TBM (Tunnel Boring Machine) jamming early warning device

Abstract

The invention relates to a TBM jamming early warning device which comprises a shield body (1), at least one gap measuring unit (2) and an early warning assembly (3). The gap measuring units (2) are arranged in the circumferential direction of the shield body (1) and used for monitoring the gap change between the shield body (1) and the rock wall in real time. And the early warning assembly (3) is in communication connection with the gap measurement unit (2) and is used for receiving the monitoring data and sending out an early warning signal. The method has the advantages that the change of the gap between the shield body and the rock wall is monitored in real time, field monitoring data such as surrounding rock pressure and displacement information and key tunneling parameters such as advancing speed and cutterhead torque are integrated, dynamic analysis is conducted through an advanced algorithm, real-time early warning of the TBM jamming risk is achieved, and the safety and efficiency of tunnel construction are remarkably improved.

Description

Technical Field

[0001] This invention relates to a TBM card reader early warning device, belonging to the field of early warning. Background Technology

[0002] Currently, domestic research on monitoring and early warning of TBM jamming processes mostly employs predictive models to assess risks. Existing results primarily focus on theoretical analysis based on model analysis and construction experience to explore early warning mechanisms, while research involving real-time on-site monitoring and early warning systems is relatively scarce. Currently, the most common early warning methods rely on monitoring the strain on the shield surface.

[0003] TBM jamming risk early warning provides crucial decision support for safe tunneling. This study proposes an early warning method based on gap measurement. By collecting real-time monitoring data of the annular gap between the shield and the excavation diameter, and analyzing the dynamic changes at each measuring point, a jamming risk early warning can be achieved. This technical solution integrates dedicated mechanical structure design, sensor signal acquisition, data transmission and preprocessing modules, and relies on the real-time computing power of a programmable logic controller (PLC) to implement precise early warning based on the numerical changes in the relative displacement between the shield and the excavation diameter. This method not only provides real-time early warning of jamming risks but also provides decision-making basis for subsequent tunneling parameter optimization and emergency response, possessing significant engineering value for ensuring tunnel construction safety.

[0004] The main limitation of existing technologies is that they rely solely on models for analysis without fully considering the actual situation, resulting in insufficient accuracy and reliability of prediction results in practical applications. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides a TBM card reader early warning device. The technical solution of this invention is as follows: A TBM (Tunnel Boring Machine) malfunction warning device includes: a shield body (1), at least one gap measuring unit (2), and a warning component (3); the gap measuring unit (2) is arranged circumferentially along the shield body (1) and is used to monitor the gap change between the shield body (1) and the rock wall in real time; the warning component (3) is communicatively connected to the gap measuring unit (2) and is used to receive monitoring data and issue a warning signal.

[0006] The gap measuring unit (2) includes an outer cover (21), a contact rod (22), a measuring plate (23), and a spring (24). The outer cover (21) is welded to the shield body (1) and has an opening for the contact rod (22) to pass through. One end of the contact rod (22) passes through the shield body (1) and contacts the rock wall, while the other end passes through the shield body (1) and is welded to the measuring plate (23). The spring (24) is fitted onto the contact rod (22). One end of the spring (24) is welded to the measuring plate (23), and the other end abuts against the stepped groove of the outer cover (21) and moves in cooperation with the outer cover (21).

[0007] The gap measuring unit (2) also includes a laser rangefinder (25), which is fixedly installed on the shield (1) and is used to emit lasers to the measuring plate (23) and receive reflected signals to measure the displacement of the measuring plate (23).

[0008] The output signal of the laser rangefinder (25) is a 4-20mA analog signal, corresponding to a linear range of 0-30mm.

[0009] The early warning system (3) includes a data acquisition module (31), a PLC controller (32), a human-machine interface (33), and a communication module (34); the data acquisition module (31) is used to acquire signal data from the gap measurement unit (2); the PLC controller (32) is used to process the signal data and determine whether an early warning is triggered; the human-machine interface (33) is used to display monitoring data and early warning information; and the communication module (34) is used to push the early warning information to a mobile terminal.

[0010] The PLC controller (32) is a Siemens S7-1500 series controller, which automatically triggers an alarm when the monitored value reaches the threshold.

[0011] The number of gap measuring units (2) is 6 sets, which are evenly arranged along the circumference of the shield body (1), and the azimuth angle interval between adjacent units is 60°.

