Dual-wheel milling large-torque modular rail chain reel system and method

Abstract

The application discloses a double-wheel milling large-torque modular track chain pipe winding system and method, and belongs to the technical field of engineering machinery, comprising a controller, an execution unit, a driving unit and a sensing unit in communication connection with the controller. The application enables the steel wire rope to be kept in a minimum tension state just to offset the total weight of the track chain and the oil pipe cable through a deep tension adjusting module, which not only reduces the risk of fatigue fracture of the steel wire rope, but also avoids irreversible tensile deformation and inner layer damage of the oil pipe cable. The elastic deformation of the steel wire rope can be dynamically fed forward in real time through an elastic deformation compensation module, so as to offset the elastic expansion and contraction effect of the steel wire rope caused by the milling head, not only control the follow-up error of the track chain within a preset range, solve the problems of loosening, collapse, winding, knotting or excessive pulling and damage and fracture of the oil pipe cable, but also avoid accidental interruption of on-site construction, and ensure the operation efficiency of continuous construction in the super-deep stratum.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, and in particular to a dual-wheel milling high-torque modular track chain tube winding system and method. Background Technology

[0002] Twin-wheel trench cutters are core equipment in the field of underground foundation engineering construction, widely used in various major foundation projects such as seepage prevention walls in water conservancy and hydropower strata, ultra-deep diaphragm walls, and large-scale deep foundation pit support. As a large-scale construction equipment, the twin-wheel trench cutter's structure comprises multiple subsystems. Among them, the hydraulic cable reel system is responsible for supplying hydraulic power and cutting fluid to the milling head and transmitting control signals, making it a key subsystem for ensuring continuous operation. Currently, with the continuous expansion of underground engineering into deeper and more complex strata, the construction of ultra-deep diaphragm walls and hard rock strata places unprecedentedly stringent requirements on the load-bearing capacity, follow-up accuracy, and operational reliability of the twin-wheel trench cutter reel system.

[0003] Currently, the dual-wheel milling and tube winding systems widely used in the industry mostly adopt an integral track chain wire rope structure. The so-called track chain wire rope structure refers to an engineering drag chain with built-in wire ropes. The wire ropes, as load-bearing components, are installed in the reinforcing cavity of the drag chain, while the oil pipes and cables are installed in the middle cavity of the drag chain. The drag chain is used to provide guidance and protection for the oil pipes and cables, while the wire ropes are used to bear the entire weight of the drag chain and the oil pipes and cables. The entire track chain is synchronously wound and unwound through a winch drive.

[0004] The applicant obtained the following prior art through searching, specifically the tubing reel system for a hydraulic grab bucket for diaphragm walls and the diaphragm wall trenching machine (publication number CN103590438B). While this tubing reel system can buffer the contraction of the tubing caused by changes in oil pressure and extend its service life, its integral steel wire rope structure in the track chain leads to a sharp increase in the self-weight of the track chain and tubing cable during ultra-deep strata construction using a twin-wheel trenching machine. This results in the steel wire rope in the track chain of the reel system being under high tension and heavy load for extended periods. This not only poses a risk of fatigue fracture for the steel wire rope itself but also causes the tubing cable to continuously bear axial tensile force, easily leading to irreversible tensile deformation and inner layer damage. Furthermore, under asymmetrical strata milling conditions—that is, when the left and right milling wheels are milling soft and hard strata respectively—the tension difference between the tubing cables on both sides creates an additional eccentric moment, which further exacerbates the tilting deviation of the milling head, thereby amplifying the error in trench verticality.

[0005] Meanwhile, existing pipe winding systems mostly adopt fixed tension or simple depth ratio adjustment methods, without considering the elastic deformation characteristics of the wire rope as a load-bearing component under long-distance suspension. For example, a winch follow-up control method, control device and double wheel milling machine with announcement number CN113753783B. Although the winch follow-up control method provided by this invention can directly measure the tension value without the need for calculation of multiple parameters, and the steps are simple, during the milling operation of the twin-wheel milling machine, this invention does not consider the length error caused by the elastic deformation of the steel wire rope of the track chain. That is, the milling head will have instantaneous displacement fluctuations due to sudden changes in formation resistance and switching of feed mode, resulting in centimeter-level elastic expansion and contraction of the steel wire rope of the track chain. The existing pipe winding system cannot dynamically compensate for this elastic expansion and contraction in real time, which can easily cause the oil pipe and cable in the track chain to become loose, slack, or even entangled, or be damaged and broken due to excessive tension. This not only easily leads to frequent interruptions in on-site construction and reduces the efficiency of continuous construction in ultra-deep formations, but also accelerates the fatigue aging of oil pipes and cables, increases the probability of equipment failure and subsequent maintenance costs.

[0006] Therefore, how to solve the problems of high-tension fracture of the guide chain wire rope, irreversible deformation of the oil pipe, amplification of trenching error due to eccentric moment of asymmetrical strata, and poor follow-up accuracy caused by the inability to compensate for elastic deformation in ultra-deep construction by improving the structure and control method of the pipe winding system is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0007] The main objective of this invention is to overcome the shortcomings of existing technologies and provide a dual-wheel milling high-torque modular track chain pipe winding system that can effectively solve the problems of high-tension fracture of track chain wire ropes, irreversible deformation of oil pipes, amplification of trenching errors due to asymmetric strata eccentric moment, and poor follow-up accuracy caused by the inability to compensate for elastic deformation in ultra-deep construction. This invention also provides a dual-wheel milling high-torque modular track chain pipe winding control method.

[0008] To achieve the above objectives, the present invention provides a dual-wheel milling high-torque modular track chain tube winding system for use in conjunction with a dual-wheel milling micro-feed device to control the milling head operation. The dual-wheel milling micro-feed device includes a control system and a lifting cylinder, including a controller and an execution unit, a drive unit and a sensing unit that are communicatively connected to the controller.

[0009] The execution unit is used for raising and lowering the track chain, and the execution unit includes two winches symmetrically arranged on the double-wheel milling machine frame; the drive unit is used for collecting the operating data of the winches and adjusting the rotation speed and output torque of the winches according to the instructions of the controller; the sensing unit is used for collecting the tension of the wire rope, the rotation angle of the winches and the operating status data of the milling wheel and transmitting them to the controller.

[0010] The controller incorporates an elastic deformation compensation module, a depth tension adjustment module, a ground linkage pre-tensioning module, a dual-winch balancing module, a mode synchronization switching module, and a status monitoring module. Specifically, the elastic deformation compensation module provides real-time feedforward compensation for the elastic deformation of the wire rope; the depth tension adjustment module dynamically sets the reference pre-tensioning force of the winch based on the construction depth; the ground linkage pre-tensioning module dynamically fine-tunes the reference pre-tensioning force according to ground characteristics to match the tension requirements of different ground layers; the dual-winch balancing module enables independent tension balancing control of the two winches; the mode synchronization switching module enables shock-free synchronous switching between the winch retraction / unwinding actions and the milling head feed mode; and the status monitoring module monitors the health status of the wire rope online and issues early warnings.

[0011] Preferably, the track chain includes several drag chains that are sequentially hinged end to end by chain plates; each of the two winches includes several motor reducers, a drum, and a guide mechanism; each of the several motor reducers is used to drive the corresponding winch to rotate; the drum is used to wind and store the track chain, and the top and bottom of the drum are respectively detachably mounted with semi-circular plates; the guide mechanism is used to guide the track chain to extend to the milling head after it is released from the drum.

[0012] Preferably, the drive unit includes a servo proportional valve connected to each of the two winches in a one-to-one correspondence, a tension sensor disposed on the straight section of the wire rope, an angle encoder coaxially disposed on the winch shaft, and an accumulator buffer circuit; the servo proportional valve is used to control the rotation speed and output torque of the winch; the tension sensor is used to detect the real-time tension of the wire rope; the angle encoder is used to detect the rotation angle of the winch to obtain the real-time rotational speed of the winch and the lowering length of the track chain; the accumulator buffer circuit is used to absorb the instantaneous impact load during the milling process.

[0013] Preferably, the mode synchronization switching module has built-in feed mode synchronization logic and impact suppression logic; the feed mode synchronization logic is configured to control the winch to synchronously adjust the take-up and release speed of the track chain when the milling head switches to different feed modes; the impact suppression logic is configured to maintain the tension fluctuation of the track chain not exceeding a preset threshold through the coordinated adjustment of the accumulator buffer circuit and the servo proportional valve when the milling head switches to different feed modes.

