TBM hob abnormal damage monitoring device

Abstract

The utility model provides a TBM hob abnormal damage monitoring device. The monitoring device comprises a shell, a temperature monitoring assembly, an automatic flushing assembly and a light supplementing assembly. The temperature monitoring assembly, the automatic flushing assembly and the light supplementing assembly are installed in the shell. The light supplementing assembly and the temperature monitoring assembly are arranged adjacently. The automatic flushing assembly is located in front of the temperature monitoring assembly and used for automatically cleaning shielding objects on the temperature monitoring assembly. The temperature monitoring assembly is used for monitoring the temperature and the abrasion state of the hob on the TBM cutterhead in real time. The light supplementing assembly is used for supplementing visible light for the temperature monitoring assembly. According to the utility model, the problems of poor pertinence, large workload and low working efficiency of hobbing cutter inspection and maintenance of a mode of manually inspecting all hobbing cutters can be solved, and the purposes of monitoring the state of the hobbing cutter in real time and improving the working efficiency of hobbing cutter inspection are achieved.

Description

Technical Field

[0001] This utility model relates to the field of TBM equipment monitoring technology, and in particular to a TBM cutter abnormal damage monitoring device. Background Technology

[0002] Disc cutters are a key functional component of a TBM, primarily used for breaking up the surrounding rock at the tunnel face. Because the rock-breaking capacity and range of a single cutter are limited, a group of cutters working together is essential to ensure complete breaking and spalling of the surrounding rock at the tunnel face. If a cutter becomes abnormally damaged during the rock-breaking process (e.g., uneven wear, chipping), not only will its own rock-breaking capacity decrease or even become ineffective, but it will also worsen the stress state of adjacent cutters. If this damage is not detected and addressed promptly, it will cause successive damage to surrounding cutters, reducing TBM tunneling efficiency and increasing unnecessary cutter consumption.

[0003] A total of 68 cutters are installed on the TBM cutterhead of the CZXZZQ-2 section, including 8 double-edged center cutters in 4 groups, 48 ​​front cutters, and 12 side cutters. After every 2-3 cycles (120-180 minutes) of TBM tunneling and during the mandatory maintenance period of the day shift (4 hours), the cutter engineer enters the cutterhead compartment to conduct cutter inspection. The specific contents are as follows: (1) visually inspect and touch the cutter rings to check for abnormal damage such as uneven wear, chipping, and breakage; (2) measure the wear of each cutter with calipers; (3) tap to check whether the cutter bolts are loose and tighten them; (4) summarize the cutter inspection results and organize the cutter replacement operation.

[0004] Due to the large number of cutting tools and the varying forms and degrees of abnormal damage, manually inspecting all hobs is not targeted enough, is too labor-intensive, and reduces the efficiency of hob inspection and maintenance. Research has found that when a hob experiences uneven wear, the movement between the hob and the tunnel face is sliding friction, and its temperature will be abnormally higher than that of a hob under normal conditions. This phenomenon can be detected in time using infrared sensing. Utility Model Content

[0005] In view of the above problems, this utility model is proposed to provide a TBM hob abnormal damage monitoring device that overcomes or at least partially solves the above problems. It can solve the problems of low pertinence, large workload, and low efficiency of hob inspection and maintenance caused by manual inspection of all hobs, and achieve the purpose of real-time monitoring of hob status and improving the efficiency of hob inspection.

[0006] Specifically, this utility model provides a TBM cutter abnormal damage monitoring device. The monitoring device includes a housing, a temperature monitoring component, an automatic rinsing component, and a supplementary lighting component. The temperature monitoring component, the automatic rinsing component, and the supplementary lighting component are installed inside the housing. The supplementary lighting component is arranged adjacent to the temperature monitoring component. The automatic rinsing component is located in front of the temperature monitoring component and is used to automatically clean any obstructions on the temperature monitoring component. The temperature monitoring component is used to monitor the temperature and wear status of the cutter on the TBM cutter head in real time. The supplementary lighting component is used to supplement the temperature monitoring component with visible light.

[0007] Optionally, the temperature monitoring components include an infrared camera and a visible light camera.

[0008] Optionally, the monitoring device also includes a first optical transceiver, a network switch, and a display screen; the first optical transceiver is communicatively connected to the temperature monitoring component and the network switch; the network switch is communicatively connected to the display screen.

[0009] Optionally, the monitoring device also includes a second optical transceiver; the temperature monitoring component includes an infrared light sensor; the second optical transceiver is communicatively connected to the first optical transceiver and the automatic rinsing component respectively; the second optical transceiver is used to control the automatic rinsing component to automatically clean the obstructions on the temperature monitoring component.

