A visual device for identifying cutterhead wear and monitoring the tunnel face of a tunnel boring machine.

Abstract

This invention belongs to the field of shield tunneling construction monitoring technology and discloses a vision device for identifying cutterhead wear and monitoring the tunnel face of a shield tunneling machine. The vision device mainly consists of a lifting linear module, a translational telescopic fork, a rotating mechanism, a scissor-type telescopic mechanism, and a vision inspection device. The vision inspection device, with the help of the other four components, can identify the wear of the cutterhead at different positions on the shield tunneling machine's cutterhead and monitor the surrounding rock conditions at different locations on the tunnel face. Through remote operation of this device, it is possible to achieve unmanned monitoring of the cutterhead wear status and the tunnel face in the confined space inside the shield tunneling machine during construction, ensuring the personal safety of inspection personnel, improving tunnel construction efficiency, and saving economic costs.

Description

Technical Field

[0001] This invention belongs to the field of shield tunneling construction monitoring technology, and relates to a visual device for identifying cutter wear and monitoring the tunnel face of a shield machine. Background Technology

[0002] Under the backdrop of Industry 4.0, the rapid development of advanced technologies such as artificial intelligence, robotics, big data, and cloud computing has provided theoretical support and technical guarantees for the intelligentization of tunnel boring machines (TBMs). Intelligentization is an inevitable trend, and my country is moving towards high-end and digitalized TBM design and manufacturing. TBMs have numerous and complex structural systems, and many factors affect their operational efficiency, making precise and intelligent management impossible through manual methods alone. Furthermore, insufficient precision and predictability in TBM maintenance lead to frequent foreseeable failures and low utilization rates, making intelligent monitoring technology for tunneling machine systems a current development trend and a problem to be solved. TBMs operate in extreme environments with long distances and great depths, where geological conditions are extremely complex. During tunnel excavation, they primarily rely on cutters mounted on the cutterhead to cut through rock layers. These cutters, subjected to fluctuating loads under long-term contact with the rock layers, are prone to wear, resulting in significant cutter consumption. In current tunnel boring machine (TBM) construction, cutterhead inspection and replacement primarily rely on manual labor. The harsh working environment, including confined spaces and high humidity and dust, poses safety hazards and hinders efficiency. Furthermore, TBM construction inevitably disturbs the surrounding environment. When geological conditions and the construction environment are complex, this can easily lead to large-scale surface subsidence and collapse, causing severe social impacts and significant economic losses. Therefore, early warning systems for potential accidents at the tunnel face are crucial for ensuring the safety and stability of the tunnel project and its surrounding environment. To address these issues, a vision device for identifying cutterhead wear and monitoring the tunnel face is designed. Remote operation of this device enables unmanned monitoring of the cutterhead wear status within the confined space of the TBM during construction, ensuring personnel safety, improving tunnel construction efficiency, and saving costs. Summary of the Invention

[0003] The purpose of this invention is to provide a vision device for identifying cutter wear and monitoring the tunnel face of a tunnel boring machine (TBM). This device enables unmanned monitoring of the cutter wear status within the confined space of the TBM during construction, improving the efficiency of cutter detection, providing real-time monitoring of tunnel excavation, and offering timely warnings. It also ensures personnel safety, increases tunnel construction efficiency, and saves economic costs.

[0004] The technical solution of this invention:

[0005] A vision device for identifying cutter wear and monitoring the tunnel face of a tunnel boring machine mainly consists of a lifting mechanism 1, a translational telescopic fork 2, a rotating mechanism 3, a scissor-type telescopic mechanism 4, and a vision detection device 5.

[0006] The lifting mechanism 1 mainly consists of a double-row I-beam 1-1, a linear module 1-2, a servo motor 1-3, and a sliding connecting plate 1-4. The double-row I-beam 1-1 is fixed inside the observation cabin of the tunnel boring machine, the linear module 1-2 is fixed on the double-row I-beam 1-1, and the sliding connecting plate 1-4 is embedded in the linear module 1-2. The linear movement is achieved by the drive of the servo motor 1-3.

