Gas disaster active prevention and control system and method for TBM cutterhead

Abstract

The invention relates to a gas disaster active prevention and control system and method for a TBM cutterhead, and the system comprises a laser methane sensor disposed at a position close to a hob, the laser methane sensor is equipped with a protective housing, a lens cavity of a protective lens is provided with a purging port, and a flexible buffer layer is disposed between the laser methane sensor and the protective housing. The protective shell is embedded in a panel of the cutter head and is fixedly connected with the cutter head; the explosion suppression device further comprises a high-pressure inert gas rapid explosion suppression mechanism, a high-pressure gas rotating connector is further connected with a purging pipeline, and a second proportional electromagnetic valve is arranged on the purging pipeline. And the first proportional electromagnetic valve, the second proportional electromagnetic valve and the plurality of laser methane sensors are electrically connected with an intelligent control module. The invention further comprises a gas disaster active prevention and control method. According to the invention, the laser methane sensor is fixed with the cutterhead through the protective shell to detect the gas on the working surface, and the high-pressure inert gas rapid explosion suppression mechanism is arranged to realize timely active prevention and control.

Description

Technical Field

[0001] This invention relates to the field of coal mine safety technology and roadway construction equipment technology, specifically to an active gas disaster prevention and control system and method for TBM cutterheads. Background Technology

[0002] In high-gas coal mine roadways, especially in TBM excavation of gas drainage roadways, gas hazards are the primary threat to construction safety. The key to achieving safe excavation lies in "accurate measurement and control," which means that the concentration of gas in the core gas emission zone—the cutterhead-rock wall interface—must be monitored in real time and continuously, and rapid and effective active suppression must be implemented the instant that gas exceeds the limit.

[0003] Currently, gas control technologies in TBM construction mainly revolve around two research approaches: advanced detection and subsequent extraction. For example, the subsequent drilling rig detection described in patent CN212690035U is intermittent and point-based, unable to provide continuous, real-time gas concentration field information at the working face during tunneling, resulting in "monitoring blind spots." On the control side, methods such as the medium-to-long-distance extraction and sealing method represented by patent CN1273772A have slow responses, are considered subsequent extraction, and cannot cope with the extreme risk of sudden gas outbursts at the working face, which could be instantly ignited by cutterhead sparks. Given the unique and high-risk nature of TBM construction in high-gas coal mine bottom drainage roadways, existing technologies cannot achieve real-time perception and immediate proactive suppression of gas risks at the tunneling face.

[0004] Therefore, there is an urgent need for an active safety system that can directly advance monitoring and explosion suppression capabilities to the source of disasters and deeply integrate with TBM tunneling technology to ensure the inherent safety of TBM construction in coal mines. Summary of the Invention

[0005] To address the issues of poor real-time performance and slow response in existing gas control technologies used in TBM construction, this invention provides an active gas disaster prevention and control system and method for TBM cutterheads. By designing a laser methane sensor fixed to the cutterhead through a protective shell to detect gas at the working face, and setting up a high-pressure inert gas rapid explosion suppression mechanism, timely active prevention and control can be achieved.

[0006] To achieve the above objectives, the first aspect of this invention proposes an active gas disaster prevention and control system for a TBM cutterhead, comprising a cutterhead and a trolley. Multiple roller cutters are arranged on the cutterhead, and the roller cutters are rotatably connected to the cutterhead. A laser methane sensor is provided on the cutterhead panel near the roller cutters. The laser methane sensor is equipped with a protective housing, and a protective cavity is formed inside the protective housing. A protective lens is installed at the optical window of the laser methane sensor, and a purge port is opened in the lens cavity of the protective lens. A flexible buffer layer is provided between the laser methane sensor and the protective housing. The protective housing is embedded in the cutterhead panel and fixedly connected to the cutterhead. It also includes a high-pressure inert gas rapid explosion suppression mechanism, which includes a high-pressure inert gas storage tank group, a pressure gauge, a high-pressure pipeline, a high-pressure gas rotary joint, and multiple nozzles. The high-pressure inert gas storage tank group is connected to the high-pressure gas rotary joint through the high-pressure pipeline. The high-pressure gas rotary joint is connected to multiple nozzles respectively, and a first proportional solenoid valve is provided between the high-pressure gas rotary joint and each nozzle. An anti-clogging mechanism is provided at the outlet of the nozzle. The nozzle is embedded in the panel of the cutter head and is fixedly connected to the cutter head. The high-pressure gas rotary joint is also connected to a purging pipe, which is equipped with a second proportional solenoid valve. The purging pipe is connected to the lens cavity of the protective lens through a purging port. The first proportional solenoid valve, the second proportional solenoid valve, and multiple laser methane sensors are electrically connected to an intelligent control module.

