A cutter head rotating stratum uneven settlement test system based on digital twinning

Abstract

The utility model provides a kind of cutter head rotation stratum uneven settlement test system based on digital twinning, it is characterized by, including: model box and shield tunneling test device;The shield tunneling test device includes shield machine, mounting bracket and operation platform, the model box and the operation platform are respectively arranged at the both ends of the mounting bracket, the shield machine is set on the mounting bracket;Data acquisition system for monitoring the stress distribution of two sides bottom layer in the model box is provided in the model box, the data acquisition system, shield machine and the operation platform signal connection.The utility model innovatively applies digital twinning technology to shield tunneling test, solves the problem that traditional method cannot quantize the influence of cutter head rotation on asymmetric settlement, realizes the intelligent optimization control of tunneling parameter, with high settlement prediction accuracy, fast response speed, good visual effect and other advantages, provides important technical support for the safe and efficient construction of shield tunnel engineering.

Description

Technical Field

[0001] This utility model relates to the field of shield tunnel construction technology, and in particular to a test system for uneven settlement of strata based on cutterhead rotation using digital twins. Background Technology

[0002] As shield tunnel construction moves towards mechanization and intelligence, the disturbance to the strata during shield excavation is becoming increasingly prominent. When the cutterhead rotates and cuts the soil, the dynamic characteristics of the cutterhead (such as eccentric load and asymmetrical cutter layout) and the heterogeneity of the strata lead to uneven stress distribution on both sides of the excavation axis, resulting in asymmetrical surface settlement (e.g., the settlement on the right side increases by 5% to 20% compared to the left side when rotating clockwise). If the settlement difference exceeds a threshold (usually >5mm), this asymmetrical settlement may cause engineering risks such as leakage at segment joints and tilting of adjacent buildings, and in severe cases, even surface collapse. Especially when traversing sensitive areas, how to accurately control the differential settlement caused by cutterhead rotation has become a key technical challenge to ensure project safety.

[0003] Based on this, existing research in this field suffers from three main shortcomings: numerical simulations primarily employ continuous medium theory, failing to accurately characterize the dynamic interaction between the cutterhead and soil using the discrete element method; experimental monitoring generally adopts a single-sided settlement detection scheme, neglecting the settlement differences caused by cutterhead rotation; and control strategies still rely on manual experience adjustments, lacking the ability to dynamically optimize cutterhead parameters based on real-time data. For example, while patent CN116776553A achieves settlement prediction, it does not consider the impact of cutterhead rotation; the CN118780077A experimental device only monitors overall settlement, failing to consider the asymmetric settlement caused by uneven stress distribution on both sides of the strata due to cutterhead rotation during shield tunneling. These technological limitations force the adoption of conservative construction parameters in engineering practice, not only reducing construction efficiency but also directly increasing energy consumption and construction costs. Utility Model Content

[0004] The main purpose of this invention is to provide a test system for uneven settlement of strata based on cutterhead rotation using digital twins. This system aims to solve the problem that traditional methods cannot quantify the impact of cutterhead rotation on asymmetric settlement, and to achieve intelligent optimization control of tunneling parameters. It has advantages such as high settlement prediction accuracy, fast response speed, and good visualization effect, and provides important technical support for the safe and efficient construction of shield tunnel projects.

[0005] To achieve the above objectives, this utility model proposes a test system for uneven settlement of strata with rotating cutterhead based on digital twins, comprising: a model box and a shield tunneling test device; the shield tunneling test device includes a shield machine, a mounting frame and an operating platform, the model box and the operating platform are respectively disposed at both ends of the mounting frame, and the shield machine is disposed on the mounting frame;

[0006] The model box is equipped with a data acquisition system for monitoring the stress distribution on both sides of the bottom layer inside the model box. The data acquisition system, the tunnel boring machine, and the control panel are connected by signals.