[0007] The telescopic fork 2 mainly consists of a connecting plate 2-1, a base 2-2, and a three-stage telescopic joint 2-3; one end of the connecting plate 2-1 is fixed to the sliding connecting plate 1-4, and the other end is fixed to the base 2-2; the three-stage telescopic joint 2-3 is installed on the base 2-2, and the three-stage telescopic joint 2-3 is driven by a servo motor to achieve synchronous retraction and extension;

[0008] The rotating mechanism 3 mainly consists of a connecting housing 3-1, a servo motor 3-2, a reducer bracket 3-3, a harmonic reducer 3-4, and a connecting flange 3-5. The connecting housing 3-1 is fixed on the three-stage expansion joint 2-3, and the servo motor 3-2 is installed inside it. The servo motor 3-2 is installed on the harmonic reducer 3-4. The entire assembly is fixed to the reducer bracket 3-3 through the outer ring connecting flange of the harmonic reducer 3-4. The reducer bracket 3-3 is fixed to the connecting housing 3-1 through its outer ring through hole, thus assembling the connecting housing 3-1, the servo motor 3-2, the reducer bracket 3-3, and the harmonic reducer 3-4 into a whole. A connecting flange 3-5 is installed at the front end of the harmonic reducer 3-4.

[0009] The scissor mechanism 4 mainly consists of a platform 4-1, an upper support 4-2, a connecting rod 4-3, a connecting pin 4-4, rollers 4-5, a track 4-6, and an electric actuator 4-7. The upper support 4-2 is connected to the connecting flange 3-5 of the rotating mechanism 3 to realize the rotation of the scissor mechanism 4. The scissor mechanism 4 is composed of the connecting rod 4-3 and the connecting pin 4-4 being connected in an alternating manner. The round hole interface at the rear end of the electric actuator 4-7 is connected to the connecting pin 4-4 on one side of the roller 4-5, and the fisheye interface on the drive rod of the electric actuator 4-7 is connected to the connecting pin 4-4 on the opposite side of the roller 4-5. The drive rod of the electric actuator 4-7 pushes the connecting pin 4-4 connected to it to realize the extension and retraction of the scissor mechanism 4. The inner walls of the platform 4-1 and the upper support 4-2 are equipped with a track 4-6. 6. Of the two connecting pins 4-4 near the platform 4-1, one connecting pin 4-4 is connected to the roller 4-5, and the other connecting pin 4-4 on the opposite side is fixed to the platform 4-1; the installation method of the connecting pin 4-4 and roller 4-5 on the bracket 4-2 is the same as the installation method of the connecting pin 4-4 and roller 4-5 on the platform 4-1; when the scissor mechanism 4 extends and retracts, the vertical and horizontal spacing between the different connecting pins 4-4 changes. The connecting pin 4-4 near the platform 4-1 slides along the track 4-6 on the inner side of the platform 4-1 within a certain range through the roller 4-5, and at the same time, the roller 4-5 on the upper bracket 4-2 also moves synchronously to adapt to the changes in the vertical and horizontal spacing of the different connecting pins 4-4;

[0010] The visual inspection device 5 mainly consists of a protective box 5-1, a top cover 5-2, side ears 5-3, a protective glass 5-4, a wiper 5-5, a 3D camera 5-6, and a 2D camera 5-7. The top cover 5-2 is installed on the top of the protective box 5-1, which contains the 3D camera 5-6 and the 2D camera 5-7. The 3D camera 5-6 identifies cutter wear, and the 2D camera 5-7 monitors the tunnel face. The protective glass 5-4 is located at the front of the protective box 5-1 to ensure the camera's imaging and protect it. The wiper 5-5 is installed below the protective glass 5-4 to clean the protective glass and ensure clear imaging. The visual inspection device 5 is connected to the scissor mechanism 4 through the side ears 5-3 on both sides. The visual inspection device 5 moves and detects inside the tunnel boring machine through the coordinated movement of the lifting mechanism 1, the translational telescopic fork 2, the rotating mechanism 3, and the scissor telescopic mechanism 4.

[0011] Beneficial results of this invention: This invention enables unmanned monitoring of different cutter wear states and the working face of the cutterhead within the confined space of the tunnel boring machine, ensuring personnel safety and improving tunnel construction efficiency. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the overall vision device for identifying cutter wear and monitoring the tunnel face of a tunnel boring machine.

[0013] Figure 2 This is a schematic diagram of the lifting mechanism.

