CN114091544A - TBM disc cutter abrasion identification system based on vibration signal and neural network - Google Patents
TBM disc cutter abrasion identification system based on vibration signal and neural network Download PDFInfo
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Abstract
The invention discloses a TBM disc cutter abrasion recognition system based on a vibration signal and a neural network, which comprises a vibration signal acquisition processing subsystem and a neural network recognition model, wherein the vibration signal acquisition processing subsystem comprises a sensor module, a data acquisition module and a data processing output module which are sequentially connected; the sensor module is arranged on the hob and used for acquiring a rock breaking vibration signal of the hob and converting the vibration signal into a piezoelectric signal; the data processing and outputting module calculates the time domain signals by adopting a fast Fourier method to obtain frequency domain signals and outputs frequency domain data; and the neural network identification model identifies the wear state of the single-blade disc cutter according to the frequency domain data. The recognition system has better stability and reliability, has good feature extraction and recognition capability, can comprehensively capture the features of the vibration frequency domain data, and achieves a good accuracy level.
Description
Technical Field
The invention belongs to the field of TBM hob abrasion state identification and diagnosis, and particularly relates to a TBM disc hob abrasion identification system based on a vibration signal and a neural network.
Background
The disc cutter is an important core component of the TBM, and plays a role in the most important rock breaking function, the state of the disc cutter directly influences whether the TBM can normally operate, and the disc cutter is a major risk source in tunneling construction. The conventional common method for diagnosing the abrasion of the TBM disc cutter is shutdown and open-bin inspection, and an operator must frequently shut down and enter a bin to manually overhaul a cutter head cutter so as to judge whether the cutter head needs to be repaired and replaced. High time cost and economic cost are brought by cutter replacement and maintenance due to shutdown inspection, and the health and safety of operating personnel cannot be effectively guaranteed due to the high-temperature and high-pressure environment in the bin. Therefore, the hob abrasion state identification system is established, and the hob abrasion state information is provided in time, so that the hob abrasion state identification system has important practical significance.
At present, most of the existing TBM hob abrasion identification and diagnosis methods are to indirectly calculate the integral abrasion condition of a hob from integral parameters of a hob head, such as torque, rotating speed, temperature rise and the like, or to establish a prediction model by means of geological parameters and tunneling parameters. However, these methods using indirect parameters are not suitable for evaluating the wear state of a single hob. Some studies have used sensors, such as eddy current sensors, ultrasonic sensors, laser sensors, etc., to evaluate the wear of a single knife by acquiring corresponding signals. However, due to the strong damp heat and dusty noise of the construction environment, the above electric, acoustic and optical signals have the problems of stability and reliability in application.
In the field of machine manufacturing, sensors using vibration as a measurement signal are robust and more suitable for industrial environments. The vibration signal is converted to extract characteristic information, so that the tool wear identification is convenient. With the development of AI technology, sufficient potential and advantages are gradually exhibited in the field of intelligent state monitoring, and one of typical representatives is a neural network algorithm. In 1987, the neural network technology is combined with the sensor technology for the first time, so that the reliability of cutter monitoring is improved. At present, a neural network algorithm is researched and applied more in the state monitoring of a common cutting tool, and in the aspect of TBM disc cutter abrasion, researchers establish an abrasion evaluation model by utilizing a one-dimensional convolution neural network and combining field parameters. Therefore, the neural network has potential and feasibility for identifying the abrasion state of the hob based on the vibration signal.
In the existing research, the vibration signal is rarely used for detecting the wear state of a single disc cutter, and part of the neural network algorithm is also primarily applied to the disc cutter state monitoring, but there is no example of combining the vibration signal and the neural network algorithm for identifying the wear state of the single disc cutter.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a TBM disc cutter abrasion recognition system based on vibration signals and a neural network, which takes vibration frequency domain signals as input data, can exert the advantages of firmness, durability and high reliability and stability of a vibration sensor, and enables the whole abrasion recognition system to have better stability and reliability.
The purpose of the invention is realized by the following technical scheme: the TBM disc cutter abrasion identification system based on the vibration signal and the neural network comprises a vibration signal acquisition processing subsystem and a neural network identification model, wherein the vibration signal acquisition processing subsystem comprises a sensor module, a data acquisition module and a data processing output module which are sequentially connected;
the sensor module is arranged on the hob and used for acquiring a rock breaking vibration signal of the hob and converting the vibration signal into a piezoelectric signal; the data processing and outputting module calculates the time domain signals by adopting a fast Fourier method to obtain frequency domain signals and outputs frequency domain data; and the neural network identification model identifies the wear state of the single-blade disc cutter according to the frequency domain data.