[0007] A further technical solution of this utility model is that the model box is provided with a shield tunneling space, and the data acquisition system includes a support set in the shield tunneling space of the model box, and several slide rails set parallel to the top of the model box on the support. Several displacement sensors are fixedly set on each slide rail by a clamp.

[0008] A further technical solution of this utility model is that the tunnel boring machine includes a cutterhead cutting part, a soil removal part, a tunnel boring machine shell, a cutterhead rotating motor, a propulsion motor, and a soil removal rotating motor;

[0009] The cutterhead cutting part includes a rotating cutterhead installed in the front soil chamber baffle of the tunnel boring machine. The rotating cutterhead is connected to one end of the rear rotating main shaft, and the other end of the rotating main shaft is connected to the cutterhead rotating motor.

[0010] The excavation section includes an excavation steel pipe and a spiral excavator. The spiral excavator is installed inside the excavation steel pipe and connected to the excavation rotating motor at the rear.

[0011] The propulsion motor is used to propel the entire tunnel boring machine through tunneling.

[0012] A further technical solution of this utility model is that it also includes a reducer and a flange, wherein the reducer is connected to the propulsion motor through the flange.

[0013] A further technical solution of this utility model is that the bottom of the mounting frame is provided with support bolts for calibrating and aligning the shield tunneling test device.

[0014] A further technical solution of this utility model is that the rotating cutter head includes a cross-shaped strip and a blade, one end of the rotating spindle is connected to the center of the cross-shaped strip, and the blade is disposed at the end of the cross-shaped strip.

[0015] A further technical solution of this utility model is that the model box includes a square steel frame and steel support beams arranged around the square steel frame. An angle steel is provided at the connection between the top of the square steel frame and the top of the steel support beams. A circular hole with a diameter slightly larger than that of the excavated steel pipe is opened on the model box.

[0016] A further technical solution of this utility model is that the operating console is equipped with an operating console display screen, a USB flash drive port for copying tunneling parameters, a power indicator light A, a power indicator light B, an equipment power start button, a wear machine start button, and a tunneling machine start button.

[0017] The beneficial effects of this invention, a test system for uneven settlement of formations based on a cutterhead rotation using digital twins, are as follows:

[0018] This invention innovatively applies digital twin technology to shield tunneling tests, solving the problem that traditional methods cannot quantify the impact of cutterhead rotation on asymmetric settlement. It realizes intelligent optimization control of tunneling parameters and has advantages such as high settlement prediction accuracy, fast response speed, and good visualization effect, providing important technical support for the safe and efficient construction of shield tunnel projects. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of a preferred embodiment of the test system for uneven settlement of strata based on digital twins with rotating cutterhead according to this utility model;

[0020] Figure 2 This is a structural diagram of the model box;

[0021] Figure 3 This is a schematic diagram of the rotating cutter head;

[0022] Figure 4 This is a schematic diagram of the circular hole structure on the front of the model box;

[0023] Figure 5 This is a schematic diagram of the control panel structure;

[0024] Figure 6 This is an assembly diagram of the displacement sensor;

[0025] Figure 7 This is a schematic diagram of the system framework of a preferred embodiment of the digital twin-based test system for uneven settlement of strata with rotating cutterhead.

[0026] Explanation of icon numbers:

[0027] 1. Control panel; 2. Reducer; 3. Mounting flange; 4. Propulsion motor; 5. Cutterhead rotating motor; 6. Excavation rotating motor; 7. Spiral excavator; 8. Support bolts; 9. Rotating cutterhead; 10. Model box; 11. Tunnel boring machine shell; 12. Excavation steel pipe; 13. Displacement sensor; 14. Tunnel boring space; 15. Blade; 16. Cross-shaped banner; 17. Rotating spindle; 18. Angle steel; 19. Square steel frame; 20. Steel support beam; 21. Circular hole; 22. Control panel display screen; 23. USB port for copying tunneling parameters; 24. Power indicator light A; 25. Power indicator light B; 26. Equipment power start button; 27. Wear machine start button; 28. Tunnel boring machine start button; 29. ​​Clamp; 30. Slide rail.

