Hydraulic self-adaptive correction system and correction method for TBM (Tunnel Boring Machine) belt conveyor

Abstract

The invention discloses a TBM belt conveyor hydraulic self-adaptive deviation correction system and a deviation correction method thereof.The deviation correction system comprises a detection unit, a control unit and an execution unit, the detection unit is used for monitoring the running state of a belt of a belt conveyor in real time and obtaining belt deviation data, and the control unit receives the belt deviation data transmitted by the detection unit and sends the belt deviation data to the execution unit; and a control instruction is generated according to the deviation data, and the execution unit adjusts the belt conveyor according to the control instruction so as to rectify the deviation of the belt. The deviation correcting device can automatically, quickly and accurately correct the deviated belt, effectively solves the problem of deviation of the belt of the belt conveyor in TBM construction, improves the stability and reliability of operation of the belt conveyor, reduces the maintenance cost and guarantees the construction progress.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of TBM belt conveyor deviation correction, and particularly relates to a TBM belt conveyor hydraulic self-adaptive deviation correction system and a deviation correction method thereof. BACKGROUND

[0002] In the TBM construction process, the belt conveyor, as an important slag transportation equipment, plays a key role in the construction progress and efficiency. However, due to the vibration generated by the TBM in the complex geological conditions, the installation error of the belt conveyor itself, the uneven distribution of materials and other factors, the belt conveyor often appears the phenomenon of belt deviation. The belt deviation not only causes the belt to wear out, shortens the service life of the belt, increases the maintenance cost, and in severe cases, may cause the belt to tear and off the groove, so that the belt conveyor cannot transport the slag normally, and further causes the TBM to stop, greatly affecting the construction progress and causing huge economic losses. At present, the existing belt conveyor deviation correction methods mainly include mechanical deviation correction and manual deviation correction. The mechanical deviation correction device has a relatively simple structure, but its deviation correction accuracy is limited, and it is difficult to adapt to the complex and changeable working conditions in the TBM construction. Moreover, when the belt deviation is large, the deviation correction effect is not good. Manual deviation correction requires the construction personnel to frequently check and adjust the position of the belt, which not only has a large labor intensity, but also has certain safety risks in the harsh environment of TBM construction. At the same time, the timeliness and accuracy of manual adjustment are difficult to guarantee, and it cannot meet the requirements of efficient construction. Therefore, there is an urgent need for a system that can correct the deviation of the TBM belt conveyor in real time, accurately and efficiently, so as to ensure the smooth progress of the TBM construction. SUMMARY

[0003] The purpose of the present application is to overcome the problems that the existing TBM in the complex geological conditions produces vibration, the belt conveyor itself has installation error, the materials are unevenly distributed and other factors, and the belt conveyor often appears the phenomenon of belt deviation. By providing a TBM belt conveyor hydraulic self-adaptive deviation correction system and method based on multi-sensor fusion, the deviated belt can be automatically, quickly and accurately corrected, the problem of belt deviation of the belt conveyor in the TBM construction is effectively solved, the stability and reliability of the belt conveyor operation are improved, the maintenance cost is reduced, and the construction progress is ensured.

[0004] In order to achieve the above-mentioned application purpose, the technical solutions adopted by the present application are as follows: According to one aspect of the present application, a TBM belt conveyor hydraulic self-adaptive deviation correction system and a deviation correction method thereof are provided, comprising a detection unit, a control unit and an execution unit: The detection unit is used for real-time monitoring the running state of the belt conveyor belt, and acquiring the belt deviation data; The control unit receives the belt deviation data transmitted by the detection unit, and generates a control instruction according to the deviation data; The execution unit adjusts the belt conveyor according to the control instruction to correct the deviation of the belt.

[0005] Preferably, the detection unit comprises an inclination sensor, a pressure sensor and a laser displacement sensor. The inclination sensor is distributed on the two side edges of the belt to detect the inclination deviation of the belt edge relative to the reference position. The pressure sensor is arranged at the contact position between the idler of the belt conveyor and the belt to detect the pressure distribution of the belt on the idler during operation. The laser displacement sensor is used to detect the slight deviation of the current section of the belt in real time.

[0006] Preferably, the control unit comprises a host computer and a controller, the host computer is connected with the controller, and the controller is connected with the detection unit and the execution unit respectively.