[0007] Furthermore, multiple laser methane sensors are installed on the cutterhead panel in a partitioned manner. The placement of the laser methane sensors includes behind the outermost hobbing cutting point of the cutterhead, the fan-shaped area between each bucket, and the central area of ​​the cutterhead. The protective housing has internal reinforcing ribs and a flange installed on its side. The protective housing is fixedly connected to the cutter head through the flange. A flexible buffer layer, made of silicone, is filled between the protective shell and the laser methane sensor.

[0008] Laser methane sensors are deployed in specific zones to achieve distributed monitoring of methane concentration at the cutterhead working face. They accurately capture methane information from different locations, including coal and rock exposure areas, spoil heaps, and the central area of ​​the cutterhead where methane tends to accumulate, providing a complete picture of the methane concentration field distribution at the working face. The protective housing features internal reinforcing ribs to enhance structural strength and adapt to the high-intensity working environment of the cutterhead. A flange securely connects the sensor to the cutterhead, strengthening the installation and preventing displacement due to cutterhead rotation and vibration. A flexible silicone buffer layer effectively isolates high-frequency vibrations generated by the cutterhead breaking rock, preventing damage to the precision optical components of the laser methane sensor and ensuring its detection accuracy and lifespan.

[0009] Furthermore, the protective housing has a wire outlet hole, the laser methane sensor is electrically connected to the intelligent control module, the wire outlets of multiple laser methane sensors are connected to conductive slip rings, the wire outlets of the laser methane sensors are fixedly connected to the stationary housing of the conductive slip rings, and the rotating shaft of the conductive slip rings is fixedly connected to the drive shaft of the cutter head.

[0010] The protective housing has a wire outlet hole to facilitate the wiring layout of the laser methane sensor. The conductive slip ring ensures a stable electrical connection between the sensor on the rotating cutter head and the intelligent control module at the stationary end, solving the problems of wire entanglement and poor contact during the rotation of the cutter head and ensuring continuous and stable transmission of gas monitoring data.

[0011] Furthermore, the placement of the nozzles on the cutterhead panel is determined based on computational fluid dynamics simulation results of the gas transport and accumulation patterns in front of the cutterhead and within the soil chamber.

[0012] The nozzle placement is determined based on computational fluid dynamics simulations, ensuring the nozzle layout matches the gas migration and accumulation patterns in front of the cutterhead and within the soil chamber. This allows for targeted coverage of high-risk gas areas and improves the accuracy of inert gas injection. Precise nozzle placement creates an effective inert gas curtain in gas-risk areas, preventing ineffective consumption of inert gas, improving explosion suppression efficiency, and achieving precise local explosion suppression while minimizing interference with normal tunneling operations.

[0013] Furthermore, the anti-clogging mechanism includes a compression spring and a mechanical dust cover. A nozzle mounting groove is provided on the panel of the cutter head. One side of the mechanical dust cover is hinged to the inner side of the nozzle mounting groove, and the other side is fixedly connected to the compression spring. The other side of the compression spring and the nozzle are both fixed to the nozzle mounting groove through a flange.

[0014] The anti-clogging mechanism, which combines a compression spring with a mechanical dust cover, closes the dust cover using spring force when not in spraying mode, effectively sealing the nozzle opening and preventing rock powder and slag from entering and clogging the nozzle, thus ensuring unobstructed flow. During spraying, the high-pressure gas opens the dust cover, eliminating the need for additional drive components and simplifying the structural design. This allows for automatic opening and closing of the dust cover. The mechanical dust cover is hinged, and the compression spring and nozzle are fixed via a flange, ensuring a secure installation and easy maintenance. This design is suitable for the harsh operating environment of the cutterhead and guarantees long-term reliable operation of the anti-clogging mechanism.