[0028] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0029] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0030] This invention proposes a test system for uneven settlement of strata based on a cutterhead rotation using digital twins, such as... Figures 1 to 7 As shown, the preferred embodiment of the test system for uneven settlement of strata based on digital twin based on cutterhead rotation includes: model box 10, shield tunneling test device, data acquisition system, numerical simulation model and virtual-real interaction platform.

[0031] The shield tunneling test device includes a shield machine, a mounting frame, and an operating platform 1. The model box 10 and the operating platform 1 are respectively located at both ends of the mounting frame, and the shield machine is mounted on the mounting frame.

[0032] The model box 10 is equipped with a data acquisition system for monitoring the stress distribution on both sides of the bottom layer inside the model box 10. The data acquisition system, the tunnel boring machine, and the operating platform 1 are connected by signals.

[0033] The model box 10 is provided with a shield tunneling space 14. The data acquisition system includes a support set in the shield tunneling space 14 of the model box 10, and several slide rails 30 arranged parallel to the top of the model box 10 on the support. Several displacement sensors 13 are fixedly set on each slide rail 30 by a clamp.

[0034] Specifically, in this embodiment, the tunnel boring machine includes a cutterhead cutting section, a soil removal section, a tunnel boring machine shell 11, a cutterhead rotating motor 5, a propulsion motor 5, and a soil removal rotating motor 6.

[0035] The cutterhead cutting part includes a rotating cutterhead 9 installed in the soil chamber baffle at the front of the tunnel boring machine. One end of the rotating cutterhead 9 is connected to a rotating main shaft 17 at the rear, and the other end of the rotating main shaft 17 is connected to the cutterhead rotating motor 5 to realize the synchronous rotation of the rotating cutterhead 9.

[0036] The soil removal section includes a soil removal steel pipe 12 and a spiral soil removal device 7. The spiral soil removal device 7 is installed inside the soil removal steel pipe 12 and connected to the soil removal rotating motor 6 behind it to realize synchronous soil removal during the shield tunneling process.

[0037] The propulsion motor 5 is used to propel the entire tunnel boring machine. In this embodiment, the digital twin-based test system for uneven settlement of the ground under rotating cutterhead also includes a reducer 2 and a flange 3, with the reducer 2 connected to the propulsion motor 5 via the flange 3.

[0038] In this embodiment, the bottom of the mounting frame is provided with support bolts 8 for calibrating and aligning the shield tunneling test device.

[0039] In this embodiment, the rotating cutter head 9 includes a cross-shaped strip 16 and a blade 15. One end of the rotating main shaft 17 is connected to the center of the cross-shaped strip 16, and the blade 15 is disposed at the end of the cross-shaped strip 16.

[0040] In this embodiment, the model box 10 includes a square steel frame 19 and steel support beams 20 arranged around the square steel frame 19. An angle steel 18 is provided at the connection between the top of the square steel frame 19 and the top of the steel support beams. The model box 10 has a circular hole 21 with a diameter slightly larger than that of the excavated steel pipe 12.

[0041] Specifically, the model box 10 has its sides made of high-hardness, high-transparency acrylic, and its bottom plate is made of thick steel plate. The outer perimeter is fixed to the square steel frame 19 by angle steel 18, and each side is reinforced with steel support beams 20.

[0042] In this embodiment, the control panel 1 is equipped with a control panel display screen 22, a USB flash drive port for copying tunneling parameters 23, a power indicator light A 24, a power indicator light B 25, an equipment power start button 26, a wear machine start button 27, and a tunneling machine start button 28.

[0043] In this embodiment, the tunneling process of the tunnel boring machine is carried out synchronously in the digital twin system, including three aspects:

[0044] a) Three-dimensional laser scanning acquires point cloud data, which is then preprocessed to construct a discrete element numerical model; b) Model parameters are dynamically updated based on real-time settlement data to predict future settlement trends; c) A virtual-real interaction system enables bidirectional control of the physical device and the digital model, automatically optimizing tunneling parameters to suppress asymmetric settlement; d) A three-dimensional visualization platform is used to display the stratum deformation field and settlement distribution characteristics in real time.

