Shield tunneling machine cutterhead control method, electronic device, and storage medium

Abstract

Embodiments of the present application provide a shield machine cutter control method, an electronic device and a storage medium. The method comprises: when original motor load data of each cutter motor in a previous working cycle is detected, determining a target number of cutter motors to be started according to the original motor load data and a preset motor selection rule; controlling each cutter motor to be started to start; obtaining real-time load rate data of each cutter motor; determining a cutter motor to be adjusted according to the real-time load rate data; controlling a frequency converter according to a preset frequency converter control strategy to adjust the working state of the cutter motor to be adjusted, and jumping to the step of obtaining the real-time load rate data of each cutter motor until the current working cycle ends. By dynamically matching the number of cutter motors to be put into operation and the actual tunneling load, the long-time low-load operation and unnecessary motor input are reduced under the premise of meeting the construction requirements, the power utilization rate is improved, and the overall operation economy is improved.

Description

Technical Field

[0001] This application relates to the field of tunnel boring machine technology, and in particular to a tunnel boring machine cutterhead control method, electronic equipment and storage medium. Background Technology

[0002] A tunnel boring machine (TBM) is a type of tunnel excavation equipment. The cutterhead, as the main working component of the TBM, is responsible for breaking up the soil and rock strata ahead to achieve continuous excavation. To cope with complex and varied geological conditions and high torque and power requirements, the cutterhead drive typically employs a structure where multiple motors work together. The power output from these motors is transmitted to the cutterhead via a multi-stage reduction mechanism, thereby achieving stable rotation control of the cutterhead.

[0003] In existing cutterhead drive control schemes, most adopt fixed combinations or limited gear switching for operation control. One common method is to keep all drive motors continuously running throughout the entire tunneling process, adjusting only the cutterhead speed, output torque, or overall machine propulsion speed to adapt to different geological conditions, while keeping the actual number of motors in operation constant. Another method is based on the overall machine energy consumption adjustment approach, adjusting the operating status of subsystems such as muck removal, hydraulics, or power supply according to parameters such as propulsion speed, cutterhead resistance, muck removal rate, or hydraulic system pressure to indirectly achieve energy saving.

[0004] However, these methods mostly focus on overall machine-level operational optimization, lacking independent control over the operating status of each motor within the cutterhead motor unit. Prolonged operation with a fixed number of motors can lead to low overall motor load under certain operating conditions, resulting in significant energy loss through circuitry and equipment, leading to low energy utilization efficiency and poor overall operational economy. Summary of the Invention

[0005] This application provides a method for controlling the cutterhead of a tunnel boring machine, an electronic device, and a storage medium to improve operational economy.

[0006] In a first aspect, embodiments of this application provide a method for controlling the cutterhead of a tunnel boring machine, including:

[0007] When the original motor load data of each cutter head motor in the previous working cycle is detected, the target number of cutter head motors to be started is determined according to the original motor load data and the preset motor selection rules.

[0008] Control each cutterhead motor to start, so that the cutterhead motor drives the cutterhead to rotate and start the tunneling operation;

[0009] Obtain real-time load rate data for each cutter head motor;

[0010] Based on the real-time load rate data, determine the cutter head motor to be adjusted;

[0011] The inverter is controlled according to the preset inverter control strategy to adjust the working state of the cutter head motor to be adjusted, and then jumps to the step of obtaining the real-time load rate data of each cutter head motor until the current working cycle ends.

[0012] In one possible implementation, the preset motor selection rules include priority matching rules and mechanically symmetrical motor rules;

[0013] The step of determining the target number of cutterhead motors to be started based on the original motor load data and preset motor selection rules includes:

[0014] Based on the original motor load data, determine the usage time of each cutter head motor;

[0015] The priority of each cutter head motor is determined based on its usage time.

[0016] Based on the usage priority of each cutter head motor, the priority matching rule, and the mechanical symmetry motor rule, the cutter head motors to be started are selected sequentially until the number of cutter head motors to be started meets the target number.

[0017] In one possible implementation, the step of sequentially selecting the cutter head motors to be started based on the usage priority of each cutter head motor, the priority matching rule, and the mechanical symmetry motor rule includes:

[0018] Based on the usage priority of each cutter head motor and the priority matching rule, the cutter head motor is determined to be either a first priority motor or a second priority motor, wherein the priority of the first priority motor is higher than the priority of the second priority motor.

[0019] When the cutter head motor is detected as a first priority motor, the cutter head motor symmetrical to the first priority motor is determined according to the rules of the first priority motor and the mechanically symmetrical motor. If there is no fault, the cutter head motor symmetrical to the first priority motor is selected as the cutter head motor to be started. Otherwise, it is not selected. This process continues until all mechanically symmetrical cutter head motors have been detected and the number of cutter head motors to be started does not meet the target number. Then, the first priority motor is selected as the cutter head motor to be started.

[0020] Alternatively, if the cutter head motor is detected to be a second priority motor, then according to the rules of the second priority motor and the mechanically symmetrical motor, it is determined whether the cutter head motor symmetrical to the second priority motor is faulty. If there is no fault, the cutter head motor symmetrical to the second priority motor is selected as the cutter head motor to be started; otherwise, it is not selected. This process continues until all mechanically symmetrical cutter head motors have been detected and the number of cutter head motors to be started does not meet the target number. At this point, the second priority motor is selected as the cutter head motor to be started.

[0021] In one possible implementation, determining the cutter head motor to be adjusted based on the real-time load rate data includes:

[0022] Based on the real-time load rate data, determine the load duration and average load rate;

[0023] When the load duration is detected to reach a preset duration threshold and the average load rate is less than a preset first load rate threshold, the number of motors to be reduced is determined based on the real-time load rate data, the first load rate threshold and the preset second load rate threshold, and the cutter head motor to be adjusted is determined based on the number of motors to be reduced and the real-time load rate data.

[0024] Alternatively, when the load duration is detected to reach a preset duration threshold and the average load rate is greater than a preset second load rate threshold, the number of motors to be added is determined based on the real-time load rate data, the preset first load rate threshold, and the second load rate threshold, and the cutter head motor to be adjusted is determined based on the number of motors to be added and the real-time load rate data.

[0025] In one possible implementation, determining the cutter head motor to be adjusted based on the number of motors to be added and the real-time load rate data includes:

[0026] When the number of motors to be added is detected to be 1, all non-running cutter head motors and their corresponding running times are determined based on the real-time load rate data, and the cutter head motor to be adjusted is determined from all non-running cutter head motors based on the running time.

[0027] Alternatively, if the number of motors to be added is greater than 1, then all non-running cutterhead motors and their corresponding running times are determined based on the real-time load rate data, and at least one pair of mechanically symmetrical cutterhead motors are determined from all non-running cutterhead motors based on the running time as cutterhead motors to be adjusted.

[0028] The step of determining the cutter head motor to be adjusted based on the number of motors to be reduced and the real-time load rate data includes:

[0029] When the number of motors to be reduced is detected to be 1, all running cutterhead motors and their corresponding running times are determined based on the real-time load rate data, and the cutterhead motor to be adjusted is determined from all running cutterhead motors based on the running time.

[0030] Alternatively, if the number of motors to be reduced is greater than 1, then all running cutterhead motors and their corresponding running times are determined based on the real-time load rate data, and at least one pair of mechanically symmetrical cutterhead motors are determined from all running cutterhead motors based on the running time as cutterhead motors to be adjusted.

[0031] In one possible implementation, the calculation formula for determining the number of motors to be reduced based on the real-time load rate data, the first load rate threshold, and the second load rate threshold includes:

[0032]

[0033]

[0034]

[0035] In the formula, a% is a preset first load rate threshold, b% is a preset second load rate threshold, and n is the number of currently operating cutter head motors determined based on the real-time load rate data. s The number of motors to be reduced is η%, where η% is the average load rate determined based on the real-time load rate data.

[0036] The calculation formula for determining the number of motors to be added based on the real-time load rate data, the preset first load rate threshold, and the preset second load rate threshold includes:

[0037]

[0038]

[0039] In the formula, a% is a preset first load rate threshold, b% is a preset second load rate threshold, and n is the number of currently operating cutter head motors determined based on the real-time load rate data. a The number of motors to be added is η%, and η% is the average load rate determined based on the real-time load rate data.