[0015] Furthermore, the intelligent control module includes a controller, a data acquisition module, and an alarm unit. Multiple laser methane sensors are connected to the data acquisition module, which is connected to the input terminal of the controller. The output terminal of the controller is connected to a first proportional solenoid valve and multiple second proportional solenoid valves, respectively, and the output terminal of the controller is also connected to the alarm unit.

[0016] A second aspect of this invention proposes a method for proactive prevention and control of gas disasters, comprising the following steps: Step 1: Install and fix the protective shell and nozzle to the cutter head, establish a communication channel between the laser methane sensor and the intelligent control module, and electrically connect the intelligent control module to the first proportional solenoid valve and the second proportional solenoid valve respectively; Step 2: During the TBM tunneling process, the gas concentration and concentration change rate of each zone of the cutterhead are collected synchronously through the laser methane sensor, and the TBM tunneling parameters and pressure data from the pressure gauge are also collected. Step 3: Based on the data collected in Step 2, integrate and analyze the spatial distribution characteristics and temporal evolution patterns of gas, dynamically assess the gas disaster risk level, and locate the core risk area; Step 4: If it is determined that explosion suppression operation needs to be started, the intelligent control module controls the first proportional solenoid valve and multiple second proportional solenoid valves to operate, so that the high-pressure inert gas in the high-pressure inert gas storage tank group is transported to each nozzle through the high-pressure pipeline and the high-pressure gas rotary joint and sprayed out. The high-pressure gas pushes open the mechanical dust cover to implement local control of the risk area. Step 5: Monitor the gas concentration changes in the risk area in real time after the explosion suppression using a laser methane sensor to verify the explosion suppression effect, and optimize the control parameters for subsequent prevention and control as well as the action parameters of the proportional solenoid valve based on the monitoring feedback data.

[0017] Further, step 3 specifically includes: calculating the gas concentration value and concentration change rate of each zone based on the data collected by the laser methane sensor; When the gas concentration or concentration change rate in any zone exceeds the first-level threshold, the alarm unit activates an audible and visual warning and identifies the specific risk location. When the gas concentration or the rate of change of concentration exceeds a higher second-level threshold, the intelligent control module activates the first proportional solenoid valve corresponding to the nozzles of the risk zone and adjacent zones to perform timed injection operations; when the gas concentration reaches the danger threshold or is determined to be a sudden gas surge, the maximum flow explosion suppression operation is immediately activated, and the ventilation system is adjusted accordingly.

[0018] Calculating the gas concentration and change rate in each zone allows for precise understanding of real-time gas trends, providing a quantitative basis for risk classification and improving the objectivity and accuracy of risk assessment. The tiered early warning mechanism provides timely audible and visual warnings and identifies risk locations when gas levels exceed the first-level threshold, enabling staff to quickly identify gas risk points and facilitate early intervention. When the second-level threshold is exceeded, timed spraying from nozzles in the risk zone and adjacent zones is activated to achieve targeted localized explosion suppression, controlling gas risk while reducing inert gas consumption. When gas reaches a dangerous threshold or experiences a sudden surge, maximum flow explosion suppression is activated in conjunction with the ventilation system, rapidly increasing the suppression intensity. Simultaneously, the ventilation system assists in diluting the gas, forming multiple control measures to effectively address extreme gas disaster situations, minimizing explosion risk. Different control actions are triggered at different levels, ensuring gas control matches risk levels, achieving refined control, improving the system's scientific rigor and reliability, and avoiding over- or under-control measures.

[0019] The beneficial effects of the present invention through the above technical solution are as follows: 1. This invention enables gas detection during cutterhead operation. Through the embedded integration design of a laser methane sensor and the TBM cutterhead panel, combined with the matching configuration of an alloy steel protective shell, a silicone buffer layer, and a lens purging structure, the sensing components are adapted to the extreme tunneling conditions of high vibration and high dust. At the same time, the sensors are deployed in a zoned manner at key gas monitoring locations such as behind the cutting point on the outer ring of the cutterhead, the fan-shaped area between the buckets, and the central area, realizing distributed and continuous acquisition of gas concentration at the tunneling face. With the stable signal transmission design of the conductive slip ring, the line transmission problems caused by the rotation of the cutterhead are eliminated, ensuring the real-time and accurate uploading of gas concentration field information, completely eliminating the spatial and temporal lag of traditional intermittent rear monitoring, and accurately capturing the initial moment and spatial distribution of gas outburst.

