Hob abrasion monitoring device
By installing pressure sensors, torque sensors and wear detection devices on the TBM, combined with neural network model, real-time and accurate monitoring of hob wear is achieved, and the real-time and accuracy of hob wear monitoring in the existing technology is solved, the working efficiency and safety of TBM are improved, and the construction cost is reduced.
Patent Information
- Application Number
- CN202422729353.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-10
- Publication Date
- 2025-08-19
- Estimated Expiration
- 2034-11-10
AI Technical Summary
In the prior art, the TBM hob wear monitoring method has problems such as poor real-time, low accuracy, and susceptible to geological conditions, resulting in low excavation efficiency, high cost and poor safety.
The pressure sensor, torque sensor, counting device and surrounding rock wear detection device are adopted, combined with the neural network learning model, and the force, torque and rotation distance of the hob are monitored in real time, and the surrounding rock abrasiveness is evaluated through the change of the resistance of the wear steel needle, so as to achieve high-precision prediction and early warning of hob wear.
Real-time and accurate monitoring of the wear status of the hob is achieved, improving the working safety and efficiency of TBM, reducing the risk of abnormal wear and construction costs, optimizing the excavation strategy, and improving the safety and economic benefits of the construction site.
Smart Images
Figure CN223241436U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of tunnel boring machines, in particular to a device for monitoring the wear state of a TBM cutter. Background Art
[0002] When a full-face hard rock tunnel boring machine (TBM) is operating, it uses the cutters on a rotating cutterhead to crush rock. However, this crushing of rock by the cutters causes significant wear on the cutter rings. When the cutter rings are worn to a certain extent, the tunneling efficiency of the full-face hard rock tunnel boring machine will be significantly reduced. To avoid affecting the tunneling schedule, the cutter rings need to be replaced promptly, so cutter ring wear monitoring is often required. Broken rock can pose a significant obstacle to cutter wear monitoring equipment. For example, broken rock can block light and sound wave signals, making optical and ultrasonic monitoring instruments unsuitable. In addition, when broken rock falls from the cutterhead, it will impact the monitoring equipment, posing a significant threat to its safety.
[0003] In underground engineering construction, TBMs are highly efficient, fully mechanized construction equipment. Their cutters are key components, responsible for breaking rock and advancing the tunnel. Cutter wear directly impacts TBM excavation efficiency, costs, and project safety.
[0004] Current methods for monitoring TBM cutter wear primarily include manual inspections during downtime, analysis of cut rock samples, and monitoring of cutterhead torque and thrust. These methods have the following limitations: manual inspections during downtime can interrupt tunneling operations, severely impacting project progress; rock sample analysis is time-consuming and requires specialized laboratory support, making real-time monitoring difficult; and while cutterhead torque and thrust monitoring can provide some insight into cutter wear, it is often inaccurate and susceptible to various factors, including geological conditions.
[0005] Given the limitations of these existing technologies, there remains a significant need for real-time, accurate monitoring of TBM cutter wear. To ensure continued efficient and safe operation of TBMs while reducing maintenance costs and downtime, a novel TBM cutter wear monitoring method and device is urgently needed to enable online, dynamic, and highly accurate wear monitoring and early warning capabilities. Summary of the Invention
[0006] The technical problem to be solved by the present invention is: in view of the defects of the existing method for monitoring the wear of the roller cutter, a roller cutter wear monitoring device is proposed to realize real-time, accurate and comprehensive monitoring of the wear status of the roller cutter, improve the safety and efficiency of TBM work, reduce operating costs, promote technological innovation and development in the field of underground engineering construction, provide reference for on-site construction personnel, improve the utilization efficiency of the roller cutter, reduce the risk of abnormal wear, and save construction costs.
[0007] In order to solve the above technical problems, the utility model proposes the following technical solutions: a roller cutter wear monitoring device, which includes a rotatable cutter shaft, a cutter body mounted on the cutter shaft, a cutter disc mounted on the cutter body, a pressure sensor arranged at the cutter shaft and capable of detecting the roller cutter pressure, a torque sensor arranged at the cutter shaft and capable of detecting the roller cutter torque, a cutter box arranged on one side of the cutter shaft and covering the cutter body and cutter disc located on the side, a counting device arranged inside the cutter box and capable of calculating the actual rotation distance of the roller cutter, and a surrounding rock wear detection device arranged on the surface of the cutter disc and capable of quantitatively evaluating the abrasiveness of the surrounding rock.
