A shield cutter wear real-time detection device based on a multi-modal sensor

Abstract

This utility model relates to the field of tunnel and underground engineering construction technology, specifically a real-time detection device for shield tunneling cutter wear based on multimodal sensors. It includes a micro-vibration sensor, a fiber optic strain sensor, and a data acquisition unit. The micro-vibration sensor and the fiber optic strain sensor are fixed together by filling with high-temperature resistant epoxy resin, and the outside is protected by a tungsten carbide alloy shell. This real-time detection device for shield tunneling cutter wear, by integrating the micro-vibration sensor and the fiber optic strain sensor into an impact-resistant tungsten carbide alloy shell and fixing them with high-temperature resistant epoxy resin, combined with an optimized signal processing and data transmission structure, achieves high-precision, real-time online monitoring of shield tunneling cutter wear and crack initiation. It effectively overcomes the shortcomings of traditional methods, such as requiring machine shutdown for inspection, susceptibility to interference, and short sensor lifespan, significantly improving construction efficiency and reducing maintenance costs and safety risks.

Description

Technical Field

[0001] This utility model relates to the field of tunnel and underground engineering construction technology, specifically to a real-time detection device for shield tunneling cutter wear based on multimodal sensors. Background Technology

[0002] During the tunneling process, the cutterheads of tunnel boring machines are subjected to severe friction and impact from complex geological conditions (such as rock, sand, and gravel layers). Cutter wear is the main reason for the decline in construction efficiency, frequent cutter replacement, and increased project costs.

[0003] Currently, tool wear detection mainly relies on manual inspection during machine shutdown or indirect evaluation methods based on vibration and torque signals, which have the following drawbacks:

[0004] Poor real-time performance: Manual inspection requires stopping the machine to disassemble the cutting tools, which is inefficient and cannot capture the dynamic wear process; Insufficient accuracy: Traditional vibration analysis methods are easily affected by tunneling parameters (thrust, rotation speed) and environmental noise, making it difficult to distinguish between normal wear and abnormal chipping.

[0005] Short sensor lifespan: The working environment of cutting tools is harsh (high temperature, high humidity, strong impact), and ordinary sensors are easily damaged and difficult to monitor stably for a long time.

[0006] To address this, we propose a real-time shield cutter wear detection device based on multimodal sensors. Utility Model Content

[0007] One of the technical problems to be solved by this application is: how to provide a real-time detection device for shield cutter wear that integrates multimodal sensors and has an impact-resistant protective structure, so as to realize online monitoring of wear and cracks without disassembling the cutter.

[0008] To address the aforementioned technical problems, this application provides a real-time shield cutter wear detection device based on multimodal sensors, including a micro vibration sensor, a fiber optic strain sensor data acquisition unit;

[0009] The miniature vibration sensor and the fiber optic strain sensor are fixed together by filling with high-temperature resistant epoxy resin, and are protected by an outer shell made of tungsten carbide alloy.

[0010] In some embodiments, a micro vibration sensor detects the impact frequency and amplitude during tool cutting, and determines the degree of wear by combining a preset threshold; a fiber optic strain sensor monitors the strain distribution on the tool surface, and identifies the location of crack initiation by strain abrupt changes.

[0011] In some embodiments, the detection data from the miniature vibration sensor and the fiber optic strain sensor are transmitted to the data acquisition unit via a first cable and a second cable.

[0012] In some embodiments, the device further includes a high-strength steel cable protection device and a soil chamber partition. The first cable and the second cable are installed inside the high-strength steel cable protection device, and the first cable and the second cable are connected to the data acquisition device through drilling holes in the soil chamber partition.

[0013] In some embodiments, the shape of the tungsten carbide alloy shell matches the surface contour of the substrate of the tunnel boring machine cutter, and is welded and fixed in a preset groove on the surface of the cutter by a high-temperature brazing process, so that the working surface of the tungsten carbide alloy shell is flush with the working surface of the cutter substrate.

[0014] In some embodiments, multiple fiber optic strain sensors are arranged in an array along the main force direction of the tool and encapsulated in a tungsten carbide alloy shell to measure the strain gradient distribution on the tool surface.

[0015] In some embodiments, the data acquisition unit has a built-in signal processing module, which is configured to perform frequency domain analysis on the vibration signal to extract characteristic frequency energy values ​​and to perform differential calculation on the strain signals of multiple fiber Bragg grating sensors.

[0016] In some embodiments, the high-strength steel of the cable protection device is a spiral wound metal flexible hose, the two ends of which are connected to the tungsten carbide alloy shell and the sealed through-wall joint on the earthen chamber partition through anti-loosening joints.

