Energy-saving control method and system for shield tunneling machine

Abstract

Disclosed is an energy-saving control method for a shield tunneling machine, the method comprising: when an advance speed of a shield tunneling machine changes during a tunneling process, according to the change in the advance speed, adjusting one or more of a spoil discharge system (7), a fluid system (10) and an electrical system (11). The spoil discharge system (7) performs adjustment in the following method: calculating a corresponding amount of excavated spoils according to the advance speed, then calculating a theoretical spoil discharge speed according to the amount of excavated spoils, and a matched spoil discharge system (9) adjusting the spoil discharge speed thereof according to the theoretical spoil discharge speed. The fluid system (10) performs adjustment in the following method: according to the magnitude of the advance speed of the shield tunneling machine, the fluid system (10) adjusts the flow rate of a fluid in the corresponding fluid system. The electrical system (11) performs adjustment in the following method: according to the magnitude of the advance speed of the shield tunneling machine, the electrical system adjusts the active power of a transformer of the electrical system. The present application can solve the problems of high apparatus energy consumption and severe energy waste of shield tunneling machines caused by large apparatus installation power, numerous auxiliary apparatuses, unreasonable design, etc. in the prior art. Also disclosed is a system using the method.

Description

Energy-saving control method and system for shield machine Technical Field

[0001] The invention relates to an energy-saving control method and system for a shield machine, and belongs to the field of tunnel construction equipment. Background Art

[0002] As a large-scale tunnel construction machine integrating mechanical, electrical, fluid, and hydraulic systems, shield machines have been equipped with more advanced equipment and become increasingly intelligent with the advancement of technology and improvements in tunnel construction efficiency in recent years. The total installed power of TBMs has also increased significantly, almost doubling for machines of the same diameter and type. This growth is primarily driven by the continued demand for higher torque, speed, and thrust, as well as the astonishing increase in the amount of auxiliary equipment installed on backup equipment.

[0003] However, this increased power is only required in special cases, while in most cases only a small fraction is needed. The same applies to many auxiliary devices.

[0004] Chinese invention patent application publication number CN105864126A discloses an energy-saving hydraulic system for propulsion and support of a TBM. The system comprises an oil source system, a propulsion system, a support system, and a fuel tank. The propulsion and support systems are connected to the fuel tank via the oil source system, and the propulsion and support systems are connected in parallel. The oil source system, propulsion system, support system, and fuel tank are connected via a main oil circuit and a pilot oil circuit. The pilot oil circuit includes a load-sensing valve, a variable cylinder, a pressure switching valve, and an accumulator to control support and propulsion. The invention optimizes the propulsion and support system by configuring a pump to supply oil to the large chamber of the support cylinder under pressure-off conditions. After support is completed, the accumulator maintains pressure, and the pump supplies oil to the propulsion cylinder under load-sensing conditions. However, this energy-saving optimization is achieved by redesigning the hardware structure of the hydraulic system. However, existing shield machines consume a lot of energy and waste a lot of energy due to their high installed power, numerous auxiliary equipment, and inherently irrational designs. Simply saving energy on individual devices or systems alone cannot achieve the goal of overall energy saving for shield machines.

[0005] The development of green energy-saving shield machines is to manage the huge energy of modern shield machines. The purpose is to maximize their energy efficiency through automatic management operations and the design of the shield machine itself. Currently, there is relatively little research on green energy-saving shield machines in China.

[0006] Summary of the Invention

[0007] The purpose of the present invention is to provide an energy-saving control method and system for a shield machine, so as to solve the problems of high energy consumption and serious energy waste caused by large installed power, many auxiliary equipment and unreasonable design of shield machines in the prior art.

[0008] To achieve the above object, the solution of the present invention includes:

[0009] A shield machine energy-saving control method, when the propulsion speed of the shield machine changes during tunneling, adjusts one or more of the slag discharge system, the fluid system, and the electrical system according to the propulsion speed change value:

[0010] The slag discharge system is adjusted by the following method: the corresponding excavated volume is calculated according to the propulsion speed, and then the theoretical slag discharge speed is calculated according to the excavated volume. The slag discharge system then adjusts its slag discharge speed according to the theoretical slag discharge speed.