[0020] 2. Based on the results of CFD simulation of gas migration and accumulation, this invention employs a non-uniform optimized layout for the explosion suppression nozzles, combining a ring-shaped periphery arrangement with a reinforced arrangement in key areas. This ensures that the nozzles can be activated instantly and that inert gas accurately covers high-risk gas areas. The intelligent control module integrates gas monitoring data and TBM tunneling parameters, dynamically assessing the risk level and locating the core area through a built-in algorithm. When the gas concentration exceeds the threshold, it can precisely drive the proportional solenoid valves of the risk zone and adjacent zones to achieve rapid injection of high-pressure inert gas, forming an inert gas curtain at the gas outburst point and quickly eliminating the conditions for explosion. Simultaneously, the system constructs a closed-loop prevention and control system from perception and explosion suppression to feedback. By monitoring the changes in gas concentration after explosion suppression in real time, it continuously optimizes the risk assessment model and explosion suppression parameters. Combined with multiple prevention and control measures such as graded early warning and coordinated ventilation, it achieves proactive, precise, and efficient prevention and control of gas disasters. Attached Figure Description

[0021] Figure 1 This is one of the structural schematic diagrams of an active gas disaster prevention and control system for a TBM cutterhead according to the present invention; Figure 2 This is a schematic diagram of the cutterhead panel of an active gas disaster prevention and control system for TBM cutterheads according to the present invention; Figure 3 This is a second schematic diagram of the structure of an active gas disaster prevention and control system for a TBM cutterhead according to the present invention; Figure 4 This is a flowchart illustrating the steps of an active gas disaster prevention and control method for a TBM cutterhead according to the present invention.

[0022] Attached figures and numbers: 1 is cutter head, 2 is trolley, 3 is roller cutter, 4 is laser methane sensor, 5 is protective housing, 6 is protective lens, 7 is purge port, 8 is flexible buffer layer, 9 is high-pressure inert gas storage tank group, 10 is pressure gauge, 11 is high-pressure pipeline, 12 is high-pressure gas rotary joint, 13 is nozzle, 14 is first proportional solenoid valve, 15 is purge pipeline, 16 is second proportional solenoid valve, 17 is compression spring, 18 is mechanical dust cover, 19 is controller, 21 is flange, 22 is communication channel. Detailed Implementation

[0023] The present invention will be further described below with reference to the accompanying drawings and specific embodiments: Example

[0024] like Figures 1-4As shown, an active gas disaster prevention and control system for a TBM cutterhead includes a cutterhead 1 and a trolley 2. Multiple roller cutters 3 are arranged on the cutterhead 1 and are rotatably connected to it. A laser methane sensor 4 is located on the panel of the cutterhead 1 near the roller cutters 3. The laser methane sensor 4 is equipped with a protective housing 5, and a protective cavity is formed inside the protective housing 5. A protective lens 6 is installed at the optical window of the laser methane sensor 4, and a purge port 7 is opened in the lens cavity of the protective lens 6. A flexible buffer layer 8 is provided between the laser methane sensor 4 and the protective housing 5. The protective housing 5 is embedded in the panel of the cutterhead 1 and is fixedly connected to the cutterhead 1. It also includes a high-pressure inert gas rapid explosion suppression mechanism, which includes a high-pressure inert gas storage tank group 9 (nitrogen), a pressure gauge 10, a high-pressure pipeline 11, a high-pressure gas rotary joint 12, and multiple nozzles 13. The high-pressure inert gas storage tank group 9 is connected to the high-pressure gas rotary joint 12 through the high-pressure pipeline 11. The high-pressure gas rotary joint 12 is connected to multiple nozzles 13 respectively, and a first proportional solenoid valve 14 is provided between the high-pressure gas rotary joint 12 and each nozzle 13. An anti-clogging mechanism is provided at the outlet of the nozzle 13. The nozzle 13 is embedded in the panel of the cutter head 1 and is fixedly connected to the cutter head 1. The high-pressure gas rotary joint 12 is also connected to a purge pipe 15, and a second proportional solenoid valve 16 is provided on the purge pipe 15. The purge pipe 15 is connected to the lens cavity of the protective lens 6 through the purge port 7. The first proportional solenoid valve 14, the second proportional solenoid valve 16, and multiple laser methane sensors 4 are electrically connected to an intelligent control module.