Further, the wear state of the TBM disc cutter comprises four states of a normal wear state, a wear failure state, an eccentric wear failure state and a tipping failure state.
Further, the hob rock breaking vibration signal is acquired by the vibration sensor at the positions of the hob ring, the cutter hub, the cutter shaft and the cutter holder respectively under the working condition that the TBM disc hob breaks rock on the hard rock sample according to set parameters. The vibration sensor adopts a three-axis acceleration vibration sensor.
Furthermore, the neural network recognition model adopts a long-short term memory network model (LSTM) in a cyclic neural network, the model recognizes the wear state according to the vibration frequency domain characteristics, and the recognition object is the overall wear state of the single hob.
Further, the construction process of the long-short term memory network model data set is as follows: respectively collecting vibration acceleration signals of hobs in four wear states of a normal wear state, a wear failure state, an eccentric wear failure state and a tipping failure state on a hard rock sample at the positions of a cutter ring, a cutter hub, a cutter shaft and a cutter seat of the TBM disc-shaped hob by using a vibration sensor, and respectively carrying out a rock breaking test on the hob with penetration degrees of 1mm, 2mm and 3mm and a feeding speed of 30mm/s, and converting the vibration acceleration signals into piezoelectric signals; sampling the piezoelectric signal by the data acquisition module at a sampling rate of 5000Hz to obtain a vibration time domain signal, and transmitting the vibration time domain signal to the data processing output module; the data processing and outputting module converts a time domain signal into a frequency domain signal with 1Hz resolution ratio by using a fast Fourier method, the frequency domain range is 0-2500 Hz, the time-frequency domain data is visually output to a PC (personal computer) end, signal segments with obvious time-frequency domain characteristics are selected, the selected signal segments are output as time sequence frequency domain data at 1s time intervals to form a data set, and the long-short term memory network model is trained by using the data set.
The invention has the beneficial effects that: the wear identification system provided by the invention can specifically identify the wear state of a single hob; the disc cutter abrasion identification model takes the vibration frequency domain signal as input data, can exert the advantages of firmness, durability and high reliability and stability of the vibration sensor, greatly avoid the adverse effect of the construction environment on the sensor and ensure that the whole abrasion identification system has better stability and reliability; the neural network model has good feature extraction and recognition capability, can comprehensively capture the features of vibration frequency domain data, and achieves a good accuracy level; the invention preliminarily verifies and explores the application feasibility and application effect of the wear identification system combining the vibration signal and the neural network model on the single disc cutter, and accumulates experience for subsequent perfection and deep application.
Drawings
FIG. 1 is a hob wear identification flow chart;
FIG. 2 is a schematic view of a vibration sensor;
FIG. 3 is a schematic diagram of a neural network model;
FIG. 4 is a schematic diagram of the position of the sensor to detect the vibrations of the hob;
FIG. 5 is a schematic axial diagram of a time domain signal X of a normal wear hob;
FIG. 6 is a schematic diagram of X-axis frequency domain signals of a normal wear hob and a wear failure hob;
FIG. 7 is a schematic diagram of X-axis time-frequency domain signals of an eccentric wear failure hob in an eccentric wear surface grinding condition.
Wherein: 1. the position of the cutter ring; 2. a cutter hub position; 3. the position of the cutter shaft; 4. a tool holder position.
Detailed Description
According to the invention, a triaxial vibration acceleration sensor is arranged on a hob, vibration signals generated when the hob breaks rock are directly collected, time domain analysis is carried out on the vibration signals, a periodic waveform section is taken for FFT calculation, frequency domain characteristics of the periodic waveform section are obtained, the frequency domain characteristics are output as time series data to train an LSTM (local state transform) model, and identification and diagnosis of the abrasion state of a single hob are realized. The technical scheme of the invention is further explained by combining the attached drawings.
As shown in fig. 1, the TBM disc cutter wear identification system based on vibration signals and neural network of the present invention includes a vibration signal acquisition processing subsystem and a neural network identification model, the vibration signal acquisition processing subsystem includes a sensor module, a data acquisition module and a data processing output module which are connected in sequence; the data processing output module and the neural network identification model are positioned at the PC end of the upper computer, and the sensor module and the data acquisition module are connected with the upper computer to transmit data and acquire electric energy;
the sensor module is arranged on the hob and used for acquiring a rock breaking vibration signal of the hob and converting the vibration signal into a piezoelectric signal; the data processing and outputting module calculates the time domain signals by adopting a Fast Fourier Transform (FFT) method to obtain frequency domain signals and outputs frequency domain data, and visually outputs the time domain signals and the frequency domain signals; and the neural network identification model identifies the wear state of the single-blade disc cutter according to the frequency domain data.