[0017] In some embodiments, the high-temperature resistant epoxy resin is a thermally conductive and insulating material with a thermal conductivity greater than 0.5 W / (m·K).

[0018] This utility model has at least the following beneficial effects:

[0019] This invention integrates a miniature vibration sensor and a fiber optic strain sensor into an impact-resistant tungsten carbide alloy shell, and fixes them with high-temperature resistant epoxy resin. Combined with an optimized signal processing and data transmission structure, it achieves high-precision, real-time online monitoring of shield tunneling cutter wear and crack initiation. This effectively overcomes the shortcomings of traditional methods, such as the need for machine shutdown for inspection, susceptibility to interference, and short sensor lifespan. It significantly improves construction efficiency, reduces maintenance costs and safety risks, and the entire system can be installed during the manufacturing process of the cutterhead and cutters, making installation convenient and operation easy. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0021] Figure 2 This is a schematic diagram of the drill hole on the earthwork partition of this utility model;

[0022] Figure 3 This is a schematic diagram of the structure of each sensor device of this utility model.

[0023] In the diagram: 1-cutting tool; 2-cutting head; 3-shield body; 4-high-strength steel cable protection device; 5-first cable; 6-second cable; 7-data acquisition unit; 8-screw conveyor; 9-drill hole; 10-sensor device; 11-optical fiber; 12-soil chamber partition; 13-miniature vibration sensor; 14-fiber grating sensor; 15-tungsten carbide alloy shell; 16-high temperature resistant epoxy resin. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without making inventive efforts are within the protection scope of the present utility model.

[0025] Please see Figure 1-3 This utility model provides a technical solution: a real-time detection device for shield tunnel cutter wear based on multi-modal sensors. This device achieves real-time online monitoring of the status of the cutter 1 by embedding a multi-sensor fusion unit inside the cutter 1.

[0026] Its core sensor device 10 consists of a miniature vibration sensor 13 and a fiber optic strain sensor 14. The two are filled and fixed by high-temperature resistant epoxy resin 16. This epoxy resin is a special thermally conductive and insulating material with a thermal conductivity greater than 0.5 W / (m·K). It can effectively transmit mechanical stress, achieve electrical isolation, and dissipate the heat generated by the sensor during operation in a timely manner.

[0027] The entire sensing unit is fully protected by a tungsten carbide alloy shell 15. This shell is metallurgically bonded to the tool base material through a high-temperature brazing process, ensuring that its mechanical properties are consistent with those of the tool base.

[0028] During monitoring, the miniature vibration sensor 13 collects high-frequency vibration signals generated when the tool 1 cuts the rock and soil. By analyzing the frequency components and amplitude variation trends of the vibration signals, the wear state of the tool 1 can be determined. When the cutting edge wears, the spectral characteristics of the vibration signal will shift significantly. By comparing with a preset threshold, the degree of wear can be quantitatively assessed. Simultaneously, an array of fiber optic strain sensors 14 are arranged along the main force direction of the tool. They measure the strain distribution on the tool surface by monitoring the Bragg wavelength shift. When microcracks appear on the tool surface, a strain concentration effect occurs at the crack tip, causing the corresponding sensor to detect a sudden strain signal, thereby achieving early identification and precise location of the crack initiation site.

[0029] The transmission of sensor signals is accomplished through a specially designed protective system. The first cable 5 and the second cable 6 transmit vibration and strain signals respectively, and these cables are encapsulated within a high-strength steel protective device 4 made of a spiral-wound metal flexible conduit. Both ends of the protective device are connected to the tungsten carbide alloy shell 15 and the sealed through-wall joints on the soil chamber partition 12 via anti-loosening connectors, ensuring the stability of signal transmission under the high pressure and high humidity conditions of the tunnel boring machine. The cables pass through pre-drilled boreholes 9 in the soil chamber partition 12 and connect to the data acquisition unit 7.

[0030] The data acquisition unit 7 has a built-in professional signal processing module that uses the fast Fourier transform algorithm to perform frequency domain analysis on the vibration signal and extract the energy value of the characteristic frequency band as the basis for wear assessment. At the same time, it performs differential calculation on the signals of multiple fiber optic grating sensors 14 to eliminate environmental interference such as thermal strain and accurately extract the mechanical strain component.

[0031] It should be noted that the assembly of this device mainly involves the following steps:

[0032] 1. A mounting groove is machined behind the cutting edge of the tool 1, and a tungsten carbide alloy shell 15 is placed in it. The micro vibration sensor 13, the fiber optic grating sensor 14, the first cable 5, and the second cable 6 are then placed in sequence.