[0010] Optionally, the housing includes a housing body and a protective mesh; the protective mesh is installed at the front end of the housing body to prevent damage to the electronic components inside the housing body.

[0011] Optionally, the housing also includes a mounting plate and a protective plate; one end of the mounting plate is fixedly installed on both sides of the housing body, and the other end is installed on the bottom of the main beam inside the TBM cutter head compartment; the protective plate is installed on the upper front end of the housing body to further prevent damage to the electronic components inside the housing body.

[0012] This utility model discloses a TBM cutter abnormal damage monitoring device. Because the temperature monitoring device integrates an infrared camera and a visible light camera, it can provide real-time infrared and visible light imaging information within the field of view. Its temperature measurement accuracy reaches ±2℃, enabling timely detection and handling of abnormal cutter temperatures, thus improving the efficiency of cutter inspection. A supplementary lighting control unit is included to assist visible light imaging and ensure image quality. Simultaneously, as the TBM cutter head rotates, the cutter head area covered by the camera's field of view also changes accordingly, achieving full coverage of key areas on the cutter head. This solves the problem of delayed detection of cutter wear caused by traditional manual visual and tactile inspection methods, facilitating early detection and handling of problems, preventing abnormal damage to adjacent cutters due to delayed handling, reducing unnecessary tool consumption, improving the efficiency of cutter inspection, and reducing the labor intensity of cutter inspection work.

[0013] Furthermore, in this utility model of a TBM cutter abnormal damage monitoring device, an automatic water vapor rinsing component is included. This component will periodically (adjustable, generally 30 seconds) rinse the lens at a set interval to promptly remove obstructions from the lens surface and ensure imaging quality.

[0014] Furthermore, this utility model provides a TBM cutter abnormal damage monitoring device, which is applicable to open-type, single-shield, and double-shield TBMs, and is especially suitable for working conditions such as hard rock and rockburst formations that are prone to causing abnormal cutter damage. It has a wide range of applications.

[0015] The above and other objects, advantages and features of this utility model will become more apparent to those skilled in the art from the following detailed description of specific embodiments of this utility model in conjunction with the accompanying drawings. Attached Figure Description

[0016] The following sections will describe some specific embodiments of the present invention in a detailed manner by way of example and not limitation, with reference to the accompanying drawings. The same reference numerals in the drawings denote the same or similar parts or components. Those skilled in the art should understand that these drawings are not necessarily drawn to scale. In the drawings:

[0017] Figure 1 This is a schematic structural diagram of a TBM hobbing cutter abnormal damage monitoring device according to an embodiment of the present invention;

[0018] Figure 2 This is a structural diagram of the housing of a TBM cutter abnormal damage monitoring device according to an embodiment of the present invention;

[0019] Figure 3 This is a schematic diagram of the temperature monitoring component of a TBM cutter abnormal damage monitoring device according to an embodiment of the present invention;

[0020] Figure 4 This is a schematic diagram of the supplementary lighting component of a TBM cutter abnormal damage monitoring device according to an embodiment of the present invention;

[0021] Figure 5 This is an installation position diagram of a TBM hobbing cutter abnormal damage monitoring device according to an embodiment of the present invention;

[0022] Figure 6 This is a connection diagram of the components of a TBM cutter abnormal damage monitoring device according to an embodiment of the present invention.

[0023] In the diagram: 1. Outer shell; 101. Outer shell body; 102. Mounting plate; 103. Protective plate; 104. Protective net; 2. Temperature monitoring component; 201. Infrared camera; 202. Visible light camera; 3. Supplemental lighting component; 301. Supplemental light; 4. Automatic rinsing component; 401. Spray brush; 402. Rotating component; 403. Water pipe; 404. Water tank. Detailed Implementation

[0024] The following reference Figures 1 to 6 This invention describes a TBM hobbing cutter abnormal damage monitoring device according to an embodiment of the present invention. In this description, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature, that is, include one or more of that feature. In the description of the present invention, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified. When a feature "includes or contains" one or more of the features it encompasses, unless otherwise specifically described, this indicates that other features are not excluded and may be further included.

