*x+b

[0021] In the formula, ya represents the data dependent variable, m represents the slope, x represents the data independent variable, and b represents the intercept, which reflects the direction and strength of the trend.

[0022] Preferably, the S3 adjusts the working state of the cutter disc in real time according to the above processed and calculated data, and calculates the propulsion force of the cutter disc. The calculation formula is as follows:

[0023] F=Psxl*Jxxl

[0024] In the formula, F represents the propulsion force of the cutter disc, Psxl represents the input power, and Jxxl represents the mechanical efficiency.

[0025] Preferably, the S3 adjusts the working state of the cutter disc in real time according to the above processed and calculated data, and calculates the cutter disc speed. The calculation formula is as follows:

[0026]

[0027] In the formula, Dpzs represents the cutter head speed, fc represents the frequency, Pjds represents the dimensionless pole pair number, 60 represents 60 seconds per minute, and 60*fc represents the speed to be generated in revolutions per minute.

[0028] Preferably, the formula for predicting the change in cutter head temperature in S3 is as follows:

[0029]

[0030] In the formula, T(t) represents the temperature value at time t, T 0 represents the initial temperature, the reference temperature of the system under no load, ΔT represents the temperature change, t represents the duration of the temperature change, t max Indicates the total time required to reach the maximum temperature. The time value is directly monitored and obtained through the timestamp;

[0031] The ΔT calculation formula is as follows:

[0032]

[0033] In the formula, T2 represents the temperature value at the next moment, and T1 represents the temperature value at the previous moment.

[0034] Preferably, the formula for calculating the control error in S4 is as follows:

[0035] e(t)=R(t)-Y(t)

[0036] In the formula, e(t) represents the control error, R(t) represents the target that the system expects to achieve, and Y(t) represents the actual measured process variable.

[0037] Preferably, the formula for PID control of the error by S4 is as follows:

[0038]

[0039] In the formula, U(t) represents the output of the controller, which is used to adjust the system to reach the set target value, e(t) represents the control error, and K i represents the integral gain, ∫e(t)dt represents the integral of the error, which is used to obtain the cumulative value of the error over a period of time. The integral greater than zero will gradually increase over time, strengthening the control effect. K d It represents the differential gain, which determines the responsiveness of the control system to the rate of error change. It predicts future error changes. If the error increases rapidly, the differential term will produce a reverse control output, thereby reducing system overshoot. Represents the derivative of the error, that is, the rate of change of the error over time. This term is used to slow down the dynamic response of the system and prevent over-adjustment.

[0040] Preferably, the S5 performs threshold monitoring on the cutter head rotation speed, torque and temperature parameters to judge the abnormality of the cutter head drive system, and the judgment method is as follows:

[0041] When the cutter disc speed exceeds the cutter disc speed threshold, the cutter disc torque exceeds the cutter disc torque threshold, and the cutter disc temperature exceeds the cutter disc temperature threshold, the cutter disc drive system actively warns of abnormalities, and the main control system sends an optimization control command to the cutter disc drive system for system control optimization.

[0042] Compared with the prior art, the present invention provides a control method for a shield machine cutter head drive system, which has the following beneficial effects:

[0043] The present invention collects data of the cutter disc drive system through sensors, including cutter disc rotation speed, shield machine propulsion force, motor current and power, tool wear status, soil moisture, soil density, motor temperature and vibration data, filters the above collected data, performs time series analysis on the filtered data, calculates trends and means, adjusts the working state of the cutter disc in real time according to the above processed and calculated data, calculates the cutter disc propulsion force and cutter disc rotation speed, predicts the cutter disc temperature change through a formula, calculates the control error, performs PID control adjustment output on the error, and after controlling the error, performs threshold monitoring on the cutter disc rotation speed, torque and temperature parameters, judges the abnormal situation of the cutter disc drive system, and adjusts and optimizes the cutter disc drive system through the main control system when an abnormality occurs. The application of this method makes up for the defects of manually checking the abnormality of the cutter disc drive system, monitors the cutter disc drive system in real time and autonomously warns of abnormalities, and promptly performs system fault abnormality control and repair, thereby improving the working efficiency of the shield machine. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a schematic diagram of the steps of the method of the present invention. DETAILED DESCRIPTION

[0045] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0046] In view of the problem that the fault diagnosis of the current cutterhead drive control system relies on manual inspection and post-analysis, and cannot achieve real-time monitoring and autonomous fault warning, delaying the opportunity for emergency treatment and reducing the working efficiency of the shield machine, a control method for the cutterhead drive system of the shield machine is proposed. Figure 1 , the method comprises the following steps:

[0047] S1. Collect data of the cutterhead drive system through sensors, including cutterhead speed, shield machine propulsion force, motor current and power, cutter wear status, soil moisture, soil density, motor temperature and vibration data;

[0048] The cutter head speed sensor can accurately measure the rotation speed of the cutter head to ensure the stability of the cutting process. The thrust sensor monitors the thrust changes of the shield machine under different soil conditions in real time to help optimize the thrust efficiency. In addition, the motor current and power sensors provide energy consumption data of the motor operation to monitor the working status and energy efficiency of the equipment. At the same time, the tool wear status sensor evaluates the wear degree of the tool and promptly reminds maintenance needs to reduce the risk of equipment downtime and maintain construction efficiency.

[0049] In terms of soil, soil moisture sensors and soil density sensors can obtain dynamic changes in the construction environment and provide soil information so that the cutting strategy of the cutter disc can be adjusted according to the geological conditions, thereby achieving more efficient earthwork operations. At the same time, the motor temperature sensor monitors the thermal state of the motor to prevent overheating damage, while the vibration sensor can detect abnormal vibration of the equipment and identify potential faults in time, thereby improving overall work safety;

[0050] S2, filtering all the data collected in S1, performing time series analysis on the filtered data and calculating the trend and mean of the processed data;

[0051] The data filtering formula is as follows:

[0052]

[0053] During the sensor acquisition process, environmental noise, vibration interference, etc. will affect the data. Filtering technology can eliminate short-term fluctuations and outliers and improve the signal-to-noise ratio of the data. In the formula, SMA t,a represents the moving average at time t, N represents the filter window size, x t-i represents the original data, i represents the data count subscript, and subscript a refers to the collected cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor, It means summing the collected data from the first data to the N-1th data and dividing it by the selected size N of the filter window to obtain the filtered data. The filtered data is smoother and reduces random fluctuations, making subsequent data analysis and decision-making more accurate;

[0054] The formula for calculating the mean of the data is as follows:

[0055]

[0056] By comparing with the mean of historical data, we can find the changing trend of equipment performance and ensure that the shield machine always maintains the best working conditions. In the formula, Jx represents the data mean, M represents the total number of data points, and Kc represents the average value of the data. i represents the i-th data point, i represents the data count subscript, It means that the filtered data from the first data to the Mth data are summed and divided by the total number of data points M to obtain the mean of the data. d represents the cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear state data, the soil moisture data, the soil density data, the temperature and vibration data of the motor. The calculation of the mean value can help evaluate the stability of the system in a specific time period and identify the gradually deteriorating problems that may occur in long-term operation.

[0057] The formula for trend analysis of filtered data is as follows:

[0058] ya=m*x+b

[0059] Trend analysis can help predict future behaviors and needs by identifying patterns of data changes, so as to take measures in advance, such as timely adjusting the operation of the cutterhead to adapt to soil changes. In the formula, ya represents the data dependent variable, m represents the slope, x represents the data independent variable, and b represents the intercept, which reflects the direction and strength of the trend. Through long-term trend data monitoring, problems such as wear and performance degradation can be discovered in time, and more reasonable maintenance plans can be formulated to reduce the failure rate;

[0060] S3, adjusting the working state of the cutter disc in real time according to the above processed and calculated data, calculating the propulsion force and rotation speed of the cutter disc, and predicting the temperature change of the cutter disc;

[0061] The calculation formula of the cutter disc propulsion force is as follows:

[0062] F=Psxl*Jxxl

[0063] By optimizing the calculation of the propulsion force, the cutting parameters of the cutter disc can be adjusted to achieve the best efficiency and reduce energy consumption and time. In the formula, F represents the propulsion force of the cutter disc, Psxl represents the input power, and Jxxl represents the mechanical efficiency. According to the change of propulsion force, the working mode of the cutter disc can be adjusted in time to adapt to the properties of different soils and improve work efficiency.

[0064] The calculation formula of cutter head speed is as follows:

[0065]

[0066] The cutter head speed directly affects the cutting effect. Real-time monitoring of the speed can ensure that it works within the optimal range, thereby improving cutting efficiency and earthwork quality. In the formula, dpzs represents the cutter head speed, fc represents the frequency, Pjds represents the dimensionless pole pair number, 60 represents 60 seconds per minute, and 60*fc represents the speed to be generated in revolutions per minute. Abnormal changes in the cutter head speed may indicate a fault or potential problem. Through real-time monitoring, measures can be taken in advance to prevent accidents.