[0025] Multiple laser methane sensors 4 are installed on the cutter head 1 panel in a partitioned manner. The placement of the laser methane sensors 4 includes behind the cutting point of the outermost hob 3 of the cutter head 1, the fan-shaped area between each bucket, and the central area of ​​the cutter head 1. The protective housing 5 has internal reinforcing ribs and a flange 21b is installed on its side. The protective housing 5 is fixedly connected to the cutter head 1 through the flange 21b. A flexible buffer layer 8 is filled between the protective shell 5 and the laser methane sensor 4. The flexible buffer layer 8 is made of silicone.

[0026] The protective housing 5 has a wire outlet hole. The laser methane sensor 4 is electrically connected to the intelligent control module. The wire outlets of multiple laser methane sensors 4 are connected to conductive slip rings. The wire outlets of the laser methane sensors 4 are fixedly connected to the stationary housing of the conductive slip rings. The rotating shaft of the conductive slip rings is fixedly connected to the drive shaft of the cutter head 1.

[0027] The placement of the nozzles 13 on the cutterhead 1 panel is determined based on the computational fluid dynamics simulation results of the gas transport and accumulation patterns in front of the cutterhead 1 and inside the soil chamber.

[0028] The anti-clogging mechanism includes a compression spring 17 and a mechanical dust cover 18. A nozzle mounting groove is provided on the panel of the cutter head 1. One side of the mechanical dust cover 18 is hinged to the inner side of the nozzle mounting groove, and the other side is fixedly connected to the compression spring 17. The other side of the compression spring 17 and the nozzle 13 are fixed to the nozzle mounting groove through a flange 21a.

[0029] The intelligent control module includes a controller 19, a data acquisition module, and an alarm unit. Multiple laser methane sensors 4 are connected to the data acquisition module. The data acquisition module is connected to the input terminal of the controller 19. The output terminal of the controller 19 is connected to a first proportional solenoid valve 14 and multiple second proportional solenoid valves 16, respectively. The output terminal of the controller 19 is also connected to the alarm unit.

[0030] A proactive method for preventing and controlling gas disasters includes the following steps: Step 1: Install and fix the protective shell 5 and nozzle 13 to the cutter head 1, establish the communication channel 22 between the laser methane sensor 4 and the intelligent control module, and electrically connect the intelligent control module to the first proportional solenoid valve 14 and the second proportional solenoid valve 16 respectively. Step 2: During the TBM tunneling process, the gas concentration and concentration change rate of each zone of the cutterhead 1 are collected synchronously by the laser methane sensor 4, and the TBM tunneling parameters and pressure data of the pressure gauge 10 are also collected. Step 3: Based on the data collected in Step 2, integrate and analyze the spatial distribution characteristics and temporal evolution patterns of gas, dynamically assess the gas disaster risk level, and locate the core risk area; Step 4: If it is determined that explosion suppression operation needs to be started, the intelligent control module controls the first proportional solenoid valve 14 and multiple second proportional solenoid valves 16 to operate, so that the high pressure inert gas in the high pressure inert gas storage tank group 9 is delivered to each nozzle 13 through the high pressure pipeline 11 and the high pressure gas rotary joint 12 and sprayed out. The high pressure gas pushes open the mechanical dust cover 18 to implement local control of the risk area. Step 5: Monitor the gas concentration change in the risk area after explosion suppression in real time using the laser methane sensor 4 to verify the explosion suppression effect, and optimize the control parameters for subsequent prevention and control as well as the action parameters of the proportional solenoid valve based on the monitoring feedback data.

[0031] Step 3 specifically includes: calculating the gas concentration value and concentration change rate of each zone based on the data collected by the laser methane sensor 4; When the gas concentration or concentration change rate in any zone exceeds the first-level threshold, the alarm unit activates an audible and visual warning and identifies the specific risk location. When the gas concentration or the rate of change of concentration exceeds a higher second-level threshold, the intelligent control module activates the first proportional solenoid valve 14 corresponding to the risk zone and the nozzle 13 of the adjacent zone to perform timed injection operations; when the gas concentration reaches the danger threshold or is determined to be a sudden gas surge, the maximum flow explosion suppression operation is immediately activated, and the ventilation system is adjusted in conjunction with it.