[0011] The fluid system is adjusted by the following method: the fluid system adjusts the flow rate of the fluid in the corresponding fluid system according to the propulsion speed of the shield machine;

[0012] The electrical system is adjusted by the following method: the electrical system adjusts the active power of the electrical system transformer according to the propulsion speed of the shield machine.

[0013] The shield machine of the present invention can adjust the discharge speed of its supporting slag discharge system in real time based on changes in propulsion speed; its fluid system can adjust the flow rate of its fluid based on propulsion speed; and its electrical system can automatically correct its power factor based on propulsion speed to meet high power quality requirements. As a result, the shield machine can adjust the operation of various system equipment accordingly to changes in propulsion speed during tunneling, allowing it to start according to actual needs, improve equipment utilization, reduce energy consumption, and maximize energy efficiency.

[0014] Furthermore, the excavated volume is also calculated based on the excavation area and the looseness coefficient.

[0015] The excavation volume is calculated by adding the excavation area and loose coefficient, making the calculation result of the excavation volume more accurate.

[0016] Furthermore, the relationship between the theoretical slag discharge speed and the slag discharge speed of the subsequent supporting slag discharge system is: N = μ × Ns

[0017] Where: Ns is the slag discharge speed of the subsequent slag discharge system, N is the theoretical slag discharge speed, and μ is the conversion coefficient.

[0018] According to the above formula, the corresponding relationship between the slag discharge speed of the subsequent slag discharge system and the theoretical slag discharge speed can be adjusted, so that the slag discharge speed of the subsequent slag discharge system can be accurately controlled following the changes in the theoretical slag discharge speed, which is easy to implement and control in engineering.

[0019] Furthermore, the fluid system includes a coolant circulation system, and the coolant circulation system adjusts the frequency of the circulating water pump according to the propulsion speed of the shield machine, thereby adjusting the exchanged coolant flow rate.

[0020] This solution adjusts the exchange coolant flow rate by adjusting the frequency of the circulating water pump to match the changes in the shield machine's propulsion speed, which can better achieve green energy saving of the shield machine's coolant circulation system, reduce energy consumption, and maximize energy efficiency.

[0021] Furthermore, the frequency of the circulating water pump is adjusted and controlled according to the detected temperature difference between the temperature of the inner circulating coolant and the temperature of the outer circulating coolant used for cooling the relevant systems of the shield machine.

[0022] The frequency of the circulating water pump is controlled by adjusting the temperature difference between the internal circulating coolant temperature and the external circulating coolant temperature of the shield machine's related systems. The method is simple and easy to implement during engineering implementation.

[0023] Furthermore, the relationship between the exchanged coolant flow rate and the temperature difference between the inner circulation coolant temperature and the outer circulation coolant temperature is: Q = t × (T1-T0)

[0024] Among them, Q is the exchanged coolant flow rate, T1 is the internal circulation coolant temperature, T0 is the external circulation coolant temperature, and t is the heat conversion coefficient.

[0025] The exchange coolant flow rate is calculated by the difference between the internal circulation coolant temperature and the external circulation coolant temperature. When the temperature difference becomes larger, the exchange coolant flow rate is increased, and when the temperature difference becomes smaller, the exchange coolant flow rate is reduced. The exchange coolant flow rate can be accurately controlled by the change in temperature difference, thereby reducing energy consumption.

[0026] Furthermore, the fluid system also includes a foam system, a bentonite system and a grouting system. When the propulsion speed increases, the injection amount of the fluid of the corresponding system is adjusted to increase; when the propulsion speed decreases, the injection amount of the fluid of the corresponding system is adjusted to decrease.