[0014] Preferably, the depth tension adjustment module incorporates depth segmentation adjustment logic and tension closed-loop control logic; the depth segmentation adjustment logic is configured to divide the reference preload of the track chain into multiple adjustment intervals according to different construction depths, and output the reference preload value corresponding to the depth and transmit it to the formation linkage preload module; the tension closed-loop control logic is configured to dynamically adjust the output torque of the winch in conjunction with the real-time feedback of the tension sensor to maintain the minimum tension of the oil pipe cable in the track chain.

[0015] Preferably, the formation linkage pre-tightening module incorporates formation matching logic and pre-tightening force adaptive adjustment logic; the formation matching logic is configured to receive the formation identification signal from the control system and automatically match the pre-tightening force correction coefficient for the corresponding formation; the pre-tightening force adaptive adjustment logic is configured to dynamically fine-tune the pre-tightening force parameters of the winch to the track chain based on the reference pre-tightening force value and combined with the real-time torque fluctuation of the milling wheel, through the pre-tightening force correction coefficient, in order to adapt to changes in local formation characteristics.

[0016] Preferably, the elastic deformation compensation module incorporates an elastic deformation pre-calculation model and feedforward compensation logic, wherein the elastic deformation pre-calculation model is... The feedforward compensation logic is configured to pre-calculate the elastic deformation of the wire rope based on the real-time tension and effective suspension length of the wire rope, and to perform reverse compensation on the winch's winding and unwinding commands.

[0017] Preferably, the dual-winch equalization module incorporates a power deviation rate calculation model and tension equalization adjustment logic, wherein the power deviation rate calculation model is as follows: The tension balancing adjustment logic is configured to automatically adjust the output torque of the winch on the corresponding side when the power deviation rate of the two milling wheels exceeds a preset threshold, so that the tension difference of the rail chains on both sides is controlled within a preset range, so as to counteract the eccentric torque generated by the asymmetrical strata on the milling head.

[0018] Preferably, the state monitoring module incorporates a layered deformation model and an equivalent elastic modulus identification model; the layered deformation model is... The equivalent elastic modulus identification model is: The status monitoring module is configured to inject step displacement excitation into the winch using the reset gap of the lifting cylinder, collect tension change data and calculate the current equivalent elastic modulus of the track chain, and issue a replacement warning when the equivalent elastic modulus drops to a preset threshold.

[0019] A method for controlling high-torque modular track chain tube winding using a dual-wheel milling system, comprising the following steps:

[0020] S1: The controller completes the self-test of each sensor, communication link detection, actuator calibration, and loading of control parameters and safety thresholds. After the self-test and calibration are completed, it enters the standby state.

[0021] S2: The controller controls the drive unit to drive the winch to operate, so that the track chain and the dual-wheel milling micro-feed device can synchronously lower the milling action of the milling head; at the same time, the formation linkage pre-tightening module receives the formation identification signal from the control system and automatically matches the pre-tightening force correction coefficient of the corresponding formation.

[0022] S3: The controller activates the elastic deformation compensation module, which compensates for the elastic deformation of the wire rope in real time through the elastic deformation pre-calculation model and feedforward compensation logic; at the same time, it activates the depth tension adjustment module and the stratum linkage pre-tightening module to dynamically adjust the output torque of the winch, so that the track chain maintains the predetermined minimum tension and adapts to changes in stratum characteristics.

[0023] S4: The dual winch equalization module monitors the power deviation rate of the two milling wheels in real time. When the power deviation rate exceeds the preset threshold, it automatically adjusts the output torque of the winch on the corresponding side to control the tension difference of the rail chains on both sides within the preset range, so as to offset the eccentric torque generated by the tension difference of the rail chains on both sides due to the asymmetrical strata on the milling head.

[0024] S5: When the milling head switches between different feed modes, the mode synchronization switching module executes the feed mode synchronization logic and impact suppression logic, controls the winch to synchronously adjust the winding and unwinding speed of the track chain, and adjusts in coordination with the accumulator buffer circuit and the servo proportional valve to suppress the tension fluctuation of the track chain within a preset threshold during the switching process.

[0025] S6: The status monitoring module uses the reset gap of the lifting cylinder to control the winch to output a small step displacement, collect the tension change data of the wire rope and calculate the current equivalent elastic modulus of the wire rope in the track chain; when the equivalent elastic modulus drops to a preset threshold, a replacement warning is issued.

[0026] Beneficial effects:

[0027] 1. This invention, through a depth tension adjustment module, can establish graded pre-tension control based on the construction depth, ensuring that the wire rope within the track chain is always kept at the minimum tension state that just offsets the entire self-weight of the track chain and the oil pipeline cable. At the same time, the oil pipeline cable only retracts and extends synchronously with the track chain without bearing any axial tensile force. This not only reduces the risk of fatigue fracture of the wire rope but also avoids irreversible tensile deformation and inner layer damage of the oil pipeline cable, significantly extending the service life of the oil pipeline cable.

[0028] 2. This invention, through its elastic deformation compensation module, can dynamically feedforward compensate for the elastic deformation of the wire rope in real time. This effectively counteracts the elastic expansion and contraction effect of the wire rope caused by sudden changes in formation resistance and instantaneous displacement fluctuations when the milling head is switched between feed modes. It not only controls the tracking error of the track chain within a preset range and solves the problems of loosening, tangling, knotting, or excessive pulling and breakage of oil pipe cables, but also avoids unexpected interruptions in on-site construction and ensures the operational efficiency of continuous construction in ultra-deep formations.

[0029] 3. This invention can receive the running status data of the milling wheels in real time through the dual winch equalization module, and automatically adjust the output torque of the corresponding side winch based on the power deviation rate of the left and right milling wheels. This can control the tension difference of the two side tracks within a preset range, thereby actively counteracting the additional eccentric torque formed on the milling head by the large tension difference of the oil pipeline cables on both sides during ultra-deep strata construction. This helps the milling head to always maintain the preset feed direction and reduce the tilting deviation of the milling head, thereby improving the verticality of the trench.

[0030] 4. This invention, through a mode synchronization switching module, can adjust the winch winding speed and maintain constant track chain tension in advance when the winch and lifting cylinder cooperate to switch the feed mode of the milling head. This eliminates the instantaneous impact load generated by the milling head when switching feed modes, thereby avoiding the pulling damage to the oil pipe and cable in the track chain. This not only improves the service life and reliability of the oil pipe and cable, but also ensures the continuity and safety of construction during the mode switching process.

[0031] 5. This invention, through a condition monitoring module, utilizes the no-load reset gap of the lifting cylinder to control the winch output of minute step displacement excitation and collect changes in wire rope tension. This allows for online identification of the equivalent elastic modulus of the wire rope, and based on the attenuation of the equivalent elastic modulus, it can predict the degree of fatigue damage to the wire rope in advance. This enables a shift in equipment maintenance from post-fault repair to pre-prevention maintenance, not only reducing subsequent operation and maintenance costs but also effectively preventing major safety accidents caused by sudden wire rope breakage. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the structure of a twin-wheel groove milling machine according to an embodiment of the present invention;

[0034] Figure 2This is a schematic diagram of the winch structure from a first-view perspective in a dual-wheel milling high-torque modular track chain reeling system according to an embodiment of the present invention;

[0035] Figure 3 This is a schematic diagram of the winch structure in a dual-wheel milling high-torque modular track chain reel system according to an embodiment of the present invention from a second-view perspective.

[0036] Figure 4 This is a schematic diagram of the winch structure in a dual-wheel milling high-torque modular track chain reeling system according to an embodiment of the present invention, viewed from a third-person perspective.

[0037] Figure 5 This is an exploded view of the winch and semi-circular plate in a dual-wheel milling high-torque modular track chain reel system according to an embodiment of the present invention;

[0038] Figure 6 This is a flowchart illustrating the steps of a dual-wheel milling high-torque modular track chain tube winding control method according to an embodiment of the present invention.

[0039] In the diagram: 1-Micro-feed device for dual-wheel milling; 2-Milling head; 3-Catalog; 4-Windlass; 5-Wire rope; 6-Drag chain; 7-Motor reducer; 8-Drum; 9-Semi-circular plate; 10-Guide mechanism. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0041] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0042] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0043] In the description of this application, it should be noted that the use of terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" to indicate orientation or positional relationships is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationships commonly used when the product is in use. These terms are used solely for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the use of terms such as "first" and "second" in the description of this application is only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0044] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this application does not imply that the component is required to be absolutely horizontal or suspended, but rather that it may be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but rather that it may be slightly tilted.

[0045] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0046] Example 1:

[0047] This invention proposes a dual-wheel milling high-torque modular track chain tube winding system.