[0032] During operation, the protective housing 5 and nozzle 13 are respectively embedded and fixed in the preset positions on the cutter head 1 panel, completing the assembly of the laser methane sensor 4 in the protective cavity of the protective housing 5. At the same time, the explosion suppression mechanism components such as the high-pressure inert gas storage tank group 9, high-pressure pipeline 11, and high-pressure gas rotary joint 12 are connected, as well as the purge pipe 15 is connected to the purge port 7 of the protective lens 6 cavity. A communication channel 22 is established between the laser methane sensor 4 and the intelligent control module. The output terminal of the laser methane sensor 4 is connected to the stationary housing of the conductive slip ring, and the rotating shaft of the conductive slip ring is fixed to the drive shaft of the cutter head 1 to achieve stable signal transmission between the rotating cutter head and the stationary control terminal. The controller 19 of the intelligent control module is electrically connected to the first proportional solenoid valve 14, the second proportional solenoid valve 16, and the alarm unit respectively to complete the system hardware assembly and circuit debugging, ensuring that the linkage of each component is normal.

[0033] The cutterhead 1 drives the roller cutter 3 to break rocks. Laser methane sensors 4, strategically positioned behind the cutting points of the outer ring roller cutters, in the fan-shaped area between the buckets, and in the central area, continuously operate, collecting real-time methane concentration data for their respective zones and measuring the methane concentration values ​​(C1, C2, ..., C6) at their locations. n The data acquisition module simultaneously collects monitoring data from all laser methane sensors 4, high-pressure gas pressure data from pressure gauge 10, and TBM tunneling parameters (cutterhead torque, thrust, speed, etc.), and transmits the multi-source data to controller 19 in real time, providing complete data support for risk assessment. Combining the physical coordinates of the sensors, spatial interpolation analysis is performed on the discrete point concentration data to dynamically generate a two-dimensional gas concentration simulation cloud map of the cutterhead working face, intuitively visualizing key areas of gas accumulation. During this process, the intelligent control module can control the second proportional solenoid valve 16 to activate as needed, allowing inert gas in the high-pressure gas rotary joint 12 to enter the protective lens 6 cavity through the purging pipe 15 and purging port 7 to purge the lens, preventing rock dust adhesion from affecting sensor detection accuracy. The silicone buffer layer 8 and the protective shell 5 together buffer cutterhead vibration and isolate dust, ensuring stable operation of the laser methane sensor 4.

[0034] After receiving multi-source data, the controller 19 integrates and analyzes the spatial distribution characteristics and temporal evolution of gas, calculates the gas concentration value and change rate of each monitoring zone, dynamically assesses the gas disaster risk level, and accurately locates the core risk area. If the gas concentration or concentration change rate of any zone exceeds the first-level threshold (e.g., 0.8% CH4), the controller 19 immediately triggers the alarm unit to activate the audible and visual warning and marks the specific risk location on the operation interface to remind staff to pay attention. If the concentration or change rate exceeds the higher second-level threshold (e.g., 1.5% CH4), the controller 19 locks the core risk zone and adjacent zones, pre-activates the explosion suppression gas path, and prepares for subsequent explosion suppression operations. If the concentration reaches the danger threshold (e.g., 2.5% CH4) or is determined to be a sudden gas surge (a sharp increase in concentration gradient at multiple points), it is directly determined to be high-risk, and the highest-level explosion suppression response procedure is activated.

[0035] When the controller 19 determines that explosion suppression operations need to be initiated, it sends a control command within a sub-second delay, driving the first proportional solenoid valves 14 corresponding to the core risk zone and adjacent zones to operate synchronously. Nitrogen gas in the high-pressure inert gas storage tank group 9 is transported to the high-pressure gas rotary joint 12 via the high-pressure pipeline 11, and then to the corresponding nozzle 13 through the opened first proportional solenoid valve 14. The pressure of the high-pressure nitrogen gas pushes open the mechanical dust cover 18, which is reset by the compression spring 17, and sprays out at high speed from the nozzle 13. The nozzle 13 is deployed based on CFD simulation results, which can quickly form a local inert gas curtain in the gas risk area. By diluting oxygen, cooling and absorbing heat, and inhibiting free radical reactions, it can quickly eliminate the conditions for explosion, achieving precise local control of the risk area. Depending on the risk level, the controller 19 controls the inert gas injection flow rate by adjusting the opening of the first proportional solenoid valve 14. The second-level threshold triggers timed and quantitative injection, and the maximum flow injection is activated when the danger threshold or gas surge occurs. At the same time, the TBM matching ventilation system is adjusted to assist in diluting the gas and improve the explosion suppression effect.