[0033] 2. High-temperature resistant epoxy resin 16 is poured into the tungsten carbide alloy shell 15 and cured. The tungsten carbide alloy shell 15 is connected to the tool 1 substrate by threads.

[0034] 3. Weld high-strength steel 4 for cable protection device between cutter head 2 and earth chamber partition 12 for storing first cable 5 and second cable 6;

[0035] 4. A borehole 9 is made in the earth chamber partition 12 to insert the first cable 5 and the second cable 6 of the micro vibration sensor 13 and the fiber optic grating sensor 14, and to connect the first cable 5 and the second cable 6 to the data acquisition unit 7.

[0036] During testing:

[0037] 1. The miniature vibration sensor 13 detects the impact frequency and amplitude of the cutting tool 1 during cutting, and judges the degree of wear by combining the preset threshold; the fiber optic grating sensor 14 monitors the strain distribution on the surface of the cutting tool 1, and identifies the crack initiation location by strain abrupt change.

[0038] 2. The sensor signal is transmitted to the data acquisition unit 7 at the center of the cutter head via the first cable 5 and the second cable 6, and then sent to the ground monitoring terminal via the optical fiber 11;

[0039] 3. Wear assessment: The ground system comprehensively judges the wear status based on the vibration signal spectrum energy (0.5-2kHz), cumulative strain, and temperature threshold >150℃, and indicates when to replace the tool.

[0040] 4. Following the above method, continue in this manner to complete the tool wear detection and replacement work.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0042] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention.

Claims

1. A multi-modal sensor based real-time detection device for shield cutter wear, characterized in that: Includes a miniature vibration sensor (13), a fiber optic strain sensor (14), and a data acquisition unit (7); The micro vibration sensor (13) and the fiber optic strain sensor (14) are fixed together by filling with high-temperature resistant epoxy resin (16), and are protected by a tungsten carbide alloy shell (15).

2. The multi-modal sensor based real-time detection of shield cutter wear device according to claim 1, wherein: The micro vibration sensor (13) detects the impact frequency and amplitude during tool cutting and judges the wear degree in combination with the preset threshold. The fiber optic strain sensor (14) monitors the strain distribution on the tool surface and identifies the crack initiation location through strain abrupt change.

3. The multi-modal sensor based real-time detection of shield cutter wear device according to claim 2, characterized in that: The detection data from the micro vibration sensor (13) and the fiber optic strain sensor (14) are transmitted to the data acquisition unit (7) via the first cable (5) and the second cable (6).

4. The multi-modal sensor based real-time detection of shield cutter wear device according to claim 3, wherein: It also includes a high-strength steel cable protection device (4) and a soil chamber partition (12). The first cable (5) and the second cable (6) are installed inside the high-strength steel cable protection device (4). The first cable (5) and the second cable (6) are connected to the data acquisition device (7) through drilling holes in the soil chamber partition (12).

5. The multi-modal sensor based real-time detection of shield cutter wear device according to claim 1, wherein: The shape of the tungsten carbide alloy shell (15) matches the surface contour of the base material of the shield cutter, and is welded and fixed in the preset groove on the surface of the cutter by high temperature brazing process, so that the working surface of the tungsten carbide alloy shell (15) is flush with the working surface of the cutter base material. 6.The multi-modal sensor based real-time detection of shield cutter wear device according to claim 1, wherein: Multiple fiber optic strain sensors (14) are arrayed and encapsulated in the tungsten carbide alloy shell (15) along the main force direction of the tool, and are used to measure the strain gradient distribution on the tool surface.

7. The real-time shield cutter wear detection device based on multimodal sensors according to claim 1, characterized in that: The data acquisition unit (7) has a built-in signal processing module, which is configured to perform frequency domain analysis on the vibration signal to extract the characteristic frequency energy value and to perform differential calculation on the strain signals of multiple fiber optic grating sensors. 8.The multi-modal sensor based real-time detection device of shield cutter wear according to claim 4, wherein: The high-strength steel (4) of the cable protection device is a spiral wound metal hose, and its two ends are connected to the sealed through-wall joints on the tungsten carbide alloy shell (15) and the earthen silo partition (12) through anti-loosening joints. 9.The multi-modal sensor based real-time detection of shield cutter wear device according to claim 1, wherein: The high-temperature resistant epoxy resin (16) is a thermally conductive and insulating material with a thermal conductivity greater than 0.5 W / (m·K).

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