[0027] This solution achieves green energy saving of the foam system, bentonite system and grouting system by adjusting the increase or decrease of the fluid injection volume to match the increase or decrease of the propulsion speed, thereby achieving overall energy saving of the shield machine.

[0028] Furthermore, the active power of the transformer of the electrical system is achieved by adjusting the power factor of the transformer.

[0029] Active power is achieved by adjusting the power factor of the transformer, and the control result is more accurate.

[0030] Furthermore, the relationship between the active power of the transformer and the power factor of the transformer is: S 2 =P 2 +Q 2

[0031] Among them: S is the apparent power, P is the active power, Q is the reactive power, is the power factor.

[0032] An energy-saving control system for a shield machine comprises a controller, wherein the controller is used to execute computer program instructions to implement any of the above-mentioned energy-saving control methods for a shield machine. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIG1 is a schematic diagram of the entire machine structure of this embodiment;

[0034] FIG2 is a control flow chart of the present embodiment;

[0035] In the figure: 1. Cutterhead system; 2. Shield system; 3. Main drive system; 4. Propulsion system; 5. Segments; 6. Segment assembly system; 7. Shield slag discharge system (screw conveyor system); 8. Post-supporting system; 9. Post-supporting slag discharge system (belt conveyor system); 10. Fluid system; 11. Electrical system; 12. Hydraulic system; 13. Host computer intelligent control system. DETAILED DESCRIPTION

[0036] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below with reference to the accompanying drawings and embodiments.

[0037] During the tunneling process of the shield machine, the electrical system, hydraulic system and fluid system of the shield machine are automatically managed to realize automatic adjustment of the cutter head speed, main drive torque and propulsion force tunneling parameters; at the same time, by automatically controlling the equipment usage of the hydraulic system and fluid system and automatically adjusting the power factor compensation of the electrical system, the energy utilization of the shield machine is maximized and energy consumption is saved.

[0038] The green and energy-saving shield machine of the present invention includes a cutterhead system, a shield system, a main drive system, a propulsion system, an assembly machine system, a shield slag discharge system, tunnel support segments, a rear supporting system, a rear supporting slag discharge system, a fluid system, an electrical system, a hydraulic system and an upper computer intelligent control system.

[0039] The main drive system and propulsion system are fixedly installed within the shield system. The cutterhead system is connected to the main drive system, and the propulsion system generates reaction force from the segments supported by the tunnel to propel the shield machine forward. The segment assembly system assembles segments during the shield machine's propulsion process to support the excavated tunnel, and the propulsion system is supported by the segments to propel the shield machine forward. The shield slag discharge system is fixed within the shield system. The auxiliary slag discharge system, hydraulic system, electrical system, and fluid system are installed in the auxiliary system, which is connected to the shield system. The fluid system is located in the auxiliary system and includes a coolant circulation system.

[0040] As the shield machine advances, the cutterhead system, main drive system, and propulsion system excavate the ground and advance the machine according to the machine's set excavation parameters. The shield's slag discharge system and its associated slag discharge system discharge the excavated soil out of the tunnel. The hydraulic system, fluid system, and electrical system coordinate according to the machine's excavation needs to complete the entire excavation process.

[0041] During the shield machine excavation construction process, the rock breaking efficiency of the excavation face mainly depends on the cutter spacing, penetration (the depth of the cutterhead cutting into the rock layer or excavation face after one rotation of the cutterhead) and the propulsion force applied to the cutterhead system by the propulsion system. In principle, maintaining a constant penetration for the same or similar strata can achieve the most economical and efficient construction efficiency.

