Method and system for synchronous pushing and assembling reconstruction based on traditional pushing and assembling mode of shield machine

Abstract

The application is a method and system for synchronous pushing and assembling based on the traditional pushing and assembling mode of a shield machine. The method is as follows: the hydraulic system and electrical system of the traditional shield machine that first pushes and then assembles are improved, specifically, the original proportional flow valve is removed, and a proportional flow valve is added to the main hydraulic oil pipe; the original partition pressure control valve is removed, and a pressure control valve is added to each oil cylinder; a hydraulic pump is added to one side of the hydraulic oil tank for the extension and retraction of the corresponding oil cylinder for assembling segments in the synchronous pushing and assembling mode; the original electrical control system is removed, and a control box is added to each oil cylinder, and a high-precision displacement sensor and a pressure sensor are arranged; a control method is set for the improved hydraulic system to achieve the synchronous control target of pushing and assembling. The application improves the conventional shield machine pushing and assembling system, realizes the synchronous operation of conventional shield machine pushing and assembling, and significantly improves the efficiency, accuracy and safety of shield construction.

Description

Technical Field

[0001] This invention relates to the modification of the shield tunneling machine's pushing and assembling system, specifically a synchronous pushing and assembling modification system and control method based on the conventional shield tunneling machine's pushing and assembling mode. Background Technology

[0002] Traditional tunnel boring machine (TBM) construction primarily employs a sequential "tunneling-assembly" mode, relying on the TBM to complete processes such as soil excavation, soil removal, and segment assembly. First, the cutterhead at the front of the TBM cuts the soil, and the excavated soil is transported to the surface via a soil removal system. After tunneling one ring's width of segments, the machine stops, and an assembly machine assembles precast concrete segments at the tail of the shield. After segment assembly, tunneling continues, with an average operation time of 70-120 minutes per ring. During construction, the propulsion system often uses a 4-zone control system, with cylinders within the same zone sharing a proportional pressure reducing valve. Thrust distribution relies on manual adjustment, and the propulsion and assembly modes must be switched via a hydraulically controlled directional valve. This results in low construction efficiency and long construction periods. However, in large-diameter, long-distance tunnel projects, this "stop-and-go" construction mode is insufficient to meet the demands of efficient construction.

[0003] As major projects such as urban rail transit and cross-river / sea tunnels place increasingly higher demands on construction efficiency, safety, and precision, the shortcomings of the traditional intermittent "pushing the shield first, then assembling the segments" mode of conventional tunnel boring machines (TBMs) are becoming increasingly prominent. For example, in coastal cities with dense soft soil layers, projects often require shortened construction periods to reduce the impact of construction on traffic and residents' lives; while in deep and complex strata (such as high water pressure and high hardness rock layers), prolonged pauses in advancement may trigger more serious geological disasters. Against this backdrop, the industry urgently needs a technical solution that can break the disconnect between "pushing" and "assembling." Synchronous pushing and assembling of TBMs is an innovation of the traditional mode. With "tunneling and assembling" in parallel as its core, it achieves simultaneous progress through technological transformation. This technology can shorten the operation time of a single loop, such as reducing the time of a conventional TBM single loop from 70 minutes to 60 minutes, and the time of a 14-meter-class TBM from 120 minutes to 90 minutes. Some technologies can even improve efficiency by 30%-35%. There are already examples such as Japan's LoseZero method and China's ACTT technology. For instance, the Shanghai "Jiyue" shield tunnel set a record of 351 rings (702m) of tunneling in a single month. These methods are suitable for long-distance, large-diameter shield tunnels, and can significantly reduce construction time and costs, promoting the development of shield tunneling towards intelligence and efficiency.

[0004] Research on synchronous tunnel boring machine (TBM) assembly technology continues to advance, resulting in numerous patents. Patent CN115949416A discloses a control method and system for TBM propulsion cylinders based on synchronous assembly. This patent focuses on solving the control challenges of synchronous assembly by calculating the synchronous theoretical pressure of other propulsion cylinders to ensure that the combined propulsion force remains constant before and after synchronous assembly, thus achieving synchronous segment assembly. Patent CN120487128A discloses a synchronous propulsion and assembly TBM and a synchronous assembly construction method. Its innovation lies in the design of a unique thrust transmission device and other structures. During TBM propulsion, the segment assembler completes one ring of assembly. After one ring is propelled and assembled, a face balancing device is used to connect the entire ring of segments and move the thrust transmission device forward, thereby continuing propulsion and assembly, significantly improving construction progress. The patent for a human-machine collaborative control system and method for shield tunneling push-and-assemble synchronization disclosed in publication number CN120100460A constructs a system composed of a shield tunneling machine PLC module, an edge computing module, and a visualization module, realizing efficient transmission of commands and thrust distribution calculation results during the push-and-assemble synchronization process, as well as visualization of the shield tunneling machine status.

[0005] In addition, existing patents related to the push-and-assemble synchronization technology cover aspects such as the torque vector control algorithm of the propulsion system, while others focus on the push-and-assemble synchronization device to solve the problems of low accuracy in grasping the segments to be assembled and poor assembly results, thus ensuring assembly accuracy. These patents contribute from multiple dimensions, including control methods, construction devices, and collaborative systems, to jointly promote the continuous improvement of the tunnel boring machine push-and-assemble synchronization technology.

