CN210483736U - Real-time monitoring system for shield cutter abrasion - Google Patents
Real-time monitoring system for shield cutter abrasion Download PDFInfo
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- CN210483736U CN210483736U CN201920662770.0U CN201920662770U CN210483736U CN 210483736 U CN210483736 U CN 210483736U CN 201920662770 U CN201920662770 U CN 201920662770U CN 210483736 U CN210483736 U CN 210483736U
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Abstract
A real-time monitoring system for shield cutter abrasion is used for accurately monitoring the abrasion loss of a cutter in real time and avoiding engineering delay and cost increase. The device comprises an ultrasonic lateral thickness device, a tunneling parameter acquisition module, a wear data acquisition module, a data processing module, a wireless communication module, an upper computer and a remote monitoring module; the ultrasonic side thickness device is fixedly arranged on the side of the cutter and the hob, and the thickness of the cutter and the hob in real time is measured according to the preset interval time. The wear data acquisition module receives real-time cutter thickness data through the wireless communication module to obtain real-time cutter wear data; the tunneling parameter acquisition module is used for acquiring dynamic tunneling parameters; the data processing module is used for carrying out noise reduction processing on the real-time cutter wear data and the dynamic tunneling parameters and then transmitting the data to the upper computer for storage and data analysis by the wireless communication module according to a preset interval time; and the remote monitoring module receives real-time cutter wear data and data analysis results through the wireless communication module.
Description
Technical Field
The utility model relates to a shield constructs equipment, especially relates to a shield constructs cutter wearing and tearing real-time monitoring system.
Background
With the shortage of land resources, underground space is increasingly emphasized by all countries in the world and developed and utilized, and the underground space has a wide utilization prospect and abundant resources, so that the underground space is taken as a new land resource. The excavator method is a modern construction method specially used for excavation of long and large dangerous roads, has the advantages of high excavation rate, good construction quality, high safety factor, small damage to the environment, reduction of labor intensity of constructors and the like, and is more and more emphasized and adopted nowadays.
The cutter ring used by the shield cutter is of an integral structure, is directly contacted with rocks, and is one of the most important parts in the integration of a cutter head system and a switchboard. Because the damage of the hob must be stopped for changing the hob during construction, the hob changing consumes long time and large labor consumption, and the construction progress is seriously influenced. Meanwhile, if the cutter is not replaced in time after being damaged, the tunneling efficiency is greatly reduced, even the cutter head is damaged, the construction period is prolonged in delay, the cost for maintenance and cutter replacement is obviously increased, a large number of engineering cases show that the cutter needs to be periodically checked and maintained in the tunnel excavation engineering, and the cutter needs to be replaced when being damaged, so that the time spent is about 30% -40% of the total operation time. In the actual tunneling construction process, the damage forms of the disc cutter comprise bearing damage, cutter ring eccentric wear and the like, and normal wear is the main cause of cutter damage and accounts for more than half of the damage of the cutter.
At present, the tool changing in construction is mainly based on experience, and the tool changing has a great unstable factor. The existing method for detecting the abrasion by the shield cutter is single, and the abrasion loss of the shield cutter cannot be measured in real time and further predicted at the same time; the reliability of calculation of the wear amount by a single method is not high enough; the corresponding ultrasonic thickness measuring devices are arranged on each cutter, so that the abrasion condition of each cutter can be monitored in real time, a large amount of construction cost can be increased, and a large amount of thickness measuring devices can not be reused.
SUMMERY OF THE UTILITY MODEL
The utility model aims to solve the technical problem that a shield constructs cutter wearing and tearing real-time monitoring system is provided to realize the wearing and tearing volume of accurately monitoring the cutter in real time, effectively monitor the cutter inefficacy, accurately master the tool changing opportunity, avoid arousing engineering delay and cost surge.
The utility model provides an above-mentioned technical problem adopted technical scheme as follows:
the utility model discloses a shield constructs cutter wearing and tearing real-time monitoring system, characterized by: the device comprises an ultrasonic lateral thickness device, a tunneling parameter acquisition module, a wear data acquisition module, a data processing module, a wireless communication module, an upper computer and a remote monitoring module; the ultrasonic side thickness device is fixedly arranged on the side of the cutter and the hob, and the real-time cutter thickness of the cutter and the hob is measured according to the preset interval time; the wear data acquisition module receives real-time cutter thickness data through the wireless communication module to obtain real-time cutter wear data; the tunneling parameter acquisition module is used for acquiring dynamic tunneling parameters; the data processing module is used for carrying out noise reduction processing on the real-time cutter wear data and the dynamic tunneling parameters and then transmitting the data to the upper computer for storage and data analysis by the wireless communication module according to a preset interval time; and the remote monitoring module receives real-time cutter wear data and data analysis results through the wireless communication module.