[0040] In one possible implementation, it also includes:

[0041] When multiple integer values ​​are detected for the number of motors to be added, the number of non-operating and fault-free motors is determined based on the real-time load rate data, and the final number of motors to be added is determined based on the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate.

[0042] In one possible implementation, the calculation formula for determining the final number of motors to be added based on the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate includes:

[0043]

[0044] In the formula, n a This represents the final number of motors to be added, where n is the number of currently operating cutter head motors determined based on the real-time load rate data. max This indicates the number of motors that are not running and are not faulty. This represents the ratio of the average load rate to the first load rate threshold.

[0045] Secondly, embodiments of this application provide a shield tunneling machine cutterhead control device, comprising:

[0046] The data detection module is used to determine the target number of cutter head motors to be started based on the original motor load data and preset motor selection rules when the original motor load data of each cutter head motor in the previous working cycle is detected.

[0047] The start control module is used to control the start of each cutterhead motor to be started, so that the cutterhead motor drives the cutterhead to rotate and start the tunneling operation;

[0048] The data acquisition module is used to acquire real-time load rate data of each cutter head motor;

[0049] The adjustment execution module is used to determine the cutter head motor to be adjusted based on the real-time load rate data;

[0050] The adjustment execution module is also used to control the frequency converter according to the preset frequency converter control strategy to adjust the working state of the cutter head motor to be adjusted, and jump to the step of obtaining the real-time load rate data of each cutter head motor until the end of the current working cycle.

[0051] Thirdly, embodiments of this application provide an electronic device, including: a memory and a processor;

[0052] The memory stores computer-executed instructions;

[0053] The processor executes computer execution instructions stored in the memory, causing the processor to perform the first aspect and / or various possible implementations of the first aspect as described above.

[0054] Fourthly, embodiments of this application provide a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, are used to implement the first aspect and / or various possible implementations of the first aspect.

[0055] Fifthly, embodiments of this application provide a computer program product, including a computer program that, when executed by a processor, implements the first aspect and / or various possible implementations of the first aspect.

[0056] This application provides a shield tunneling machine cutterhead control method, electronic device, and storage medium. By setting a control process based on a combination of historical load information and real-time load rate data in the shield tunneling machine cutterhead drive, adaptive adjustment of the number and working status of multiple cutterhead motors is achieved. Specifically, at the beginning of each work cycle, the original motor load data of each cutterhead motor in the previous work cycle is used, and a reasonable number of cutterhead motors to be started is pre-determined in conjunction with preset motor selection rules, so that the initial number of motors put into operation can match the load level of typical working conditions. During the tunneling process, real-time load rate data of each cutterhead motor is continuously acquired, and the cutterhead motors that need to be adjusted are identified accordingly. Then, the relevant motors are started, stopped, or switched in state through a preset frequency converter control strategy, forming a closed-loop control of real-time monitoring, load determination, motor adjustment, and re-monitoring until the end of the current work cycle. This method dynamically matches the number of cutterhead motors in operation with the actual tunneling load. Under the premise of ensuring that the output torque and power of the cutterhead meet the construction requirements, it reduces long-term low-load operation and unnecessary motor input, reduces the no-load loss and line loss of the frequency converter and motor, improves the energy efficiency and power utilization of the cutterhead drive, and at the same time reduces the mechanical and electrical impact of the motor and transmission mechanism, extends the service life of components, and improves the operational stability and economy of the tunnel boring machine during the tunneling process. Attached Figure Description

[0057] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0058] Figure 1 This is a schematic diagram of the structure of the tunnel boring machine cutterhead control system provided in this application;

[0059] Figure 2 A schematic flowchart illustrating the shield machine cutterhead control method provided in an embodiment of this application;

[0060] Figure 3A schematic diagram illustrating the overall execution process provided for embodiments of this application;

[0061] Figure 4 This is a schematic diagram of the structure of the tunnel boring machine cutterhead control device provided in the embodiments of this application;

[0062] Figure 5 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application.

[0063] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0064] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0065] Figure 1 This is a structural schematic diagram of the tunnel boring machine cutterhead control system provided in this application. It is also a scenario schematic diagram of this application, such as... Figure 1 As shown, in the application scenario of this application, the tunnel boring machine (TBM) cutterhead control system is set in the electrical control subsystem of the TBM, used to provide power for cutterhead excavation and realize the coordinated control of multiple cutterhead motors. This TBM cutterhead control system includes a transformer, at least one frequency converter, cutterhead motors corresponding to each frequency converter, and a controller. The transformer is electrically connected to the power grid, and is used to convert the electrical energy provided by the power grid into suitable electrical energy. That is, it converts the high-voltage electrical energy provided by the power grid into suitable electrical energy that matches the voltage level and frequency input to the frequency converter.

[0066] The frequency converter is electrically connected to the transformer, and is used to convert the adaptive electrical energy output by the transformer into driving electrical energy; the transformer is electrically connected to the cutterhead motor, and the cutterhead motor is used to convert the driving electrical energy output by the frequency converter into kinetic energy; the cutterhead motor is fixedly connected to the tunnel boring machine cutterhead, and is used to drive the cutterhead to rotate; the controller is electrically connected to the transformer, frequency converter, and cutterhead motor, and is used to read data from the transformer, frequency converter, and cutterhead motor.

[0067] Specifically, each cutterhead motor is electrically connected to its corresponding frequency converter and then to the tunnel boring machine cutterhead. The motor serves as the cutterhead drive, arranged circumferentially. Each motor's output undergoes a first-stage reduction via a reducer, followed by a second-stage reduction through a small gear meshing with a large gear, driving the cutterhead to rotate. After receiving electrical energy, it converts it into mechanical kinetic energy, which drives the cutterhead to rotate via a reduction gear transmission mechanism, achieving the breaking and excavation of the soil or rock ahead. The controller is electrically connected to the transformer, each frequency converter, and each cutterhead motor via cables. On one hand, it periodically collects the transformer's operating parameters, the output status of each frequency converter, and the operating data of each cutterhead motor, such as current, voltage, speed, and torque, forming load rate data and status information for the cutterhead motors. On the other hand, it executes preset cutterhead control methods based on the collected data, controlling the number of operating cutterhead motors and their working status by sending start / stop commands and power adjustment commands to the frequency converters, ensuring the cutterhead receives appropriate driving torque and power output under different tunneling conditions. The aforementioned cutterhead control system provides the specific hardware operating environment and data source for the shield machine cutterhead control method of this application.

[0068] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0069] Figure 2 This is a flowchart illustrating the shield machine cutterhead control method provided in an embodiment of this application, as shown below. Figure 2 As shown, this method is applied to the controller in the above application scenario, and the method includes:

[0070] S21, when the original motor load data of each cutter head motor in the previous working cycle is detected, the target number of cutter head motors to be started is determined according to the original motor load data and the preset motor selection rules.

[0071] In this embodiment, before the tunnel boring machine (TBM) enters the current work cycle, the original motor load data of each cutterhead motor from the previous work cycle is first detected to confirm whether complete historical operating information has been collected and stored. The original motor load data may include parameters such as the real-time load rate changes of each cutterhead motor in the previous work cycle, the corresponding running time, the number of starts and stops, and whether overload or faults occurred. This data comprehensively reflects the load level and usage status of each cutterhead motor in the previous work cycle. By reading and parsing this original motor load data, the actual load demand and power utilization of each cutterhead motor in the previous work cycle are obtained, providing basic data support for determining the number of cutterhead motors to be deployed in the current work cycle. By utilizing the original motor load data from the previous work cycle, the reliance on fixed configurations or manual experience to set the number of motors at the start of the current work cycle is reduced, achieving full utilization of historical operating conditions.