[0006] However, existing simultaneous pushing and assembling technologies primarily rely on newly manufactured tunnel boring machines (TBMs), and there is no application of this technology to existing conventional TBMs. Furthermore, there is a lack of systematic discussion on the design, modification, and control methods for conventional TBM systems. Given the high overall cost of TBM equipment, if a new technology requires new equipment, it significantly increases the cost of TBM construction. Moreover, a TBM has a relatively long service life. Integrating new technologies into traditional TBMs would not only greatly improve efficiency and address the efficiency and safety issues of traditional construction methods but also save on construction costs. Therefore, a solution is needed to improve traditional TBMs to enable the implementation of the new simultaneous pushing and assembling technology. Summary of the Invention

[0007] The purpose of this invention is to fill the gap in existing technology by providing a method and system for synchronous push-and-assemble transformation based on the traditional shield machine push-and-assemble mode through minor hardware modifications to the valve group of the conventional shield propulsion system and upgrades to the control system. This transformation system enables synchronous push-and-assemble technology by modifying the hydraulic and electrical system hardware of the conventional shield machine. At the same time, combined with new control methods, it breaks through the bottleneck of "serial" operation in the conventional propulsion and assembly mode, successfully realizing the synchronous operation of conventional shield machine propulsion and assembly, and significantly improving the efficiency, accuracy and safety of shield construction.

[0008] To achieve the above technical objectives, this invention provides a method for synchronous push-and-assemble transformation based on the traditional shield tunneling machine push-and-assemble mode. It improves the hydraulic and electrical systems of the shield tunneling machine in the traditional push-and-assemble mode, where the machine first pushes forward and then assembles. The hydraulic system of the shield tunneling machine is divided into four zones, each zone equipped with a proportional flow valve to control the flow rate, and a pressure control valve to control the cylinder pressure within each zone. Each group of cylinders is equipped with a separate directional valve. The flow rate and pressure of each group of pushing cylinders within each zone are the same, and all cylinders within each zone extend and retract at the same frequency. The specific steps of the transformation method are as follows:

[0009] S1. Remove the original proportional flow valve for each zone and add a proportional flow valve to the main hydraulic oil line to control the flow rate of the main hydraulic oil line; remove the original pressure control valve for each zone and add a pressure control valve to each group of cylinders to independently control the pressure of a single group of propulsion cylinders.

[0010] S2. Add another hydraulic pump to one side of the hydraulic oil tank. The added hydraulic pump is connected to each set of cylinders individually through hydraulic pipelines and is used for the extension and retraction of the cylinders corresponding to the assembled segments in the synchronous push-assemble mode.

[0011] S3. Remove all propulsion components from the original electrical control system and add a control box at the shield propulsion control valve group of each set of hydraulic cylinders. Also, equip each set of hydraulic cylinders with high-precision displacement sensors and pressure sensors; the control box is equipped with a data acquisition module and a data output module.

[0012] S4. A control method is set for the improved hydraulic system to achieve the goal of synchronous control of pushing and plucking; the specific process is as follows:

[0013] S401. During the operation of the propulsion system, the displacement sensor and pressure sensor configured in each set of cylinders collect the pressure and stroke data of the corresponding cylinder during propulsion in real time and feed it back to the corresponding control box. Each set of control boxes transmits the collected pressure and stroke data to the PLC controller of the original electrical control system. The PLC controller receives the data collected in real time by the displacement sensor and pressure sensor and calculates the original thrust and torque direction of the tunnel boring machine.

[0014] S402. Receive the original thrust and torque direction of the tunnel boring machine and the number of the retraction cylinder from the PLC controller through the host computer, and calculate the target thrust of each group of propulsion cylinders in the segment assembly state after the retraction cylinder.

[0015] S403. Feed back the target thrust of each group of propulsion cylinders calculated in step S402 under the segment assembly state to the PL controller, and adjust the opening of the proportional flow valve and the pressure control valve of the corresponding propulsion cylinder through the PLC controller so that the thrust of each group of propulsion cylinders reaches the target value, thereby ensuring that the magnitude and direction of the thrust remain unchanged and maintaining the stability of the shield machine attitude.

[0016] S404. At the same time, the PLC controller controls the newly added hydraulic pump to start, and controls the retraction of the corresponding cylinder through the pressure control valve according to the retraction cylinder number, so as to realize the segment assembly.

[0017] A further technical solution of the present invention: In step S401, the process by which the PLC controller receives real-time data collected by the displacement sensor and pressure sensor to calculate the original thrust and original thrust torque of the tunnel boring machine is as follows:

[0018] ① The original thrust of the tunnel boring machine is the thrust of all the propulsion cylinders, and the formula is:

[0019]

[0020] In the above formula, n represents the number of propulsion cylinders; This represents the sum of the original thrust of all hydraulic cylinders.