[0048] In one embodiment of the present invention, the dual-wheel milling high-torque modular track chain tube winding system is used in conjunction with the dual-wheel milling micro-feed device 1 to control the operation of the milling head 2. The dual-wheel milling micro-feed device 1 includes a control system and a lifting cylinder, including a controller and an execution unit, a drive unit and a sensing unit that are communicatively connected to the controller.

[0049] The execution unit is used to retract and carry the track chain 3. The execution unit includes two winches 4 symmetrically arranged on the double wheel milling machine frame. The drive unit is used to collect the operating data of the winches 4 and adjust the speed and output torque of the winches 4 according to the instructions of the controller. The sensing unit is used to collect the tension of the wire rope 5, the rotation angle of the winches 4 and the operating status data of the milling wheel and transmit them to the controller.

[0050] The controller incorporates an elastic deformation compensation module, a depth tension adjustment module, a ground linkage pre-tensioning module, a dual-winch balancing module, a mode synchronization switching module, and a status monitoring module. Specifically, the elastic deformation compensation module provides real-time feedforward compensation for the elastic deformation of the wire rope 5; the depth tension adjustment module dynamically sets the reference pre-tension force of the winch 4 based on the construction depth; the ground linkage pre-tensioning module dynamically fine-tunes the reference pre-tension force according to ground characteristics to match the tension requirements of different ground layers; the dual-winch balancing module enables independent tension balancing control of the two winches 4; the mode synchronization switching module enables shock-free synchronous switching between the winch 4's winding and unwinding actions and the milling head 2's feed mode; and the status monitoring module monitors the health status of the wire rope 5 online and issues early warnings.

[0051] It should be noted that, as Figure 1 As shown, the micro-feed device 1 for the dual-wheel milling machine in this embodiment can be the micro-feed device 1 for the dual-wheel milling machine disclosed in the applicant's patent with publication number CN106245698A. The micro-feed device 1 for the dual-wheel milling machine uses a hollow mast as the basic carrier. A crane is set at the top of the mast. A guide pulley and a transition pulley are set on the crane. A lifting cylinder is set in the cavity inside the mast. An intermediate pulley is set at the power output end of the lifting cylinder. The device can drive the intermediate pulley to move up and down through the lifting cylinder. Together with the hoist's winding and unwinding action, it can realize the milling head 2's feed milling of the stratum.

[0052] Working Principle: During construction in ultra-deep hard rock formations, this invention, through a controller and its communication-connected execution, drive, and sensing units, can collect real-time multi-source working condition data, including the real-time tension of the wire rope 5 within the track chain 3, the rotational speed of the winch 4, the operating power of the milling wheel, and the overall formation identification signal. After collaborative analysis and calculation by multiple functional modules built into the controller, precise control commands are sent to the drive unit to independently adjust the winding and unwinding speeds and output torques of the left and right winches 4. This achieves dynamic adaptive matching and follow-up synchronous control of the track chain 3 tension, effectively solving the problems of high-tension breakage of the wire rope 5, irreversible deformation of the tubing, amplification of trenching errors due to asymmetrical formation eccentric torque, and poor follow-up accuracy caused by the inability to compensate for elastic deformation in existing pipe winding systems.

[0053] Specifically, such as Figures 1 to 5As shown, during operation, the present invention firstly uses the sensing unit as the signal acquisition entry point of the system to continuously collect three core data types: the real-time tension of the wire rope 5 within the track chain 3, the rotation angle of the winch 4, and the operating status of the milling wheel. These data are then integrated into a unified format multi-source dataset and transmitted to the controller. Next, the controller, as the core computing hub, processes different types of working condition data through its six built-in functional modules and outputs corresponding control commands to the drive unit. Subsequently, the drive unit adjusts the rotational speed and output torque of the two winches 4 in real time according to the controller's commands, thereby driving the execution unit to complete the synchronous winding and unwinding of the track chain 3. Finally, the sensing unit continuously collects the adjusted operating status data and transmits it back to the controller, thus achieving closed-loop correction of the entire control process of the hose reel system of the present invention.

[0054] Furthermore, this invention can compensate for the elastic expansion and contraction of the wire rope 5 inside the track chain 3 in real time through the built-in elastic deformation compensation module; it can dynamically match the minimum tension of the oil pipe cable in the track chain 3 through the depth tension adjustment module and the ground linkage pre-tightening module; it can actively counteract the eccentric torque generated by asymmetrical ground through the double winch balancing module; it can eliminate the impact load when switching feed modes through the mode synchronization switching module; and it can realize preventive maintenance of the wire rope 5 through the status monitoring module. Thus, it can ensure that the track chain 3 can achieve stable, accurate and continuous winding and unwinding operations under ultra-deep and complex ground conditions, significantly improving the service life of the oil pipe cable in the track chain 3 and the trenching quality during construction.

[0055] Furthermore, addressing the problem of high-tension fracture and irreversible deformation of the tubing caused by the integral structure of the wire rope 5 in the existing pipe winding system during ultra-deep strata construction, this invention employs two symmetrically arranged winches 4, each capable of receiving independent commands from the controller and adjusting its own rotation speed and output torque without interference. Simultaneously, in conjunction with the depth tension adjustment module built into the controller, it is possible to establish graded pre-tension control of the wire rope 5 within the track chain 3 based on the construction depth. The theoretical total weight of the track chain 3 and the oil pipe cable is dynamically calculated based on the lowering length of the track chain 3, thereby adjusting the output torque of the winch 4 in real time. This ensures that the wire rope 5 inside the track chain 3 is always kept at the minimum tension state that just offsets the total weight of the track chain 3 and the oil pipe cable. This avoids the loosening of the track chain 3 due to insufficient tension and eliminates the drawback of the wire rope 5 being under high tension and heavy load far exceeding its own weight in the traditional fixed tension mode. This reduces the risk of fatigue fracture of the wire rope 5 from the root. At the same time, the oil pipe cable is run through the cavity in the middle of the track chain 3 and moves synchronously with the track chain 3 body without bearing any axial tensile force. This effectively avoids irreversible tensile deformation and inner layer damage, and significantly extends the service life of the oil pipe cable.

[0056] Understandably, to address the problem of poor follow-up accuracy of oil pipe cables in existing pipe winding systems due to the lack of consideration for the elastic deformation characteristics of the wire rope 5, this invention utilizes an elastic deformation compensation module to provide real-time dynamic feedforward compensation for the elastic deformation of the wire rope 5. Specifically, the sensing unit can collect real-time data on the tension and lowering length of the wire rope 5, enabling the controller to dynamically calculate the elastic deformation of the wire rope 5 under different operating conditions. This data is then used to correct the winding and lowering commands of the winch 4, effectively offsetting the instantaneous displacement fluctuations of the milling head 2 caused by sudden changes in formation resistance and feed mode switching. The elastic stretching effect of the wire rope 5 can control the tracking error of the oil pipe and cable within a preset range. This effectively solves the problems of loosening, slackness, or even tangling of the oil pipe and cable caused by the inability of the existing pipe winding system to dynamically compensate for the elastic deformation of the wire rope 5, or the problem of damage and breakage of the oil pipe and cable due to excessive tension of the wire rope 5. This not only reduces unexpected interruptions in on-site construction and ensures the efficiency of continuous construction in ultra-deep formations, but also slows down the fatigue aging process of oil pipes and cables, reducing the probability of equipment failure and subsequent maintenance costs.

[0057] It is worth noting that, in response to the problem that existing pipe-winding systems generate eccentric torque and amplify trenching errors due to the tension difference between the two sides during construction in asymmetrical strata, this invention uses a dual-winch equalization module to receive the running status data of the milling wheels in real time and automatically adjust the output torque of the corresponding side winch 4 based on the power deviation rate of the left and right milling wheels. This allows the tension difference between the two side rail chains 3 to be controlled within a preset range, thereby actively counteracting the additional eccentric torque generated by the large tension difference between the oil pipe cables on both sides on the milling head 2 during ultra-deep strata construction. This helps the milling head 2 to always maintain the preset feed direction and reduce the tilting deviation of the milling head 2, thereby improving the verticality of the trenching.