[0025] Unless otherwise expressly specified and limited, the terms "set," "install," "connect," "link," "fix," and "couple" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art should be able to understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0026] Furthermore, in the description of this embodiment, "above" or "below" the second feature can include direct contact between the first and second features, or it can include contact between the first and second features through another feature between them. That is, in the description of this embodiment, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "below" of the second feature can mean the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0027] In the description of this embodiment, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this utility model. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0028] Figure 1 This is a schematic structural diagram of a TBM hobbing cutter abnormal damage monitoring device according to an embodiment of the present invention, as shown below. Figure 1 As shown, and refer to Figures 2 to 4 This utility model embodiment provides a TBM cutter abnormal damage monitoring device, which includes a housing 1, a temperature monitoring component 2, an automatic rinsing component 4, and a supplementary lighting component 3. The temperature monitoring component 2, the automatic rinsing component 4, and the supplementary lighting component 3 are installed inside the housing 1. The supplementary lighting component 3 is arranged adjacent to the temperature monitoring component 2. The automatic rinsing component 4 is located in front of the temperature monitoring component 2 and is used to automatically clean any obstructions on the temperature monitoring component 2. The temperature monitoring component 2 is used to monitor the temperature and wear status of the cutter on the TBM cutter head in real time. The supplementary lighting component 3 is used to supplement the temperature monitoring component 2 with visible light.

[0029] Temperature monitoring component 2 includes an infrared camera 201 and a visible light camera 202. The infrared camera 201 includes an infrared light sensor integrated inside the infrared camera 201 (not shown in the figure). Supplemental lighting component 3 includes a supplemental light lamp 301. In this embodiment, the cutter abnormality damage monitoring device uses the infrared camera 201 to observe the temperature of the cutters in the cutter head area inside the TBM cutter head chamber in real time, and simultaneously uses the visible light camera 202 to monitor the real-time wear status of the cutters at the corresponding positions. The supplemental light lamp 301 is used to supplement the visible light camera 202 with visible light. When the TBM cutter head rotates, the cutter head area covered by the infrared camera 201 and the visible light camera 202 also changes accordingly, enabling full coverage monitoring of the cutter temperature in key areas of the cutter head.

[0030] The automatic rinsing assembly 4 includes a water tank 404, a water pipe 403, a rotating component 402, and a spray brush 401. One end of the water pipe 403 is connected to the water tank 404, and the other end is connected to the rotating component 402. The rotating component 402 is fixedly installed inside the housing 1, and the spray brush 401 is rotatably connected to the rotating component 402. The spray brush 401 is installed in front of the infrared camera 201 and the visible light camera 202 for cleaning the infrared camera 201 and the visible light camera 202. The rotating component 402 controls the spray brush 401 to perform a fan-shaped oscillation to clean the obstruction at the front end of the temperature monitoring assembly 2.

[0031] In some embodiments of this utility model, such as Figure 2 and Figure 5 As shown, the outer casing 1 includes an outer casing body 101 and a protective mesh 104. The protective mesh 104 is installed at the front end of the outer casing body 101 to prevent damage to the internal electronic components of the outer casing body 101. The outer casing 1 also includes a mounting plate 102 and a protective plate 103. One end of the mounting plate 102 is fixedly installed on both sides of the outer casing body 101, and the other end is installed at the bottom of the main beam inside the TBM cutter head compartment. Specifically, it is installed above the main drive belt inside the TBM cutter head compartment, at the bottom of the main drive rear load-bearing beam, such as... Figure 5 As shown. The protective plate 103 is installed on the upper front end of the housing body 101 to further prevent damage to the electronic components inside the housing body 101.

[0032] In some embodiments of this utility model, such as Figure 6 As shown, the monitoring device also includes a first optical transceiver, a network switch, and a display screen. The temperature monitoring component 2 includes an infrared camera 201 and a visible light camera 202. The infrared camera 201 includes an infrared light sensor. The first optical transceiver is communicatively connected to both the temperature monitoring component 2 and the network switch. The network switch is communicatively connected to the display screen. Specifically, the infrared camera 201 transmits the collected signal to the first optical transceiver, which then transmits the signal to the network switch. The network switch converts the signal and ultimately displays the real-time temperature monitoring image and wear status of the cutting tool on the display screen.