[0072] Having confirmed the existence of the original motor load data for each cutterhead motor in the previous work cycle, the target number of cutterhead motors to be started is determined based on the original motor load data and preset motor selection rules. The preset motor selection rules can be pre-set based on factors such as the rated total power of the tunnel boring machine cutterhead drive system, the load range in typical geological formations, the rated torque and power factor of the cutterhead motors, etc., to establish a mapping relationship between the original motor load data and the number of cutterhead motors required for the current work cycle. For example, if the original motor load data reflects a low overall load level in the previous work cycle, the preset motor selection rules can determine a smaller target number of cutterhead motors to be started, allowing each cutterhead motor to operate in a higher load rate range; if the original motor load data shows a high overall load level in the previous work cycle, close to the rated operating condition, the preset motor selection rules can determine a larger target number of cutterhead motors to be started, thereby starting more cutterhead motors in the current work cycle to meet torque and power requirements. By analyzing the original motor load data using preset motor selection rules, the target number of cutterhead motors to be started is determined, so that the initial number of motors put into operation in the current work cycle can be closer to the actual tunneling load requirements. This not only reduces the impact and energy loss caused by frequent subsequent switching, but also creates conditions for the cutterhead motors to operate in the high-efficiency load rate range.

[0073] S22 controls the start of each cutterhead motor to be started, so that the cutterhead motor drives the cutterhead to rotate and start the tunneling operation.

[0074] In this embodiment, after determining the target number of cutterhead motors to be started, unified start control is executed on these motors according to the start command of the current work cycle. Specifically, the controller sends a start control signal to the frequency converter corresponding to each cutterhead motor to be started, causing each frequency converter to switch from standby mode to output mode, and gradually providing drive power to the cutterhead motors to be started according to the preset frequency and voltage. After receiving drive power, each cutterhead motor to be started completes the excitation, self-check, and speed-up processes in sequence, converting electrical energy into mechanical rotational kinetic energy. Its output torque is applied to the cutterhead through the reduction transmission mechanism, enabling the cutterhead to start smoothly from a stationary state and gradually increase to the target speed. By centrally controlling the start of each cutterhead motor to be started, a stable torque output is established during the controlled speed-up process, reducing the current and mechanical shocks that may be caused by direct full-voltage starting of the motor, and ensuring the safe and reliable operation of the cutterhead and related transmission components.

[0075] With all the target number of cutterhead motors ready to be started operating normally, these motors, arranged along the circumference of the cutterhead, work together to drive the cutterhead to rotate continuously, enabling the tunneling operation of the tunnel boring machine (TBM). After the cutterhead starts, the controller continues to monitor the operating parameters of each motor in real time through electrical connections with the frequency converter and the cutterhead motors, providing basic data for subsequent motor switching adjustments based on real-time load rate data. By controlling the start of each cutterhead motor, the current work cycle begins with a predetermined number of motors driving the cutterhead to rotate, ensuring that the tunneling torque and power output meet the requirements of the construction conditions, and laying a stable initial operating state for subsequent dynamic adjustments based on load changes.

[0076] S23, obtain the real-time load rate data of each cutter head motor.

[0077] In this embodiment, after the cutterhead begins tunneling, it enters the operation monitoring phase, acquiring real-time load rate data of each cutterhead motor at a preset sampling period. Specifically, the controller continuously collects operating parameters related to motor load through electrical connections with each cutterhead motor and its corresponding frequency converter, such as motor output current, voltage, speed, and torque estimates reported by the frequency converter or motor sensors. These operating parameters are then converted into real-time load rate data reflecting the current load level of the cutterhead motor. Optionally, the load rate of the cutterhead motor can be defined as the ratio of the actual output torque of the motor to the rated torque or torque limit of the motor. The load rate of each cutterhead motor at the current sampling moment is calculated based on the collected torque-related parameters and stored in chronological order to form a load rate data sequence. By continuously acquiring real-time load rate data of each cutterhead motor during tunneling, the load changes of the tunnel boring machine cutterhead can be quantified and reflected in a timely manner, providing a reliable data basis for subsequent judgment of the overall load status of the cutterhead and whether the number of cutterhead motors involved in operation needs to be adjusted.

[0078] During the acquisition of real-time load rate data, the collected raw operating parameters can be filtered, outlier removed, and data calibrated to reduce the impact of sensor noise, instantaneous inrush current, and other factors on the load rate calculation results, ensuring the stability and accuracy of the real-time load rate data. By adopting continuous sampling and rolling updates, the load rate change trend of each cutterhead motor can be completely recorded within the current working cycle, and statistical indicators within a preset time window can be further calculated when needed. By acquiring the real-time load rate data of each cutterhead motor, online monitoring of the operating conditions of multiple cutterhead motors is achieved. This allows subsequent motor switching control to no longer rely on fixed empirical parameters but to be based on actual load conditions, thus laying the foundation for improving the energy utilization efficiency and operational reliability of the cutterhead drive.

[0079] S24, determine the cutter head motor to be adjusted based on real-time load rate data.

[0080] In this embodiment, real-time load rate data is analyzed to determine the overall load status of the cutterhead drive within the current work cycle and identify cutterhead motors whose operating status needs to be changed. Specifically, within a preset time window, the real-time load rate data of each cutterhead motor is statistically calculated to obtain load rate characteristic quantities characterizing the current working condition, such as the average load rate of each cutterhead motor within the time window, the load fluctuation range, and the degree of deviation from the preset load rate range. By comparing the load rate characteristic quantities of each cutterhead motor with the preset reasonable load rate range, the controller can identify whether the current cutterhead drive system is in a state of low load, moderate load, or high load, and accordingly determine whether to adjust the number of cutterhead motors involved in operation. By analyzing real-time load rate data, the decision-making process of adjusting the motors is based on objective and quantitative data, which is beneficial for adaptively reflecting the actual load of the cutterhead under different geological conditions and tunneling stages.

[0081] When identifying scenarios requiring operational status adjustments, the system further combines the load rate characteristics of each cutterhead motor with its position within the cutterhead drive system to determine the cutterhead motors constituting the adjustment set. For example, if the overall cutterhead load is determined to be low, a portion of cutterhead motors that have been operating at low loads for extended periods and contribute relatively little to the overall drive capability can be identified from the real-time load rate data and designated as those to be removed for adjustment. Conversely, if the overall cutterhead load is determined to be high, cutterhead motors that are not currently running but are in normal condition and suitable for use can be identified and designated as those to be put into operation for adjustment. Through this determination process, the controller first uses real-time load rate data to filter out the cutterhead motors to be adjusted without directly changing the motor's operating status. This provides a clear target for subsequent start-stop or power adjustment of these motors according to the preset inverter control strategy. By identifying the cutterhead motors to be adjusted based on real-time load rate data, the switching control of multiple cutterhead motors can be targeted at motor units that have a greater impact on system energy efficiency, thereby helping to improve the load matching degree of the cutterhead motors and overall operating efficiency.

[0082] S25, control the inverter according to the preset inverter control strategy to adjust the working state of the cutter head motor to be adjusted, and jump to the step of obtaining the real-time load rate data of each cutter head motor until the end of the current working cycle.

[0083] In this embodiment, after identifying the cutterhead motor to be adjusted, a control command is issued to the inverter corresponding to the cutterhead motor to be adjusted according to a preset inverter control strategy, so as to adjust the working state of the cutterhead motor to be adjusted. Specifically, the preset inverter control strategy can predefine the control mode of the inverter under different load conditions and the switching rules of the working state of the cutterhead motor. When it is necessary to reduce the number of cutterhead motors participating in operation, a load reduction or shutdown command is sent to the corresponding inverter according to the preset inverter control strategy, so that some of the cutterhead motors to be adjusted can be smoothly switched from the running state to the shutdown state. During the shutdown process, the output torque is reduced by gradually decreasing the frequency and voltage to reduce the impact on the transmission mechanism and the cutterhead. When it is necessary to increase the number of cutterhead motors participating in operation, a start or parallel system command is sent to the corresponding inverter according to the preset inverter control strategy, so that the cutterhead motors to be adjusted in the standby state are gradually put into operation with increased frequency and voltage, and the output power is coordinated with the currently running cutterhead motors. By controlling the frequency converter based on a preset frequency converter control strategy to adjust the working state of the cutterhead motor to be adjusted, the start-up and shutdown process and power distribution process of the cutterhead motor are completed under controlled conditions. While ensuring the continuity of tunneling torque and power output, the impact of motor start-up and shutdown on the power grid and mechanical structure is reduced.