[0067] The formula for predicting the temperature change of the cutter head is as follows:

[0068]

[0069] By predicting the change trend of the cutter head temperature, the potential overheating risk can be identified early, the cutter head and related components can be prevented from being damaged due to overheating, and the maintenance cost and downtime can be reduced. In the formula, T(t) represents the temperature value at time r, T 0 represents the initial temperature, the reference temperature of the system under no load, ΔT represents the temperature change, r represents the duration of the temperature change, r max Indicates the total time required to reach the maximum temperature. The time value is obtained through timestamp monitoring. Predicting temperature changes can provide data support for the cooling system and adjust the cooling strategy in time to ensure that the cutter disc operates at the optimal working temperature, thereby extending the service life of the tool;

[0070] The ΔT calculation formula is as follows:

[0071]

[0072] In the formula, T2 represents the temperature value at the next moment, and T1 represents the temperature value at the previous moment;

[0073] S4, calculate the control error based on the system's desired target and the actual measured process variable, and perform PID control to adjust the error output;

[0074] The formula for calculating the control error is as follows:

[0075] e(t)=R(t)-Y(t)

[0076] The control error provides data support for operators, helping them to compare the actual operation status with the expected target, so as to make more reasonable decisions. In the formula, e(t) represents the control error, R(t) represents the target that the system expects to achieve, and Y(t) represents the actual measured process variable. Through error analysis, the operating parameters can be adjusted in time, and the changes in the external environment can be quickly responded to, ensuring that the shield machine continues to operate in the best condition.

[0077] The formula for PID control of the error is as follows:

[0078]

[0079] PID control achieves fast and smooth response through appropriate proportional, integral and differential adjustments, adapts to the needs of dynamic changes in the system, and avoids oscillation and overshoot. In the formula, U(t) represents the output of the controller, which is used to adjust the system to the set target value, e(t) represents the control error, and K irepresents the integral gain, ∫e(t)dt represents the integral of the error, which is used to obtain the cumulative value of the error over a period of time. The integral greater than zero will gradually increase over time, strengthening the control effect. K d It represents the differential gain, which determines the responsiveness of the control system to the rate of error change. It predicts future error changes. If the error increases rapidly, the differential term will produce a reverse control output, thereby reducing system overshoot. Represents the derivative of the error, that is, the rate of change of the error over time. This term is used to slow down the dynamic response of the system and prevent over-adjustment. The PID controller can adjust its parameters based on real-time feedback to adapt to different working conditions and environmental changes, thereby maintaining the efficiency and stability of the system;

[0080] S5. After the error is controlled, the cutter head speed, torque and temperature parameters are monitored by threshold value to determine the abnormality of the cutter head drive system. When an abnormality occurs, the cutter head drive system is adjusted and optimized through the main control system;

[0081] The abnormal situation is judged as follows:

[0082] When the cutter disc speed exceeds 60RPM, the cutter disc torque exceeds 600N / m, and the cutter disc temperature exceeds 90 degrees Celsius, the cutter disc drive system will actively warn of abnormalities. After detecting the operating abnormality, the main control system will automatically issue optimization control instructions to guide the cutter disc drive system to perform system control optimization. This optimization includes adjusting the cutter disc speed and torque output, and optimizing the operation of the cooling system to reduce the cutter disc temperature and ensure that the equipment is within a safe operating range. At this time, the system adopts a proportional-integral-differential control strategy to achieve precise adjustment of the cutter disc working state, thereby improving the system's response speed and stability. Through this multi-level technical means, the shield machine cutter disc drive system can not only respond to sudden failures in real time, but also automatically make fine adjustments under dynamic conditions to ensure construction safety, efficiency and reliability.

[0083] The application of this method makes up for the defects of manual inspection of cutter head drive system abnormalities, conducts real-time monitoring of the cutter head drive system and autonomously warns of abnormalities, and promptly controls and repairs system faults and abnormalities, thereby improving the working efficiency of the shield machine.

[0084] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A control method for a shield machine cutter head drive system, characterized in that: The following steps are involved: S1, collects the cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor through sensors; S2, filtering all the data collected in S1, performing time series analysis on the filtered data and calculating the trend and mean of the processed data; S3, adjusting the working state of the cutter disc in real time according to the above processed and calculated data, calculating the propulsion force and rotation speed of the cutter disc, and predicting the temperature change of the cutter disc; S4, calculate the control error based on the system's expected target and the actual measured process variable, and perform PED control adjustment output on the error; S5. After the error is controlled, threshold monitoring is performed on the cutter disc speed, torque and temperature parameters to determine the abnormality of the cutter disc drive system. When an abnormality occurs, the cutter disc drive system is adjusted and optimized through the main control system.