[0012] The spring (24) is a compression spring, and its extension and retraction direction is consistent with the movement direction of the contact rod (22). It is used to buffer the pressure of the rock wall on the contact rod (22) and reset it.

[0013] The advantages of this invention are: real-time monitoring of the changes in the gap between the shield and the rock wall, integration of on-site monitoring data such as surrounding rock pressure and displacement information, and key tunneling parameters such as propulsion speed and cutterhead torque, dynamic analysis using advanced algorithms, real-time early warning of TBM jamming risk, and significant improvement in tunnel construction safety and efficiency. Attached Figure Description

[0014] Figure 1This is a schematic diagram of the main structure of the present invention.

[0015] Figure 2 yes Figure 1 A schematic diagram of the structure of the gap measuring unit.

[0016] Figure 3 yes Figure 2 AA sectional view.

[0017] Figure 4 yes Figure 2 Side view.

[0018] Figure 5 yes Figure 4 BB cross-sectional view.

[0019] Figure 6 yes Figure 1 A schematic diagram of the structure of the early warning component. Detailed Implementation

[0020] The present invention will be further described below with reference to specific embodiments, and the advantages and features of the present invention will become clearer as a result. However, these embodiments are merely exemplary and do not constitute any limitation on the scope of the present invention. Those skilled in the art should understand that modifications or substitutions can be made to the details and form of the technical solutions of the present invention without departing from the spirit and scope of the present invention, but all such modifications and substitutions fall within the protection scope of the present invention.

[0021] See Figures 1 to 6 This invention relates to a TBM jamming early warning device, comprising: a shield body 1, at least one gap measuring unit 2, and an early warning component 3; the gap measuring unit 2 is arranged circumferentially along the shield body 1 and is used to monitor the gap change between the shield body 1 and the rock wall in real time; the early warning component 3 is communicatively connected to the gap measuring unit 2 and is used to receive monitoring data and issue early warning signals.

[0022] The gap measuring unit 2 includes an outer cover 21, a contact rod 22, a measuring plate 23, and a spring 24. The outer cover 21 is welded to the shield body 1 and has an opening for the contact rod 22 to pass through. One end of the contact rod 22 passes through the shield body 1 and contacts the rock wall, while the other end passes through the shield body 1 and is welded to the measuring plate 23. The spring 24 is fitted onto the contact rod 22. One end of the spring 24 is welded to the measuring plate 23, and the other end abuts against the stepped groove of the outer cover 21, thus engaging with the outer cover 21.

[0023] The structure of the gap measuring unit 2 (including the specific connection and engagement of the outer cover 21, contact rod 22, measuring plate 23, and spring 24) has the following significant advantages: One end of the contact rod is in direct contact with the rock wall, which can truly and directly sense the convergence or deformation of the rock wall. This avoids the signal attenuation or misjudgment problems that may be caused by environmental factors such as dust and water mist in non-contact measurement, making the measurement results more reliable.

[0024] A spring is fitted onto the contact rod, with one end welded to the measuring plate and the other end resting against the stepped groove of the outer casing in a dynamic fit. This design allows: When the rock wall contracts violently or suddenly compresses the contact rod, the spring can effectively absorb and buffer the impact force, protecting the internal precision sensors such as the laser rangefinder from damage.

[0025] The preload or compression force of the spring can always push the measuring plate and contact rod outward, ensuring that the end of the contact rod maintains continuous and stable contact with the rock wall. Even if the rock wall rebounds slightly or loosens, it can keep up in time and avoid loss of measurement data.

[0026] The spring is fitted onto the contact rod, which also serves as an auxiliary guide for the movement of the contact rod, making its movement trajectory more stable, reducing lateral swaying, and thus improving the accuracy of displacement measurement.

[0027] The gap measuring unit 2 also includes a laser rangefinder 25, which is fixedly mounted on the shield body 1. The laser rangefinder 25 emits a laser beam to the measuring plate 23 and receives the reflected signal to measure the displacement of the measuring plate 23. The macroscopic gap change between the rock wall and the shield body is transmitted through the displacement of the contact rod, and the displacement is read by the laser rangefinder, ensuring the accuracy and real-time nature of displacement transmission and providing an accurate and stable foundation for subsequent electrical signal measurements.

[0028] The laser rangefinder 25 outputs a 4-20mA analog signal, corresponding to a linear range of 0-30mm. There is no physical contact between the laser rangefinder and the measuring plate, avoiding interference from mechanical wear and frictional resistance on the measurement results. This enables high-precision, high-resolution measurement of minute displacements of the measuring plate, thereby accurately deducing the gap changes between the shield and the rock wall.