The wear state of the TBM disc cutter comprises a normal wear state, a wear failure state, an eccentric wear failure state and a tipping failure state. The hob rock breaking vibration signal is acquired by a vibration sensor at the positions of a hob ring, a hob hub, a hob shaft and a hob seat respectively under the working condition that a TBM disc hob breaks rock on a hard rock sample according to set parameters.
The sensor module is an IEPE triaxial acceleration vibration sensor, the sensor model is DYTRAN 3263A3, the mass of a single sensor is 5.6g, the sensitivity is 500mV/g, and the measurement range is +/-100 g; the sensor is schematically shown in fig. 2. The sensor is composed of a light titanium alloy shell, a shear type piezoelectric ceramic element, a low-noise JFET circuit and the like, has the characteristics of firmness, durability, strong anti-interference capability, good sealing performance and high reliability, and still has excellent performance under complex environmental conditions of high humidity, dustiness and the like.
Specifically, the model of the data acquisition module is a DEWEsoft SIRIUS multi-channel data acquisition module, each channel is synchronized with microsecond precision, and the sampling rate is set to be 5000 Hz; the sensor and the upper computer are connected by an additional data line to transmit signals, the upper computer provides electric energy through the USB port, and the sensor is powered.
Specifically, the data processing output module is a PC-side dewoft X312 software platform. The software integrates the functions of data storage, data analysis and data visualization, has the multithreading data calculation capability and a high-performance storage engine, has the FFT analyzer module with most of functions for spectrum analysis, and can perform frequency domain analysis on vibration signals.
The neural network identification model adopts a long-short term memory network (LSTM) model in a cyclic neural network, identifies the wear state according to the vibration frequency domain characteristics, and identifies the overall wear state of the single hob as an object; the LSTM has a gating mechanism (forgetting gate, input gate, output gate), can effectively solve the long-term dependence problem existing in the conventional recurrent neural network, and is suitable for processing time series events, and the LSTM model schematic diagram is shown in fig. 3 (a). The LSTM initial model is built on a pystorm platform by using a pytorech framework, the number of nodes of a double-layer, one-way and hidden layer is 128, a Dropout parameter is set to 0.3 to reduce the overfitting risk, the output of the LSTM model is imported to a Linear layer (Linear, input feature dimension 128, output feature dimension 3) for outputting a prediction result, and a schematic diagram of the Linear layer is shown in fig. 3 (b). And then, training and optimizing by using a training data set, wherein the batch size of input data is 128, the learning rate is 0.008 (the learning rate is attenuated, and the learning rate is reduced to 95 percent of the previous learning rate every two training periods), and the optimizer selects Adam and selects a cross entropy loss function to calculate a loss value. In the training process, once a period of training is completed, a verification data set is imported, and the verification accuracy is obtained. And if the verification accuracy rate is continuously reduced in 24 continuous periods, stopping the training process and storing the model parameters corresponding to the optimal verification accuracy rate. So as to ensure that the overfitting phenomenon does not occur in the training process.
The initial model is established on a Pycharm platform according to selected parameters by using a Pythrch frame, and then training optimization is carried out by using a training data set obtained by a rock breaking test. And importing the test data set after the training is finished to obtain the test accuracy so as to check the training effect of the model.
The construction process of the long-short term memory network model data set is as follows: using a triaxial acceleration vibration sensor to respectively collect vibration acceleration signals of a hob in four wear states of a normal wear state, a wear failure state, an eccentric wear failure state and a tipping failure state on a hard rock sample at the rock breaking test by respectively using penetration degrees of 1mm, 2mm and 3mm and a feed speed of 30mm/s at the positions of a cutter ring, a cutter hub, a cutter shaft and a cutter seat of the TBM disc hob (the positions of the sensors are shown in a figure 4(a) and a figure 4(b), wherein 1 is the position of the cutter ring, 2 is the position of the cutter hub, 3 is the position of the cutter shaft, and 4 is the position of the cutter seat), and converting the vibration acceleration signals into piezoelectric signals; sampling the piezoelectric signal by the data acquisition module at a sampling rate of 5000Hz to obtain a vibration time domain signal, and transmitting the vibration time domain signal to the data processing output module; the data processing and outputting module converts a time domain signal into a frequency domain signal with 1Hz resolution ratio by using a fast Fourier method, the frequency domain range is 0-2500 Hz, the time-frequency domain data is visually output to a PC (personal computer) end, signal segments with obvious time-frequency domain characteristics are selected, the selected signal segments are output as time sequence frequency domain data at 1s time intervals to form a data set, the data set is divided into training, verifying and testing data sets according to the proportion of 7:2:1, then a long-term and short-term memory network model is trained by using the training set data in the data set, the verifying set is used for verifying to prevent overfitting, and the testing data set is used for testing the accuracy of the trained model.