[0014] Figure 3 This is a schematic diagram of a telescopic fork.

[0015] Figure 4 This is an exploded view of the rotating mechanism.

[0016] Figure 5 This is a schematic diagram of a scissor-type telescopic mechanism.

[0017] Figure 6 This is a schematic diagram of a visual inspection device.

[0018] In the diagram: 1 Lifting mechanism; 2 Telescopic fork; 3 Rotating mechanism; 4 Scissor telescopic mechanism; 5 Vision inspection device; 1-1 Double-row I-beams; 1-2 Linear module; 1-3 Servo motor; 1-4 Sliding connecting plate; 2-1 Connecting plate; 2-2 Base; 2-3 Three-stage telescopic joint; 3-1 Connecting housing; 3-2 Servo motor; 3-3 Reducer bracket; 3-4 Harmonic reducer; 3-5 Connecting flange; 4-1 Platform; 4-2 Upper bracket; 4-3 Connecting rod; 4-4 Connecting pin; 4-5 Roller; 4-6 Rail; 4-7 Electric actuator; 5-1 Protective box; 5-2 Top cover; 5-3 Side lugs; 5-4 Protective glass; 5-5 Wiper; 5-6 3D camera; 5-7 2D camera. Detailed Implementation

[0019] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings and technical solutions.

[0020] Example

[0021] Step 1: When the device is running, the linear module 1-2 of the lifting mechanism 1 is driven by the servo motor 1-3, which drives the entire device to move up and down, and is responsible for moving the device to the opening of the tunnel boring machine observation chamber.

[0022] Step Two: After moving to the opening, the telescopic fork 2 extends forward and moves to the back of the cutterhead. The scissor-type telescopic mechanism 4 extends to the vicinity of the cutterhead to be identified and monitored. The rotating mechanism 3 then rotates and fine-tunes the mechanism to ensure that the cutterhead is completely within the field of view of the visual inspection device 5. Afterward, the rotating mechanism 3 continues to adjust the mechanism so that the visual inspection device 5 is positioned at the gap between the tunnel boring machine's cutterhead. The telescopic fork 2 continues to move forward to observe the surrounding rock conditions at the tunnel face.

[0023] Step 3: After observation, the lifting mechanism 1 returns to the position of Step 1, and the rotating mechanism 3 rotates 180° to observe the cutterhead and surrounding rock above the tunnel boring machine. Similar to the operation in Step 2, the device uses a scissor-type telescopic mechanism 4 in conjunction with the rotating mechanism 3 to ensure that the cutterhead or surrounding rock to be detected is within the field of view of the visual inspection device 5, thus realizing the identification and monitoring of the cutterhead and surrounding rock above the tunnel boring machine.

[0024] Step 4: After completing steps 2 and 4, the scissor telescopic mechanism 4 retracts to its shortest position, the rotating mechanism 3 rotates to its initial position, the translation telescopic fork 2 retracts, and the device is moved into the observation chamber of the tunnel boring machine. Finally, the lifting mechanism 1 moves the device to the top of the chamber and returns it to its initial position.

Claims

1. A vision device for identifying cutterhead wear and monitoring the tunnel face of a tunnel boring machine, characterized in that, The vision device for identifying cutter wear and monitoring the tunnel face of a tunnel boring machine mainly consists of a lifting mechanism (1), a telescopic fork (2), a rotating mechanism (3), a scissor telescopic mechanism (4), and a vision detection device (5). The vision detection device (5) is connected to the scissor mechanism (4) through side ears (5-3) on both sides. The movement detection of the vision detection device (5) inside the tunnel boring machine is achieved through the coordinated movement of the lifting mechanism (1), the telescopic fork (2), the rotating mechanism (3), and the scissor telescopic mechanism (4). The visual inspection device (5) mainly consists of a protective box (5-1), a top cover (5-2), a side ear (5-3), a protective glass (5-4), a wiper (5-5), a 3D camera (5-6), and a 2D camera (5-7). The top cover (5-2) is installed on the top of the protective box (5-1), which contains the 3D camera (5-6) and the 2D camera (5-7). The 3D camera (5-6) is used to identify the wear of the cutting tool, and the 2D camera (5-7) is used to monitor the working face. The protective glass (5-4) is provided at the front of the protective box (5-1) to ensure the imaging of the camera and to protect the camera. The wiper (5-5) is installed below the protective glass (5-4) to clean the protective glass (5-4) and ensure clear imaging.