[0036] During and after the explosion suppression operation, the laser methane sensor 4 continuously monitors the changes in gas concentration in the risk area and transmits the concentration decay data to the controller 19 in real time. The controller 19 automatically evaluates the effectiveness of the explosion suppression operation based on the concentration decay rate and stability value. At the same time, the system stores the parameters of the explosion suppression, gas change data, and prevention and control effect. Based on the monitoring feedback data, it optimizes the control parameters (risk threshold, injection duration, etc.) and the action parameters (opening degree, response time, etc.) of the proportional solenoid valve for subsequent prevention and control, forming a closed-loop prevention and control system from perception, evaluation, explosion suppression, feedback to optimization. This continuously improves the accuracy and reliability of the system in preventing and controlling gas disasters and ensures the operational safety of the TBM high-gas tunneling face.

[0037] When the gas concentration in the risk area drops to the safety threshold, the controller 19 sends a command to close the first proportional solenoid valve 14 and the second proportional solenoid valve 16, the inert gas injection stops, the mechanical dust cover 18 is reset under the elastic force of the compression spring 17, sealing the outlet of the nozzle 13 to prevent rock powder from entering and causing blockage, the system returns to normal monitoring status, and continues to cooperate with TBM tunneling to carry out real-time gas control, and cyclically execute the above monitoring, assessment and control process.

[0038] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention should be included within the scope of the present invention.

Claims

1. A gas disaster active prevention and control system for a TBM cutterhead, comprising a cutterhead (1) and a trolley (2), wherein a plurality of roller cutters (3) are arranged on the cutterhead (1), and the roller cutters (3) are rotatably connected to the cutterhead (1), characterized in that, A laser methane sensor (4) is provided on the panel of the cutter head (1) near the roller cutter (3). The laser methane sensor (4) is equipped with a protective shell (5). A protective cavity is formed inside the protective shell (5). A protective lens (6) is installed at the optical window of the laser methane sensor (4). A purge port (7) is opened in the lens cavity of the protective lens (6). A flexible buffer layer (8) is provided between the laser methane sensor (4) and the protective shell (5). The protective shell (5) is embedded in the panel of the cutter head (1) and is fixedly connected to the cutter head (1). It also includes a high-pressure inert gas rapid explosion suppression mechanism, which includes a high-pressure inert gas storage tank group (9), a pressure gauge (10), a high-pressure pipeline (11), a high-pressure gas rotary joint (12), and multiple nozzles (13). The high-pressure inert gas storage tank group (9) is connected to the high-pressure gas rotary joint (12) through the high-pressure pipeline (11). The high-pressure gas rotary joint (12) is connected to multiple nozzles (13) respectively. A first proportional solenoid valve (14) is provided between the high-pressure gas rotary joint (12) and each nozzle (13). An anti-clogging mechanism is provided at the outlet of the nozzle (13). The nozzle (13) is embedded in the panel of the cutter head (1) and is fixedly connected to the cutter head (1). The high-pressure gas rotary joint (12) is also connected to a purge pipe (15), and a second proportional solenoid valve (16) is provided on the purge pipe (15). The purge pipe (15) is connected to the lens cavity of the protective lens (6) through the purge port (7). The first proportional solenoid valve (14), the second proportional solenoid valve (16), and multiple laser methane sensors (4) are electrically connected to an intelligent control module.

2. The active gas disaster prevention and control system for TBM cutterhead (1) according to claim 1, characterized in that, Multiple laser methane sensors (4) are installed on the cutter head (1) panel in a partitioned manner. The placement of the laser methane sensors (4) includes behind the cutting point of the outermost hob (3) of the cutter head (1), the fan-shaped area between each bucket, and the central area of ​​the cutter head (1). The protective shell (5) has reinforcing ribs inside and a flange is installed on its side. The protective shell (5) is fixedly connected to the cutter head (1) through the flange. A flexible buffer layer (8) is filled between the protective shell (5) and the laser methane sensor (4), and the flexible buffer layer (8) is made of silicone.