[0007] Preferably, the execution unit comprises a hydraulic oil tank, a hydraulic oil circuit, an oil suction assembly, a flow control assembly, a reversing valve group and an execution cylinder assembly. The hydraulic oil circuit is connected with the hydraulic oil tank, the oil suction assembly and the flow control assembly are connected with the hydraulic oil circuit, the reversing valve group is connected with the hydraulic oil circuit, and the reversing valve group is connected with the execution cylinder assembly.

[0008] Preferably, the oil suction assembly comprises a variable frequency motor and a variable plunger pump, the variable frequency motor is connected with the variable plunger pump, and the variable plunger pump is connected with the hydraulic oil circuit.

[0009] Preferably, the flow control assembly comprises an overflow valve, and the overflow valve is connected with the hydraulic oil circuit.

[0010] Preferably, the reversing valve group comprises a first reversing valve and a second reversing valve, the first reversing valve and the second reversing valve are connected with the hydraulic oil circuit respectively, and the first reversing valve and the second reversing valve are proportional servo valves.

[0011] Preferably, the execution cylinder assembly comprises a first execution cylinder and a second execution cylinder, the first execution cylinder is connected with the first reversing valve, and the second execution cylinder is connected with the second reversing valve.

[0012] Preferably, the deviation correction method of the TBM belt conveyor hydraulic self-adaptive deviation correction system comprises the following steps: S1, the inclination sensor is used to obtain the inclination deviation of the belt edge relative to the reference position, the pressure sensor is used to obtain the pressure distribution data of the belt on the idler during operation, and the laser displacement sensor is used to obtain the slight deviation of the current section of the belt. S2, the controller receives the inclination offset, pressure distribution data and the small offset of the belt, calculates the action parameters required by the execution unit; S3, the execution unit adjusts the belt according to the action parameters.

[0013] Therefore, the application has the following beneficial effects: 1, the detection unit of the application can monitor the running state of the belt in real time by using the inclination sensor, high-precision laser displacement sensor and pressure sensor, and the control unit can quickly and accurately calculate the deviation of the belt and the required parameters for correction, so as to realize accurate correction of the belt, the correction accuracy can reach ±1mm, and the stability and reliability of the belt machine operation are effectively improved. 2, the application has automatic detection and automatic correction functions, without manual intervention, greatly reducing the labor intensity of the operator, avoiding the timeliness and inaccuracy of manual correction, improving the construction efficiency, and ensuring the continuity of TBM construction. 3, the hydraulic system of the application adopts variable plunger pump and frequency converter to control the motor speed, which can automatically adjust the output flow and pressure according to the actual demand of the system, realize energy-saving operation. At the same time, the quick response and accurate correction function of the system reduces the energy loss and equipment downtime caused by the deviation of the belt, and improves the working efficiency of the whole TBM construction system. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 is the control logic diagram of the correction system of the application; Figure 2 is the hydraulic principle diagram of the execution unit of the correction system of the application; Figure 3 is the installation position diagram of each sensor of the application.

[0015] In the drawings, 1 is a hydraulic oil tank, 2 is a frequency conversion motor, 3 is a variable plunger pump, 4 is an overflow valve, 5 is a first reversing valve, 6 is a second reversing valve, 7 is a first execution cylinder, 8 is a second execution cylinder, 9 is an inclination sensor, 10 is a pressure sensor, 11 is a laser displacement sensor, and 12 is a roller. DETAILED DESCRIPTION

[0016] In order to make the purpose, technical scheme and advantages of the application more clear and obvious, the application will be further described in detail below with reference to the drawings and preferred embodiments. However, it should be noted that many details in the specification are only used to make the reader have a thorough understanding of one or more aspects of the application, and the aspects of the application can be realized without these specific details.