2. The control method of a shield machine cutter head drive system according to claim 1, characterized in that: The formula for filtering the collected data by S2 is as follows: In the formula, SMA t,a represents the moving average at time t, N represents the filter window size, x t-i represents the original data, i represents the data count subscript, and subscript a refers to the collected cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor, It means that the collected data from the first data to the N-1th data are summed and divided by the selected size N of the filter window to obtain the filtered data.

3. The control method of a shield machine cutter head drive system according to claim 2, characterized in that: S2 performs time series analysis on the filtered data, and the formula for calculating the data mean is as follows: In the formula, Jx represents the data mean, M represents the total number of data points, and Kc i represents the i-th data point, i represents the data count subscript, It means that the filtered data from the first data to the Mth data are summed and divided by the total number of data points M to obtain the mean of the required data. d represents the cutter head speed data of the cutter head drive system, the thrust data of the shield machine, the current and power data of the motor, the tool wear status data, the soil moisture data, the soil density data, the temperature and vibration data of the motor.

4. The control method of a shield machine cutter head drive system according to claim 3, characterized in that: S2 performs trend analysis on the filtered data, and the formula is as follows: ya=m*x+b In the formula, ya represents the dependent variable, m represents the slope, x represents the independent variable, and b represents the intercept.

5. The control method of a shield machine cutter head drive system according to claim 4, characterized in that: The S3 adjusts the working state of the cutter disc in real time according to the above processed and calculated data, and calculates the propulsion force of the cutter disc. The calculation formula is as follows: F=Psxl*Jxxl In the formula, F represents the propulsion force of the cutter disc, Psxl represents the input power, and Jxxl represents the mechanical efficiency.

6. The control method of a shield machine cutter head drive system according to claim 5, characterized in that: The S3 adjusts the working state of the cutter disc in real time according to the above processed and calculated data, and calculates the cutter disc speed. The calculation formula is as follows: In the formula, Dpzs represents the cutter head speed, fc represents the frequency, Pjds represents the dimensionless pole pair number, 60 represents 60 seconds per minute, and 60*fc represents the speed to be generated in revolutions per minute.

7. The control method of the shield machine cutter head drive system according to claim 6, characterized in that: The formula for predicting the temperature change of the cutter head by S3 is as follows: In the formula, T(t) represents the temperature value at time t, T0 represents the initial temperature, the reference temperature of the system under no load, ΔT represents the temperature change, t represents the duration of the temperature change, and t max Indicates the total time required to reach the maximum temperature. The time value is directly monitored and obtained through the timestamp; The ΔT calculation formula is as follows: In the formula, T2 represents the temperature value at the next moment, and T1 represents the temperature value at the previous moment.

8. The control method of the shield machine cutter head drive system according to claim 7, characterized in that: The formula for calculating the control error of S4 is as follows: e(t)=R(t)-Y(t) In the formula, e(t) represents the control error, R(t) represents the target that the system expects to achieve, and Y(t) represents the actual measured process variable.

9. A control method for a shield machine cutter head drive system according to claim 8, characterized in that: The formula for S4 to perform PID control on the error is as follows: In the formula, U(t) represents the output of the controller, which is used to adjust the system to reach the set target value, e(t) represents the control error, and K i represents the integral gain, ∫e(t)dt represents the integral of the error, which is used to obtain the cumulative value of the error over a period of time. The integral greater than zero will gradually increase over time, strengthening the control effect. K d It represents the differential gain, which determines the responsiveness of the control system to the rate of error change. It predicts future error changes. If the error increases rapidly, the differential term will produce a reverse control output, thereby reducing system overshoot. Represents the derivative of the error, that is, the rate of change of the error over time. This term is used to slow down the dynamic response of the system and prevent over-adjustment.

10. The control method of the shield machine cutter head drive system according to claim 9, characterized in that: S5 performs threshold monitoring on the cutter head speed, torque and temperature parameters to determine the abnormality of the cutter head drive system. The determination method is as follows: When the cutter disc speed exceeds the cutter disc speed threshold, the cutter disc torque exceeds the cutter disc torque threshold, and the cutter disc temperature exceeds the cutter disc temperature threshold, the cutter disc drive system actively warns of abnormalities, and the main control system sends an optimization control command to the cutter disc drive system for system control optimization.

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