[0008] A further limitation of the above technical solution is that the counting device consists of a magnet, a battery, a magnetic sensor, a counter, a wireless transmission module and a metal protective shell, wherein the magnet is arranged on the cutter disc, the battery, the magnetic sensor, the counter and the wireless transmission module are electrically connected, and the metal protective shell is installed and fixed outside the battery, the magnetic sensor, the counter and the wireless transmission module. As the hob rotates one circle, the magnet is driven, and when it passes the magnetic sensor, a signal is generated and the counter is turned on to record the number of rotations of the hob.
[0009] A further limitation of the above technical solution is that the surrounding rock wear detection device consists of a wear-resistant protective block, an insulating protective shell and a wear steel needle; the wear steel needle is wrapped in an insulating protective shell and then embedded in the wear-resistant protective block; when the cutter head rotates, the length of the wear steel needle is obtained by measuring the resistance change of the wear steel needle, and the abrasiveness of the surrounding rock is quantitatively evaluated based on the wear amount of the wear steel needle as the cutter head rotates.
[0010] Compared with the prior art, the present invention has the following beneficial effects:
[0011] 1. This new hob wear monitoring device can accurately detect the force, torque, and rolling distance acting on the hob. As a result, the hob's operating status can be determined based on the measured force and torque. Under normal operating conditions, the amount of hob wear can be predicted using theoretical formulas combined with a neural network learning model. In abnormal conditions, an early warning can be issued, allowing appropriate measures to be taken.
[0012] 2. The utility model of the roller cutter wear monitoring device provides a reference for on-site construction personnel, improves the utilization efficiency of the roller cutter, reduces the risk of abnormal wear, and saves construction costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Figure 1 It is a structural diagram of the hob wear monitoring device of the utility model.
[0014] Figure 2 It is a structural schematic diagram of the surrounding rock wear detection device of the present utility model. DETAILED DESCRIPTION
[0015] like Figure 1 and Figure 2 As shown, the utility model proposes a roller cutter wear monitoring device, which includes a rotatable cutter shaft 1, a cutter body 2 mounted and fixed on the cutter shaft 1, a cutter disc 3 mounted and fixed on the cutter body 2, a pressure sensor 4 arranged at the cutter shaft 1, a torque sensor 5 arranged at the cutter shaft 1, a cutter box 8 arranged on one side of the cutter shaft 1 and covering the cutter body 2 and the cutter disc 3 located on the side, a counting device 6 arranged inside the cutter box 8 and capable of calculating the actual rotation distance of the roller cutter, and a surrounding rock wear detection device 7 arranged on the surface of the cutter disc 3 and capable of quantitatively evaluating the abrasiveness of the surrounding rock.
[0016] When the cutter shaft 1 rotates, it drives the cutter body 2 and the cutter disc 3 to rotate together.
[0017] The pressure sensor 4 is used to directly and accurately detect the actual pressure on the hob in the vertical direction (referred to as: hob pressure).
[0018] The torque sensor 5 is used to directly and accurately detect the actual torque of the reel in the rotation direction (referred to as reel torque).
[0019] The counting device 6 is composed of a magnet 61 , a battery 62 , a magnetic sensor 63 , a counter 64 , a wireless transmitting module 65 and a metal protective shell 66 .
[0020] The magnet 61 is arranged on the cutter head 3 , and the battery 62 , the magnetic sensor 63 , the counter 64 and the wireless transmitting module 65 are electrically connected.
[0021] The metal protective shell 66 is installed and fixed outside the battery 62 , the magnetic sensor 63 , the counter 64 and the wireless transmission module 65 .
[0022] As the cutter rotates one circle, it drives the magnet 61, which generates a signal when passing the magnetic sensor 63 and starts the counter 64 to record the number of circles the cutter rotates. The monitored data is sent to the control room of the TBM equipment (not shown) via wireless transmission mode.