[0021] The original actual thrust of the i-th cylinder is where

[0022] ②The original thrust moment of the tunnel boring machine and the sum of the X and Y direction moments, including the original thrust of all hydraulic cylinders;

[0023] The X-direction torque of the original thrust of all hydraulic cylinders and The calculation is as follows:

[0024]

[0025] The Y-direction torque of the original thrust of all hydraulic cylinders and The calculation is as follows:

[0026]

[0027]

[0028] In the above formula, For the first Original thrust and torque in the X direction of each hydraulic cylinder; To increase the radius of action of the hydraulic cylinder center; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. No. The original thrust torque in the Y direction of each hydraulic cylinder; For the first The original actual thrust of each cylinder.

[0029] A further technical solution of the present invention: In step S402, when calculating the target thrust of each group of propulsion cylinders under the segment assembly state, the target thrust satisfies four constraints: resultant force conservation constraint, total torque conservation constraint, cylinder state constraint, and thrust range constraint; the target thrust of each group of propulsion cylinders under the segment assembly state is calculated based on the above four constraints. And according to the target thrust of each group of propulsion cylinders Calculate the torque of each group of propulsion cylinders under the segment assembly state.

[0030] A further technical solution of the present invention: In step S402, after calculating the target thrust of each group of propulsion cylinders under the segment assembly state, the calculated target thrust is verified by calculating the least squares index and the difference index between the original and new states. After verification that the requirements are met, it is then sent to the PLC controller of the original electrical control system.

[0031] A further technical solution of the present invention: Calculate the target thrust of each group of propulsion cylinders under the segment assembly state based on four constraint conditions. The process is as follows:

[0032] Under the constraint of conservation of resultant force, the sum of the thrust of each group of propulsion cylinders in the segment assembly state after the retraction cylinder is equal to the sum of the original thrust of all cylinders in the propulsion state. That is, we get:

[0033]

[0034]

[0035] Under the constraint of total torque conservation, the sum of the new thrust torques in the X and Y directions of each group of propulsion cylinders in the segment assembly state after the retraction cylinder is completed is equal to the sum of the original thrust torques in the X and Y directions of all cylinders, resulting in the following formula:

[0036]

[0037]

[0038] Under the constraints of the hydraulic cylinder's state, the formula is:

[0039]

[0040] Under the constraint of the thrust range of the hydraulic cylinder, the formula is as follows:

[0041]

[0042] A further technical solution of the present invention: the torque of each group of propulsion cylinders in the segment assembly state includes the torque in the X direction and the torque in the Y direction, based on the target thrust of each group of propulsion cylinders. The specific process for calculating the sum of the torques of each group of propulsion cylinders under the segment assembly state is as follows:

[0043] The torque in the X direction of each propulsion cylinder during segment assembly and The calculation is as follows:

[0044]

[0045]

[0046] The torque in the Y direction of each propulsion cylinder during segment assembly and The calculation is as follows:

[0047]

[0048]

[0049] A further technical solution of the present invention: uniformity is evaluated by calculating the mean least squares index, and the specific calculation formula is as follows:

[0050]

[0051] in, This represents the average thrust of each group of propulsion cylinders during the segment assembly process. In other words, there are k propulsion cylinders in the segment assembly state. The calculation process is as follows:

[0052] .

[0053] A further technical solution of the present invention: the original-new state difference index includes the resultant force difference between the new state and the original state. The torque and difference in the X direction between the new state and the original state The torque and difference in the Y direction between the new state and the original state The calculation formula is as follows:

[0054]

[0055]

[0056] .

[0057] In all formulas of this invention, the same parameter refers to the same thing. In the above formulas, n is the number of propulsion cylinders. To increase the radius of action of the hydraulic cylinder center; The number of the hydraulic cylinder. ; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. For the first The target thrust of each hydraulic cylinder; For the first The original actual thrust of each cylinder; For the first The status of each hydraulic cylinder; To push the lower limit of the hydraulic cylinder thrust; To increase the upper limit of the hydraulic cylinder thrust; The sum of the torques in the Y direction of the original thrust of the hydraulic cylinder; Let X be the torque in the X direction of the original thrust of the hydraulic cylinder.

[0058] To achieve the aforementioned technical objectives, this invention also provides a synchronous pushing and assembling modification system based on the traditional shield tunneling machine pushing and assembling mode. The system includes the original propulsion pump, hydraulic oil tank, and multiple sets of hydraulic cylinders of the original hydraulic system of the shield tunneling machine, as well as a host computer and PLC controller of the original electrical control system. The host computer and PLC controller are communicatively connected. The multiple sets of hydraulic cylinders are divided into four zones. The hydraulic oil tank supplies oil to each set of cylinders through a main hydraulic oil pipe and multiple branch hydraulic oil pipes. The original propulsion pump is installed on the main hydraulic oil pipe, and a reversing valve is installed on each branch hydraulic oil pipe. The hydraulic system also includes a new hydraulic pump, a proportional flow valve installed on the main hydraulic oil pipe, and a pressure control valve installed on each branch hydraulic oil pipe. The newly added hydraulic pump has its inlet end connected to the hydraulic tank via a first hydraulic oil pipe, and its outlet end connected to the supply ends of multiple directional valves via a second hydraulic oil pipe, for controlling the retraction of each set of cylinders. The electronic control system also includes displacement sensors and pressure sensors installed on each set of cylinders. A control box is added at the shield propulsion control valve group of each set of cylinders. The control box is equipped with a data acquisition module and a data output module. The displacement sensors and pressure sensors of each set of cylinders are connected to the data acquisition module in the corresponding control box, and the data output module in the control box is connected to the PLC controller.