[0084] After completing a working state adjustment based on real-time load rate data, the controller does not terminate the cutterhead control process. Instead, it jumps back to the step of acquiring real-time load rate data for each cutterhead motor, continues to collect new real-time load rate data according to the preset sampling period, and repeatedly executes the closed-loop control logic of load analysis, determination of cutterhead motors to be adjusted, and working state adjustment until the end of the current working cycle. Through this cyclical execution method, the tunnel boring machine cutterhead control method can continuously sense changes in cutterhead load and dynamically correct the number and working state of the participating cutterhead motors within a working cycle, ensuring that the cutterhead motors operate within a more reasonable load level range over the long term. By repeatedly jumping to the step of acquiring real-time load rate data for each cutterhead motor within the current working cycle, continuous adaptive control based on real-time working conditions is achieved. This helps reduce the no-load losses of the frequency converter and cutterhead motors, improves the power factor and overall energy efficiency of the cutterhead drive system, and extends the service life of key electrical components while meeting the requirements of tunneling conditions.

[0085] In one embodiment, the preset motor selection rules include priority matching rules and mechanically symmetrical motor rules.

[0086] In this embodiment, the preset motor selection rule consists of two parts: a priority matching rule and a mechanically symmetrical motor rule. This rule is used to comprehensively determine multiple cutter head motors when it is necessary to identify which cutter head motor to start or stop. After obtaining the original motor load data of each cutter head motor in the previous work cycle, the controller first assigns a corresponding usage priority to each cutter head motor according to the priority matching rule. Then, combining this with the mechanically symmetrical motor rule, it performs group judgment and selection on cutter head motors with mechanical symmetry relationships, thereby providing a motor combination that conforms to the operating strategy while meeting the target quantity. By simultaneously introducing the priority matching rule and the mechanically symmetrical motor rule into the preset motor selection rule, the motor selection process considers both the usage status of individual cutter head motors and the overall torque distribution and structural symmetry of the cutter head, providing an executable strategy basis for the subsequent activation and deactivation of motors.

[0087] Priority matching rules can be constructed based on the usage time of each cutterhead motor over multiple work cycles, using usage time as an indicator of the motor's cumulative workload. By statistically analyzing the usage time recorded in the original motor load data, each cutterhead motor is assigned a different priority level according to its usage time from shortest to longest. Cutterhead motors with shorter usage times are more likely to be selected as the motors to be started in the current work cycle, while cutterhead motors with longer usage times are more likely to be selected as the motors to be stopped when the number of running motors needs to be reduced. By arranging the cutterhead motors in an orderly manner through priority matching rules, the usage time of each cutterhead motor is kept relatively balanced over long-term operation while ensuring the power requirements of the current tunneling condition. This reduces the premature aging of individual motors due to prolonged high-load operation, and at the same time improves the service life and maintainability of the entire cutterhead drive system.

[0088] The mechanically symmetrical motor rule combines the geometric arrangement of cutterhead motors on the tunnel boring machine (TBM) cutterhead with paired constraints on motors with mechanically symmetrical positions. In conventional structures, cutterhead motors are uniformly arranged along the circumference of the cutterhead, exhibiting centrosymmetry or axisymmetry. The mechanically symmetrical motor rule requires that when selecting cutterhead motors to start or stop, pairs of motors in symmetrical positions should be prioritized. Provided that the corresponding symmetrical motors are fault-free, this symmetrical combination is considered the preferred option. By explicitly considering the symmetrical arrangement of cutterhead motors during motor selection, the mechanically symmetrical motor rule ensures that the cutterhead maintains a basically symmetrical driving torque distribution after the motors are engaged or disengaged. This reduces vibration and off-center loading caused by unbalanced motor arrangement, contributing to the smoothness of the cutterhead tunneling process and the overall stability of the TBM structure.

[0089] Next, the determination of the target number of cutterhead motors to be started in step S21 above will be further explained. Based on the above embodiment, it includes:

[0090] S211, Determine the usage time of each cutter head motor based on the original motor load data;

[0091] S212, determine the usage priority of each cutter head motor based on the usage time of each cutter head motor;

[0092] S213, based on the usage priority, priority matching rules and mechanical symmetry rules of each cutter head motor, select the cutter head motors to be started in sequence until the number of cutter head motors to be started meets the target number.

[0093] In this embodiment, the usage duration of each cutter head motor is determined based on the original motor load data. The original motor load data may include records of the operating time of each cutter head motor in the previous work cycle. By accumulating the start-stop time or continuous operating time of each cutter head motor, the corresponding usage duration parameter is obtained, and this usage duration is used as a quantitative indicator characterizing the cumulative workload of the cutter head motor. This step, by calculating the usage duration based on the original motor load data, allows the historical usage of the cutter head motors to be depicted on a uniform time scale, providing a basis for introducing a usage balance principle in subsequent motor selection.

[0094] After obtaining the usage duration of each cutterhead motor, its usage priority is determined based on this duration. Priority matching rules can be predefined to correspond to different usage duration ranges. For example, cutterhead motors with shorter usage durations can be assigned a higher priority, while those with longer usage durations can be assigned a lower priority. This ensures that when a new cutterhead motor needs to be added, the shorter-duration motor is prioritized, and when some motors need to be stopped, the longer-duration motor is prioritized. By prioritizing usage based on duration, dynamic rotation and balanced use of cutterhead motors across multiple work cycles are achieved. While maintaining drive capability, this helps reduce premature aging of individual cutterhead motors due to prolonged high-frequency operation, thus improving overall reliability and lifespan.

[0095] Next, based on the usage priority, priority matching rules, and mechanical symmetry rules of each cutterhead motor, the cutterhead motors to be started are selected sequentially until the number of cutterhead motors to be started meets the target number. Specifically, each cutterhead motor is traversed in descending order of usage priority. Under the premise of satisfying the mechanical symmetry rules, high-priority cutterhead motors are selected in pairs as the cutterhead motors to be started. If the target number is still not reached through pair selection, unpaired high-priority cutterhead motors are selected as supplements until the total number of selected cutterhead motors to be started matches the target number. By comprehensively considering usage priority and mechanical symmetry rules, while ensuring that the cutterhead driving torque distribution is as symmetrical as possible, the cutterhead motors participating in the startup meet both the current power requirements and long-term usage balance, providing a more reasonable motor combination and a stable operating foundation for the tunnel boring machine cutterhead at the start of the current work cycle.

[0096] In one specific embodiment, step S213 is further described below. Based on the usage priority of each cutter head motor, priority matching rules, and mechanically symmetrical motor rules, the cutter head motors to be started are selected sequentially, including:

[0097] S2131, based on the usage priority and priority matching rules of each cutter head motor, determine whether the cutter head motor is a first priority motor or a second priority motor, wherein the priority of the first priority motor is higher than the priority of the second priority motor.

[0098] In this embodiment, based on the usage priority determined by the usage duration of each cutterhead motor, a priority matching rule is further used to classify the cutterhead motors into either first-priority or second-priority motors. The priority matching rule can set different threshold ranges based on the distribution of usage duration. For example, cutterhead motors with usage duration below a first threshold are classified as first-priority motors, while those with usage duration in a higher range are classified as second-priority motors, thus forming a hierarchical structure where first-priority motors have a higher priority than second-priority motors. In this way, when selecting a cutterhead motor to be started, first-priority motors with shorter usage durations and more remaining lifespans can be given priority, while second-priority motors with longer usage durations can be reserved for later supplementation or priority consideration when removal is necessary. By introducing a hierarchical determination of first-priority and second-priority motors, the motor selection process has a clear hierarchical order, which is beneficial for achieving balanced usage of the cutterhead motors during long-term operation.

[0099] S2132, when the cutter head motor is detected as the first priority motor, the cutter head motor symmetrical to the first priority motor is judged according to the rules of the first priority motor and the mechanically symmetrical motor. If there is no fault, the cutter head motor symmetrical to the first priority motor is selected as the cutter head motor to be started. Otherwise, it is not selected. This process continues until all mechanically symmetrical cutter head motors have been detected and the number of cutter head motors to be started does not meet the target number. Then, the first priority motor is selected as the cutter head motor to be started.