[0033] The monitoring device also includes a second optical transceiver; the temperature monitoring component 2 includes an infrared light sensor; the second optical transceiver is communicatively connected to both the first optical transceiver and the automatic flushing component 4; the second optical transceiver is used to control the automatic flushing component 4 to automatically clean obstructions on the temperature monitoring component 2. Specifically, the infrared light sensor collects light signals and transmits them to the first optical transceiver, which converts the received light signals into electrical signals and transmits them to the second optical transceiver. The internal contact switch of the second optical transceiver controls the operation and stoppage of the automatic flushing component 4. Specifically, when the infrared light intensity is below 200 nits, the internal contact switch of the second optical transceiver is activated, and the automatic flushing component is powered on to begin cleaning obstructions on the temperature monitoring component 2; when the infrared light intensity is above 500 nits, the internal contact switch of the second optical transceiver is deactivated, and the automatic flushing component 4 is powered off and stops cleaning. During TBM tunneling, the automatic flushing component 4 will periodically (adjustable, typically 30 seconds) flush the lens of the temperature monitoring component 2 at set intervals to promptly remove obstructions from the lens surface.

[0034] Application and effectiveness of TBM hobbing cutter abnormal damage monitoring device:

[0035] Application: Since December 20, 2022, the TBM hob abnormality damage monitoring system has been installed on the right-line TBM of the CZXZZQ-2 section, and all hardware and software systems have been operating normally. Before the application, tool engineers needed to visually observe and manually inspect each hob for uneven wear. Inspecting all 68 hobs took 45-50 minutes, which was not targeted, labor-intensive, and inefficient. Using the TBM hob abnormality monitoring system, hobs with uneven wear can be quickly identified. Engineers no longer need to observe and manually inspect each hob. Inspecting all 68 hobs can save 10-15 minutes, reducing the workload of engineers and improving work efficiency. Furthermore, this device can monitor hob temperature in real time, allowing for early detection and handling of uneven wear issues, preventing unnecessary tool wear caused by delayed intervention worsening the stress state of surrounding hobs.

[0036] Results: Manually inspecting 68 cutterheads takes 45-50 minutes. Using the TBM cutterhead abnormal damage monitoring device saves 10-15 minutes, improving work efficiency by 20%-37.5%. The cost of cutterheads required for a single TBM to excavate 1km is approximately 9.1 million yuan, nearly 9100 yuan per linear meter. After applying this monitoring device, the on-site cutterhead management level was improved, and the cost for TBM excavation of 1km is now approximately 8.45 million yuan, or 8450 yuan per linear meter, representing a reduction of 650 yuan per linear meter in cutterhead costs, a decrease of 7.14%.

[0037] Therefore, those skilled in the art should recognize that although many exemplary embodiments of the present invention have been shown and described in detail herein, many other variations or modifications conforming to the principles of the present invention can be directly determined or derived from the disclosure of the present invention without departing from the spirit and scope of the present invention. Therefore, the scope of the present invention should be understood and recognized as covering all such other variations or modifications.

Claims

1. A TBM hobbing cutter abnormal damage monitoring device, characterized in that, Includes the housing, temperature monitoring components, automatic rinsing components, and supplemental lighting components; The temperature monitoring component, automatic rinsing component, and supplementary lighting component are installed inside the housing; the supplementary lighting component is arranged adjacent to the temperature monitoring component; the automatic rinsing component is located in front of the temperature monitoring component and is used to automatically clean obstructions on the temperature monitoring component; the temperature monitoring component is used to monitor the temperature and wear status of the rollers on the TBM cutter head in real time; the supplementary lighting component is used to supplement the temperature monitoring component with visible light.

2. The TBM hobbing cutter abnormal damage monitoring device according to claim 1, characterized in that, The temperature monitoring component includes an infrared camera and a visible light camera.

3. The TBM hobbing cutter abnormal damage monitoring device according to claim 1, characterized in that, It also includes a first optical transceiver, a network switch, and a display screen; the first optical transceiver is communicatively connected to the temperature monitoring component and the network switch; the network switch is communicatively connected to the display screen.

4. The TBM hobbing cutter abnormal damage monitoring device according to claim 3, characterized in that, It also includes a second optical transceiver; the temperature monitoring component includes an infrared light sensor; the second optical transceiver is communicatively connected to the first optical transceiver and the automatic rinsing component; the second optical transceiver is used to control the automatic rinsing component to automatically clean the obstructions on the temperature monitoring component.

5. The TBM hobbing cutter abnormal damage monitoring device according to claim 1, characterized in that, The housing includes a housing body and a protective mesh; the protective mesh is installed at the front end of the housing body to prevent damage to the electronic components inside the housing body.

6. The TBM hobbing cutter abnormal damage monitoring device according to claim 5, characterized in that, The housing also includes a mounting plate and a protective plate; one end of the mounting plate is fixedly installed on both sides of the housing body, and the other end is installed on the bottom of the main beam inside the TBM cutter head compartment; the protective plate is installed on the upper front end of the housing body to further prevent damage to the electronic components inside the housing body.

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