[0059] The preferred technical solution of this invention is as follows: The electronic control system is further equipped with an automatic / manual dual-mode switching module and a fault diagnosis module; In automatic mode, the host computer and PLC controller automatically perform pressure distribution by calculating the target thrust based on the real-time pressure of each group of hydraulic cylinders; In manual mode, the automatic / manual dual-mode switching module allows input of zoned pressure through the operation interface; The fault diagnosis module addresses four typical alarms: "deviation between actual pressure and target pressure of propulsion cylinder > 5%", "deviation between actual and target thrust of total thrust > 5%", "deviation of horizontal point of action of total thrust > 5%", and "deviation of vertical point of action of total thrust > 5%"; A three-level processing mechanism is preset for these four typical alarms: Level 1 fault 0% <= deviation value < 2%, automatically adjusts the hydraulic cylinder pressure; Level 2 fault 2% <= deviation value < 5%, triggers an audible and visual alarm and suspends the assembly action; Level 3 fault deviation value >= 5%, immediately cuts off the propulsion enable and locks the assembly machine.

[0060] The modified hydraulic system of this invention offers significant advantages, meeting the requirements of simultaneous push-and-assemble construction. The original four-zone control system suffered from issues such as the inability of cylinders in the same zone to operate independently and difficulty in balancing thrust. The modified system upgrades this to independent control of each propulsion pump group, with each cylinder equipped with an independent valve group, achieving precise control. Two independent hydraulic pump systems are used, one for propulsion and the other for assembly, resolving flow conflicts and system interference. The modified cylinders exhibit fast pressure response and small deviations, ensuring stable total thrust and resultant force application points, guaranteeing stable shield posture, and significantly improving construction efficiency and safety, providing hardware support for the implementation of simultaneous push-and-assemble technology. The modified electrical system of this invention also offers outstanding advantages, adapting to simultaneous push-and-assemble construction. The original system struggled to provide precise control; the upgraded sensors and control box enable independent and precise control of the propulsion cylinders.

[0061] Based on the conventional tunnel boring machine (TBM) propulsion and assembly system, this invention breaks through the bottleneck of "serial" operation in the conventional propulsion and assembly mode by reconstructing the hardware of the propulsion system, iterating the software, and innovating the algorithm. At the same time, it relies on the PLC control program and the precise control logic of the propulsion cylinder pressure adaptive algorithm to achieve synchronous operation of conventional TBM propulsion and assembly, which significantly improves the efficiency, accuracy and safety of TBM construction. Attached Figure Description

[0062] Figure 1 This is a schematic diagram of the shield machine propulsion cylinder partitioning in an embodiment of the present invention;

[0063] Figure 2 This is a schematic diagram of the shield machine propulsion hydraulic system before improvement in this embodiment of the invention;

[0064] Figure 3 This is a schematic diagram of the improved shield tunneling machine propulsion hydraulic system in an embodiment of the present invention;

[0065] Figure 4 This is a schematic diagram of the improved shield tunneling machine propulsion electrical control system in an embodiment of the present invention;

[0066] Figure 5 This is a schematic diagram of the propulsion system control logic in an embodiment of the present invention;

[0067] Figure 6 This is a schematic diagram illustrating the torque calculation and analysis of each group of hydraulic cylinders in this invention;

[0068] Figure 7 This is a logic block diagram in an embodiment of the present invention for calculating the thrust of the propulsion cylinder in the segment assembly state based on the thrust of the propulsion cylinder in the propulsion state.

[0069] In the diagram: 1—Hydraulic cylinder, 2—Directional control valve, 3—Pressure control valve, 4—Proportional flow valve, 5—Original propulsion pump, 6—Hydraulic oil tank, 7—New hydraulic pump, 8—Shield body propulsion control valve group, 9—Control box, 10—Host computer, 13—PLC controller, 14—Main hydraulic oil pipe, 15—Sub-hydraulic oil pipe. Detailed Implementation

[0070] The present invention will be further described below with reference to the accompanying drawings and embodiments. The drawings are all embodiments, drawn in a simplified manner, and are only used to clearly and concisely illustrate the purpose of the embodiments of the present invention. The technical solutions shown in the drawings below are specific solutions of the embodiments of the present invention and are not intended to limit the scope of the claimed invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0071] The embodiment takes a traditional 16-cylinder tunnel boring machine as an example. Based on functional requirements, such as... Figure 1 As shown, the sixteen sets of hydraulic cylinders are generally divided into four zones (A, B, C, and D). The hydraulic system of a traditional tunnel boring machine is as follows: Figure 2As shown, the extension and retraction of cylinder 1 is controlled by a "proportional flow valve 4 + pressure control valve 3" mode. That is, each zone uses proportional flow valve 4 to control the zone flow and pressure control valve 3 to control the pressure of cylinder 1 in each zone. The flow and pressure of each group of cylinders 1 in each zone are the same, that is, each cylinder 1 in each zone extends and retracts at the same frequency. When assembly is required, proportional flow valve 4, pressure control valve 3, and reversing valve 2 are activated in sequence to control the retraction of the propulsion cylinder 1 in each zone, thereby assembling the tunnel segments. Traditional tunnel boring machines (TBMs) employ a push-and-assemble method, where the machine advances first and then assembles. To enable simultaneous push-and-assemble technology in traditional TBMs, improvements were made to their hydraulic systems. These improvements primarily involved hardware modifications to the hydraulic and electrical systems. The original hydraulic system consisted of the original propulsion pump 5, hydraulic oil tank 6, and sixteen sets of cylinders 1. Each zone of the TBM's hydraulic system had four sets of cylinders 1, and each zone was equipped with a proportional flow valve 4 to control the flow rate within that zone. Pressure control valves 3 controlled the pressure of the cylinders within each zone, and each set of cylinders 1 was equipped with a separate directional valve 2. The specific steps of the modification method are as follows:

[0072] S1. Remove the original proportional flow valve for each zone and add a proportional flow valve to the main hydraulic oil line to control the flow rate of the main hydraulic oil line; remove the original pressure control valve for each zone and add a pressure control valve to each group of cylinders to independently control the pressure of a single group of propulsion cylinders.

[0073] S2. Add another hydraulic pump to one side of the hydraulic oil tank. The added hydraulic pump is connected to each set of cylinders individually through hydraulic pipelines and is used for the extension and retraction of the cylinders corresponding to the assembled segments in the synchronous push-assemble mode.

[0074] S3. Remove all propulsion components from the original electrical control system and add a control box at the shield propulsion control valve group of each set of hydraulic cylinders. Also, equip each set of hydraulic cylinders with high-precision displacement sensors and pressure sensors; the control box is equipped with a data acquisition module and a data output module.

[0075] S4. A control method is set for the improved hydraulic system to achieve the goal of synchronous control of pushing and plucking; the specific process is as follows:

[0076] S401. During propulsion system operation, the displacement and pressure sensors configured in each set of cylinders collect real-time pressure and stroke data during cylinder propulsion and feed it back to the corresponding control box. Each control box transmits the collected pressure and stroke data to the PLC controller of the existing electrical control system. The PLC controller receives the real-time data collected by the displacement and pressure sensors and calculates the original thrust and torque direction of the tunnel boring machine. The process of the PLC controller receiving the real-time data collected by the displacement and pressure sensors and calculating the original thrust and torque of the tunnel boring machine is as follows:

[0077] ① The initial thrust of the tunnel boring machine (TBM) is the thrust of all the propulsion cylinders. In this embodiment, the TBM uses 16 sets of cylinders simultaneously during propulsion. The formula for calculating the initial thrust of the TBM is:

[0078]

[0079] In the above formula, This represents the sum of the original thrust of all hydraulic cylinders. For the first The original actual thrust of each cylinder, of which ;

[0080] ② The original thrust moment of the tunnel boring machine and the sum of the X and Y direction moments of the original thrust of all cylinders; the X and Y direction component moments of the i-th cylinder on the system are calculated by "radius of action × thrust × angle trigonometric function" (lever arm = radius × angle trigonometric function), the formula is:

[0081]

[0082]

[0083] The X-direction torque of the original thrust of all hydraulic cylinders and The calculation is as follows:

[0084]

[0085] The Y-direction torque of the original thrust of all hydraulic cylinders and The calculation is as follows:

[0086]

[0087] In the above formula, For the first Original thrust and torque in the X direction of each hydraulic cylinder; To increase the radius of action of the hydraulic cylinder center; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. No. The original thrust torque in the Y direction of each hydraulic cylinder; For the first The original actual thrust of each cylinder.

[0088] S402. The host computer receives the original thrust and torque direction of the tunnel boring machine and the number of the retraction cylinders calculated by the PLC controller. It then calculates the target thrust of each group of propulsion cylinders in the segment assembly state after the retraction cylinders are in place. Because the propulsion cylinders retract, the total thrust vector must remain unchanged. The propulsion cylinder pressure must meet the following four constraints. The new thrust vector is solved using the fsolve function. (Corresponding to the x vector in the code), the objective function is essentially 23 constraint equations, ensuring that the new thrust satisfies the constraints of resultant force conservation, total torque conservation, cylinder state constraints, and thrust range constraints, specifically as follows: Figure 7 As shown; the target thrust of each group of propulsion cylinders in the segment assembly state is calculated based on the above four constraints. And according to the target thrust of each group of propulsion cylinders Calculate the torque of each set of propulsion cylinders under the segment assembly state;

[0089] The target thrust of each group of propulsion cylinders under the segment assembly state was calculated based on four constraints. The process is as follows:

[0090] Under the constraint of conservation of resultant force, the sum of the thrust of each group of propulsion cylinders in the segment assembly state after the retraction cylinder is equal to the sum of the original thrust of all cylinders in the propulsion state. That is, we get:

[0091]

[0092]

[0093] Under the constraint of total torque conservation, the sum of the new thrust torques in the X and Y directions of each group of propulsion cylinders in the segment assembly state after the retraction cylinder is completed is equal to the sum of the original thrust torques in the X and Y directions of all cylinders, resulting in the following formula:

[0094]

[0095]

[0096] Under the constraints of the hydraulic cylinder state (with 16 equations), based on the hydraulic cylinder state... (0 = propulsion, 1 = retraction) Limiting new thrust: when During (retraction), the new thrust is forced to be equal to the original thrust in the propulsion state (because...). Therefore );when (During the process of advancement), this equation always holds true (because...). The formula is:

[0097]

[0098] Thrusting range constraints of hydraulic cylinders (16 equations) when During propulsion, the new thrust needs to be... Within the scope, constraints are enforced through functional relationships; when During (retraction), this equation always holds true (because) The formula is:

[0099]

[0100] In the above formula: To increase the radius of action of the hydraulic cylinder center; The number of the hydraulic cylinder. ; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. For the first The target thrust of each hydraulic cylinder; For the first The original actual thrust of each cylinder; For the first The status of each hydraulic cylinder; To push the lower limit of the hydraulic cylinder thrust; To increase the upper limit of the hydraulic cylinder thrust; The sum of the torques in the Y direction of the original thrust of the hydraulic cylinder; Let X be the torque in the X direction of the original thrust of the hydraulic cylinder.

[0101] The new thrust is obtained by solving the problem. Then, based on the target thrust of each group of propulsion cylinders... The sum of the torques of each group of propulsion cylinders under segment assembly conditions is calculated. The sum of the torques of each group of propulsion cylinders under segment assembly conditions includes the sum of the torques in the X direction and the sum of the torques in the Y direction. The specific calculation process is as follows:

[0102] The torque in the X direction of each propulsion cylinder during segment assembly and The calculation is as follows:

[0103]

[0104]

[0105] The torque in the Y direction of each propulsion cylinder during segment assembly and The calculation is as follows:

[0106]

[0107]

[0108] In the above formula: To increase the radius of action of the hydraulic cylinder center; The number of the hydraulic cylinder. ; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. For the first The target thrust of each hydraulic cylinder.

[0109] In step S402, after calculating the target thrust of each group of propulsion cylinders under the segment assembly state, the calculated target thrust is verified by calculating the least squares index and the difference index between the original and new states. After verification that the requirements are met, the thrust is then transmitted to the PLC controller of the original electrical control system. Among them, the uniformity is evaluated by calculating the least squares index, and the specific calculation formula is as follows:

[0110]

[0111] in, This represents the average thrust of each group of propulsion cylinders during the segment assembly process. In other words, there are k propulsion cylinders in the segment assembly state. The calculation process is as follows:

[0112] .

[0113] The original-new state difference index includes the resultant force difference between the new state and the original state. The torque and difference in the X direction between the new state and the original state The torque and difference in the Y direction between the new state and the original state The calculation formula is as follows:

[0114]

[0115]

[0116] .

[0117] S403. Feed back the target thrust of each group of propulsion cylinders calculated in step S402 under the segment assembly state to the PL controller, and adjust the opening of the proportional flow valve and the pressure control valve of the corresponding propulsion cylinder through the PLC controller so that the thrust of each group of propulsion cylinders reaches the target value, thereby ensuring that the magnitude and direction of the thrust remain unchanged and maintaining the stability of the shield machine attitude.

[0118] S404. At the same time, the PLC controller controls the newly added hydraulic pump to start, and controls the retraction of the corresponding cylinder through the pressure control valve according to the retraction cylinder number, so as to realize the segment assembly.

[0119] The modified system of this invention is as follows Figure 3 and Figure 4As shown, the original hydraulic system of the tunnel boring machine includes the original propulsion pump 5, hydraulic oil tank 6, and multiple sets of cylinders, as well as the host computer and PLC controller 13 of the original electrical control system. The host computer 10 and PLC controller 13 are communicatively connected. The multiple sets of cylinders are divided into four zones. The hydraulic oil tank 6 supplies oil to each set of cylinders 1 through the main hydraulic oil pipe 14 and multiple branch hydraulic oil pipes 15. The original propulsion pump 5 is installed on the main hydraulic oil pipe 14, and a reversing valve 2 is installed on each branch hydraulic oil pipe 15. The hydraulic system also includes a new hydraulic pump 7, a proportional flow valve 4 installed on the main hydraulic oil pipe 14, and a pressure control valve 3 installed on each branch hydraulic oil pipe 15. The newly added hydraulic pump 7 has its inlet end connected to the hydraulic oil tank 6 via a first hydraulic oil pipe, and its outlet end connected to the supply end of multiple directional valves 2 via a second hydraulic oil pipe, for controlling the retraction of each set of cylinders 1. The electronic control system also includes displacement sensors 11 and pressure sensors 12 installed on each set of cylinders 1. A control box 9 is added at the shield propulsion control valve group 8 of each set of cylinders 1. The control box 9 is equipped with a data acquisition module and a data output module. The displacement sensors 11 and pressure sensors 12 of each set of cylinders 1 are connected to the corresponding data acquisition module in the control box 9. The data output module in the control box 9 is connected to the PLC controller 13.