[0100] In this embodiment, when a cutterhead motor is identified as a first-priority motor, the controller further determines the fault status of the cutterhead motors that are mechanically symmetrical to the first-priority motor according to the rules of first-priority motors and mechanically symmetrical motors. Specifically, based on real-time monitored status variables and fault flags, it confirms whether the cutterhead motors symmetrical to the first-priority motor have faults such as overcurrent, overtemperature, or communication abnormalities. If the detection result indicates that the symmetrical cutterhead motor is fault-free, the first-priority motor and its symmetrical cutterhead motor are added to the set of cutterhead motors to be started, so that the pair of cutterhead motors can be put into operation in pairs in the current work cycle. If a fault is detected in the symmetrical cutterhead motor, the controller does not select this pair of cutterhead motors as the cutterhead motors to be started in the current round, but continues to traverse other first-priority motors and their symmetrical motors according to the rules of mechanically symmetrical motors. When the number of cutterhead motors to be started is still insufficient after traversing all mechanically symmetrical relationships, the controller then selects a single first-priority motor as a supplementary cutterhead motor to be started. By prioritizing the selection of paired motors during the first-priority motor selection process and then reverting to single-motor supplementation when the quantity is insufficient, the cutter head maintains the symmetry of torque distribution as much as possible while meeting the target quantity. At the same time, it ensures that motors with shorter usage time are prioritized, thus balancing the requirements of mechanical balance and usage equilibrium.

[0101] S2133, when the cutter head motor is detected as a second priority motor, the cutter head motor symmetrical to the second priority motor is judged according to the rules of second priority motor and mechanically symmetrical motor. If there is no fault, the cutter head motor symmetrical to the second priority motor is selected as the cutter head motor to be started. Otherwise, it is not selected. This process continues until all mechanically symmetrical cutter head motors have been detected and the number of cutter head motors to be started does not meet the target number. Then, the second priority motor is selected as the cutter head motor to be started.

[0102] In this embodiment, when a cutterhead motor is identified as a second-priority motor, the controller performs fault assessment on the cutterhead motors that are mechanically symmetrical to the second-priority motor, according to the rules for second-priority motors and mechanically symmetrical motors. If the cutterhead motor symmetrical to the second-priority motor is fault-free, the controller adds the second-priority motor and its symmetrical cutterhead motor as a pair of cutterhead motors to be started into the set to be started. This allows the second-priority motors to supplement the operation when the first-priority motors cannot fully meet the target number. If the symmetrical cutterhead motor is faulty, the controller does not select the pair of motors temporarily, but continues to iterate through other second-priority motors and their symmetrical motors. When all mechanically symmetrical relationships have been iterated and the number of cutterhead motors to be started is still less than the target number, the controller then selects a single second-priority motor as a supplementary cutterhead motor to be started. By reusing the same mechanically symmetrical motor rules as the first-priority motors during the selection phase of the second-priority motors, when the paired combinations provided by the first-priority motors are insufficient to meet the target quantity, the second-priority motors can participate in the supplementation in an orderly manner, either in pairs or individually. This ensures that the total number of cutterhead motors to be started reaches the target quantity while reducing the problems of eccentric force and vibration of the cutterhead caused by uneven motor distribution.

[0103] Through the aforementioned motor selection process based on usage priority and mechanical symmetry motor rules, the controller can, under the same set of preset motor selection rules, successively construct a set of motors to be started that meet the target number, utilizing first-priority motors and second-priority motors. This ensures that the final selected cutterhead motors reflect both a balanced strategy prioritizing usage time and, as far as possible, a symmetrical layout in terms of mechanical arrangement. This selection mechanism, which involves priority-based batch traversal, priority pair selection, and selection of individual motors only when insufficient, achieves a reasonable configuration of the multi-motor combination of the cutterhead at the initial stage of the current work cycle, contributing to improved reliability and economy of the cutterhead drive system during long-term operation.

[0104] In one embodiment, the cutter head motor to be adjusted, as determined in step S24 above, will be further explained. Based on the above embodiment, it includes:

[0105] S241 determines the load duration and average load rate based on real-time load rate data.

[0106] In this embodiment, real-time load rate data of each cutterhead motor is continuously acquired, and statistical processing is performed on the real-time load rate data in the time dimension to determine the load duration and average load rate. Specifically, the controller can set a preset duration threshold to divide the current work cycle into several consecutive statistical time windows. Within each statistical time window (5 minutes, 6 minutes, etc., time window values ​​can be set according to requirements), the real-time load rate data of each cutterhead motor is sampled, accumulated, and time-marked. Within the corresponding time period, the real-time load rate data is statistically analyzed to obtain the load duration of the cutterhead as a whole or each motor within that time period, as well as the average load rate calculated based on the real-time load rate data (i.e., the average load rate calculation result). By determining the load duration and average load rate under the constraint of the preset duration threshold, the interference of instantaneous fluctuations and short-term impacts is reduced.

[0107] S242, when the load duration is detected to reach a preset duration threshold and the average load rate is less than a preset first load rate threshold, the number of motors to be reduced is determined based on the real-time load rate data, the first load rate threshold and the preset second load rate threshold, and the cutter head motor to be adjusted is determined based on the number of motors to be reduced and the real-time load rate data.

[0108] When the detected load duration reaches a preset duration threshold and the average load rate is less than a preset first load rate threshold, it is considered that the current cutter head motors are operating under low load. This means that the load rate of each cutter head motor is consistently below the lower limit of its efficient operating range, indicating an excessive number of motors, significant power redundancy, and high no-load losses. In this case, the number of motors to be reduced is determined based on real-time load rate data, the first load rate threshold, and a preset second load rate threshold. Specifically, a mathematical constraint relationship between the current number of operating cutter head motors, the average load rate, and the first and second load rate thresholds can be established. This allows for the calculation of the minimum number of motors to be reduced so that the expected average load rate of the remaining operating motors is between the first and second load rate thresholds after stopping several cutter head motors.

[0109] After determining the number of motors to be reduced, the controller, combining real-time load rate data and the operating status of each cutterhead motor, selects the cutterhead motors to be adjusted from the currently operating motors. This provides a target for smoothly disconnecting these motors from operation using the inverter control strategy. By reducing the number of operating motors in low-load scenarios, the load rate of the remaining operating cutterhead motors is increased, bringing them closer to the preset high-efficiency range. This reduces the no-load losses and line losses of redundant motors and their corresponding inverters, thus improving the overall energy efficiency of the cutterhead drive system.

[0110] S243, when the load duration is detected to reach a preset duration threshold and the average load rate is greater than a preset second load rate threshold, the number of motors to be added is determined based on the real-time load rate data, the preset first load rate threshold and the second load rate threshold, and the cutter head motor to be adjusted is determined based on the number of motors to be added and the real-time load rate data.

[0111] When the detected load duration reaches a preset duration threshold and the average load rate exceeds a preset second load rate threshold, it is considered that the current cutterhead motors are operating under high load or even close to overload conditions. This means that the load rate of each cutterhead motor consistently exceeds the upper limit of its efficient operating range, posing a risk of excessive load on individual motors, high temperature rise, and decreased reliability. In this case, the number of motors to be added is determined based on real-time load rate data and the preset first and second load rate thresholds. Specifically, based on the relationship between the number of currently operating cutterhead motors, the average load rate, and the two load rate thresholds, the number of additional motors required to reduce the expected average load rate of all operating cutterhead motors to between the first and second load rate thresholds can be calculated.

[0112] After calculating the number of motors to be added, and combining real-time load rate data with the health status of each non-operating cutterhead motor, the cutterhead motors to be adjusted are selected from those that are not operating and have no faults. This provides a basis for the smooth commissioning of these adjusted cutterhead motors through a preset inverter control strategy. By increasing the number of cutterhead motors operating under high load conditions, the load rate of a single motor is distributed and reduced, decreasing the risk of overload and thermal stress, which helps improve the safety and continuous output capability of the cutterhead drive system under heavy load conditions.

[0113] Furthermore, when the average load rate is detected to be between the first load rate threshold and the second load rate threshold, it is determined that the overall load of the currently operating cutterhead motor is within a preset high-efficiency range, meaning there is neither significant power redundancy nor overload. In this case, the number of currently operating cutterhead motors remains unchanged. By maintaining a stable number of operating motors when the average load rate falls within a reasonable range, unnecessary frequent start-stop operations are reduced, minimizing the impact on the electrical and mechanical transmission systems, and contributing to the smoothness of the cutterhead tunneling process and the simplicity of the control strategy. Through judgment and branch control based on load duration and average load rate, this implementation method can adopt strategies of reducing motors, increasing motors, or keeping them unchanged under three typical working conditions: low load, high load, and moderate load. This achieves adaptive matching between the number of cutterhead motors and the actual tunneling load, thereby dynamically balancing energy consumption and reliability within a working cycle.

