Hob abrasion real-time monitoring system with built-in sensor

Abstract

The utility model discloses a hob abrasion real-time monitoring system with a built-in sensor, which belongs to the technical field of tunnel engineering shield tunneling machines and comprises a hob in a hob cylinder, a transmitting device, a wireless receiving device and a cutter detection device. The hobbing cutters comprise a single-blade hobbing cutter and a double-blade hobbing cutter, a plurality of neodymium magnets are annularly distributed in a detection hole of a floating sealing assembly of the single-blade hobbing cutter, and a first sensor is fixedly mounted on an upper end cover of a cutter shaft of the cutter; a plurality of neodymium magnets are arranged on the inner side of the double-edged hob body, and a second sensor is fixedly mounted on the upper end cover of the cutter shaft; the transmitting device adopts two hydraulic pipes to respectively penetrate through pressure-bearing connecting seats of the single / double-edged hobs and are connected with corresponding sensors through threads, and signal lines are arranged in the hydraulic pipes and extend to the pressure-bearing seats to be fixed; and the wireless receiving device is connected with the cutter detection device. According to the system, real-time monitoring of the abrasion loss of the hob is achieved through magnetic induction and wireless transmission, and the problem that a traditional detection mode is low in shutdown efficiency is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of tunnel engineering shield machine, and particularly relates to a sensor-embedded cutter wear real-time monitoring system. BACKGROUND

[0002] In the process of tunnel shield construction, the cutter is a key component of the shield machine directly acting on the rock-soil body, and the wear state directly affects the tunneling efficiency, construction cost and engineering safety. The cutter state in the normal pressure cutter head is often inefficient in the traditional monitoring method, and it is difficult to accurately find the wear condition of the cutter in time, and the monitoring device is easily worn, and there is no basis for blind disassembly and inspection, which reduces the construction efficiency and has great danger. CONTENT OF THE UTILITY MODEL

[0003] In view of the above problems in the prior art, the sensor-embedded cutter wear real-time monitoring system provided by the present application can effectively solve the above technical problems.

[0004] In order to achieve the above utility model purposes, the technical scheme adopted by the present application is:

[0005] The present application provides a sensor-embedded cutter wear real-time monitoring system, which comprises a cutter installed in a cutter barrel, a transmitting device, a wireless receiving device and a cutter detection device.

[0006] The cutter comprises a single-blade cutter and a double-blade cutter, wherein the single-blade cutter comprises a plurality of neodymium magnets arranged in a ring shape in a floating seal assembly detection hole thereof and a first sensor fixedly installed at an opening position of an upper end cover thereof; and the double-blade cutter comprises a plurality of neodymium magnets arranged on the inner side of a cutter body thereof and a second sensor fixedly installed at an opening position of an upper end cover thereof.

[0007] The transmitting device comprises two hydraulic pipes, the hydraulic pipes respectively pass through pressure-bearing connecting seats of the single-blade cutter and the double-blade cutter, and the first sensor, the second sensor and the transmitting device are threadedly connected; the signal lines of the first sensor and the second sensor are integrated in the interior of the hydraulic pipes, and the terminal ends are fixedly installed at the pressure-bearing connecting seats.

[0008] The wireless receiving device is connected with the cutter detection device.

[0009] Further, the first sensor is spaced apart from the plurality of neodymium magnets arranged in a ring shape in the floating seal assembly detection hole by 5mm; and the second sensor is spaced apart from the plurality of neodymium magnets arranged on the inner side of the cutter body by 5mm.

[0010] Furthermore, both the first sensor and the second sensor are integrated from a speed and temperature sensor and a Hall sensor. The resistance wire of the speed and temperature sensor is brazed through the wear-resistant alloy sheet body, and the Hall sensor is brazed onto the wear-resistant alloy sheet body.

[0011] Furthermore, the upper end cap is located at the upper end of the cutter shaft of the single-edged hob and the double-edged hob, respectively.

[0012] Furthermore, the transmitting device is fixed above the sealing gate plate; the wireless receiving device is installed on the earth chamber wall of the shield body of the tunnel boring machine.