[0042] Method Example:

[0043] This embodiment provides an energy-saving control method for a shield machine. Specifically, as shown in Figure 1, the green and energy-saving shield machine of the present invention comprises a cutterhead system 1, a shield system 2, a main drive system 3, a propulsion system 4, segments 5, a segment assembly system 6, a shield slag discharge system 7, a rear-end system 8, a rear-end slag discharge system 9, a fluid system 10, an electrical system 11, a hydraulic system 12, and a host computer intelligent control system 13. The main drive system 3 and propulsion system 4 are fixedly mounted within the shield system 2, and the cutterhead system 1 is connected to the main drive system 3. The segment assembly system 6 assembles segments to support the excavated tunnel during the shield machine's propulsion process. The propulsion system 4 generates reaction force from the segments 5 supported in the tunnel, enabling the shield machine to advance. The shield slag discharge system 7 is fixed within the shield system 2, while the rear-end slag discharge system 9, hydraulic system 12, electrical system 11, and fluid system 10 are mounted on the rear-end system 9. The rear-end system 8 is connected to the shield system 2. When the shield machine is excavating, the cutterhead system 1 rotates relative to the shield system 2 and discharges the excavated soil out of the tunnel through the shield slag discharge system 7 and the subsequent supporting slag discharge system 9.

[0044] As shown in Figure 2, during the tunneling process of the shield machine, after setting the parameter values ​​of the penetration of the cutterhead system 1 and the propulsion speed of the propulsion system 4, the rotation speed of the cutterhead system 1 is adjusted to make the propulsion speed of the propulsion system 4 reach the preset propulsion speed value. The mutual adjustment relationship is as follows: S = N × Pr

[0045] Where N is the cutter head speed (r / min), Pr is the penetration rate (mm / r), and S is the advancement speed (mm / min).

[0046] When the penetration value remains constant, the cutter head speed increases and the advancement speed increases; otherwise, the advancement speed decreases.

[0047] At the same time, the host computer intelligent control system 13 calculates the theoretical shield machine excavation volume based on the propulsion speed, excavation area, and loose coefficient. The shield body slag discharge system 7 calculates the theoretical slag discharge speed N based on its slag discharge efficiency. The subsequent slag discharge system 9 automatically adjusts its slag discharge speed Ns based on the slag discharge speed N of the shield body slag discharge system 7. The adjustment relationship is as follows: N = μ × Ns

[0048] Among them, Ns is the slag discharge speed of the subsequent slag discharge system 9, N is the slag discharge speed of the shield slag discharge system 7, and μ is the conversion coefficient.

[0049] The coolant circulation system of the fluid system 10 varies with the tunneling speed (propulsion speed) of the shield machine. The temperature of the internal circulating cooling water used to cool the electrical system 11, main drive system 3, and hydraulic system 12 will also change. In this embodiment, the exchanged coolant is water, and the external water temperature is constant. The host computer intelligent control system 13 automatically adjusts the frequency of the circulating water pump based on the detected temperature difference, thereby automatically adjusting the exchanged water flow rate. The adjustment relationship is as follows: Q = t × (T1 - T0)

[0050] Among them, Q is the exchange water flow rate, T1 is the internal circulation water temperature, T0 is the external circulation water temperature, and t is the heat conversion coefficient.

[0051] When the temperature difference between the internal and external circulating water increases, the operating frequency of the corresponding circulating water pump is increased, thereby increasing the exchange water flow rate; conversely, the exchange water flow rate decreases. The coolant circulation system of fluid system 10 automatically adjusts the frequency of the circulating water pump according to the change in the temperature difference between the internal and external circulating water.

[0052] The foam system of the fluid system 10 changes with the size of the shield machine's tunneling speed, and the amount of foam injected into the excavation surface and soil bin also changes accordingly. Since the soil adjusted by foam has good fluidity, plasticity and waterproof permeability, it can ensure the smooth discharge of slag, maintain the stability of the excavation surface, expand the scope of soil types suitable for excavation of the shield machine, and at the same time reduce the torque of the cutter head and reduce the wear of the tool. When the shield machine's tunneling speed increases, the amount of foam injected into the foam system also increases accordingly to improve the soil. The host computer intelligent control system 13 automatically adjusts the number of its corresponding injection pumps according to the change in its injection amount; when the shield machine's tunneling speed decreases, the amount of foam injected into the foam system decreases accordingly. The host computer intelligent control system 13 automatically adjusts the number of its corresponding injection pumps according to the change in its injection amount; thereby achieving green energy saving of the shield machine's foam system during the tunneling process and reducing energy consumption.