Referring to fig. 5, the vibration time domain signals are schematic, when a hob performs a rock breaking test on a granite sample, a characteristic waveform appears, when the rock sample is fractured in a powdery form, a stable periodic wave characteristic shown in the diagram (a) appears, and when the rock sample is fractured in a deep and long crack form, a single sawtooth wave characteristic shown in the diagram (b) appears; referring to fig. 6, it is shown that the acceleration components are distributed in a plurality of frequency bands in a concentrated manner, and the frequency band positions are different due to different wear states of the hob. Acceleration and frequency signals of the eccentric wear failure hob in the eccentric wear surface grinding condition are respectively shown in fig. 7(a) and 7(b), under the special working condition of the eccentric wear surface grinding, the vibration acceleration amplitude change in the time domain is far larger than that in other working conditions due to violent vibration, and a large amount of high-order harmonic waves are excited in the frequency domain.
It will be appreciated by those of ordinary skill in the art that the embodiments described herein are intended to assist the reader in understanding the principles of the invention and are to be construed as being without limitation to such specifically recited embodiments and examples. Those skilled in the art can make various other specific changes and combinations based on the teachings of the present invention without departing from the spirit of the invention, and these changes and combinations are within the scope of the invention.
Claims (6)
1. The TBM disc cutter abrasion identification system based on the vibration signal and the neural network is characterized by comprising a vibration signal acquisition and processing subsystem and a neural network identification model, wherein the vibration signal acquisition and processing subsystem comprises a sensor module, a data acquisition module and a data processing and outputting module which are sequentially connected;
the sensor module is arranged on the hob and used for acquiring a rock breaking vibration signal of the hob and converting the vibration signal into a piezoelectric signal; the data processing and outputting module calculates the time domain signals by adopting a fast Fourier method to obtain frequency domain signals and outputs frequency domain data; and the neural network identification model identifies the wear state of the single-blade disc cutter according to the frequency domain data.
2. The TBM disc cutter wear identification system based on the vibration signal and the neural network is characterized in that the wear states of the TBM disc cutter comprise four states, namely a normal wear state, a wear failure state, an eccentric wear failure state and a tipping failure state.
3. The TBM disc cutter abrasion recognition system based on the vibration signal and the neural network as claimed in claim 1, wherein the hob rock breaking vibration signal is acquired by the vibration sensor at the positions of a hob ring, a hob hub, a hob shaft and a hob seat respectively under the working condition that the TBM disc cutter breaks rock on a hard rock sample according to set parameters.
4. The TBM disc cutter wear identification system based on the vibration signal and the neural network is characterized in that the vibration sensor is a three-axis acceleration vibration sensor.
5. The TBM disc cutter wear identification system based on the vibration signal and the neural network is characterized in that the neural network identification model adopts a long-short term memory network model in a cyclic neural network, and identifies the wear state according to the vibration frequency domain characteristics, wherein the model identifies the overall wear state of the object as a single-handle disc cutter.
6. The TBM disc cutter wear identification system based on the vibration signal and the neural network is characterized in that the long-short term memory network model data set is constructed by the following process: respectively collecting vibration acceleration signals of hobs in four wear states of a normal wear state, a wear failure state, an eccentric wear failure state and a tipping failure state on a hard rock sample at the positions of a cutter ring, a cutter hub, a cutter shaft and a cutter seat of the TBM disc-shaped hob by using a vibration sensor, and respectively carrying out a rock breaking test on the hob with penetration degrees of 1mm, 2mm and 3mm and a feeding speed of 30mm/s, and converting the vibration acceleration signals into piezoelectric signals; sampling the piezoelectric signal by the data acquisition module at a sampling rate of 5000Hz to obtain a vibration time domain signal, and transmitting the vibration time domain signal to the data processing output module; the data processing and outputting module converts a time domain signal into a frequency domain signal with 1Hz resolution ratio by using a fast Fourier method, the frequency domain range is 0-2500 Hz, the time-frequency domain data is visually output to a PC (personal computer) end, signal segments with obvious time-frequency domain characteristics are selected, the selected signal segments are output as time sequence frequency domain data at 1s time intervals to form a data set, and the long-short term memory network model is trained by using the data set.
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