[0017] Please refer to Figure 1The application provides a TBM belt conveyor hydraulic self-adaptive deviation correction system and a deviation correction method thereof, and the technical scheme is as follows: The TBM belt conveyor hydraulic self-adaptive deviation correction system comprises a detection unit, a control unit and an execution unit. The detection unit is used for monitoring the running state of the belt conveyor in real time and acquiring related data of belt deviation. Specifically, the detection unit comprises an inclination sensor 9, a pressure sensor 10 and a laser displacement sensor 11. The inclination sensor 9 is distributed on the two side edges of the belt and is used for detecting the inclination deviation of the belt edge relative to the reference position. The pressure sensor 10 is installed at the contact position between the carrier roller 12 and the belt and is used for detecting the pressure distribution of the belt on the carrier roller 12 during the running process, so as to indirectly judge the deviation degree of the belt through the pressure change. The laser displacement sensor 11 is arranged above the belt. The laser displacement sensor 11 above the belt can detect the slight deviation of the belt in the current section in real time through laser scanning. The inclination sensor 9, the pressure sensor 10 and the laser displacement sensor 11 detect the belt deviation and convert the deviation physical signal into an electrical signal transmitted to the control unit.

[0018] The control unit is used for receiving the data transmitted by the detection unit, generating control instructions after analysis and calculation. Specifically, the control unit comprises a host computer and a controller. The host computer is connected with the controller, and the controller is connected with the inclination sensor 9, the pressure sensor 10 and the laser displacement sensor 11. The controller is a PLC controller. According to the deviation amount, the deviation speed and the pressure distribution of the belt, the controller can quickly and accurately calculate the action parameters required by the execution unit, such as the extension amount and extension speed of the hydraulic oil cylinder. Meanwhile, the controller also has a communication interface and can interact with the host computer of the TBM to realize remote monitoring and operation. Meanwhile, the control unit is equipped with a host computer man-machine interface, and the operator can check the running state of the belt conveyor, set system parameters and perform fault diagnosis through the man-machine interface. After receiving the signals from the inclination sensor 9, the pressure sensor 10 and the laser displacement sensor 11, the controller processes the data by using a preset deviation correction algorithm.

[0019] The execution unit adjusts the related components of the belt conveyor according to the instructions of the control unit to realize the deviation correction of the belt. The execution unit comprises a hydraulic oil tank 1, a hydraulic oil circuit, an oil suction assembly, a flow control assembly, a reversing valve group and an execution cylinder assembly. The hydraulic oil circuit is connected with the hydraulic oil tank 1, the oil suction assembly is connected with the hydraulic oil circuit, the oil suction assembly comprises a variable frequency motor 2 and a variable plunger pump 3, the variable frequency motor 2 is connected with the variable plunger pump 3, and the variable plunger pump 3 is connected with the hydraulic oil circuit. The variable frequency motor 2 drives the variable plunger pump 3 to rotate, and the variable plunger pump 3 sucks the hydraulic oil in the hydraulic oil tank 1 into the hydraulic oil circuit. The flow control assembly is connected with the hydraulic oil circuit, and the flow control assembly comprises an overflow valve 4, the overflow valve 4 is arranged behind the variable plunger pump 3, and the overflow valve 4 is connected with the hydraulic oil circuit. The size of the outlet pressure of the variable plunger pump 3 is changed through the overflow valve 4, so as to control the flow of the hydraulic oil in the hydraulic oil circuit. The hydraulic oil circuit is connected with the reversing valve group, and the reversing valve group comprises a first reversing valve 5 and a second reversing valve 6. The first reversing valve 5 and the second reversing valve 6 are both proportional servo valves, and are respectively a first proportional servo valve and a second proportional servo valve. The oil inlet of the first reversing valve 5 and the oil inlet of the second reversing valve 6 are both connected to the hydraulic oil circuit. The oil return ports of the first reversing valve 5 and the second reversing valve 6 are connected with each other. The oil outlets of the first reversing valve 5 and the second reversing valve 6 are respectively connected with the execution cylinder assembly. The execution cylinder assembly comprises a first execution cylinder 7 and a second execution cylinder 8. One oil outlet of the first reversing valve 5 is connected with the large cavity of the first execution cylinder 7, and the large cavity is also the rodless cavity of the first execution cylinder 7. The other oil outlet of the first reversing valve 5 is connected with the small cavity of the first execution cylinder 7, and the small cavity is also the rod cavity of the first execution cylinder 7. One oil outlet of the second reversing valve 6 is connected with the large cavity of the second execution cylinder 8, and the large cavity is also the rodless cavity of the second execution cylinder 8. The other oil outlet of the second reversing valve 6 is connected with the small cavity of the second execution cylinder 8, and the small cavity is also the rod cavity of the second execution cylinder 8.