[0045] The working process of the digital twin-based test system for uneven settlement of formations with rotating cutterhead is as follows:

[0046] 1. Before conducting the test, the shield tunneling test device and model box 10 need to be assembled as required. The assembly of the shield tunneling test device includes the following steps: At the front of the tunnel segment, the shield machine shell 11 is connected to the soil chamber partition plate with high-strength screws. At the rear of the tunnel segment, the shield machine shell 11 is also connected to the support partition plate with high-strength screws. Then, the whole assembly is installed on the rotating main shaft 17. Under the constraint of the two support points provided at the front and rear, the shield machine can be kept at a fixed height. At the same time, a steel pipe support is set at the rear to prevent the shield machine from deforming. The rotating cutterhead 9 is fixed to the rotating main shaft 17 with bolts and lock nuts through the cutterhead shaft hole opened in the soil chamber partition plate. Rubber washers are placed on the contact surface between the lock nut and the soil chamber partition plate to prevent large friction between the cutterhead and the soil chamber partition plate during the rotation of the cutterhead. The excavation steel pipe 12 is fixed to the excavation port below the soil chamber partition and support partition using AB glue. The spiral excavator 7 is placed inside the excavation steel pipe 12, with its rear end welded to a screw rod. The screw rod is fixed to the center of the excavation rotation gear, thus achieving synchronous excavation. The assembly of the model box 10 includes: using high-hardness, high-transparency acrylic sheets for the sides of the model box 10; using thick steel plates for the bottom plate; and fixing the model box 10 to the outer perimeter using angle steel 18 and a square steel frame 19 to enhance its overall rigidity. To prevent cracking due to excessive soil pressure on the sides, steel support beams 20 are installed on each side for reinforcement. A circular hole 21, slightly larger than the diameter of the tunnel boring machine, is made on the front of the model box 10 to allow the tunnel boring machine to pass through.

[0047] 2. After assembling the shield tunneling test device and model box 10, the shield machine and model box 10 need to be calibrated, including the following steps: Adjust the support bolts 8 at the four corners of the shield device to a suitable height, ensuring that the shield machine is vertically aligned with the circular hole 21 in the center of the acrylic baffle, while ensuring that the device is not tilted in the horizontal direction. After alignment, push the shield tunnel section completely into the model box 10, and observe whether there is a gap that is too small or too large between the tunnel section and the circular hole 21 during the advancement process. If a problem is found, further refine the position of the device.

[0048] 3. After the device is assembled and calibrated, the test will begin. This includes three processes: a) backfilling with sand and soil and reinforcing the strata; b) deploying the surface settlement monitoring device; c) starting the test and monitoring.

[0049] a) Sand backfilling and ground reinforcement: Sand is backfilled using a sand dropper, and the soil layers are leveled and compacted using a layered backfilling and compaction method. Long wooden planks are used to level the soil layers, and then each layer is compacted using a compaction hammer. It is important to ensure that the number of hammer drops and the drop height are consistent for each compaction operation.

[0050] b) Deployment of the surface settlement monitoring device: First, the sensors are erected and assembled. The linear displacement sensor 13 is fixed to the clamp, which is connected to the aluminum rail with bolts. The sensor spacing is adjusted according to the surface settlement monitoring layout plan. After the sand filling and compaction are completed, the aluminum rail is erected on the model box 10, allowing the displacement sensor 13 to suspend above the ground surface. By adjusting the height of the clamp, the sensor probe can be made to contact the soil, ensuring that the measurement range of each sensor is within the required monitoring range. The sensor wires are connected to the data acquisition instrument to realize the monitoring of surface settlement by the displacement sensor 13.