The utility model has the advantages that the real-time monitoring system analyzes the monitoring data in real time to obtain the real-time abrasion and early warning result, and the all-weather 24-hour automatic monitoring can be realized; the method has the advantages that the response is rapid, the forecast is timely, the abrasion and the failure of the cutter can be accurately forecasted, and a basis is provided for the shield machine to carry out cutter changing plan and advance cutter changing; and the unattended full-automatic monitoring is adopted, so that the long-term continuous operation is ensured, the warehouse opening and tool changing cost is greatly reduced, and the reliability of monitoring data is improved.
Drawings
Fig. 1 is a schematic structural view of a data acquisition part in a real-time shield cutter wear monitoring system of the present invention;
fig. 2 is a schematic block diagram of the utility model relates to a shield constructs cutter wearing and tearing real-time monitoring system.
The figure shows the part names and the corresponding labels: the ultrasonic thickness measuring device comprises a cutter 1, a hob 2, an ultrasonic thickness measuring device 3, a tunneling parameter acquisition module 4, a wear data acquisition module 5, a data processing module 6, a wireless communication module 7, an upper computer 8, a data storage module 9, a data analysis module 10, a display 12 and a wear warning lamp 13.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
Fig. 1 and fig. 2, the utility model discloses a shield constructs cutter wearing and tearing real-time monitoring system includes that ultrasonic wave inclines thick device 3, tunnelling parameter acquisition module 4, wearing and tearing data acquisition module 5, data processing module 6, wireless communication module 7, host computer 8 and remote monitoring module 11. The ultrasonic side thickness device 3 is fixedly arranged on the sides of the cutter 1 and the hob 2, and the real-time cutter thicknesses of the cutter 1 and the hob 2 are measured according to preset interval time. The real-time cutter thickness data is sent to the wear data acquisition module 5 through the wireless communication module 7, the real-time cutter thickness is subtracted from the original cutter thickness to obtain real-time cutter wear data, and meanwhile, the tunneling parameter acquisition module 4 acquires dynamic tunneling parameters. After noise reduction processing is carried out on the real-time cutter wear data and the dynamic tunneling parameters by the data processing module 6, the real-time cutter wear data and the dynamic tunneling parameters are transmitted to the upper computer 8 by the wireless communication module 7 according to preset interval time for storage and data analysis, real-time cutter wear data and data analysis results are transmitted to the remote monitoring module 11 by the wireless communication module 7, and real-time monitoring and early warning of cutter wear amount are achieved.
Referring to fig. 2, the upper computer 8 is composed of a data storage module 9 and a data analysis module 10, the data storage module 9 synchronously stores cutter wear data and dynamic tunneling parameters, and regression analysis and wear empirical formula calculation are performed through the data analysis module 10 to obtain different cutter wear predicted values and predicted tunneling speed-actual tunneling speed deviation values.
Referring to fig. 2, the remote monitoring module 11 is composed of a display 12 and a wear warning lamp 13, and the display 12 displays real-time tool wear data, predicted values of wear at different tool positions, and a predicted tunneling speed-actual tunneling speed deviation value map, so as to realize real-time monitoring of the tool wear amount. When the real-time cutter wear data, the predicted cutter position wear value and the predicted tunneling speed-actual tunneling speed deviation value reach the threshold value, the display 12 and the wear warning lamp 13 simultaneously send out an alarm instruction.
The ultrasonic thickness measuring device 3 measures the metal thickness through an ultrasonic probe, is respectively arranged on a cutter 1 and a hob 2 which are reserved at the positions of modules, can set measuring interval time, can normally preset cutter ring thickness and alloy tooth thickness which are measured once per hour, a tunneling parameter acquisition module 4 collects dynamic data during shield tunneling through a wireless communication module 7, and the real-time data are transmitted to a data processing module 6 through the wireless module 7 to perform shield tunneling data noise reduction processing.