[0120] The electronic control system is also equipped with an automatic / manual dual-mode switching module and a fault diagnosis module. In automatic mode, the host computer 10 and PLC controller 13 calculate the target thrust based on the real-time pressure of each group of hydraulic cylinders 1 and automatically perform pressure distribution. In manual mode, the automatic / manual dual-mode switching module allows the input of zone pressure through the operation interface. In automatic mode, the program calls the initial value of the target thrust vector of the thrust distribution adaptive algorithm program and automatically performs pressure distribution. In manual mode, the function of the driver inputting zone pressure through the virtual operation interface is retained. After the program converts the manual command into a thrust vector, it still needs to be verified by the dynamic distribution algorithm to avoid loss of control due to human operation deviation.

[0121] The fault diagnosis module addresses four typical alarm types: "deviation between actual and target pressure of propulsion cylinder > 5%", "deviation between actual and target total thrust > 5%", "deviation of total thrust horizontal direction of application point > 5%", and "deviation of total thrust vertical direction of application point > 5%". A three-level processing mechanism is preset for these four types of alarms: Level 1 fault (0% <= deviation < 2%) automatically adjusts cylinder pressure; Level 2 fault (2% <= deviation < 5%) triggers audible and visual alarms and suspends assembly; Level 3 fault (deviation >= 5%) immediately cuts off propulsion enable, locks the assembly machine to prevent segment damage, and displays fault location and troubleshooting guidance on the host computer software interface.

[0122] This invention is based on the "double-center coincidence" thrust vector balance theory. It calls the thrust distribution adaptive algorithm program in the program and controls the pressure of each group of oil cylinders in real time through PID14 closed-loop regulation to ensure that the total thrust deviation is controlled within ±5%.

[0123] Taking a 1.5m wide segment as an example, the tunnel boring machine (TBM) starts its advance using a full hydraulic cylinder mode. Once the cylinder's advance stroke exceeds 1600mm, the system enters a synchronous pushing and assembling mode. The current ring K-block position is then set, and the assembly block is selected. The system calls an adaptive algorithm for the cylinder pressure. When the algorithm has a solution, the corresponding cylinder for the assembly block stops advancing and retracts, assembling the corresponding segment while the TBM continues to advance. After the current segment is assembled, the corresponding cylinder extends and thrust is redistributed, finally resuming full hydraulic cylinder mode. This cycle continues until the cylinders reach their maximum advance stroke.

[0124] The above description is merely one embodiment of the present invention, and while it is detailed and specific, it should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A method for synchronous push-and-assemble transformation based on the traditional shield tunneling machine push-and-assemble mode, which improves the hydraulic and electrical systems of the shield tunneling machine in the traditional push-and-assemble mode of first pushing and then assembling. The hydraulic system of the shield tunneling machine is divided into four zones, each zone is equipped with a proportional flow valve to control the zone flow, and a pressure control valve to control the cylinder pressure in each zone. Each group of cylinders is equipped with a separate reversing valve. The flow and pressure of each group of pushing cylinders in each zone are the same, and all cylinders in each zone extend and retract at the same frequency. The method is characterized by... The specific steps of the modification method are as follows: S1. Remove the original proportional flow valve for each zone and add a proportional flow valve to the main hydraulic oil line to control the flow rate of the main hydraulic oil line; remove the original pressure control valve for each zone and add a pressure control valve to each group of cylinders to independently control the pressure of a single group of propulsion cylinders. S2. Add another hydraulic pump to one side of the hydraulic oil tank. The added hydraulic pump is connected to each set of cylinders individually through hydraulic pipelines and is used for the extension and retraction of the cylinders corresponding to the assembled segments in the synchronous push-assemble mode. S3. Remove all propulsion components from the original electrical control system and add a control box at the shield propulsion control valve group of each set of hydraulic cylinders. Also, equip each set of hydraulic cylinders with high-precision displacement sensors and pressure sensors; the control box is equipped with a data acquisition module and a data output module. S4. A control method is set for the improved hydraulic system to achieve the goal of synchronous control of pushing and plucking; the specific process is as follows: S401. During the operation of the propulsion system, the displacement sensor and pressure sensor configured in each set of cylinders collect the pressure and stroke data of the corresponding cylinder during propulsion in real time and feed it back to the corresponding control box. Each set of control boxes transmits the collected pressure and stroke data to the PLC controller of the original electrical control system. The PLC controller receives the data collected in real time by the displacement sensor and pressure sensor and calculates the original thrust and torque direction of the tunnel boring machine. S402. Receive the original thrust and torque direction of the tunnel boring machine and the number of the retraction cylinder from the PLC controller through the host computer, and calculate the target thrust of each group of propulsion cylinders in the segment assembly state after the retraction cylinder. S403. Feed back the target thrust of each group of propulsion cylinders calculated in step S402 under the segment assembly state to the PLC controller, and adjust the opening of the proportional flow valve and the pressure control valve of the corresponding propulsion cylinder through the PLC controller so that the thrust of each group of propulsion cylinders reaches the target value, thereby ensuring that the magnitude and direction of the thrust remain unchanged and maintaining the stability of the shield machine attitude. S404. At the same time, the PLC controller controls the newly added hydraulic pump to start, and controls the retraction of the corresponding cylinder through the pressure control valve according to the retraction cylinder number, so as to realize the segment assembly.