[0114] In one specific embodiment, a method is provided for determining the cutter head motor to be adjusted based on the number of motors to be added and real-time load rate data in step S243 above. Based on the above embodiment, it includes:

[0115] S2431, when the number of motors to be added is detected to be 1, then based on the real-time load rate data, determine all non-running cutter head motors and their corresponding running times, and determine the cutter head motor to be adjusted from all non-running cutter head motors based on the running time.

[0116] S2432, when the number of motors to be added is greater than 1, all non-running cutter head motors and their corresponding running times are determined based on the real-time load rate data, and at least one pair of mechanically symmetrical cutter head motors are determined from all non-running cutter head motors as cutter head motors to be adjusted based on the running time.

[0117] In this embodiment, based on real-time load rate data and the operating records associated with the cutterhead motors, a set of all currently non-operating cutterhead motors is determined, and the operating time corresponding to each non-operating cutterhead motor is read from this set. Operating time can be understood as the cumulative duration of the cutterhead motor's operation within the current or multiple work cycles, reflecting the cumulative workload borne by each cutterhead motor. After obtaining the operating time of all non-operating cutterhead motors, the operating time is used as the sorting criterion, prioritizing the cutterhead motors with shorter operating times among all non-operating motors, and identifying them as the cutterhead motors to be adjusted and put into operation this time. By prioritizing the non-operating cutterhead motor with shorter operating times when only one additional cutterhead motor is needed, dynamic balancing of the cutterhead motor utilization is achieved, improving the overall lifespan and reliability of the cutterhead drive system while meeting current load requirements.

[0118] When the number of motors to be added is greater than one, all currently non-operating cutterhead motors and their corresponding running times are determined based on real-time load rate data. However, a mechanical symmetry constraint is introduced when selecting the cutterhead motors to be adjusted. After counting all non-operating cutterhead motors and their running times, pairs of cutterhead motors in a mechanically symmetrical position are first identified from the set of non-operating motors. Combining this with the running time information, one or more pairs of cutterhead motors with shorter running times and mechanical symmetry are prioritized and put into operation as the cutterhead motors to be adjusted. This selection method, which uses at least one pair of mechanically symmetrical cutterhead motors as the cutterhead motors to be adjusted, ensures a relatively balanced running time for the newly added motors and maintains the torque symmetry of the cutterhead circumferential arrangement, reducing the problem of unbalanced force and vibration on the cutterhead caused by putting multiple motors on one side. By introducing a mechanically symmetrical motor priority selection strategy in scenarios where the number of motors to be added is greater than one, the motor switching control can improve load adaptability while taking into account mechanical balance and structural stability.

[0119] In another specific embodiment, step S242 above, which determines the cutter head motor to be adjusted based on the number of motors to be reduced and real-time load rate data, is provided as an implementation method. Based on the above embodiment, it includes:

[0120] S2421, when the number of motors to be reduced is detected to be 1, then based on the real-time load rate data, determine all running cutter head motors and their corresponding running times, and determine the cutter head motor to be adjusted from all running cutter head motors based on the running time.

[0121] S2422, when the number of motors to be reduced is greater than 1, all running cutter head motors and their corresponding running times are determined based on real-time load rate data, and at least one pair of mechanically symmetrical cutter head motors are determined from all running cutter head motors based on their running times as cutter head motors to be adjusted.

[0122] In this embodiment, when the number of motors to be reduced is detected to be 1, the set of all currently running cutterhead motors is determined based on real-time load rate data, and the running time corresponding to each running cutterhead motor is read. Running cutterhead motors with longer running times are considered to have heavier accumulated loads. Among all running cutterhead motors, they are sorted from longest to shortest running time, and the cutterhead motor with the longest running time is preferentially selected as the cutterhead motor to be adjusted, and it is preferentially disconnected from operation in this adjustment. By prioritizing the cutterhead motor with the longest running time as the target for adjustment when only one cutterhead motor needs to be reduced, motors with higher accumulated usage can obtain more downtime for rest while ensuring the system's drive capability, thereby slowing down their aging rate and improving the maintainability and long-term reliability of components.

[0123] When the number of motors to be reduced is greater than one, all running cutterhead motors and their corresponding running times are determined based on real-time load rate data. However, when specifically selecting cutterhead motors to be adjusted, mechanical symmetry is used as an additional constraint. Pairs of cutterhead motors with a mechanically symmetrical arrangement are identified among the currently running motors. Priority is given to finding one or more pairs of mechanically symmetrical cutterhead motors among those with longer running times. These motors are then removed as the cutterhead motors to be adjusted, ensuring that the cutterhead maintains a basic symmetry in torque distribution while reducing the number of running motors.

[0124] When pairwise selection still cannot fully meet the requirement of reducing the number of motors, the controller can further select a single cutterhead motor with a longer remaining operating time as a supplementary removal target, while maintaining an acceptable overall mechanical impact. By prioritizing cutterhead motors with longer operating times and mechanical symmetry as the adjustment targets in scenarios where the number of motors to be reduced is greater than one, the controller allows the heavily loaded motors to be taken out of operation first, reducing their long-term working pressure. On the other hand, it maintains the symmetry of the force on the cutterhead after reducing the number of motors, reducing off-center loading and vibration during tunneling. Thus, energy saving and consumption reduction are achieved while ensuring the operational stability and structural safety of the cutterhead drive system.

[0125] In one specific embodiment, the calculation formula for determining the number of motors to be reduced, based on real-time load rate data, a first load rate threshold, and a second load rate threshold, includes:

[0126]

[0127]

[0128]

[0129] In the formula, a% is the preset first load rate threshold, b% is the preset second load rate threshold, and n is the number of currently operating cutter head motors determined based on real-time load rate data. s The number of motors to be reduced is η%, and η% is the average load rate determined based on real-time load rate data.

[0130] Specifically, let n be the number of currently operating cutter head motors, η be the average load rate calculated based on real-time load rate data, a be the preset first load rate threshold, b be the preset second load rate threshold, and n be the number of motors to be reduced. s Based on this, constraints are established (corresponding to the first formula). These constraints indicate that, in reducing n... s After the turret motors are installed, the remaining number of operating turret motors is nn. s The corresponding expected average load rate should be between the first load rate threshold and the second load rate threshold, that is, still within the preset high-efficiency load rate range. Through the above constraints, it can be ensured that after the motor cut-off adjustment, the load rate of the cutter head motor will not exceed the upper limit of the high-efficiency zone due to excessive reduction in the number of cutters, nor will it remain in a low-load operation state below the lower limit of the high-efficiency zone due to insufficient reduction in the number of cutters.

[0131] After obtaining the above basic constraints, the inequality is further transformed to obtain the number of motors to be reduced, n. s The range of values ​​for n can be derived through algebraic operations. sThe second formula must be satisfied, meaning the number of motors to be reduced should fall within the interval determined by parameters n, η, a, and b. Since n s The integer must be a non-negative integer and cannot exceed the number of currently operating cutter head motors, n. Therefore, based on the above interval relationship, a rounding process is performed, and the smallest integer not less than n×(1-η / a) is taken as the number of motors to be reduced, n. s The specific value is determined by this rounding up method. This ensures that reducing the number of motors is sufficient to maintain the expected average load rate of the remaining motors at or above the first load rate threshold, while minimizing the number of motors to be cut off. This brings the adjusted load rate closer to the lower limit of the high-efficiency range, achieving a trade-off between increasing motor load rate and reducing no-load losses. Determining the number of motors to be reduced based on the above calculation formula provides a clear basis and constraints for motor cut-off decisions, reducing energy efficiency fluctuations caused by arbitrarily reducing motors based on experience. This helps maintain a balance between economical and safe operation of the cutterhead drive system.

[0132] In another specific embodiment, the calculation formula for determining the number of motors to be added, based on real-time load rate data, a preset first load rate threshold, and a preset second load rate threshold, includes:

[0133]

[0134]

[0135] In the formula, a% is the preset first load rate threshold, b% is the preset second load rate threshold, and n is the number of currently operating cutter head motors determined based on real-time load rate data. a The number of motors to be added is η%, and η% is the average load rate determined based on real-time load rate data.