[0058] Furthermore, this invention also enables shock-free synchronization of the winch 4's winding and unwinding actions with the milling head 2's feed mode through a mode synchronization switching module. Specifically, when the winch and lifting cylinder work together to switch the milling head 2's feed mode, the controller issues control commands through the mode synchronization switching module. The drive unit adjusts the winch 4's winding and unwinding speed in advance and maintains a constant tension in the track chain 3, thereby eliminating the instantaneous impact load generated when the milling head 2 switches feed modes, thus avoiding pulling damage to the oil pipes and cables inside the track chain 3. Simultaneously, the controller, relying on the status monitoring module, uses the no-load reset gap of the lifting cylinder to control the winch 4 to output a small step displacement excitation, and uses the sensing unit to collect the tension changes of the wire rope 5. This allows for online identification of the wire rope 5's equivalent elastic modulus, enabling the prediction of the wire rope 5's fatigue damage level based on the attenuation of the equivalent elastic modulus. This transforms equipment maintenance from post-fault repair to pre-prevention maintenance, improving construction continuity and reducing subsequent operation and maintenance costs.

[0059] Example 2:

[0060] This embodiment further refines and defines the specific structure of the execution unit based on Embodiment 1. Specifically, as follows: Figures 1 to 5 As shown, the track chain 3 includes several drag chains 6 that are hinged end to end by chain plates; both winches 4 include several motor reducers 7, drums 8 and guide mechanisms 10; the several motor reducers 7 are used to drive the corresponding winches 4 to rotate; the drums 8 are used to wind and store the track chain 3, and semi-circular plates 9 are detachably installed on the top and bottom of the drums 8 respectively; the guide mechanism 10 is used to guide the track chain 3 to connect with the milling head 2 after it is released from the drums 8.

[0061] In this embodiment, the track chain 3 adopts a segmented modular structure, specifically composed of several standard-length drag chains 6 hinged end-to-end by high-strength chain plates. The length of a single drag chain 6 can be set according to transportation requirements, and each drag chain 6 is independently equipped with a steel wire rope 5 and an oil pipe cable. The steel wire ropes 5 between adjacent drag chains 6 are connected by a dedicated connector, and the oil pipe cables are connected by quick connectors. This segmented design allows the track chain 3 to be transported in sections, and the weight and dimensions of each drag chain 6 meet road transport standards, enabling equipment relocation without disassembling the drum 8. Furthermore, when a drag chain 6 or its internal steel wire rope 5 or oil pipe cable is damaged, only the corresponding drag chain 6 section needs to be replaced, without replacing the entire track chain 3, significantly reducing maintenance costs and downtime. In addition, the hinged structure of the segmented track chain 3 can better adapt to the winding curvature of the drum 8, reducing bending stress during the winding and unwinding process of the track chain 3, further extending its service life.

[0062] Meanwhile, the winch 4 adopts a multi-motor reducer 7 parallel drive design, meaning that each winch 4 is equipped with multiple motor reducers 7 of the same specifications. The output shafts of all motor reducers 7 are connected to the rotating shaft of the drum 8 to jointly drive the drum 8 to rotate. This multi-motor parallel drive method has significant technical advantages: First, by combining multiple low-power motor reducers 7, high torque output can be achieved to meet the heavy-load winding and unwinding requirements of the track chain 3 during ultra-deep construction, while avoiding the problems of excessive size and difficult installation of a single high-power motor reducer 7; Second, the multi-motor parallel drive has a redundancy design. When one motor reducer 7 fails, the remaining motor reducers 7 can still temporarily drive the winch 4 to complete the current work cycle, avoiding significant losses caused by the milling head 2 getting stuck underground due to a sudden failure; Finally, the output torque of the multi-motor reducers 7 can be independently adjusted by the controller, enabling more precise control of the output torque and speed of the drum 8, providing hardware support for subsequent tension balance control. In addition, after the track chain 3 is released from the drum 8, it can be guided by the guide mechanism 10 to extend along the preset path to the milling head 2. The guide mechanism 10 can be a roller, and its outer wall has a groove for accommodating the track chain 3, thereby ensuring the stability and accuracy of the track chain 3's winding and unwinding.

[0063] Furthermore, the drum 8 adopts a split-type structural design. Its main body is a cylindrical cylinder, with semi-circular plates 9 detachably installed at the top and bottom of the cylinder via bolts. The two semi-circular plates 9 are spliced ​​with the cylinder to form a complete drum 8. When the drum 8 needs to be transported, the transport personnel only need to remove the top and bottom semi-circular plates 9 to lower the overall height of the drum 8 to within the height limit range, fully meeting the height limit requirements for road transport. There is no need to disassemble the main body of the drum 8 and the track chain 3 wound on it, which greatly shortens the disassembly and assembly time of the equipment during relocation. At the same time, the split semi-circular plate 9 design also facilitates the processing, manufacturing and subsequent maintenance of the drum 8. When the semi-circular plate 9 is worn or deformed, only the corresponding semi-circular plate 9 needs to be replaced, without replacing the entire drum 8.

[0064] Example 3:

[0065] This embodiment, based on Embodiment 2, further refines and defines the specific composition, working principle, and collaborative relationship of the driving unit and the sensing unit. Specifically, as follows: Figures 1 to 5 As shown, the drive unit includes a servo proportional valve connected one-to-one with the two winches 4, a tension sensor installed on the straight section of the wire rope 5, an angle encoder coaxially installed on the shaft of the winch 4, and an accumulator buffer circuit. The servo proportional valve is used to control the rotation speed and output torque of the winch 4. The tension sensor is used to detect the real-time tension of the wire rope 5. The angle encoder is used to detect the rotation angle of the winch 4 to obtain the real-time rotation speed of the winch 4 and the lowering length of the track chain 3. The accumulator buffer circuit is used to absorb the instantaneous impact load during the milling process.

[0066] In this embodiment, the servo proportional valve in the drive unit can be a high-frequency electro-hydraulic servo proportional valve, which features a fast response time and high flow regulation accuracy. This allows for precise control of the hydraulic oil flow and pressure entering the motor reducer 7 based on analog commands issued by the controller, thereby achieving stepless continuous adjustment of the winch 4's speed and output torque, and effectively ensuring that the controller's control commands can be executed quickly and accurately. Furthermore, each winch 4 is equipped with an independent servo proportional valve. The two servo proportional valves do not interfere with each other and can each receive independent commands from the controller, thus providing hardware support for independent tension control of the two winches 4.

[0067] Meanwhile, the tension sensor can be an S-type tension / compression sensor, which is installed in series in the straight section of the wire rope 5 inside the track chain 3, specifically in the vertical section between the connection point of the track chain 3 and the milling head 2. This avoids the influence of the bending deformation of the wire rope 5 and the frictional resistance of the guide wheel on the measurement results, allowing the tension sensor to directly detect the axial tension of the wire rope 5. This provides core data input for the tension closed-loop control of the depth tension adjustment module, the deformation calculation of the elastic deformation compensation module, and the identification of the equivalent elastic modulus of the state monitoring module.

[0068] Furthermore, the angle encoder can be a high-precision absolute encoder, coaxially fixed to the non-drive end of the winch 4 shaft, thus enabling real-time detection of the winch 4's rotation angle and direction. The controller, based on the rotation angle data collected by the angle encoder and combined with the diameter of the drum 8 and the number of winding layers, can accurately calculate the real-time rotational speed of the winch 4 and the cumulative lowering length of the track chain 3. This length data can be used not only for the depth segmentation control of the depth tension adjustment module but also, combined with the tension data of the wire rope 5, to provide effective suspension length parameters for the elastic deformation compensation module, thereby ensuring the accuracy of the calculation of the elastic deformation of the wire rope 5.

[0069] The accumulator buffer circuit is connected in parallel in the hydraulic circuit between the servo proportional valve and the motor reducer 7. A bladder-type accumulator can be used. When the milling head 2 cuts into hard rock or the formation resistance changes abruptly, an instantaneous impact load will be generated, causing the pressure in the hydraulic circuit to rise instantaneously. At this time, the accumulator can quickly absorb the excess pressure oil and buffer the pressure impact. When the oil circuit pressure decreases, the accumulator releases the stored pressure oil to replenish the oil circuit flow and maintain the system pressure stability, thereby effectively protecting the wire rope 5, oil pipe cable and hydraulic components from impact damage. At the same time, in conjunction with the impact suppression logic of the mode synchronization switching module, the tension fluctuation during the feed mode switching process is further reduced.

[0070] Example 4:

[0071] This embodiment, based on embodiment 3, further refines and defines the specific control logic, workflow, and collaborative relationship of the mode synchronization switching module and depth tension adjustment module built into the controller. Specifically, as follows: Figures 1 to 5 As shown, the mode synchronization switching module has built-in feed mode synchronization logic and impact suppression logic. The feed mode synchronization logic is configured to control the winch 4 to synchronously adjust the take-up and release speed of the track chain 3 when the milling head 2 switches to different feed modes. The impact suppression logic is configured to maintain the tension fluctuation of the track chain 3 not exceeding the preset threshold through the accumulator buffer circuit and the servo proportional valve in coordination when the milling head 2 switches to different feed modes.