2. The method for synchronous tunneling modification based on the traditional shield tunneling machine tunneling mode according to claim 1, characterized in that: In step S401, the PLC controller receives real-time data collected by displacement and pressure sensors to calculate the original thrust and torque of the tunnel boring machine as follows: ① The original thrust of the tunnel boring machine is the thrust of all the propulsion cylinders, and the formula is: ； In the above formula, n represents the number of propulsion cylinders; This represents the sum of the original thrust of all hydraulic cylinders. For the first The original actual thrust of each cylinder, of which ; ②The original thrust moment of the tunnel boring machine and the sum of the X and Y direction moments, including the original thrust of all hydraulic cylinders; The X-direction torque of the original thrust of all hydraulic cylinders and The calculation is as follows: ； ； The Y-direction torque of the original thrust of all hydraulic cylinders and The calculation is as follows: ； ； In the above formula, For the first Original thrust and torque in the X direction of each hydraulic cylinder; To increase the radius of action of the hydraulic cylinder center; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. No. The original thrust torque in the Y direction of each hydraulic cylinder; For the first The original actual thrust of each cylinder.

3. A method for synchronous tunneling modification based on the traditional shield tunneling machine's tunneling mode, as described in claim 1 or 2, characterized in that... In step S402, when calculating the target thrust of each group of propulsion cylinders under the segment assembly state, the target thrust satisfies four constraints: resultant force conservation constraint, total torque conservation constraint, cylinder state constraint, and thrust range constraint; the target thrust of each group of propulsion cylinders under the segment assembly state is calculated based on the above four constraints. And according to the target thrust of each group of propulsion cylinders Calculate the torque of each group of propulsion cylinders under the segment assembly state.

4. A method for synchronous tunneling modification based on the traditional shield tunneling machine's tunneling mode, as described in claim 1 or 2, characterized in that... In step S402, after calculating the target thrust of each group of propulsion cylinders under the segment assembly state, the calculated target thrust is verified by calculating the least squares index and the difference index between the original and new states. After verification that the requirements are met, the thrust is then sent to the PLC controller of the original electrical control system.

5. The method for synchronous tunneling modification based on the traditional shield tunneling machine tunneling mode according to claim 3, characterized in that, The target thrust of each group of propulsion cylinders under the segment assembly state was calculated based on four constraints. The process is as follows: Under the constraint of conservation of resultant force, the sum of the thrust of each group of propulsion cylinders in the segment assembly state after the retraction cylinder is equal to the sum of the original thrust of all cylinders in the propulsion state. That is, we get: ； ； Under the constraint of total torque conservation, the sum of the new thrust torques in the X and Y directions of each group of propulsion cylinders in the segment assembly state after the retraction cylinder is completed is equal to the sum of the original thrust torques in the X and Y directions of all cylinders, resulting in the following formula: ； ； Under the constraints of the hydraulic cylinder's state, the formula is: ； Under the constraint of the thrust range of the hydraulic cylinder, the formula is as follows: ； In the above formula: n is the number of propulsion cylinders; To increase the radius of action of the hydraulic cylinder center; The number of the hydraulic cylinder. ; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. For the first The target thrust of each hydraulic cylinder; For the first The original actual thrust of each cylinder; For the first The status of each hydraulic cylinder; To push the lower limit of the hydraulic cylinder thrust; To increase the upper limit of the hydraulic cylinder thrust; The sum of the torques in the Y direction of the original thrust of the hydraulic cylinder; Let X be the torque in the X direction of the original thrust of the hydraulic cylinder.

6. A method for synchronous tunneling modification based on the traditional shield tunneling machine's tunneling mode, as described in claim 5, is characterized in that... The torque of each propulsion cylinder group in the segment assembly state includes the torque in the X direction and the torque in the Y direction, based on the target thrust of each propulsion cylinder group. The specific process for calculating the sum of the torques of each group of propulsion cylinders under the segment assembly state is as follows: The torque in the X direction of each propulsion cylinder during segment assembly and The calculation is as follows: ； ； The torque in the Y direction of each propulsion cylinder during segment assembly and The calculation is as follows: ； ； In the above formula: n is the number of propulsion cylinders; To increase the radius of action of the hydraulic cylinder center; The number of the hydraulic cylinder. ; For the first The distribution angle of each hydraulic cylinder is the angle between the line connecting the center position of the hydraulic cylinder and the origin of the coordinate system and the positive half-axis of the X-axis. For the first The target thrust of each hydraulic cylinder.

7. A method for synchronous tunneling modification based on the traditional shield tunneling machine's tunneling mode, as described in claim 4, is characterized in that... The uniformity is evaluated by calculating the mean least squares index, and the specific calculation formula is as follows: ； in, This represents the average thrust of each group of propulsion cylinders during the segment assembly process. In other words, there are k propulsion cylinders in the segment assembly state. The calculation process is as follows: 。 8. A method for synchronous tunneling modification based on the traditional shield tunneling machine's tunneling mode, as described in claim 7, is characterized in that... The original-new state difference index includes the resultant force difference between the new state and the original state. The torque and difference in the X direction between the new state and the original state The torque and difference in the Y direction between the new state and the original state The calculation formula is as follows: ； ； 。

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