[0051] c) Start the test and monitoring: Open the shield tunneling operation panel on the control panel, set various tunneling parameters according to the actual situation, including the cutterhead rotation speed, shield advance rate and soil removal screw speed, and then start the automatic tunneling mode.

[0052] 4. The entire tunneling process is carried out synchronously in a digital twin. The numerical simulation model has control over all tunneling parameters of the entire shield tunneling device. It includes four processes: a) data acquisition and analysis; b) construction of numerical simulation model; c) establishment of virtual-real interaction system; d) three-dimensional visualization display system.

[0053] a) Data Acquisition and Analysis: Three-dimensional laser scanning technology was used to scan the tunnel boring machine (TBM) and geological model box 10 to acquire high-density point cloud data. Each point contains spatial information such as spatial coordinates (XYZ), reflection intensity characteristics, and color information (RGB). After acquiring the point cloud data, preprocessing was performed through outlier removal and voxel mesh simplification. A three-dimensional model was constructed based on discrete element theory, synchronously recording information such as cutterhead rotation speed, TBM advance rate, and excavation screw speed. Real-time settlement values ​​obtained by displacement sensor 13 during the tunneling process were also analyzed.

[0054] b) Constructing a numerical simulation model: The processed data is added to the constructed three-dimensional discrete element model to form a numerical simulation model. Simultaneously, information obtained from the shield tunneling process of the physical device can be used to correct and update the numerical simulation model. When the test device is tunneling, displacement sensor 13 measures the settlement value in real time, outputs the data through the data acquisition instrument, and converts the format before inputting it into the numerical simulation model for synchronous loading. Based on the uneven settlement on both sides of the already tunneled section, the numerical simulation model predicts the uneven settlement that will occur during future tunneling and feeds it back to the cutterhead speed setting of the physical device, continuously optimizing and adjusting it until the uneven settlement on both sides is controlled within a reasonable range.

[0055] c) Establishing a virtual-physical interaction system: This module achieves bidirectional dynamic coupling between the physical entity and the digital twin, establishing a synchronization mechanism through a real-time data exchange protocol. When numerical simulation parameters are adjusted, the system can automatically generate control commands to drive the physical device to respond; conversely, changes in the operating status of the physical device will trigger real-time parameter updates in the digital model. Based on a multiphysics coupling algorithm, the digital twin can anticipate the entire tunneling process and accurately predict the surface settlement distribution and the evolution characteristics of the deep soil displacement field.

[0056] d) 3D visualization display system: Based on the digital twin technology of virtual and real interaction, a real-time 3D visualization platform for the tunneling process is constructed. The dynamic rendering engine realizes the real-time display of color cloud map of the stratum deformation field, supports multi-view and multi-scale (macro-micro) visualization analysis, and intuitively presents the stratum response characteristics during the shield tunneling process.

[0057] 5. After the test, empty the soil from model box 10, dismantle the test equipment in sequence, and finally process the data.

[0058] The key points of this invention's digital twin-based test system for uneven settlement of formations with rotating cutterhead during operation are as follows:

[0059] (1) A three-dimensional numerical model is constructed using discrete element theory instead of traditional continuous medium theory. High-density point cloud data (including spatial coordinates, reflection intensity, and color information) is obtained by combining three-dimensional laser scanning. The model parameters are dynamically updated by quantifying the asymmetric settlement effect caused by the rotation of the cutterhead in real time. This can accurately present the dynamic interaction between the cutterhead and the soil and improve the accuracy of settlement prediction.

[0060] (2) A two-way dynamic coupling mechanism between the physical device and the digital model is established, which is achieved through a real-time data exchange protocol: the digital model predicts the settlement trend and automatically generates control commands to drive the physical device to adjust the cutterhead rotation speed and propulsion rate; at the same time, the operating status of the physical device triggers the parameter update of the digital model in real time. When enough high-quality data is obtained, the shield cutterhead rotation tunneling test can achieve highly digital and automated control. This mechanism breaks through the limitations of manual experience adjustment, avoids the dangers and errors that may be caused by manual operation, and can effectively suppress the asymmetric settlement generated during the cutterhead rotation tunneling process.