[0029] The early warning system 3 includes a data acquisition module 31, a PLC controller 32, a human-machine interface 33, and a communication module 34. The data acquisition module 31 is used to acquire signal data from the gap measurement unit 2. The PLC controller 32 is used to process the signal data and determine whether an early warning is triggered. The human-machine interface 33 is used to display monitoring data and early warning information. The communication module 34 is used to push early warning information to a mobile terminal.

[0030] The early warning system 3 includes a data acquisition module 31, a PLC controller 32, a human-machine interface 33, and a communication module 34. This integrated system design has the following advantages: Data acquisition module 31: used to acquire signals from multiple gap measurement units, ensuring the integrity and accuracy of the raw data and providing a reliable data foundation for subsequent judgment.

[0031] PLC controller 32: Processes the collected data and makes rapid judgments based on preset logic algorithms (such as threshold comparison and rate of change analysis), ensuring the timeliness of risk warning. Its industrial-grade design also ensures stable operation in the harsh electromagnetic and vibration environment of the tunnel.

[0032] Human-Machine Interface (HMI) 33: Presents monitoring data (such as the gap values ​​of each measuring point, trend curves, and early warning status) to operators in a graphical and visual manner. This enables operators to quickly grasp the overall situation, promptly detect anomalies, and provide intuitive decision support for adjusting tunneling parameters.

[0033] Communication module 34: Enables seamless remote transmission of early warning information from the field control layer to the management layer. By automatically pushing early warning information to the mobile terminals (such as mobile phones and tablets) of relevant personnel, the time from risk detection to the initiation of response measures is shortened.

[0034] From automatic data collection to automatic PLC processing and judgment, and then to automatic triggering of early warnings and automatic information push through the communication module, the reliance on human subjective judgment is minimized, the objectivity and efficiency of early warnings are improved, and the risk of accidents caused by human negligence is effectively reduced.

[0035] The PLC controller 32 is a Siemens S7-1500 series controller, which automatically triggers an alarm when the monitored value reaches the threshold.

[0036] In this embodiment, the number of gap measuring units 2 is 6 sets, which are evenly arranged along the circumference of the shield body 1, and the azimuth interval between adjacent units is 60°.

[0037] The spring 24 is a compression spring, and its extension and retraction direction is consistent with the movement direction of the contact rod 22. It is used to buffer the pressure of the rock wall on the contact rod 22 and reset it.

[0038] The working principle of the TBM card machine early warning device of the present invention is as follows: 1. Initial calibration and contact establishment: The device is pre-installed before the TBM begins excavation. Multiple gap measuring units 2 (e.g., 6 sets, spaced 60° apart) are evenly arranged around the circumference of the shield body 1. Their contact rods 22 extend outward under the preload of springs 24, ensuring that their ends make tight and stable contact with the excavated tunnel rock wall.

[0039] At this point, the laser rangefinder 25 measures the initial position of the measuring plate 23 and outputs a corresponding current signal (such as a value within the range of 4-20mA), which corresponds to an initial gap value (e.g., 30mm). The system sets this state as the reference.

[0040] 2. Real-time monitoring and displacement transfer: If the tunnel diameter shrinks due to factors such as surrounding rock convergence or deformation during the tunneling process, the circumferential gap between the rock wall and the shield body 1 will decrease accordingly.

[0041] The rock wall will press against the contact rod 22, overcoming the elastic force of the spring 24, and push the contact rod 22 to retract towards the inside of the shield body 1.

[0042] The movement of the contact rod 22 directly causes the measuring plate 23 welded to it to move inward together.

[0043] 3. Non-contact precision measurement: The laser rangefinder 25, which is fixedly installed on the shield body 1, continuously emits lasers to the measuring plate 23 and receives the reflected signals.

[0044] The displacement of the measuring plate 23 causes a change in the reading of the laser rangefinder 25. The device accurately converts the macroscopic amount of rock wall convergence (i.e., the amount of gap reduction) into a small amount of displacement of the measuring plate 23, and then converts it into a standard electrical signal (such as a 4-20mA analog signal) through the laser rangefinder 25.

[0045] 4. Data Acquisition and Processing: The data acquisition module 31 acquires the analog signals output by all laser rangefinders 25 in real time and converts them into digital signals.