[0013] The wireless receiving device is connected to the tool detection device via a wire, and transmits data to the tool detection device via a wired connection.

[0014] Furthermore, the transmitting device is powered by a rechargeable battery and is connected to the resistance wires of the first and second sensors via a signal cable to transmit the collected data to the wireless receiving device.

[0015] The beneficial effects of this application are:

[0016] This application provides a real-time monitoring system for cutter wear with a built-in sensor. By embedding a neodymium magnet into the cutter and combining it with an integrated sensor, it enables non-contact, real-time monitoring of cutter wear, improving the system's monitoring sensitivity and anti-interference capabilities. Furthermore, the direct connection between the sensor and the transmitting device via a hydraulic pipe simplifies the internal structure and enhances sealing and reliability. In addition, the sensor is fixed at the opening in the upper cover, facilitating disassembly and replacement and reducing downtime. Attached Figure Description

[0017] 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 embodiments can be obtained based on these drawings.

[0018] Figure 1 A schematic diagram of a real-time monitoring system for hob wear with a built-in sensor provided in this application embodiment;

[0019] Figure 2 Provided for the embodiments of this application Figure 1 Schematic diagram of sensor installation;

[0020] Figure 3 A cross-sectional schematic diagram of a single-edged hob structure provided in an embodiment of this application for a real-time hob wear monitoring system with a built-in sensor;

[0021] Figure 4 A double-blade cutter structure profile schematic diagram of a sensor-embedded cutter wear real-time monitoring system provided by the embodiment of the present application is provided.

[0022] Figure 5 A cutter body structure schematic diagram of a sensor-embedded cutter wear real-time monitoring system provided by the embodiment of the present application is provided.

[0023] Figure 6 An end cover structure schematic diagram of a sensor-embedded cutter wear real-time monitoring system provided by the embodiment of the present application is provided.

[0024] Figure 7 A floating sealing assembly structure schematic diagram of a sensor-embedded cutter wear real-time monitoring system provided by the embodiment of the present application is provided.

[0025] Among them, 2-hydraulic pipe; 3-pressure bearing connecting seat; 4-emitting device; 5-cutter barrel; 6-wireless receiving device; 7-cutter monitoring device; 8-cutter ring; 9-cutter shaft; 10-upper end cover; 11-lower end cover; 12-floating oil pipe; 13-bearing; 14-neodymium magnet; 15-floating sealing assembly; 16-cutter barrel end cover; 17-cutter body; 18-single-blade cutter, 19-double-blade cutter, 101-first sensor; 102-second sensor. DETAILED DESCRIPTION

[0026] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art based on the present application belong to the scope of protection of the present application.

[0027] Embodiment 1:

[0028] As shown in the drawings, Figures 1-7 The embodiment of the present application provides a sensor-embedded cutter wear real-time monitoring system, and the overall structure of the system can be seen from Figure 1 , Figure 1 The structure schematic diagram of a sensor-embedded cutter wear real-time monitoring system provided by the embodiment of the present application is shown, which comprises a cutter installed in a cutter barrel 5, an emitting device 4, a wireless receiving device 6 and a cutter detection device 7.

[0029] The cutter includes single blade cutter 18 and double blade cutter 19, wherein the single blade cutter 18 includes a plurality of neodymium magnets 14 distributed in the detection hole of the floating sealing assembly 15 and a first sensor 101 fixedly installed in the opening position of the upper end cover 10; the double blade cutter 19 includes a plurality of neodymium magnets 14 arranged in the inner side of the cutter body 17 and a second sensor 102 fixedly installed in the opening position of the upper end cover 10;

[0030] The launching device 4 includes two hydraulic pipes 2 respectively penetrating the pressure bearing connecting seat 3 of the single blade cutter and the double blade cutter, and the first sensor 101 and the second sensor 102 are threadedly connected with the launching device 4; the signal lines of the first sensor 101 and the second sensor 102 are integrated in the interior of the hydraulic pipe and fixed at the pressure bearing connecting seat 3 at the tail end;

[0031] The wireless receiving device 6 is connected with the cutter detection device 7.

