A kind of shield cutter abrasion real-time monitoring system and monitoring method
Technical field
The present invention relates to Suporting structure more particularly to a kind of shield cutter abrasion real-time monitoring system and monitoring methods.
Background technique
In short supply with land resource, the underground space is increasingly paid attention to and is developed and utilized by countries in the world, due to underground
Space utilization has a extensive future and resourceful, therefore is treated as a kind of new land resources.Tunnel boring machine method is to be exclusively used in danger of growing up
The Modern Construction method that road excavates, this method is high with Advance rate, construction quality is good, safety coefficient is high, to environmental disruption
It the advantages that labor intensity small while that construction personnel can be reduced, is increasingly taken seriously and uses now.
Cutter ring used in shield cutter is overall structure, it is directly and rock contact that cutter disc system or even exchange are integrated
In one of most important components.Since the damage of hobboing cutter must shut down tool changing in construction, and tool changing expenditure of time is long, labour
Consumption is big, seriously affects construction speed.If replacing not in time after tool damage simultaneously, drivage efficiency not only will be greatly reduced even
It causes cutterhead to damage, dramatically increases the maintenance tool changing expense of construction delay lengthening, cost, a large amount of Engineering Projects show in tunnel
Cutter must be carried out in road excavation project to inspect periodically maintenance, need to be replaced when damaging, the time thus spent
Usually 30%~40% or so of total operation time.The damage type of disk cutter has axis during actual tunneling construction
Damage, cutter ring eccentric wear etc. are held, and normal wear is the main reason for hobboing cutter damages, and accounts for hobboing cutter damage more than half.
Mainly still by virtue of experience, this has very big unstable factor for tool changing in construction at present.Existing shield cutter inspection
Survey is single to the detection method of abrasion, can not carry out real-time measurement to shield cutter abrasion loss simultaneously and further predict;Pass through
The calculating confidence level that single method carries out abrasion loss is also not high enough;Corresponding ultrasonic thickness measurement device is respectively mounted on each cutter
It although can guarantee to monitor each tool wear situation in real time, will increase a large amount of project costs, and be likely to result in measuring greatly
Thick device can not be reused.
Summary of the invention
Technical problem to be solved by the invention is to provide a kind of shield cutters to wear real-time monitoring system, real-time to realize
The abrasion loss of monitor cutter carries out effective monitoring to tool failure, accurate to grasp tool changing opportunity, avoids that engineering is caused to be prolonged
Accidentally increase severely with cost.
It is as follows that the present invention solves technical solution used by above-mentioned technical problem:
A kind of shield cutter of the invention wears real-time monitoring system, it is characterized in that: including ultrasonic wave side thickness device, driving
Parameter collection module, wear data acquisition module, data processing module, wireless communication module, host computer and remote monitoring module;
The ultrasonic wave side thickness device is fixedly mounted on cutter, hobboing cutter side, at predetermined intervals time measurement cutter and the real-time cutter of hobboing cutter
Thickness;Module is sent to wear data acquisition module to real-time cutter thickness data by wireless communication, is subtracted by original cutter thickness
It goes real-time cutter thickness to obtain real-time tool wear data, while dynamic boring parameter is acquired by boring parameter acquisition module;It is real
When tool wear data, dynamic boring parameter noise reduction process is carried out by data processing module after, the time is by wireless at predetermined intervals
Communication module is sent to host computer and carries out storage and data analysis, and real-time tool wear data and data analysis result pass through wireless
Communication module is sent to remote monitoring module, realizes the real-time monitoring and early warning of tool abrasion.