2. The vision device for identifying cutterhead wear and monitoring the tunnel face of a tunnel boring machine according to claim 1, characterized in that, The lifting mechanism (1) mainly consists of a double-row I-beam (1-1), a linear module (1-2), a servo motor (1-3), and a sliding connecting plate (1-4). The double-row I-beam (1-1) is fixed inside the observation cabin of the tunnel boring machine, the linear module (1-2) is fixed on the double-row I-beam (1-1), and the sliding connecting plate (1-4) is embedded in the linear module (1-2). The linear motion is achieved by the drive of the servo motor (1-3).

3. The vision device for identifying cutterhead wear and monitoring the tunnel face of a tunnel boring machine according to claim 1, characterized in that, The telescopic fork (2) mainly consists of a connecting plate (2-1), a base (2-2), and a three-stage telescopic joint (2-3); one end of the connecting plate (2-1) is fixed to the sliding connecting plate (1-4), and the other end is fixed to the base (2-2); the three-stage telescopic joint (2-3) is installed on the base (2-2), and the three-stage telescopic joint (2-3) is driven by a servo motor to achieve synchronous contraction and extension.

4. The vision device for identifying cutterhead wear and monitoring the tunnel face of a tunnel boring machine according to claim 1, characterized in that, The rotating mechanism (3) mainly consists of a connecting housing (3-1), a servo motor (3-2), a reducer bracket (3-3), a harmonic reducer (3-4), and a connecting flange (3-5). The connecting housing (3-1) is fixed on the three-stage expansion joint (2-3), and the servo motor (3-2) is installed inside it. The servo motor (3-2) is installed on the harmonic reducer (3-4). The whole is fixed to the reducer bracket (3-3) through the outer ring connecting flange of the harmonic reducer (3-4). The reducer bracket (3-3) is fixed to the connecting housing (3-1) through its outer ring through hole, thus assembling the connecting housing (3-1), the servo motor (3-2), the reducer bracket (3-3), and the harmonic reducer (3-4) into a whole. A connecting flange (3-5) is installed at the front end of the harmonic reducer (3-4).

5. The vision device for identifying cutterhead wear and monitoring the tunnel face of a tunnel boring machine according to claim 1, characterized in that, The scissor mechanism (4) mainly consists of a platform (4-1), an upper support (4-2), a connecting rod (4-3), a connecting pin (4-4), rollers (4-5), a track (4-6), and an electric actuator (4-7); the upper support (4-2) is connected to the connecting flange (3-5) of the rotating mechanism (3) to realize the rotation of the scissor mechanism (4); the scissor mechanism (4) consists of the connecting rod (4-3) and the connecting pin (4-4) intersecting each other. The connection components are as follows: the round hole interface at the rear end of the electric actuator (4-7) is connected to the connecting pin (4-4) on one side of the roller (4-5); the fisheye interface on the drive rod of the electric actuator (4-7) is connected to the connecting pin (4-4) on the opposite side of the roller (4-5); the drive rod of the electric actuator (4-7) pushes the connecting pin (4-4) connected to it to realize the extension and retraction of the scissor mechanism (4); the inner wall surfaces of the table (4-1) and the upper support (4-2) are equipped with rails. In the scissor lift mechanism (4-6), one of the two connecting pins (4-4) near the tabletop (4-1) is connected to the roller (4-5), and the other connecting pin (4-4) on the opposite side is fixed to the tabletop (4-1); the installation method of the connecting pin (4-4) and roller (4-5) on the bracket (4-2) is the same as the installation method of the connecting pin (4-4) and roller (4-5) on the tabletop (4-1); (4) During extension and retraction, the vertical and horizontal spacing between different connecting pins (4-4) changes. One connecting pin (4-4) close to the table (4-1) slides along the track (4-6) on the inner side of the table (4-1) via roller (4-5) within a certain range. At the same time, the roller (4-5) on the upper bracket (4-2) also moves synchronously to adapt to the changes in the vertical and horizontal spacing between different connecting pins (4-4).

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