[0032] In an embodiment of the present application, the plurality of neodymium magnets 14 can be selected as 8, which can be seen from Figure 7 , Figure 7 The floating sealing assembly structure schematic diagram provided in the present application is shown in the figure, 8 neodymium magnets are evenly inlaid in the detection hole of the single blade cutter floating sealing assembly 15, and the neodymium magnets distributed in the inner side of the double blade cutter body 17 are similar to those of the single blade cutter. According to the principle that the line speed of the cutter is equal to the line speed of the cutter at the same radius when the cutter head rotates, the theoretical rotating speed of the cutter is calculated, the higher the degree of cutter wear, the smaller the diameter, the faster the cutter rotating speed, and the shorter the time period of the first sensor 101 and the second sensor 102 detecting 8 pulse signals. The rotating speed of the cutter installed on the cutter head of the shield tunneling machine at different radii has a large difference, and the closer to the edge of the cutter head, the greater the rotating speed of the cutter. Therefore, the rotating speed measurement range of the cutter should cover the maximum rotating speed value of the edge cutter close to the edge of the cutter head, and the cutter head rotating speed is W, the temperature is T, the distance from the cutter to the center of the cutter head is R1, and the radius of the cutter itself is R2. According to the principle that the line speed of the cutter is equal to the line speed of the cutter at the same radius when the cutter head rotates, the formula for calculating the theoretical rotating speed of the cutter is as follows: cutter wear = new cutter radius-R2 = new cutter radius-8R1WT.

[0033] In an embodiment of the present application, when the hob is working normally, the eight evenly distributed neodymium magnets 14 make a revolution around the hob shaft 9, and each revolution of the neodymium magnet 14 close to the sensor will be detected as a change in the magnetic field intensity, and when the detected magnetic field intensity exceeds the minimum threshold set by the sensor, a pulse signal will be activated and a count will be performed, that is, the tool wear can be calculated by the tool revolution and wear corresponding relationship calculation formula, the hob wear degree is reflected, and the hob working state is judged. The tool monitoring device 7 calculates the hob wear through the formula of the revolution and wear corresponding relationship, and establishes a tool intelligent diagnosis model in real time through data acquisition of tool parameters with different distribution radii.

[0034] In an embodiment of the present application, the signal lines of the first and second sensors 101 and 102 are threaded through the holes reserved on the cutter barrel end cover 16, and the wires are tightened against the silk, so that the hydraulic pipe 2 is in a clockwise direction, the sensor outlet plug threaded through the cutter barrel end cover 16 is connected with the pressure bearing connector 3, the excess first and second sensor lines are inserted into the hole, and the bolt is fixed on the cutter barrel end cover 16.

[0035] The signal lines in the first and second sensors are arranged in the hydraulic pipe 2, which can ensure that the signal wires will not be damaged in harsh working environment.

[0036] Further, the first sensor 101 is spaced apart from the plurality of neodymium magnets 14 arranged in the detection hole of the floating seal assembly 15 by 5 mm; and the second sensor 102 is spaced apart from the plurality of neodymium magnets 14 arranged inside the cutter body 17 by 5 mm.

[0037] In an embodiment of the present application, the spacing between the plurality of neodymium magnets 14 is 5 mm, which is achieved by selecting the installation spacing multiple times, manually rotating the hob, testing whether the sensor can sense the neodymium magnet 14 signal by using the test tool, and observing whether the voltage output by the sensor 1 is normal if the monitoring is not accurate, adjusting the installation spacing until the monitoring is accurate.

[0038] In an embodiment of the present application, in order to ensure that the magnetic field intensity of the neodymium magnet 14 meets the design requirements, the surface magnetic intensity of the neodymium magnet 14 needs to be detected by a gauss meter, and the plurality of neodymium magnets 14 arranged in a ring need to be tested one by one, and the magnets close to the sensor are detected as the key. The single-point measurement value is ≥2000Gs, and the difference of all magnets in the same hob is ≤5% (to ensure the uniformity of the magnetic field). If the measurement value of any magnet is <2000Gs, or the difference of the same group of magnets is >5%, the whole group is replaced.