3. The active gas disaster prevention and control system for TBM cutterhead (1) according to claim 2, characterized in that, The protective housing (5) has a wire outlet hole. The laser methane sensor (4) is electrically connected to the intelligent control module. The wire outlets of multiple laser methane sensors (4) are connected to conductive slip rings. The wire outlets of the laser methane sensors (4) are fixedly connected to the stationary housing of the conductive slip rings. The rotating shaft of the conductive slip rings is fixedly connected to the drive shaft of the cutter head (1).

4. The active gas disaster prevention and control system for TBM cutterhead (1) according to claim 1, characterized in that, The placement of the nozzle (13) on the cutterhead (1) panel is determined based on the computational fluid dynamics simulation results of the gas transport and accumulation law in front of the cutterhead (1) and inside the soil chamber.

5. The active gas disaster prevention and control system for TBM cutterhead (1) according to claim 1, characterized in that, The anti-clogging mechanism includes a compression spring (17) and a mechanical dust cover (18). A nozzle mounting groove is provided on the panel of the cutter head (1). One side of the mechanical dust cover (18) is hinged to the inner side of the nozzle mounting groove, and the other side is fixedly connected to the compression spring (17). The other side of the compression spring (17) and the nozzle (13) are fixed to the nozzle mounting groove through a flange.

6. The active gas disaster prevention and control system for TBM cutterhead (1) according to claim 1, characterized in that, The intelligent control module includes a controller (19), a data acquisition module and an alarm unit. Multiple laser methane sensors (4) are connected to the data acquisition module. The data acquisition module is connected to the input terminal of the controller (19). The output terminal of the controller (19) is connected to the first proportional solenoid valve (14) and multiple second proportional solenoid valves (16) respectively. The output terminal of the controller (19) is also connected to the alarm unit.

7. A method for active gas disaster prevention and control based on the active gas disaster prevention and control system for TBM cutterhead (1) according to any one of claims 1-6, characterized in that, Includes the following steps: Step 1: Install and fix the protective shell (5) and nozzle (13) to the cutter head (1), establish a communication channel between the laser methane sensor (4) and the intelligent control module, and electrically connect the intelligent control module to the first proportional solenoid valve (14) and the second proportional solenoid valve (16) respectively; Step 2: During the TBM tunneling process, the gas concentration and concentration change rate of each zone of the cutterhead (1) are collected synchronously by the laser methane sensor (4), and the TBM tunneling parameters and pressure data of the pressure gauge (10) are collected at the same time. Step 3: Based on the data collected in Step 2, integrate and analyze the spatial distribution characteristics and temporal evolution patterns of gas, dynamically assess the gas disaster risk level, and locate the core risk area; Step 4: If it is determined that explosion suppression operation needs to be started, the intelligent control module controls the first proportional solenoid valve (14) and multiple second proportional solenoid valves (16) to operate, so that the high pressure inert gas in the high pressure inert gas storage tank group (9) is transported to each nozzle (13) through the high pressure pipeline (11) and the high pressure gas rotary joint (12) and sprayed out. The high pressure gas pushes open the mechanical dust cover (18) to implement local control of the risk area; Step 5: Monitor the gas concentration change in the risk area after explosion suppression in real time using the laser methane sensor (4), verify the explosion suppression effect, and optimize the control parameters for subsequent prevention and control and the action parameters of the proportional solenoid valve based on the monitoring feedback data.

8. The active prevention and control method for gas disasters according to claim 7, characterized in that, Step 3 specifically includes: calculating the gas concentration value and concentration change rate of each zone based on the data collected by the laser methane sensor (4); When the gas concentration or concentration change rate in any zone exceeds the first-level threshold, the alarm unit activates an audible and visual warning and identifies the specific risk location. When the gas concentration or the rate of change of concentration exceeds the higher second-level threshold, the intelligent control module activates the first proportional solenoid valve (14) corresponding to the risk zone and the nozzle (13) of the adjacent zone to perform timed injection operation; when the gas concentration reaches the danger threshold or is determined to be a gas instantaneous surge, the maximum flow explosion suppression operation is immediately activated and the ventilation system is adjusted in conjunction.

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