[0020] When the detection unit detects the belt deviation, a signal is transmitted to the control unit, and the control unit controls the variable frequency motor 2 in the execution unit to start according to the data calculation, drives the variable displacement piston pump 3 to rotate, and the variable displacement piston pump 3 sucks hydraulic oil from the hydraulic oil tank 1 through the oil suction port. The variable displacement piston pump 3 can automatically adjust the output flow and pressure according to the actual demand of the system to realize energy saving and high efficiency. The speed of the variable frequency motor 2 is controlled by the controller, and the output flow of the variable displacement piston pump 3 can be accurately adjusted according to the instruction of the control unit. The hydraulic oil is connected from the variable displacement piston pump 3 to the first proportional servo valve and the second proportional servo valve. The PLC controller of the control unit controls the valve core of the first proportional servo valve and the second proportional servo valve to change the flow direction of the hydraulic oil, so as to realize the extension and retraction action of the first execution cylinder 7 and the second execution cylinder 8. At the same time, through the control characteristics of the proportional servo valve, the controller calculates the action parameters required by the execution unit, converts it into the through flow of the first proportional servo valve and the second proportional servo valve, adjusts the flow of the hydraulic oil, controls the extension and retraction speed of the hydraulic oil cylinder, and makes the correction action more stable.

[0021] The application also discloses a correction method of the TBM belt conveyor hydraulic self-adaptive correction system. S1, the inclination sensor 9 is used to obtain the inclination deviation of the belt edge relative to the reference position, the pressure sensor 10 is used to obtain the pressure distribution data of the belt on the supporting roller 12 in the running process, and the laser displacement sensor 11 is used to obtain the small deviation of the current section of the belt.

[0022] Specifically, the inclination sensor 9 is SCA60C, one set of two is installed every 2m along the length direction of the belt, and is respectively located at the left side edge of the belt and the right side edge of the belt. The installation height is 100mm away from the surface of the belt and is flush with the edge of the belt, and is fixed on the rack through an L-shaped support. The inclination sensor 9 is used for detecting the inclination deviation of the belt edge relative to the reference position, and 0V corresponds to-5°, 5V corresponds to +5°, and 2.5V is the reference 0. The model of the laser displacement sensor 11 is IL-600. The laser displacement sensor 11 is installed 1.5m above the belt and is fixed through a gantry, the scanning direction is along the width direction of the belt, the scanning range covers the full width of the belt, and the scanning line is perpendicular to the running direction of the belt. The laser displacement sensor 11 detects the small deviation of the belt in the transverse direction in real time, and the distance from the laser displacement sensor 11 to the center of the belt in the reference state is 1500mm. The model of the pressure sensor 10 is PT124G-111. One is installed at each end of each supporting roller 12 in each supporting roller 12 group (three supporting rollers 12, the interval is 400mm along the width direction of the belt), and is in close contact with the bearing seat of the supporting roller 12, 50mm away from the end of the supporting roller 12. There are 20 groups of supporting roller 12 groups on each belt machine, corresponding to 120 pressure sensors 10. The pressure sensor 10 detects the pressure distribution of the belt on the supporting roller 12.

[0023] S2, the controller receives the inclination offset, pressure distribution data and the small offset of the belt, and calculates the action parameters required by the execution unit.

[0024] Specifically, the controller collects the output values of all sensors at the initial time as the reference values and stores them in the internal register. For example, the inclination sensor 9 reference voltage V0=2.5V (corresponding to 0° inclination, i.e. no inclination of the belt edge); the laser displacement sensor 11 reference distance d0=1500mm (corresponding to the alignment of the belt center and the middle line of the sensor scan); the pressure sensor 10 reference current I0=12mA (corresponding to 5MPa pressure, i.e. uniform distribution of the pressure of the belt on the roller 12). During normal operation, the controller collects the real-time output values of each sensor with a sampling period of 100ms through the analog input module.

[0025] Single sensor offset calculation: obtain the original offset of the inclination sensor 9, the original offset of the laser displacement sensor 11, and the original offset of the pressure sensor 10; Set the data weight of each sensor, and calculate the comprehensive offset by the original offset and the weight; The controller converts the weighted fusion calculation comprehensive offset into the extension amount and extension speed of the execution cylinder.

[0026] S3, the execution unit acts according to the action parameters to adjust the belt conveyor to correct the deviation of the belt.