[0061] (3) A real-time three-dimensional visualization platform is built based on a dynamic rendering engine to support multi-view and multi-scale analysis of the stratum deformation field. The settlement distribution and deep soil displacement evolution are presented intuitively with color cloud maps, providing an intuitive basis for engineering decision-making.

[0062] The beneficial effects of this invention, a test system for uneven settlement of formations based on a cutterhead rotation using digital twins, are as follows:

[0063] This invention innovatively applies digital twin technology to shield tunneling tests, solving the problem that traditional methods cannot quantify the impact of cutterhead rotation on asymmetric settlement. It realizes intelligent optimization control of tunneling parameters and has advantages such as high settlement prediction accuracy, fast response speed, and good visualization effect, providing important technical support for the safe and efficient construction of shield tunnel projects.

[0064] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural or procedural changes made based on the contents of the present utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present utility model.

Claims

1. A test system for uneven settlement of strata based on a cutterhead rotation using digital twins, characterized in that, include: A model box and a shield tunneling test device; the shield tunneling test device includes a shield machine, a mounting frame and an operating platform, the model box and the operating platform are respectively set at both ends of the mounting frame, and the shield machine is set on the mounting frame; The model box is equipped with a data acquisition system for monitoring the stress distribution on both sides of the bottom layer inside the model box. The data acquisition system, the tunnel boring machine, and the control panel are connected by signals.

2. The test system for uneven settlement of strata based on cutterhead rotation according to claim 1, characterized in that, The model box contains a shield tunneling space. The data acquisition system includes a support set in the shield tunneling space of the model box, and several slide rails set parallel to the top of the model box on the support. Several displacement sensors are fixedly set on each slide rail by a clamp.

3. The test system for uneven settlement of strata based on cutterhead rotation according to claim 1, characterized in that, The tunnel boring machine includes a cutterhead cutting section, a soil removal section, a tunnel boring machine shell, a cutterhead rotating motor, a propulsion motor, and a soil removal rotating motor; The cutterhead cutting part includes a rotating cutterhead installed in the front soil chamber baffle of the tunnel boring machine. The rotating cutterhead is connected to one end of the rear rotating main shaft, and the other end of the rotating main shaft is connected to the cutterhead rotating motor. The excavation section includes an excavation steel pipe and a spiral excavator. The spiral excavator is installed inside the excavation steel pipe and connected to the excavation rotating motor at the rear. The propulsion motor is used to propel the entire tunnel boring machine through tunneling.

4. The test system for uneven settlement of strata based on cutterhead rotation according to claim 1, characterized in that, It also includes a speed reducer and a flange, the speed reducer being connected to the propulsion motor via the flange.

5. The test system for uneven settlement of strata based on cutterhead rotation according to claim 1, characterized in that, The bottom of the mounting frame is equipped with support bolts for calibrating and aligning the shield tunneling test device.

6. The test system for uneven settlement of strata based on cutterhead rotation according to claim 3, characterized in that, The rotating cutter head includes a cross-shaped strip and a blade. One end of the rotating spindle is connected to the center of the cross-shaped strip, and the blade is disposed at the end of the cross-shaped strip.

7. The test system for uneven settlement of strata based on cutterhead rotation according to claim 1, characterized in that, The model box includes a square steel frame and steel support beams arranged around the square steel frame. Angle steel is provided at the connection between the top of the square steel frame and the top of the steel support beams. The model box has a circular hole with a diameter slightly larger than that of the excavated steel pipe.

8. The test system for uneven settlement of strata based on cutterhead rotation according to claim 1, characterized in that, The control panel is equipped with a control panel display screen, a USB flash drive port for copying tunneling parameters, power indicator light A, power indicator light B, equipment power start button, wear machine start button, and tunneling machine start button.

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