[0136] In this embodiment, the number of currently operating cutter head motors determined based on real-time load rate data is denoted as n, the average load rate calculated based on real-time load rate data is denoted as η, a preset first load rate threshold is denoted as a%, a preset second load rate threshold is denoted as b, and the number of motors to be added is denoted as n. a Based on this, a constraint relationship is established (corresponding to the first formula in this embodiment). This constraint relationship indicates that, with the increase of n... a After adding the tool turret motor, the total number of tool turret motors participating in operation becomes n+n. a The corresponding expected average load rate needs to be controlled between the first load rate threshold and the second load rate threshold, so as to ensure that the adjusted cutter head motor works in the load rate range with high linear efficiency.

[0137] After obtaining the basic constraints, algebraic transformations can be performed to determine the number of motors, n, to be added. aThe second formula in this embodiment should be satisfied, meaning the number of motors to be added falls within the range determined by the number of currently operating cutter head motors n, the average load rate η%, and the first load rate threshold a% and the second load rate threshold b%. Within this range, a specific n is selected that satisfies the integer constraint and does not exceed the total number of non-operating and fault-free motors. a The value represents the actual number of cutterhead motors required in this adjustment. By determining the number of motors to be added based on the above calculation formula, it is possible to reduce the load rate of each cutterhead motor from the excessively high range to the preset high-efficiency range under high-load conditions by reasonably increasing the number of cutterhead motors involved in operation. This reduces individual machine heat generation and overload while ensuring that the cutterhead drive system has sufficient torque redundancy and continuous tunneling capability.

[0138] Furthermore, based on the above embodiments, the method further includes: when multiple integer values ​​are detected for the number of motors to be added, the number of non-operating and fault-free motors is determined based on real-time load rate data, and the final number of motors to be added is determined based on the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate.

[0139] In this embodiment, based on real-time load rate data and monitoring information related to the operating status of the cutter head motors, all cutter head motors that are currently not running and are fault-free are identified, and the number of non-running and fault-free motors is counted. This number of motors reflects the upper limit of motors available for use in the current work cycle.

[0140] After obtaining the number of non-operating and fault-free motors, this number is comprehensively compared with the number of candidate motors to be added, analyzed based on the load rate constraint relationship. The final number of motors to be added is determined by combining this number with the relationship between the first load rate threshold and the average load rate. Candidate integer values ​​that do not exceed the number of non-operating and fault-free motors and that, after being added, will make the expected average load rate as close as possible to the first load rate threshold can be selected as the final number of motors to be added. This ensures that the adjusted cutterhead motor load rate is slightly higher than the lower limit of the high-efficiency range, reserving a certain load fluctuation margin while maintaining it within the high-efficiency range. By introducing the matching relationship between the number of non-operating and fault-free motors and the first load rate threshold and average load rate among multiple candidate motors to be added as a decision-making basis, the constraint and optimization of the number of motors to be added are achieved. On the one hand, this reduces over-investment caused by excessively large theoretical calculation values; on the other hand, it ensures that the number of added motors is sufficient to reduce the load rate of a single motor. This improves the operating efficiency and safety margin of the cutterhead drive system while meeting the current power requirements of the tunneling operation.

[0141] In one specific embodiment, based on the above embodiments, the calculation formula for determining the final number of motors to be added, according to the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate, includes:

[0142]

[0143] In the formula, n a This represents the final number of motors to be added, where n is the number of currently operating cutter head motors determined based on real-time load rate data. max This indicates the number of motors that are not running and are not faulty. This represents the ratio of the average load rate to the first load rate threshold.

[0144] In this embodiment, when there are multiple selectable integer values ​​for the number of motors to be added calculated based on real-time load rate data and load rate constraints, the candidate values ​​are further quantified and filtered based on the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate. A calculation formula is then used to determine the final number of motors to be added. By using the above calculation formula to determine the final number of motors to be added, the motor deployment decision becomes more precise and controllable.

[0145] Figure 3 This is a schematic diagram illustrating the overall execution flow of an embodiment of this application, providing an overall description of the control flow of this application. For example... Figure 3 As shown, after the tunnel boring machine (TBM) is powered on, the control system first completes a self-test process, including basic status checks on the transformer, frequency converter, each drive motor, and related sensors. After the self-test is complete, the operator or control system selects whether to adopt the economic operation mode. If not selected, the cutterhead drive is controlled according to other preset operation modes, without entering the economic control process of this application. If the economic operation mode is selected, the system continues to determine if there are any motor quantity or historical load records from the previous work cycle. When no valid records are detected from the previous cycle, the controller directly starts all drive motors in normal condition to ensure sufficient torque output during the initial tunneling stage. When records of motor quantity and related load information from the previous cycle are detected, the controller selects a set of motor combinations that meet the current initial requirements as the working motors for this cycle based on the recording results, the usage time of each motor, and the mechanical symmetry arrangement of the motors on the cutterhead. Then, a start command is issued, causing the corresponding frequency converters to engage sequentially, driving the selected motors to drive the cutterhead and begin tunneling operations.

[0146] During the tunneling process, the controller continuously monitors the cutterhead rotation speed and feed rate. When the cutterhead rotation speed reaches a given value and the feed rate remains basically constant for a period of time, the tunneling condition is considered to have entered a stable phase, and the controller begins to statistically analyze the load rate of each drive motor. Within a preset time window (e.g., 5 minutes), the controller collects parameters such as current and torque of each motor, calculates the average load rate during that time period, and determines the current load level accordingly: if the average load rate is consistently lower than the first load rate threshold a%, the current condition is marked as a low load state L_Duty; if the average load rate is consistently higher than the second load rate threshold b%, the current condition is marked as a very high load state HH_Duty; if the average load rate is between the two thresholds, it is marked as a high load state H_Duty.

[0147] When in a low-load state (L_Duty), the controller calculates the number of motors (n) that need to be reduced based on the current number of operating motors and the statistically obtained average load rate using a preset formula. s Based on the usage time and mechanical symmetry of each motor, one or more motors are selected from the currently operating motors as the targets to be removed. Then, the corresponding frequency converters are used to sequentially stop these motors, allowing the cutterhead to continue tunneling after reducing the number of motors in operation. Through this process, the load rate of the remaining operating motors is increased to a preset high-efficiency range, improving the energy utilization efficiency of the drive system. When under a very high load state HH_Duty, the controller also uses the relationship between the average load rate and the load rate threshold to calculate the number of additional motors n that need to be added. a From the motors that have never been run and have no faults, a group of motors is selected to be put into operation based on the principle of shorter operating time and maintaining mechanical symmetry as much as possible. These motors are started by controlling the corresponding frequency converters, so that the load rate of a single motor drops from the excessively high range to the efficient range, reducing the risk of overload. When in the high load state H_Duty, the controller determines that the number of currently working motors basically matches the tunneling load demand, so it will not add or remove motors, but only keep the existing motor combination running continuously.

[0148] During the above process, after each motor switching adjustment, the controller returns to the stable operating condition detection and load statistics steps, continuously performing closed-loop control of operating condition detection, load judgment, and motor adjustment until the tunneling task of this work cycle is determined to be completed. At the end of the current work cycle, the controller records the running time and combination of each motor in this cycle, providing a basis for the initial motor selection in the economic operation mode of the next work cycle; then the process enters the next work cycle and repeats the above steps. Through communication with... Figure 3 This corresponding implementation method can adaptively adjust the number of motors engaged according to real-time load changes while ensuring stable tunneling operations, so that the cutterhead drive system can maintain high energy utilization efficiency and good operating economy in multiple working cycles.

[0149] Figure 4 This is a schematic diagram of the structure of the tunnel boring machine cutterhead control device provided in the embodiments of this application, as shown below. Figure 4 As shown, the shield machine cutterhead control device 40 provided in this embodiment includes:

[0150] The data detection module 401 is used to determine the target number of cutter head motors to be started based on the original motor load data and the preset motor selection rules when the original motor load data of each cutter head motor in the previous working cycle is detected.

[0151] The start control module 402 is used to control the start of each cutterhead motor to be started, so that the cutterhead motor drives the cutterhead to rotate and start the tunneling operation;

[0152] The data acquisition module 403 is used to acquire the real-time load rate data of each cutter head motor;

[0153] The adjustment execution module 404 is used to determine the cutter head motor to be adjusted based on real-time load rate data;

[0154] The adjustment execution module 404 is also used to control the inverter according to the preset inverter control strategy to adjust the working state of the cutter head motor to be adjusted, and jump to the step of obtaining the real-time load rate data of each cutter head motor until the end of the current working cycle.