[0027] Specifically, the controller converts the extension beam and extension speed of the execution cylinder obtained according to the calculation of the comprehensive offset into analog signals, sends the analog signals to the frequency converter, adjusts the speed of the variable frequency motor 2, and the variable displacement pump 3 automatically adjusts the displacement according to the system pressure to ensure that the flow meets the action requirements of the cylinder. The controller outputs an analog signal to a proportional servo valve to control a first proportional servo valve and a first execution cylinder 7; controls a second proportional servo valve and a second execution cylinder 8. The first execution cylinder 7 and the second execution cylinder 8 are respectively connected with the roller 12, and the belt is adjusted by adjusting the angle / position of the roller 12, so that the belt returns to the reference running position.

[0028] The above only describes the preferred embodiments of the present application, and it should be noted that for those skilled in the art, without departing from the principles of the present application, a number of improvements and refinements can be made, and these improvements and refinements should also be considered as the protection scope of the present application.

Claims

1. A hydraulic self-adaptive deviation correction system for a TBM belt conveyor, characterized in that, The application relates to a belt deviation correction system for a belt conveyor, which comprises a detection unit, a control unit and an execution unit. The detection unit is used for monitoring the running state of the belt conveyor in real time, and acquiring belt deviation data. The control unit receives the belt deviation data transmitted by the detection unit, and generates a control instruction according to the deviation data. The execution unit adjusts the belt conveyor according to the control instruction, so as to correct the belt.

2. The TBM belt conveyor hydraulic self-adaptive correction system of claim 1, wherein: The detection unit comprises an inclination sensor, a pressure sensor and a laser displacement sensor. The inclination sensor is arranged on the two side edges of the belt, and is used for detecting the inclination deviation of the belt edges relative to a reference position. The pressure sensor is arranged at the contact position between the roller of the belt conveyor and the belt, and is used for detecting the pressure distribution of the belt on the roller during belt running. The laser displacement sensor is used for detecting the slight deviation of the current section of the belt in real time.

3. The TBM belt conveyor hydraulic self-adaptive correction system of claim 2, wherein: The control unit comprises a host computer and a controller, the host computer is connected with the controller, and the controller is connected with the detection unit and the execution unit respectively.

4. The TBM belt conveyor hydraulic self-adaptive correction system of claim 3, wherein: The execution unit comprises a hydraulic oil tank, a hydraulic oil circuit, an oil suction assembly, a flow control assembly, a reversing valve group and an execution cylinder assembly. The hydraulic oil circuit is connected with the hydraulic oil tank, the oil suction assembly and the flow control assembly are connected with the hydraulic oil circuit, the reversing valve group is connected with the hydraulic oil circuit, and the reversing valve group is connected with the execution cylinder assembly.

5. The TBM belt conveyor hydraulic self-adaptive correction system of claim 4, wherein: The oil suction assembly comprises a variable frequency motor and a variable plunger pump, the variable frequency motor is connected with the variable plunger pump, and the variable plunger pump is connected with the hydraulic oil circuit.

6. The TBM belt conveyor hydraulic self-adaptive correction system of claim 5, wherein: The flow control assembly comprises an overflow valve, and the overflow valve is connected with the hydraulic oil circuit.

7. The TBM belt conveyor hydraulic self-adaptive correction system of claim 6, wherein: The reversing valve group comprises a first reversing valve and a second reversing valve, the first reversing valve and the second reversing valve are connected with the hydraulic oil circuit respectively, and the first reversing valve and the second reversing valve are proportional servo valves.

8. The TBM belt conveyor hydraulic self-adaptive correction system of claim 7, wherein: The execution cylinder assembly comprises a first execution cylinder and a second execution cylinder, the first execution cylinder is connected with the first reversing valve, and the second execution cylinder is connected with the second reversing valve.

9. The method of claim 1-8, wherein the method further comprises: The application further discloses a belt deviation correction method. S1, inclination deviation of the belt edges relative to a reference position is acquired by using an inclination sensor, pressure distribution data of the belt on a roller during belt running is acquired by using a pressure sensor, and slight deviation of the current section of the belt is acquired by using a laser displacement sensor. S2, a controller receives the inclination deviation, the pressure distribution data and the slight deviation of the belt, and calculates action parameters required by an execution unit. S3, the execution unit performs action according to the action parameters, and adjusts the belt conveyor, so as to correct the belt.

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