Another technical problem to be solved by this invention is to provide using above-mentioned shield cutter abrasion real-time monitoring system
Monitoring method, this method comprises the following steps:
1. running real-time monitoring system, real-time cutter thickness data, boring parameter acquisition are acquired by ultrasonic wave side thickness device
Module acquires dynamic boring parameter, and module is sent to wear data acquisition module and obtains real-time cutter thickness data by wireless communication
To tool wear data, tool wear data, dynamic boring parameter carry out noise reduction process by data processing module;
2. data processing, module transmits by wireless communication for tool wear data, dynamic boring parameter after noise reduction process
To host computer, storage is synchronized by data memory module, regression analysis is carried out by data analysis module and abrasion experience is public
Formula calculates, and obtains different knife position Wear prediction values, the prediction practical driving speed deviation of driving speed-;
3. data transmission shows that real-time tool wear data, different knife positions are worn in display to remote monitoring module
Predicted value and the prediction practical driving speed deviation figure of driving speed-, realize the real-time monitoring of tool abrasion;
4. when real-time tool wear data, knife position Wear prediction value, the prediction practical driving speed deviation of driving speed-reach
To threshold value, display and abrasion warning lamp are simultaneously emitted by alarm command.
The invention has the advantages that by the real-time research and application data of real-time monitoring system, grinding away over time and pre- is obtained
It is alert to be monitored automatically as a result, it is possible to realize round-the-clock 24 hours;It is swift in response, forecast in time, and can more accurately predict cutter
Abrasion and failure, carry out tool changing plan and tool changing in advance for shield machine and foundation be provided;And by unattended full-automatic
Change monitoring, to guarantee long-term continuous operation, and the tool changing cost that opens a position is greatly lowered, improves the reliability of monitoring materials.
Detailed description of the invention
Fig. 1 is part of data acquisition structural schematic diagram in a kind of shield cutter abrasion real-time monitoring system of the present invention;
Fig. 2 is a kind of functional block diagram of shield cutter abrasion real-time monitoring system of the present invention.
Component names and corresponding label are shown in figure: cutter 1, hobboing cutter 2, ultrasonic thickness measurement device 3, boring parameter are adopted
Collect module 4, wear data acquisition module 5, data processing module 6, wireless communication module 7, host computer 8, data memory module 9,
Data analysis module 10, display 12, abrasion warning lamp 13.
Specific embodiment
With reference to the accompanying drawings and embodiments, the present invention will be described in further detail.
Fig. 1 and Fig. 2, a kind of shield cutter abrasion real-time monitoring system of the invention includes ultrasonic wave side thickness device 3, driving
Parameter collection module 4, wear data acquisition module 5, data processing module 6, wireless communication module 7, host computer 8 and long-range monitoring
Module 11.The ultrasonic wave side thickness device 3 is fixedly mounted on cutter 1,2 side of hobboing cutter, at predetermined intervals time measurement cutter 1 and rolling
The real-time cutter thickness of knife 2.Module 7 is sent to wear data acquisition module 5 to real-time cutter thickness data by wireless communication, by original
Beginning cutter thickness subtracts real-time cutter thickness and obtains real-time tool wear data, while being acquired and being moved by boring parameter acquisition module 4
State boring parameter.After real-time tool wear data, dynamic boring parameter carry out noise reduction process by data processing module 6, by predetermined
Interval time is sent to host computer 8 by wireless communication module 7 and carries out storage and data analysis, real-time tool wear data and data
Module 7 is sent to remote monitoring module 11 to analysis result by wireless communication, realizes the real-time monitoring and early warning of tool abrasion.
Referring to Fig. 2, the host computer 8 is made of data memory module 9 and data analysis module 10, data memory module 9
Synchronous storing cutter wear data, dynamic boring parameter, and regression analysis and abrasion experience are carried out by data analysis module 10
Formula calculates, and obtains different knife position Wear prediction values, the prediction practical driving speed deviation of driving speed-.
Referring to Fig. 2, the remote monitoring module 11 is made of display 12 and abrasion warning lamp 13, and display 12 is shown
Real-time tool wear data, different knife position Wear prediction values and the prediction practical driving speed deviation figure of driving speed-, realize knife
Has the real-time monitoring of abrasion loss.When real-time tool wear data, knife position Wear prediction value, prediction driving speed-reality driving speed
When degree deviation reaches threshold value, display 12 and abrasion warning lamp 13 are simultaneously emitted by alarm command.
Ultrasonic thickness measurement device 3 measures metal thickness by ultrasonic probe, is separately positioned on cutting for reserved module position
On knife 1 and hobboing cutter 2, measurement interval time of measurement can be set, can usually preset and test a cutter ring thickness and alloy per hour
Transverse tooth thickness degree, boring parameter acquisition module 4 by wireless communication module 7 collect shield driving when dynamic data, above-mentioned real-time number
The processing of shield driving Noise reducing of data is carried out according to data processing module 6 is sent to by wireless module 7.