[0053] The grouting system of the fluid system 10 changes with the size of the shield machine's tunneling speed, and the injection amount of slurry it injects into the annular gap between the pipe segment and the excavated tunnel body also changes accordingly. When the tunneling speed increases, the annular gap excavated within a certain period of time also increases, and the required slurry injection amount also increases. The grouting system automatically adjusts the slurry injection amount of the grouting system according to the increase in tunneling speed and increases it accordingly; when the tunneling speed decreases, the required slurry injection amount also decreases. The grouting system automatically adjusts the slurry injection amount of the grouting system according to the decrease in tunneling speed; thereby achieving green energy saving of the shield machine's grouting system during the tunneling process and reducing energy consumption.

[0054] The bentonite system of the fluid system 10 changes with the speed of the shield machine's excavation, and the amount of bentonite required to form a lubricating film between the machine head and tunnel ring and the soil also changes accordingly. When the excavation speed increases, the amount of bentonite required to be injected between the shield body and the soil also increases, and the host computer intelligent control system 13 automatically adjusts the number of injection pumps to increase accordingly according to the change in its injection amount; when the excavation speed decreases, the amount of bentonite required to be injected between the shield body and the soil also decreases, and the host computer intelligent control system 13 automatically adjusts the number of injection pumps to decrease accordingly according to the change in its injection amount; thereby achieving green energy saving of the bentonite system of the shield machine during the excavation process and reducing energy consumption.

[0055] The electrical system 11 automatically adjusts the number of motors in the main drive system based on changes in cutterhead torque. Cutterhead torque is directly proportional to cutterhead speed. When cutterhead speed increases, the torque required by the cutterhead increases, and the motor power of the main drive system 3 increases, the host computer intelligent control system 13 automatically increases the number of motors in operation. Conversely, the host computer intelligent control system 13 automatically decreases the number of motors in operation. The adjustment relationship is as follows: P1 = k × T

[0056] Among them, P1 is the motor power, k is a constant, and T is the cutter head torque.

[0057] Finally, the electrical system 11 changes with the speed of the shield machine's tunneling. When the tunneling speed changes, the load on the transformer of the entire electrical system also changes. When the power factor decreases, the electrical system's energy loss will increase accordingly. To maximize the power quality requirements during the shield machine's tunneling process and reduce energy loss, the host computer intelligent control system 13 automatically corrects the power factor of the transformer of the electrical system 11 so that the corrected power factor can reach a higher set target range, increasing active power and improving energy utilization. 2 =P 2 +Q 2

[0058] Among them, S is the apparent power, P is the active power, Q is the reactive power, is the power factor.

[0059] Finally, the working order of the shield machine's propulsion system 4 and the segment assembly system 6 is optimized and adjusted to increase equipment utilization. As the shield machine advances, the host computer's intelligent control system 13 automatically adjusts the operating time of the two processes, the propulsion system 4 and the segment assembly system 6, so that the two processes proceed simultaneously. That is, during the shield tunneling process, while the propulsion system 4 advances, the segment assembly system 6 completes the tunnel segment assembly process, and the two equipment working processes cooperate with each other. Instead of completing a single process and then proceeding to another process, the shield machine can continue tunneling construction, shortening the tunneling time used for a single ring of segments, increasing the shield machine's construction efficiency, and improving energy utilization.

[0060] As a result, the shield machine in this embodiment can adjust the discharge speed of its supporting slag discharge system in real time based on changes in propulsion speed. Its fluid system adjusts the flow rate of its fluid based on propulsion speed, thereby adjusting the frequency or number of activations of the corresponding pumps. The electrical system can automatically correct its power factor based on propulsion speed to meet high power quality requirements. As a result, the shield machine can adjust the operation of various system equipment accordingly to changes in propulsion speed during tunneling, enabling it to start according to actual needs, improve equipment utilization, reduce energy consumption, and maximize energy efficiency.