[0072] In this embodiment, the mode synchronization switching module can communicate in real time with the control system of the dual-wheel milling micro-feed device via the CAN bus, thereby obtaining the feed mode switching command and target feed speed of the milling head 2 in advance. Upon receiving the feed mode switching command, the feed mode synchronization logic controls the winch 4 to pre-adjust its take-up and release speed according to the target feed speed at a preset time. When the milling head 2 officially switches feed modes, the speed of the winch 4 is already synchronized with the feed speed of the milling head 2. After the milling head 2 completes the feed mode switch, the winch 4 enters a steady-speed following state, adjusting in real time with the feed speed of the milling head 2. This pre-synchronization control method effectively eliminates the speed difference between the winch 4 and the feed speed of the milling head 2, avoiding impact loads caused by sudden stretching or slack in the track chain 3. Furthermore, this embodiment quantifies and limits the synchronization accuracy between the speed of the winch 4 and the feed speed of the milling head 2, and establishes a feed mode synchronization speed error control formula based on the feed mode synchronization logic:

[0073]

[0074] In the formula, Let be the linear velocity (m / s) of winch 4 at time 𝑡. The feed rate (m / s) of the milling head 2 at time 𝑡 is transmitted in real time by the micro-feed device; To allow for a maximum synchronization error, the maximum speed is set to 0.005 m / s. The core innovation of this formula lies in clarifying the technical standard for shock-free synchronization between the speed of winch 4 and the feed speed of milling head 2, thus solving the defects of vague synchronization concepts and uncontrollable errors in existing technologies.

[0075] Meanwhile, the built-in impact suppression logic of the mode synchronization switching module can form a two-stage buffering mechanism with the accumulator buffer circuit: during the feed mode switching of the milling head 2, the impact suppression logic first dynamically adjusts the output torque of the winch 4 through a servo proportional valve to offset most of the tension fluctuations; the remaining instantaneous impact load is absorbed by the accumulator buffer circuit connected in parallel in the hydraulic circuit. Through this two-stage buffering mechanism, the tension fluctuations of the track chain 3 during the feed mode switching of the milling head 2 can be controlled within a reasonable range, effectively protecting the oil pipes, cables and hydraulic components in the track chain 3.

[0076] Furthermore, the depth tension adjustment module incorporates depth segmentation adjustment logic and tension closed-loop control logic. The depth segmentation adjustment logic is configured to divide the reference preload of the track chain 3 into multiple adjustment intervals based on different construction depths, and output the corresponding reference preload value for each depth, transmitting it to the formation linkage preload module. The tension closed-loop control logic is configured to dynamically adjust the output torque of the winch 4 based on real-time feedback from the tension sensor to maintain minimum tension on the oil pipe cable in the track chain 3. Further, the depth segmentation adjustment logic built into the depth tension adjustment module establishes a depth segmentation reference preload calculation formula based on the self-weight load characteristics of the track chain 3 and the oil pipe.

[0077] In the formula, For the construction depth is The reference preload (N) at that time. This is the depth segmentation correction coefficient. The mass per unit length of track chain is 3 kg / m. The total mass of the oil pipe / cable per unit length (kg / m). The acceleration due to gravity is 9.8 m / s². The actual lowering length (m) of track chain 3 is calculated in real time by the angle encoder. This formula is the first to use the self-weight of track chain 3 and oil pipe as the core calculation basis for the reference preload, which is different from the existing technology that sets a fixed tension based on experience. It ensures the accurate realization of the minimum necessary tension from the perspective of mechanical principles.

[0078] Based on the above formula, the depth segmentation adjustment logic divides the construction depth into three different adjustment ranges: 0-50m, 50m-150m, and above 150m. Each range corresponds to a different benchmark pretension calculation coefficient: 0m-50m is the shallow stratum range. Since the self-weight of the track chain 3 is relatively small, the benchmark pretension coefficient can be taken as 1.1 to ensure that the track chain 3 does not loosen; 50m-150m is the medium-deep stratum range. Since the self-weight of the track chain 3 increases significantly, the benchmark pretension coefficient is taken as 1.05 to balance the self-weight and fatigue loss; above 150m is the ultra-deep stratum range. In this range, the fatigue risk of the wire rope 5 increases sharply, and the benchmark pretension coefficient is taken as 1.0 to provide only the minimum tension force that just offsets the self-weight. The controller automatically matches the calculation coefficients for the corresponding interval based on the lowering length of the track chain 3 collected by the angle encoder, thereby calculating and outputting the reference preload value in real time. Simultaneously, the tension closed-loop control logic built into the depth tension adjustment module uses the reference preload value as the target value, combined with real-time tension data collected by the tension sensor, and dynamically adjusts the output of the servo proportional valve using a PID algorithm, ensuring that the actual tension of the track chain 3 always tracks the target value. When the real-time tension is higher than the target value, the controller reduces the output torque of the winch 4 to appropriately loosen the track chain 3; when the real-time tension is lower than the target value, the controller increases the output torque of the winch 4 to tighten the track chain 3. Understandably, this closed-loop control method can automatically compensate for tension drift caused by factors such as temperature changes and wire rope creep, ensuring that the track chain 3 is always in an optimal tension state.

[0079] Example 5:

[0080] This embodiment, based on Embodiment 4, further refines and defines the control logic, cross-system data interaction mechanism, and collaborative relationship with the depth tension adjustment module of the controller's built-in formation linkage pre-tightening module. Specifically, as follows... Figures 1 to 5 As shown, the formation linkage pre-tightening module has built-in formation matching logic and pre-tightening force adaptive adjustment logic. The formation matching logic is configured to receive the formation identification signal from the control system and automatically match the pre-tightening force correction coefficient of the corresponding formation. The pre-tightening force adaptive adjustment logic is configured to dynamically fine-tune the pre-tightening force parameters of the winch 4 to the rail chain 3 based on the reference pre-tightening force value and combined with the real-time torque fluctuation of the milling wheel, so as to adapt to the local characteristics of the formation.

[0081] In this embodiment, to achieve precise quantitative matching between tension and formation characteristics, a formula for calculating the final preload of the formation linkage is established:

[0082]

[0083] In the formula, for Time, Depth The final output preload (N) at the point. This is a macroscopic formation correction factor, matched by the overall formation identification signal. The local torque adaptive correction coefficient is calculated dynamically in real time. The depth reference preload (N) is calculated in Example 4. This formula is the first to construct a three-level tension calculation model of depth reference, formation correction and torque fine adjustment, which is different from the coarse adjustment method of single depth variable in the existing technology and realizes the fusion control of multi-source working condition data.

[0084] The formation matching logic communicates in real time with the dual-wheel milling machine control system via the CAN bus, directly receiving the macroscopic formation identification signal output by the machine and automatically matching the preload correction coefficient for the corresponding formation. The correction coefficient is based on the reference preload value output by the depth tension adjustment module in Example 4, and is set according to the hardness classification of the strata: the correction coefficient for hard rock strata is 1.05-1.1, which appropriately increases the tension to counteract the vibration of the milling head 2; the correction coefficient for ordinary soil strata is 1.0, which maintains the reference preload; the correction coefficient for soft plastic clay strata is 0.95-1.0, which reduces the tension to reduce the loss of the wire rope 5; and the correction coefficient for boulders and fractured zones is 1.1-1.15, which strengthens the tension to prevent the track chain 3 from derailing.

[0085] The preload adaptive adjustment logic compensates for the lag in macroscopic formation identification, enabling real-time response to local formation changes. The controller collects cutting torque data from the left and right milling wheels in real time and establishes a formula for calculating the milling wheel torque fluctuation coefficient.

[0086]

[0087] In the formula, for The milling wheel torque fluctuation coefficient at any given time; For the first Milling wheel torque values ​​(N·m) at each sampling point; The average milling wheel torque per unit time (N·m); The value is the number of sampling points per unit time, set to 100 (corresponding to a sampling frequency of 100Hz). This formula is the first to use the torque fluctuation coefficient as a quantitative basis for determining local abrupt changes in the formation, overcoming the shortcomings of existing technologies that can only qualitatively determine formation changes and have adjustment lags.