The real time data of ultrasonic wave side thickness device 3 by wireless communication module 7 be transmitted to host computer 8 record reach long-range prison again
On the display 12 for controlling module 11, if the wear threshold for reaching the setting of data analysis module 10 will be by display screen 12 and abrasion
Warning lamp 13 is alarmed;If setting wear threshold is 20mm, i.e. abrasion loss reaches 20mm cutter and should be replaced, and takes cutter ring initially thick
Spend δ0, the real-time side thickness of cutter ring be h, calculate δ in data analysis module 100Make display 12 and abrasion warning lamp 13 when-h=20mm
Be simultaneously emitted by warning, it is settable certain close on value and issue early warning.
Module 7 reaches host computer to the data of boring parameter acquisition module 4 and wear data acquisition module 5 by wireless communication
Data analysis module 10 in 8 carries out multiple regression analysis or wears the Wear prediction analysis of empirical equation, optional gross thrust,
Cutterhead revolving speed, cutter radius, Excavation Length, total torque etc. carry out Least Square Regression Analysis using data analysis module 10,
It obtains attrition value δ prediction curve, actual measurement abrasion loss and prediction abrasion loss curve is shown on display screen 12, tool changing is provided and is referred to
It leads.
Tunneling the driving speed data that acquisition module 4 acquires, module 7 reaches 10 He of data analysis module by wireless communication
The driving speed predicted value that multiple regression analysis obtains obtains speed deviation variation diagram and shows on the display 12, if difference goes out
Now significantly deviation, abrasion warning lamp 13 are alarmed, and staff is analyzed and determined whether go out by display difference tendency chart
Existing tool failure.
Above-mentioned all real time datas are recorded when passing through host computer 8 by wherein data memory module 9, Regression Analysis Result
It is recorded in data memory module 9 by preset interval time with driving speed prediction curve.
Referring to Fig. 2, a kind of monitoring method of shield cutter abrasion real-time monitoring system of the present invention includes the following steps:
1. running real-time monitoring system, real-time cutter thickness data, boring parameter acquisition are acquired by ultrasonic wave side thickness device 3
Module 4 acquires dynamic boring parameter, and module 7 is sent to wear data acquisition module to real-time cutter thickness data by wireless communication
5 obtain tool wear data, and tool wear data, dynamic boring parameter carry out noise reduction process by data processing module 6;
2. data processing, module 7 transmits by wireless communication for tool wear data, dynamic boring parameter after noise reduction process
To host computer 8, storage is synchronized by data memory module 9, regression analysis is carried out by data analysis module 10 and abrasion passes through
Formula calculating is tested, obtains different knife position Wear prediction values, the prediction practical driving speed deviation of driving speed-;
3. data transmission shows real-time tool wear data, different knives position in display 12 to remote monitoring module 11
Wear prediction value and the prediction practical driving speed deviation figure of driving speed-, realize the real-time monitoring of tool abrasion;
4. when real-time tool wear data, knife position Wear prediction value, the prediction practical driving speed deviation of driving speed-reach
To threshold value, display 12 and abrasion warning lamp 13 are simultaneously emitted by alarm command.
The present invention obtains grinding away over time and early warning as a result, it is possible to reality by the real-time research and application data of real-time monitoring system
Automatic monitoring in existing round-the-clock 24 hours;It being swift in response, forecast in time, and can more accurately predict the abrasion and failure of cutter,
Tool changing plan is carried out for shield machine and tool changing in advance provides foundation;And by unattended full-automatic monitoring, to protect
Long-term continuous operation is demonstrate,proved, and the tool changing cost that opens a position is greatly lowered, improves the reliability of monitoring materials.
The above is explain through diagrams a kind of shield cutter abrasion real-time monitoring system of the present invention and monitoring method
Some principles, be not intended to for the present invention to be confined to shown in and the specific structure and the scope of application in, therefore it is all it is all can
The corresponding modification that can be utilized and equivalent belong to the applied the scope of the patents of the present invention.