[0061] Compared to standard shield machines of the same type and diameter, the Green TBM addresses the existing challenges of high energy consumption and severe energy waste, often caused by high installed power, numerous auxiliary devices, and inappropriate designs, by automating the management of various system equipment and optimizing the design of the shield machine itself. While ensuring operational efficiency, this solution maximizes energy efficiency, improving equipment utilization and reducing energy waste.

[0062] System Example:

[0063] An energy-saving control system for a shield machine in this embodiment includes a controller, which is used to execute computer-readable instructions to implement an energy-saving control method for a shield machine introduced in the method implementation of the present invention. The method implementation has been introduced clearly enough in the previous description and will not be repeated here.

Claims

1. An energy-saving control method for a shield machine, characterized in that, when the propulsion speed changes during the tunneling of the shield machine, one or more of the mucking system, fluid system, and electrical system are adjusted according to the change in the propulsion speed: The mucking system is adjusted by the following method: Calculate the corresponding earth excavation volume according to the propulsion speed, then calculate the theoretical mucking speed according to the earth excavation volume, and the trailing mucking system adjusts its mucking speed according to the theoretical mucking speed; The fluid system is adjusted by the following method: The fluid system adjusts the flow rate of the fluid in the corresponding fluid system according to the magnitude of the propulsion speed of the shield machine; The electrical system is adjusted by the following method: The electrical system adjusts the active power of the electrical system transformer according to the magnitude of the propulsion speed of the shield machine.

2. The energy-saving control method for a shield machine according to claim 1, characterized in that, the earth excavation volume is also calculated according to the excavation area and the loose coefficient.

3. The energy-saving control method for a shield machine according to claim 1, characterized in that, the relationship between the theoretical mucking speed and the mucking speed of the trailing mucking system is: N = μ × Ns wherein, Ns is the mucking speed of the trailing mucking system, N is the theoretical mucking speed, and μ is the conversion coefficient.

4. The energy-saving control method for a shield machine according to claim 1, characterized in that, the fluid system includes a coolant circulation system, and the coolant circulation system adjusts the frequency of the circulation water pump according to the magnitude of the propulsion speed of the shield machine, thereby adjusting the flow rate of the exchanged coolant.

5. The energy-saving control method for a shield machine according to claim 4, characterized in that, the frequency of the circulation water pump is adjusted and controlled according to the detected temperature difference between the internal circulation coolant temperature and the external circulation coolant temperature for cooling the relevant systems of the shield machine.

6. The energy-saving control method for a shield machine according to claim 5, characterized in that, The relationship between the exchanged coolant flow rate and the temperature difference between the internal circulation coolant temperature and the external circulation coolant temperature is: Q = t×(T 1 - T 0 ) where Q is the flow rate of the exchanged coolant, T 1 is the temperature of the coolant in the internal cycle, T 0 is the temperature of the coolant in the external cycle, and t is the heat transfer conversion coefficient.

7. The energy-saving control method for a shield machine according to claim 1 or 4, characterized in that, the fluid system includes a foam system, a bentonite system, and a grouting system. When the propulsion speed increases, the injection volume of the fluid in the corresponding system is adjusted to increase; when the propulsion speed decreases, the injection volume of the fluid in the corresponding system is adjusted to decrease.

8. The energy-saving control method for a shield machine according to claim 1, characterized in that, the active power of the transformer of the electrical system is achieved by adjusting the power factor of the transformer.

9. The energy-saving control method for a shield machine according to claim 8, characterized in that, The relationship between the active power of the transformer and the power factor of the transformer is: S 2 = P 2 + Q 2 Among them, S is the apparent power, P is the active power, and Q is the reactive power. is the power factor.

10. An energy-saving control system for a shield machine, characterized in that, it includes a controller, and the controller is used to execute computer program instructions to implement the energy-saving control method for a shield machine according to any one of claims 1 to 9.

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