[0039] In one embodiment of the present application, after the first and second sensors confirm that there is no problem, the bolt is tightened, the cutter barrel 5 with the installed cutter is hoisted to the outside of the center chamber, and the first and second sensors are tested again. If the test sensor can detect the pulse signal, the transmitting device 4 and the first and second sensors are connected, the wireless receiving device 6 and the cutter monitoring device are turned on.

[0040] In one embodiment of the present application, in order to meet the built-in requirement, the structure of the upper end cover 10 of the micro-adjusting hob, the floating sealing assembly 15 and the cutter body 17 is adjusted, and a wiring groove is formed at the load bearing structure of the front-mounted cutter barrel.

[0041] Further, the first sensor 101 and the second sensor 102 are integrated by a rotating speed temperature sensor and a Hall sensor. The resistance wire of the rotating speed temperature sensor is brazed through the wear-resistant alloy body, and the Hall sensor is brazed on the wear-resistant alloy body.

[0042] In one embodiment of the present application, the rotating speed temperature sensor monitors the rotating speed and temperature of the hob in real time. If the bearing 13 of the hob is damaged, the hob will be in an abnormal working state, at which time the temperature of the cutter will abnormally rise. The temperature sensor in the first and second sensors can monitor the temperature change and can timely feedback that the hob is in an abnormal working state. The Hall sensor monitors the change in the strength of the magnetic field. Based on the same cutter rotating speed and preset cutter linear speed, the cutter wear amount is converted to reflect the wear or working state of the hob. At the same time, the sensor has the on-site detachability, which can reduce the use cost.

[0043] Further, the upper end cover 10 is located at the upper end of the cutter shaft 9 of the single-edge hob 18 and the double-edge hob 19.

[0044] Further, the transmitting device 4 is fixed above the sealing seat gate plate; and the wireless receiving device 6 is installed on the earth chamber wall plate of the shield machine shield body.

[0045] Further, the wireless receiving device 6 is connected to the cutter detection device 7 through a wire, and data is transmitted to the cutter detection device 7 through a wired transmission.

[0046] Further, the transmitting device 4 is powered by a rechargeable battery, is connected to the resistance wire of the first sensor 101 and the second sensor 102 through a signal cable, and transmits the collected data to the wireless receiving device 6.

[0047] In one embodiment of the present application, the transmitting device 4 is powered by a rechargeable battery, which can reduce the line connection in the center chamber.

[0048] Embodiment 2:

[0049] The application embodiment provides a use method of a sensor-embedded cutter wear real-time monitoring system, comprising the following steps:

[0050] S1: evenly embedding 8 neodymium magnets 14 on a floating seal assembly 15 of a single-blade cutter 19, and evenly embedding 8 neodymium magnets 14 on the inner side of a cutter body 17 of a double-blade cutter 19, using a gauss meter to test the surface magnetic strength of the neodymium magnets 14, and ensuring that the magnetic strength of the neodymium magnets 14 meets the standard, otherwise, the neodymium magnets 14 are replaced;

[0051] S2: selecting matched first and second sensors and correctly installing the first and second sensors on the single-blade and double-blade cutters with the embedded neodymium magnets 14, and then installing the cutters in a cutter drum 5;

[0052] S3: passing first and second sensor outlet plugs through the reserved holes in a cutter drum end cover 16, and tightening the plugs, ensuring that the hydraulic pipe 2 is in a clockwise direction, connecting the first and second sensor outlet plugs passing through the cutter drum end cover 16 with a pressure-bearing connecting seat 3, inserting the excess first and second sensor wires into the holes, and fixing the wires on the cutter drum end cover 16 with bolts;

[0053] S4: manually rotating the cutter, testing whether the first and second sensors can sense the neodymium magnet 14 signals by using a test tool, and observing whether the voltage output by the first and second sensors is normal while the cutter rotates one revolution and there are 8 pulse signals;

[0054] S5: after confirming that the first and second sensors are all normal, tightening the bolts, hoisting the cutter drum 5 with the installed cutters to the outside of the center chamber, and testing the first and second sensors again;

[0055] S6: after the cutter drum 5 is installed on a cutter head, connecting the transmitting device 4 and the first and second sensors, and opening the wireless receiving device 6 and the cutter monitoring device.