[0046] These data representing the real-time gaps at each point are transmitted to the PLC controller 32 (such as the Siemens S7-1500 series).

[0047] The PLC controller 32 performs high-speed data processing and logical judgment, including: real-time calculation of the current gap value, comparison with a preset safety threshold (such as 15mm), and analysis of the rate of gap reduction.

[0048] 5. Risk assessment and early warning decision-making: When the PLC controller 32 determines that the real-time gap value of any one or more monitoring points is equal to or less than the set safety threshold, or the rate of gap shrinkage exceeds the safety range, it determines that there is a risk of machine jamming.

[0049] 6. Multi-level early warning and information output: Local audible and visual alarm: The PLC immediately triggers the audible and visual alarm device on the control cabinet or on-site operating console to alert the on-site operators.

[0050] Visualized interface display: Meanwhile, real-time gap data, early warning status, alarm points and other information are displayed in a graphical and trend curve manner through the human-machine interface 33 (HMI), which makes it easy for operators to quickly locate problems and make decisions.

[0051] Remote information push: The communication module 34 automatically pushes the early warning information (including time, location, and exceeding value) to the pre-bound mobile terminal of the management personnel (such as mobile phone or tablet) through the wireless network, realizing remote and cross-space instant alarm.

[0052] 7. Reset and continuous monitoring: When the rock wall pressure decreases or the tunneling parameters are adjusted and support measures are taken, the gap widens again. Under the restoring force of the spring 24, the measuring plate 23 and the contact rod 22 are pushed outward again to maintain contact with the rock wall. The reading of the laser rangefinder 25 increases, and the system returns to normal monitoring status.

[0053] The entire device operates continuously in a cycle, enabling uninterrupted real-time monitoring of the gap between the shield and the rock wall until the tunneling is completed.

[0054] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A TBM card reader early warning device, characterized in that, include: The shield body (1), at least one gap measuring unit (2), and an early warning component (3) are provided. The gap measuring unit (2) is arranged circumferentially along the shield body (1) and is used to monitor the gap change between the shield body (1) and the rock wall in real time. The early warning component (3) is connected to the gap measuring unit (2) for receiving monitoring data and issuing early warning signals.

2. The TBM card reader early warning device according to claim 1, characterized in that, The gap measuring unit (2) includes an outer cover (21), a contact rod (22), a measuring plate (23), and a spring (24). The outer cover (21) is welded to the shield body (1) and has an opening for the contact rod (22) to pass through. One end of the contact rod (22) passes through the shield body (1) and contacts the rock wall, while the other end passes through the shield body (1) and is welded to the measuring plate (23). The spring (24) is fitted onto the contact rod (22). One end of the spring (24) is welded to the measuring plate (23), and the other end abuts against the stepped groove of the outer cover (21) and moves in cooperation with the outer cover (21).

3. The TBM card reader early warning device according to claim 2, characterized in that, The gap measuring unit (2) also includes a laser rangefinder (25), which is fixedly installed on the shield (1) and is used to emit lasers to the measuring plate (23) and receive reflected signals to measure the displacement of the measuring plate (23).

4. The TBM card reader early warning device according to claim 3, characterized in that, The output signal of the laser rangefinder (25) is a 4-20mA analog signal, corresponding to a linear range of 0-30mm.

5. The TBM card reader early warning device according to claim 1, characterized in that, The early warning system (3) includes a data acquisition module (31), a PLC controller (32), a human-machine interface (33), and a communication module (34); the data acquisition module (31) is used to acquire signal data from the gap measurement unit (2); the PLC controller (32) is used to process the signal data and determine whether an early warning is triggered; the human-machine interface (33) is used to display monitoring data and early warning information; and the communication module (34) is used to push the early warning information to a mobile terminal.

6. The TBM card reader early warning device according to claim 5, characterized in that, The PLC controller (32) is a Siemens S7-1500 series controller, which automatically triggers an alarm when the monitored value reaches the threshold.

7. The TBM card reader early warning device according to claim 1, characterized in that, The number of gap measuring units (2) is 6 sets, which are evenly arranged along the circumference of the shield body (1), and the azimuth angle interval between adjacent units is 60°.

8. The TBM card reader early warning device according to claim 2, characterized in that, The spring (24) is a compression spring, and its extension and retraction direction is consistent with the movement direction of the contact rod (22). It is used to buffer the pressure of the rock wall on the contact rod (22) and reset it.

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