[0088] Based on the torque ripple coefficient, a piecewise function for local torque adaptive correction coefficients is established:

[0089]

[0090] Existing macroscopic stratigraphic matching logic relies on pre-surveyed geological reports or lagging stratigraphic identification results from the entire system. This typically only reflects the overall characteristics of the stratigraphy at a scale of tens or even hundreds of meters, failing to identify and respond to local stratigraphic abrupt changes at the meter or even centimeter level (such as isolated boulders, hard rock protrusions, soft soil interlayers, and the edges of karst caves). In contrast, this piecewise function, by calculating the fluctuation characteristics of the milling wheel torque in real time, can quickly identify local stratigraphic changes and automatically output corresponding correction coefficients, thereby enabling dynamic fine-tuning of the final preload.

[0091] It should be noted that, based on big data statistics from hundreds of diaphragm wall construction projects in China, the milling wheel torque fluctuation coefficient in this piecewise function is typically less than 10% when the strata are uniform and stable. When the fluctuation coefficient exceeds 15%, it can be determined that there is a local strata abrupt change. Therefore, the threshold for the torque fluctuation coefficient is set to [value missing]. This threshold ensures both the accuracy of identification and avoids false triggering caused by normal vibration of the milling wheel. In addition, engineering verification shows that the change in track chain tension demand caused by local geological abrupt changes is usually within 5%. Too large a correction range will cause system oscillation, while too small a range will not be able to effectively cope with abrupt changes. Therefore, the correction range is ±5%.

[0092] When torque fluctuations exceed a preset 15% threshold, the controller automatically performs dynamic fine-tuning within a range of ±5% based on the current correction coefficient. This embodiment utilizes a two-stage tension adjustment mechanism—macro-stratum matching and micro-torque adaptation—combined with the aforementioned quantitative calculation formula, to achieve precise matching of tension and stratum characteristics based on the depth segmentation benchmark. This ensures the operational stability of the track chain 3 during complex stratum construction while preventing the wire rope 5 from being under long-term overload, further extending the service life of the wire rope 5 and the oil pipeline cable. Simultaneously, this stratum linkage pre-tensioning module can be used in conjunction with the dual-winch balance module to independently adjust the stratum adaptation of the track chains 3 on both sides of the milling head 2, improving adaptability to asymmetrical stratum conditions.

[0093] Example 6:

[0094] This embodiment, based on Embodiment 5, further refines and defines the core calculation model, feedforward compensation logic, and collaborative working mechanism with other modules of the controller's built-in elastic deformation compensation module. Specifically, as follows... Figures 1 to 5 As shown, the elastic deformation compensation module incorporates an elastic deformation pre-calculation model and feedforward compensation logic. The elastic deformation pre-calculation model is... The feedforward compensation logic is configured to pre-calculate the elastic deformation of the wire rope 5 based on the real-time tension and effective suspension length of the wire rope 5, and to perform reverse compensation on the winding and unwinding commands of the winch 4.

[0095] The elastic deformation pre-calculation model in this embodiment Based on Hooke's Law, the wire rope 5 was customized to meet the stress characteristics of the wire rope 5: the wire rope 5 inside the track chain 3 only bears the weight of the track chain 3 and the oil pipe cable, and is not affected by the main cutting load. Its elastic deformation is only caused by the change of axial tension and the change of suspension length. Therefore, Hooke's Law has extremely high applicability.

[0096] In the formula, The real-time elastic deformation of wire rope 5 (m); The real-time axial tension (N) of wire rope 5 is collected in real time by a tension sensor installed on the straight section in Example 3 at a frequency of 100Hz, and the final preload output by the ground linkage preload module in Example 5 is directly adopted. As input for calculation; The effective suspension length (m) of the wire rope 5 is accurately calculated by real-time acquisition of the winch 4 rotation angle by the coaxially mounted angle encoder in Example 3, combined with the drum 8 diameter and the number of winding layers. The equivalent elastic modulus (Pa) of wire rope 5 is initially determined by the factory parameters of wire rope 5 and is subsequently identified and updated online by the condition monitoring module. The effective cross-sectional area (m²) of wire rope 5 is a fixed parameter determined by the type of wire rope 5. This calculation model differs from existing technologies that only use fixed deformation coefficients for approximate estimation. For the first time, it uses real-time dynamic tension and real-time effective suspension length as core calculation variables for elastic deformation, which can accurately reflect the actual elastic deformation of wire rope 5 under different construction depths and different geological conditions.

[0097] Based on the above pre-calculation model, the calculation formula for the feedforward compensation of winch 4 is established as follows:

[0098]

[0099] In the formula, The feedforward compensation displacement (m) that winch 4 needs to perform at time t. This represents the elastic deformation (m) from the previous control cycle. When When the elongation is greater than 0, it indicates that the elastic elongation of the wire rope 5 has increased, and the winch 4 needs to release an additional length of wire rope 5 to compensate; when When the value is less than 0, it indicates that the elastic elongation of the wire rope 5 has decreased, and the winch 4 needs to retract the corresponding length of the wire rope 5 for compensation. In addition, the controller converts the compensation displacement into a speed compensation command for the winch 4, which can be superimposed with the basic winding and unwinding speed command output by the depth tension adjustment module and then sent to the servo proportional valve in Embodiment 3 for execution, thereby realizing real-time reverse correction of the winding and unwinding length of the winch 4.

[0100] It should be noted that the feedforward compensation logic in this embodiment is a pure feedforward control, which can perform compensation in advance without waiting for displacement deviation to occur. At the same time, in order to eliminate model errors caused by factors such as wire rope creep and temperature changes, the feedforward compensation logic retains a small closed-loop correction step: when the tension sensor detects that the deviation between the actual tension and the target tension exceeds 1%, it can automatically make fine adjustments to the compensation amount within ±2% to ensure compensation accuracy.

[0101] Understandably, this embodiment, through the combination of an elastic deformation pre-calculation model and real-time feedforward compensation logic, can precisely control the follow-up error of the track chain 3 within a preset range. This not only effectively solves the problems of slackness, loosening, and tangling of the oil pipeline cable caused by the elastic expansion and contraction of the wire rope 5, but also avoids damage and breakage of the oil pipeline cable due to excessive pulling, significantly reducing unexpected interruptions in on-site construction and ensuring the operational efficiency of continuous construction in ultra-deep formations. Simultaneously, this elastic deformation compensation module can work in conjunction with the mode synchronization switching module, enabling synchronous elastic deformation compensation during feed mode switching, further eliminating the impact of switching shocks on follow-up accuracy.

[0102] Example 7:

[0103] This embodiment, based on Embodiment 6, further refines and defines the core calculation model, tension equalization adjustment logic, and collaborative working mechanism with other modules of the controller's built-in dual-winch equalization module. Specifically, as follows... Figures 1 to 5 As shown, the dual-winch equalization module has a built-in power deviation rate calculation model and tension equalization adjustment logic. The power deviation rate calculation model is as follows: The tension balancing adjustment logic is configured to automatically adjust the output torque of the corresponding side winch 4 when the power deviation rate of the two milling wheels exceeds a preset threshold, so that the tension difference of the two side rail chains 3 is controlled within a preset range to counteract the eccentric torque generated by the asymmetrical strata on the milling head 2.

[0104] The power deviation rate calculation model in this embodiment Based on the positive correlation between milling wheel cutting power and formation cutting resistance, this method can predict the generation of asymmetric formations in advance, which is different from the existing technology that relies solely on tension feedback for hysteresis adjustment.

[0105] In the formula, The real-time power deviation rate (%) of the left and right milling wheels; , These are the real-time input power (kW) of the left and right milling wheels, respectively, transmitted in real-time by the dual-wheel milling machine control system via the CAN bus. > When this occurs, it is determined that there is an asymmetric formation condition, triggering the tension balance adjustment logic.

[0106] To quantify the degree of tension imbalance on both sides of track chain 3, a formula for calculating the real-time tension difference is established:

[0107]

[0108] In the formula, for The tension difference (N) between the left and right sides of track chain 3 at any given time; , These are the real-time tension values ​​(N) collected by the tension sensors on the left and right sides, respectively. In this embodiment, the maximum allowable tension difference between the two track chains 3 is set to 3% of the reference preload, i.e. .

[0109] Based on the above two model calculation formulas, the tension equalization adjustment logic adopts a composite control architecture of power feedforward pre-adjustment and tension feedback fine-tuning. The specific control process is as follows: First, the depth tension adjustment module and the formation linkage pre-tightening module generate independent final reference pre-tightening forces on the left and right sides respectively according to the construction depth and formation characteristics. , This serves as the initial value for the dual winch 4-way equalization control; then, the controller collects the power of the left and right milling wheels in real time and calculates the power deviation rate. .when > Immediately, the feedforward torque correction is calculated based on the power deviation rate: the output torque of winch 4 on the side with higher power is slightly increased (the correction range is 1%-5% of the reference torque), while the output torque of winch 4 on the side with lower power is slightly decreased to offset the tension difference that is about to occur; finally, the controller calculates the tension difference of the two track chains 3 in real time. .when > At that time, the torque correction amount is finely adjusted through the tension difference closed-loop feedback logic until the tension difference falls back to the allowable range.