[0056] The sensor-embedded cutter wear real-time monitoring system provided by the application can realize real-time and accurate collection of multiple parameter data of the cutter, real-time analysis of cutter wear and working state, establishment of a cutter intelligent diagnosis model, and great improvement of tunneling efficiency, accuracy and safety by real-time monitoring of the rotation speed, temperature and wear of the cutter. The sensor is embedded in the cutter, which can prevent the monitoring device from being interfered or damaged by foreign matters such as slag in the shield soil chamber, improve the monitoring accuracy and reduce the sensor damage rate, and the sensor has on-site detachability, which facilitates replacement and maintenance and improves the reuse rate of the sensor. In addition, the system has simple structure, is easy to install and maintain, has high waterproof pressure-bearing capacity and immersion resistance, is suitable for various harsh working conditions, and the use method of the monitoring system is simple and easy for operators to master and operate.

[0057] It should be noted that those skilled in the art will appreciate that the embodiments described herein are presented for the purpose of understanding the principles of the present application and should be understood as not limiting the scope of protection of the present application to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations according to the technical inspiration of the present application disclosed, which do not deviate from the essence of the present application, and these modifications and combinations are still within the scope of protection of the present application.

Claims

1. A real-time monitoring system for wear of a rolling cutter having a sensor built-in, characterized in that, The application relates to a cutter detection device for a shield tunneling machine. The cutter detection device comprises a single-blade cutter, a launching device, a wireless receiving device and a cutter detection device. The single-blade cutter comprises a plurality of neodymium magnets arranged in a ring shape in a detection hole of a floating sealing assembly and a first sensor fixedly arranged in an opening of an upper end cover. The double-blade cutter comprises a plurality of neodymium magnets arranged in the inside of a cutter body and a second sensor fixedly arranged in an opening of an upper end cover. The launching device comprises two hydraulic pipes which pass through pressure-bearing connecting bases of the single-blade cutter and the double-blade cutter respectively, and the first sensor, the second sensor and the launching device are threadedly connected.

2. The sensor built-in real-time roll tool wear monitoring system according to claim 1, wherein, The signal lines of the first sensor and the second sensor are integrated in the inside of the hydraulic pipes and fixed at the pressure-bearing connecting bases.

3. The sensor built roller cutter wear real time monitoring system as claimed in claim 1 wherein, The wireless receiving device is connected with the cutter detection device.

4. The sensor built roller cutter wear real time monitoring system according to claim 1, wherein, The first sensor is spaced apart from the plurality of neodymium magnets arranged in a ring shape in the detection hole of the floating sealing assembly by 5mm.

5. The sensor built roller cutter wear real time monitoring system as claimed in claim 1 wherein, The second sensor is spaced apart from the plurality of neodymium magnets arranged in the inside of the cutter body by 5mm.

6. The sensor built roller cutter wear real time monitoring system as claimed in claim 1 wherein, The first sensor and the second sensor are integrated by a rotating speed temperature sensor and a Hall sensor.

7. The sensor built roller cutter wear real time monitoring system as claimed in claim 1 wherein, The upper end cover is arranged on the upper end of a cutter shaft of the single-blade cutter and the double-blade cutter. The launching device is fixed above a sealing seat gate plate. The wireless receiving device is arranged on a soil cabin wall plate of a shield tunneling machine. The wireless receiving device is connected with the cutter detection device through wires and transmits data to the cutter detection device through wires. The launching device is powered by a rechargeable battery and connected with the resistance wires of the first sensor and the second sensor through a signal cable to transmit collected data to the wireless receiving device.

Images