[0023] The surrounding rock wear detection device 7 consists of a wear-resistant protective block 71, an insulating protective shell 72, and a wear-resistant steel needle 73. The wear-resistant steel needle 73 is encased in the insulating protective shell 72 and then embedded within the wear-resistant protective block 71. As the cutterhead 3 rotates, the length of the wear-resistant steel needle 73 is measured, for example, by measuring its resistance change. The wear of the wear-resistant steel needle 73 over the distance the cutterhead 3 rotates is used to quantitatively assess the surrounding rock abrasiveness.
[0024] The TBM cutter wear monitoring device proposed in this utility model has the following beneficial effects:
[0025] 1. Under normal working conditions of the hob, a large number of engineering cases show that the hob wear is highly correlated with the stress state and geological conditions. Since there are many parameters related to the hob wear and the data contains noise, directly using all parameters to adopt neural network learning has a slow convergence speed and it is difficult to accurately obtain all parameters. Therefore, it is necessary to pre-process the factors related to the hob wear and screen out the main components with large contribution rates. Finally, the hob wear is predicted by the ability of the neural network to approximate nonlinear continuous functions. Later, the prediction model is corrected by statistically analyzing the actual wear of the hob, thereby achieving accurate prediction of the hob wear.
[0026] 2. Improved real-time performance and accuracy: By using precise detection of key parameters and data analysis algorithms, real-time online monitoring of the hob working status is achieved, which can timely and accurately predict the amount of hob wear, effectively avoiding delays and misjudgments caused by lags in traditional methods.
[0027] 3. Improved work efficiency and safety: Real-time cutter wear prediction can predict cutter lifespan in advance, allowing for a more rational replacement schedule. This reduces unnecessary downtime and maintenance costs, further improving the continuity and efficiency of TBM excavation operations. It also reduces the risk of accidents caused by excessive cutter wear and ensures construction site safety.
[0028] 4. Optimize tunneling strategies: The accurate wear information provided by the monitoring device helps adjust tunneling parameters (such as propulsion speed, torque, cutterhead speed, etc.). The tunneling strategy is optimized in real time based on geological conditions and cutter wear, further improving the overall performance and economic benefits of the TBM.
Claims
1. A hob wear monitoring device, characterized in that: The invention comprises a rotatable cutter shaft (1), a cutter body (2) mounted on the cutter shaft (1), a cutter disc (3) mounted on the cutter body (2), a pressure sensor (4) arranged at the cutter shaft (1) and capable of detecting the pressure of the roller cutter, a torque sensor (5) arranged at the cutter shaft (1) and capable of detecting the torque of the roller cutter, a cutter box (8) arranged on one side of the cutter shaft (1) and covering the cutter body (2) and the cutter disc (3) located on the side, a counting device (6) arranged inside the cutter box (8) and capable of calculating the actual rotation distance of the roller cutter, and a surrounding rock wear detection device (7) arranged on the surface of the cutter disc (3) and capable of quantitatively evaluating the abrasiveness of the surrounding rock.
2. The hob wear monitoring device according to claim 1, characterized in that: The counting device (6) is composed of a magnet (61), a battery (62), a magnetic sensor (63), a counter (64), a wireless transmitter module (65) and a metal protective shell (66), wherein the magnet (61) is arranged on the cutter disc (3), the battery (62), the magnetic sensor (63), the counter (64) and the wireless transmitter module (65) are electrically connected, and the metal protective shell (66) is fixedly installed outside the battery (62), the magnetic sensor (63), the counter (64) and the wireless transmitter module (65). As the hob rotates one circle, the magnet (61) is driven, and when it passes through the magnetic sensor (63), a signal is generated and the counter (64) is turned on to record the number of rotations of the hob.
3. The hob wear monitoring device according to claim 1, characterized in that: The surrounding rock wear detection device (7) is composed of a wear-resistant protective block (71), an insulating protective shell (72) and a wear steel needle (73); the wear steel needle (73) is wrapped with the insulating protective shell (72) and then embedded in the wear-resistant protective block (71); when the cutterhead (3) rotates, the length of the wear steel needle (73) is obtained by measuring the resistance change of the wear steel needle (73), and the surrounding rock abrasiveness is quantitatively evaluated according to the wear amount of the wear steel needle (73) as the cutterhead (3) rotates.