[0155] The shield machine cutterhead control device provided in this embodiment can execute the method provided in the above method embodiment. Its implementation principle and technical effect are similar, and will not be described in detail here.

[0156] Figure 5 This is a schematic diagram of the structure of an electronic device provided in an embodiment of this application. Figure 5 As shown, the electronic device 50 provided in this embodiment includes at least one processor 501 and a memory 502. Optionally, the electronic device 50 further includes a communication component 503. The processor 501, memory 502, and communication component 503 are connected via a bus 504.

[0157] In a specific implementation, at least one processor 501 executes computer execution instructions stored in memory 502, causing at least one processor 501 to perform the above-described method.

[0158] The specific implementation process of processor 501 can be found in the above method embodiments, and its implementation principle and technical effect are similar. It will not be repeated here.

[0159] In the above embodiments, it should be understood that the processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), etc. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the method disclosed in this invention can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor.

[0160] The memory may include random access memory (RAM) and may also include non-volatile memory (NVM), such as at least one disk storage device.

[0161] The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized as address buses, data buses, control buses, etc. For ease of illustration, the buses shown in the accompanying drawings are not limited to a single bus or a single type of bus.

[0162] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the above-described method.

[0163] This application also provides a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, implement the above-described method.

[0164] The aforementioned readable storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk. The readable storage medium can be any available medium accessible to a general-purpose or special-purpose computer.

[0165] An exemplary readable storage medium is coupled to a processor, enabling the processor to read information from and write information to the readable storage medium. Of course, the readable storage medium can also be a component of the processor. The processor and the readable storage medium can reside in an Application Specific Integrated Circuit (ASIC). Alternatively, the processor and the readable storage medium can exist as discrete components in the device.

[0166] Finally, it should be noted that other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A method for controlling the cutterhead of a tunnel boring machine, characterized in that, include: When the original motor load data of each cutter head motor in the previous working cycle is detected, the target number of cutter head motors to be started is determined according to the original motor load data and the preset motor selection rules. Control each cutterhead motor to start, so that the cutterhead motor drives the cutterhead to rotate and start the tunneling operation; Obtain real-time load rate data for each cutter head motor; Based on the real-time load rate data, determine the cutter head motor to be adjusted; The inverter is controlled according to the preset inverter control strategy to adjust the working state of the cutter head motor to be adjusted, and then jumps to the step of obtaining the real-time load rate data of each cutter head motor until the current working cycle ends.

2. The method according to claim 1, characterized in that, The preset motor selection rules include priority matching rules and mechanically symmetrical motor rules; The step of determining the target number of cutterhead motors to be started based on the original motor load data and preset motor selection rules includes: Based on the original motor load data, determine the usage time of each cutter head motor; The usage priority of each cutter head motor is determined based on its usage duration. Based on the usage priority of each cutter head motor, the priority matching rule, and the mechanical symmetry motor rule, the cutter head motors to be started are selected sequentially until the number of cutter head motors to be started meets the target number.

3. The method according to claim 2, characterized in that, The step of sequentially selecting the cutter head motors to be started based on the usage priority of each cutter head motor, the priority matching rule, and the mechanical symmetry motor rule includes: Based on the usage priority of each cutter head motor and the priority matching rule, the cutter head motor is determined to be either a first priority motor or a second priority motor, wherein the priority of the first priority motor is higher than the priority of the second priority motor. When the cutter head motor is detected as a first priority motor, the cutter head motor symmetrical to the first priority motor is determined according to the rules of the first priority motor and the mechanically symmetrical motor. If there is no fault, the cutter head motor symmetrical to the first priority motor is selected as the cutter head motor to be started. Otherwise, it is not selected. This process continues until all mechanically symmetrical cutter head motors have been detected and the number of cutter head motors to be started does not meet the target number. Then, the first priority motor is selected as the cutter head motor to be started. Alternatively, if the cutter head motor is detected to be a second priority motor, then according to the rules of the second priority motor and the mechanically symmetrical motor, it is determined whether the cutter head motor symmetrical to the second priority motor is faulty. If there is no fault, the cutter head motor symmetrical to the second priority motor is selected as the cutter head motor to be started; otherwise, it is not selected. This process continues until all mechanically symmetrical cutter head motors have been detected and the number of cutter head motors to be started does not meet the target number. At this point, the second priority motor is selected as the cutter head motor to be started.

4. The method according to claim 1, characterized in that, The step of determining the cutter head motor to be adjusted based on the real-time load rate data includes: Based on the real-time load rate data, determine the load duration and average load rate; When the load duration is detected to reach a preset duration threshold and the average load rate is less than a preset first load rate threshold, the number of motors to be reduced is determined based on the real-time load rate data, the first load rate threshold and the preset second load rate threshold, and the cutter head motor to be adjusted is determined based on the number of motors to be reduced and the real-time load rate data. Alternatively, when the load duration is detected to reach a preset duration threshold and the average load rate is greater than a preset second load rate threshold, the number of motors to be added is determined based on the real-time load rate data, the preset first load rate threshold, and the second load rate threshold, and the cutter head motor to be adjusted is determined based on the number of motors to be added and the real-time load rate data.

5. The method according to claim 4, characterized in that, Based on the number of motors to be added and the real-time load rate data, determine the cutter head motors to be adjusted, including: When the number of motors to be added is detected to be 1, all non-running cutter head motors and their corresponding running times are determined based on the real-time load rate data, and the cutter head motor to be adjusted is determined from all non-running cutter head motors based on the running time. Alternatively, if the number of motors to be added is greater than 1, then all non-running cutterhead motors and their corresponding running times are determined based on the real-time load rate data, and at least one pair of mechanically symmetrical cutterhead motors are determined from all non-running cutterhead motors based on the running time as cutterhead motors to be adjusted. The step of determining the cutter head motor to be adjusted based on the number of motors to be reduced and the real-time load rate data includes: When the number of motors to be reduced is detected to be 1, all running cutterhead motors and their corresponding running times are determined based on the real-time load rate data, and the cutterhead motor to be adjusted is determined from all running cutterhead motors based on the running time. Alternatively, if the number of motors to be reduced is greater than 1, then all running cutterhead motors and their corresponding running times are determined based on the real-time load rate data, and at least one pair of mechanically symmetrical cutterhead motors are determined from all running cutterhead motors based on the running time as cutterhead motors to be adjusted.

6. The method according to claim 4, characterized in that, The calculation formula for determining the number of motors to be reduced based on the real-time load rate data, the first load rate threshold, and the second load rate threshold includes: In the formula, a% is a preset first load rate threshold, b% is a preset second load rate threshold, and n is the number of currently operating cutter head motors determined based on the real-time load rate data. s The number of motors to be reduced is η%, where η% is the average load rate determined based on the real-time load rate data. The calculation formula for determining the number of motors to be added based on the real-time load rate data, the preset first load rate threshold, and the preset second load rate threshold includes: In the formula, a% is a preset first load rate threshold, b% is a preset second load rate threshold, and n is the number of currently operating cutter head motors determined based on the real-time load rate data. a The number of motors to be added is η%, and η% is the average load rate determined based on the real-time load rate data.

7. The method according to claim 5, characterized in that, Also includes: When multiple integer values ​​are detected for the number of motors to be added, the number of non-operating and fault-free motors is determined based on the real-time load rate data, and the final number of motors to be added is determined based on the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate.

8. The method according to claim 7, characterized in that, The calculation formula for determining the final number of motors to be added based on the number of non-operating and fault-free motors, the first load rate threshold, and the average load rate includes: In the formula, n a This represents the final number of motors to be added, where n is the number of currently operating cutter head motors determined based on the real-time load rate data. max This indicates the number of motors that are not running and are not faulty. This represents the ratio of the average load rate to the first load rate threshold.

9. An electronic device, characterized in that, include: Memory, processor; The memory stores computer-executed instructions; The processor executes computer execution instructions stored in the memory, causing the processor to perform the method as described in any one of claims 1 to 8.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-executable instructions, which, when executed by a processor, are used to implement the method as described in any one of claims 1 to 8.

Images