[0110] It should be noted that this embodiment adopts a dual-winch 4 independent control architecture, with each winch 4 receiving independent commands from the controller without interference. This architecture enables completely independent adjustment of the tension of the left and right track chains 3, which can not only counteract the eccentric torque generated by asymmetrical strata, but also compensate for the tension differences of the wire ropes 5 on both sides caused by wear, creep, and other factors. Simultaneously, this module works in conjunction with the strata linkage pre-tensioning module in Embodiment 5, enabling independent strata adaptation adjustment of the left and right track chains 3, further enhancing the system's adaptability to extremely complex strata.

[0111] Example 8:

[0112] This embodiment, based on Embodiment 7, further refines and defines the core calculation model, online identification method, and early warning aircraft manufacturing of the controller's built-in state monitoring module. Specifically, as follows... Figures 1 to 5 As shown, the state monitoring module incorporates a layered deformation model and an equivalent elastic modulus identification model; the layered deformation model is... The equivalent elastic modulus identification model is as follows: The status monitoring module is configured to inject step displacement excitation into the winch 4 using the reset gap of the lifting cylinder, collect tension change data and calculate the current equivalent elastic modulus of the track chain 3, and issue a replacement warning when the equivalent elastic modulus drops to a preset threshold.

[0113] The layered deformation model in this embodiment For the first time, the total deformation of the wire rope 5 is decomposed into three independent components, which solves the problem that the traditional single deformation model cannot accurately reflect the actual damage state of the wire rope 5. This is different from the outdated method of existing technology that can only judge the health status of the wire rope 5 through periodic manual inspection.

[0114] In the formula, The total deformation of wire rope 5 (m); The elastic deformation (m) of the 5 strands of the wire rope is proportional to the axial tension of the 5 strands of the wire rope. The compression deformation (m) of the 5 cores of the wire rope gradually increases with the increase of the service time of the wire rope 5; The residual plastic deformation (m) of wire rope 5 is caused by fatigue damage and permanent deformation, and is a core indicator reflecting the health status of wire rope 5.

[0115] The equivalent elastic modulus identification model in this embodiment Based on the above-mentioned layered deformation model, the degree of internal damage of the wire rope 5 can be indirectly reflected through changes in macroscopic mechanical properties.

[0116] In the formula, The real-time equivalent elastic modulus (Pa) of wire rope 5; The effective suspension length (m) of wire rope 5 is calculated in real time by the angle encoder; Let be the effective cross-sectional area (m²) of wire rope 5, which is a fixed parameter; The change in tension (N) of the wire rope 5 caused by step displacement excitation is obtained by the tension sensor. The step displacement (m) output by winch 4 is precisely controlled by the controller.

[0117] To achieve non-destructive online monitoring of the health status of steel wire ropes, an equivalent elastic modulus threshold early warning mechanism is established: when When the elastic modulus drops to 70% of the initial value of the wire rope 5 at the factory, the controller issues a level one warning, prompting increased daily inspections; when When the equivalent elastic modulus drops to 60% of its initial value, the controller issues a level-two warning, forcibly requiring the replacement of wire rope 5. The aforementioned 70% and 60% warning thresholds are determined based on wire rope fatigue life test data. Tests show that when the equivalent elastic modulus drops to 70% of its initial value, the remaining fatigue life of the wire rope is approximately 30% of its initial life; when it drops to 60%, the remaining fatigue life is less than 10% of its initial life, approaching the critical fracture state. Specific values ​​can be preset and calibrated in actual applications according to the wire rope model and operating conditions.

[0118] It should be noted that the online identification process of the status monitoring module is as follows: First, the status monitoring module monitors the working status of the dual-wheel milling micro-feed device in real time. When it detects that the lifting cylinder has entered the no-load reset stage, it automatically triggers the identification process. Then, the controller controls the winch 4 to output three consecutive micro-step displacements, each displacement being 5mm with an interval of 0.5 seconds. At the same time, the tension sensor synchronously collects the tension change data during each step displacement at a sampling frequency of 100Hz. Finally, the controller filters the collected data and substitutes it into the equivalent elastic modulus identification model to calculate the average value of the current equivalent elastic modulus of the wire rope 5. The average value is then compared with a preset threshold, and a corresponding warning signal is issued based on the comparison result.

[0119] This embodiment uses a lifting cylinder with no-load reset gap detection, which does not affect normal construction efficiency at all. Furthermore, the use of micro-step displacement excitation will not cause any damage to the wire rope 5 or the oil pipe cable. Simultaneously, the condition monitoring module can work in conjunction with the elastic deformation compensation module, automatically synchronizing the calculated real-time equivalent elastic modulus to the elastic deformation pre-calculation model to update the equivalent elastic modulus of the wire rope 5 in the elastic deformation pre-calculation model. This further improves the accuracy of elastic deformation compensation.

[0120] A dual-wheel milling high-torque modular track chain tube winding control method, using the dual-wheel milling high-torque modular track chain tube winding system as described in any of the preceding claims, includes the following steps:

[0121] S1: The controller completes self-tests of each sensor, communication link detection, actuator calibration, and loading of control parameters and safety thresholds. After self-tests and calibrations are completed, it enters standby mode.

[0122] S2: The controller controls the drive unit to drive the winch 4 to operate, so that the track chain 3 and the dual-wheel milling micro-feed device can synchronously lower the milling action of the milling head 2; at the same time, the formation linkage pre-tightening module receives the formation identification signal from the control system and automatically matches the pre-tightening force correction coefficient of the corresponding formation.

[0123] S3: The controller starts the elastic deformation compensation module, which compensates for the elastic deformation of the wire rope 5 in real time through the elastic deformation pre-calculation model and feedforward compensation logic; at the same time, it starts the depth tension adjustment module and the ground linkage pre-tightening module to dynamically adjust the output torque of the winch 4, so that the track chain 3 maintains the predetermined minimum tension and adapts to changes in ground characteristics.

[0124] S4: The dual winch equalization module monitors the power deviation rate of the two milling wheels in real time. When the power deviation rate exceeds the preset threshold, it automatically adjusts the output torque of the corresponding side winch 4 to control the tension difference of the two side rail chains 3 within the preset range, so as to offset the eccentric torque generated by the tension difference of the two side rail chains 3 on the milling head 2 due to the asymmetrical stratum.

[0125] S5: When the milling head 2 switches between different feed modes, the mode synchronization switching module executes the feed mode synchronization logic and impact suppression logic, controls the winch 4 to synchronously adjust the winding and unwinding speed of the track chain 3, and through the accumulator buffer circuit and the servo proportional valve, it coordinates the adjustment to suppress the tension fluctuation of the track chain 3 within the preset threshold during the switching process.

[0126] S6: The status monitoring module uses the reset gap of the lifting cylinder to control the winch 4 to output a small step displacement, collect the tension change data of the wire rope 5 and calculate the current equivalent elastic modulus of the wire rope 5 in the track chain 3; when the equivalent elastic modulus drops to the preset threshold, a replacement warning is issued.

[0127] This method enables intelligent control of the entire process of the dual-wheel milling track chain 3 pipe winding system: Through a two-stage control mechanism of depth tension adjustment and ground-linked pre-tensioning, the track chain 3 can always maintain optimal tension, avoiding both insufficient tension leading to loosening and tangling, and eliminating the risk of pipeline damage caused by excessive tension; through elastic deformation feedforward compensation technology, the elastic expansion and contraction effect of the wire rope 5 can be offset in real time, significantly improving the follow-up control accuracy of the track chain 3; through independent equalization control of the dual winches 4, the additional eccentric torque generated by asymmetrical ground can be actively offset, effectively ensuring the vertical feed state of the milling head 2 and significantly improving the trenching quality; through the non-impact synchronous switching technology of feed modes, the instantaneous impact load during mode switching can be eliminated, ensuring the continuity and safety of the construction process; through online health status monitoring technology of the wire rope 5 based on the equivalent elastic modulus, the degree of fatigue damage to the equipment can be predicted in advance, realizing the transformation of equipment maintenance from post-event repair to pre-event prevention. Overall, this method significantly improves the operational reliability, efficiency, and quality of the twin-wheel milling pipe system in ultra-deep and complex geological formations, effectively reduces equipment maintenance costs and safety risks, and better meets the construction needs of modern underground foundation engineering as it develops towards deeper and more complex directions.

[0128] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A dual-wheel milling high-torque modular track chain tube winding system, used in conjunction with a dual-wheel milling micro-feed device (1) to control the operation of the milling head (2), wherein the dual-wheel milling micro-feed device (1) includes a control system and a lifting cylinder, characterized in that, It includes a controller and an execution unit, a drive unit, and a sensing unit that are communicatively connected to the controller; The execution unit is used to retract and carry the track chain (3). The execution unit includes two winches (4) symmetrically arranged on the double wheel milling machine frame. The drive unit is used to collect the running data of the winches (4) and adjust the speed and output torque of the winches (4) according to the instructions of the controller. The sensing unit is used to collect the tension of the wire rope (5), the rotation angle of the winches (4) and the running status data of the milling wheel and transmit them to the controller. The controller has a built-in elastic deformation compensation module, a depth tension adjustment module, a ground linkage pre-tightening module, a dual winch balancing module, a mode synchronization switching module, and a status monitoring module. Among them, the elastic deformation compensation module is used to realize real-time feedforward compensation of the elastic deformation of the wire rope (5); the depth tension adjustment module is used to dynamically set the reference pre-tightening force of the winch (4) according to the construction depth; the ground linkage pre-tightening module is used to dynamically fine-tune the reference pre-tightening force according to the ground characteristics to match the tension requirements of different grounds; the dual winch balancing module is used to realize independent tension balancing control of the two winches (4); the mode synchronization switching module is used to realize the shock-free synchronous switching of the winch (4) winding and unwinding action and the milling head (2) feed mode; and the status monitoring module is used to monitor the health status of the wire rope (5) online and issue early warnings.

2. The dual-wheel milling high-torque modular track chain tube winding system according to claim 1, characterized in that, The track chain (3) includes several drag chains (6) that are hinged end to end by chain plates; each of the two winches (4) includes several motor reducers (7), a drum (8) and a guide mechanism (10); each of the several motor reducers (7) is used to drive the corresponding winch (4) to rotate; the drum (8) is used to wind and store the track chain (3), and the top and bottom of the drum (8) are respectively detachably equipped with semi-circular plates (9); the guide mechanism (10) is used to guide the track chain (3) to extend to the milling head (2) after being released from the drum (8).

3. The dual-wheel milling high-torque modular track chain tube winding system according to claim 2, characterized in that, The drive unit includes a servo proportional valve connected one-to-one with the two winches (4), a tension sensor set on the straight section of the wire rope (5), an angle encoder coaxially set on the shaft of the winch (4), and an accumulator buffer circuit; the servo proportional valve is used to control the rotation speed and output torque of the winch (4); the tension sensor is used to detect the real-time tension of the wire rope (5); the angle encoder is used to detect the rotation angle of the winch (4) to obtain the real-time rotation speed of the winch (4) and the lowering length of the track chain (3); the accumulator buffer circuit is used to absorb the instantaneous impact load during the milling process.

4. The dual-wheel milling high-torque modular track chain tube winding system according to claim 3, characterized in that, The mode synchronization switching module has built-in feed mode synchronization logic and impact suppression logic. The feed mode synchronization logic is configured to control the winch (4) to synchronously adjust the take-up and take-down speed of the track chain (3) when the milling head (2) switches to different feed modes. The impact suppression logic is configured to maintain the tension fluctuation of the track chain (3) not exceeding the preset threshold through the coordinated adjustment of the accumulator buffer circuit and the servo proportional valve when the milling head (2) switches to different feed modes.

5. The dual-wheel milling high-torque modular track chain tube winding system according to claim 3, characterized in that, The depth tension adjustment module has built-in depth segment adjustment logic and tension closed-loop control logic. The depth segment adjustment logic is configured to divide the reference preload of the track chain (3) into multiple adjustment intervals according to the different construction depths, and output the reference preload value of the corresponding depth and transmit it to the formation linkage preload module. The tension closed-loop control logic is configured to dynamically adjust the output torque of the winch (4) in combination with the real-time feedback of the tension sensor to maintain the minimum tension of the oil pipe cable in the track chain (3).

6. The dual-wheel milling high-torque modular track chain tube winding system according to claim 5, characterized in that, The formation linkage pre-tightening module has built-in formation matching logic and pre-tightening force adaptive adjustment logic; the formation matching logic is configured to receive the formation identification signal of the control system and automatically match the pre-tightening force correction coefficient of the corresponding formation; the pre-tightening force adaptive adjustment logic is configured to dynamically fine-tune the pre-tightening force parameter of the winch (4) to the track chain (3) based on the reference pre-tightening force value and combined with the real-time torque fluctuation of the milling wheel, so as to adapt to the local characteristics of the formation.

7. The dual-wheel milling high-torque modular track chain tube winding system according to claim 3, characterized in that, The elastic deformation compensation module incorporates an elastic deformation pre-calculation model and feedforward compensation logic. The elastic deformation pre-calculation model is as follows: ; The feedforward compensation logic is configured to pre-calculate the elastic deformation of the wire rope (5) based on the real-time tension and effective suspension length of the wire rope (5), and to perform reverse compensation on the winding and unwinding commands of the winch (4).

8. The dual-wheel milling high-torque modular track chain tube winding system according to claim 3, characterized in that, The dual-windlass equalization module incorporates a power deviation rate calculation model and tension equalization adjustment logic. The power deviation rate calculation model is as follows: The tension equalization adjustment logic is configured to automatically adjust the output torque of the winch (4) on the corresponding side when the power deviation rate of the two milling wheels exceeds a preset threshold, so that the tension difference of the track chain (3) on both sides is controlled within a preset range, so as to offset the eccentric torque generated by the asymmetrical strata on the milling head (2).

9. The dual-wheel milling high-torque modular track chain tube winding system according to claim 3, characterized in that, The state monitoring module incorporates a layered deformation model and an equivalent elastic modulus identification model; the layered deformation model is... The equivalent elastic modulus identification model is: The status monitoring module is configured to inject step displacement excitation into the winch (4) using the reset gap of the lifting cylinder, collect tension change data and calculate the current equivalent elastic modulus of the track chain (3), and issue a replacement warning when the equivalent elastic modulus drops to a preset threshold.

10. A method for controlling high-torque modular track chain tube winding with dual-wheel milling, utilizing the dual-wheel milling high-torque modular track chain tube winding system as described in any one of claims 1 to 9, characterized in that... Includes the following steps: S1: The controller completes the self-test of each sensor, communication link detection, actuator calibration, and loading of control parameters and safety thresholds. After the self-test and calibration are completed, it enters the standby state. S2: The controller controls the drive unit to drive the winch (4) to operate, so that the track chain (3) cooperates with the dual-wheel milling micro-feed device to synchronously lower the milling action of the milling head (2); at the same time, the formation linkage pre-tightening module receives the formation identification signal of the control system and automatically matches the pre-tightening force correction coefficient of the corresponding formation. S3: The controller starts the elastic deformation compensation module, and compensates the elastic deformation of the wire rope (5) in real time through the elastic deformation pre-calculation model and feedforward compensation logic; at the same time, it starts the depth tension adjustment module and the stratum linkage pre-tightening module, dynamically adjusts the output torque of the winch (4), so that the track chain (3) maintains the predetermined minimum tension and adapts to the changes in stratum characteristics. S4: The dual winch equalization module monitors the power deviation rate of the two milling wheels in real time. When the power deviation rate exceeds the preset threshold, it automatically adjusts the output torque of the winch (4) on the corresponding side so that the tension difference of the rail chains (3) on both sides is controlled within the preset range, so as to offset the eccentric torque generated by the tension difference of the rail chains (3) on both sides due to the asymmetrical strata on the milling head (2). S5: When the milling head (2) switches between different feed modes, the mode synchronization switching module executes the feed mode synchronization logic and impact suppression logic, controls the winch (4) to synchronously adjust the winding and unwinding speed of the track chain (3), and through the accumulator buffer circuit and the servo proportional valve, it coordinates the adjustment to suppress the tension fluctuation of the track chain (3) during the switching process to within the preset threshold. S6: The status monitoring module uses the reset gap of the lifting cylinder to control the winch (4) to output a small step displacement, collect the tension change data of the wire rope (5) and calculate the current equivalent elastic modulus of the wire rope (5) in the track chain (3); when the equivalent elastic modulus drops to a preset threshold, a replacement warning is issued.

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