Real-time data of the ultrasonic lateral thickness device 3 are transmitted to an upper computer 8 through a wireless communication module 7 to be recorded and then reach a display 12 of a remote monitoring module 11, and if the real-time data reach a wear threshold set by a data analysis module 10, an alarm is given through a display screen 12 and a wear warning lamp 13; if the abrasion threshold value is set to be 20mm, namely the cutter with the abrasion amount reaching 20mm needs to be replaced, the initial thickness delta of the cutter ring is taken0The real-time side thickness of the cutter ring is h, and delta is calculated in the data analysis module 100When h is 20mm, the display 12 and the wear warning lamp 13 are simultaneously used for warning, and a certain proximity value can be set for warning.
Data of the tunneling parameter acquisition module 4 and the wear data acquisition module 5 reach a data analysis module 10 in an upper computer 8 through a wireless communication module 7 to perform multivariate regression analysis or wear prediction analysis of a wear empirical formula, total thrust, cutter head rotating speed, cutter head radius, tunneling length, total torque and the like can be selected, least square regression analysis is performed by using the data analysis module 10 to obtain a wear value delta prediction curve, and the actually measured wear amount and predicted wear amount curve is displayed on a display screen 12 to provide tool changing guidance.
The tunneling speed data acquired by the tunneling acquisition module 4 reach the data analysis module 10 through the wireless communication module 7, and a tunneling speed predicted value obtained through multivariate regression analysis is displayed on the display 12 through a speed deviation value change diagram, if the difference value has large deviation, the abrasion warning lamp 13 gives an alarm, and a worker analyzes and judges whether the cutter fails through a display difference value trend diagram.
All the real-time data are recorded by the data storage module 9 when passing through the upper computer 8, and the regression analysis result and the tunneling speed prediction curve are recorded in the data storage module 9 according to preset interval time.
Referring to fig. 2, the utility model relates to a shield constructs cutter wearing and tearing real-time monitoring system monitors according to following step:
①, operating a real-time monitoring system, acquiring real-time cutter thickness data by the ultrasonic lateral thickness device 3, acquiring dynamic tunneling parameters by the tunneling parameter acquisition module 4, sending the real-time cutter thickness data to the wear data acquisition module 5 through the wireless communication module 7 to obtain cutter wear data, and performing noise reduction processing on the cutter wear data and the dynamic tunneling parameters by the data processing module 6;
②, carrying out data processing, transmitting the cutter wear data and dynamic tunneling parameters after noise reduction processing to an upper computer 8 through a wireless communication module 7, synchronously storing the data by a data storage module 9, and carrying out regression analysis and wear empirical formula calculation through a data analysis module 10 to obtain different cutter wear predicted values and predicted tunneling speed-actual tunneling speed deviation values;
③, the data is transmitted to the remote monitoring module 11, real-time cutter wear data, predicted values of different cutter positions and a predicted tunneling speed-actual tunneling speed deviation value graph are displayed on the display 12, and real-time monitoring of cutter wear amount is achieved;
④ when the real-time cutter wear data, the predicted cutter position wear value and the deviation value between the predicted tunneling speed and the actual tunneling speed reach the threshold value, the display 12 and the wear warning lamp 13 simultaneously send out alarm instructions.
The utility model analyzes the monitoring data in real time through the real-time monitoring system to obtain real-time abrasion and early warning results, and can realize all-weather 24-hour automatic monitoring; the method has the advantages that the response is rapid, the forecast is timely, the abrasion and the failure of the cutter can be accurately forecasted, and a basis is provided for the shield machine to carry out cutter changing plan and advance cutter changing; and the unattended full-automatic monitoring is adopted, so that the long-term continuous operation is ensured, the warehouse opening and tool changing cost is greatly reduced, and the reliability of monitoring data is improved.
The above is only used for illustration the utility model relates to a shield constructs some principles of cutter wearing and tearing real-time supervision system, not will the utility model discloses the limitation show with concrete structure and application scope in, all corresponding modifications and equivalents that probably are utilized all belong to the utility model discloses the patent range who applies for.
Claims (3)
1. The utility model provides a shield constructs cutter wearing and tearing real-time monitoring system which characterized by: the device comprises an ultrasonic lateral thickness device (3), a tunneling parameter acquisition module (4), a wear data acquisition module (5), a data processing module (6), a wireless communication module (7), an upper computer (8) and a remote monitoring module (11); the ultrasonic side thickness device (3) is fixedly arranged on the sides of the cutter (1) and the hob (2), and real-time cutter thickness data of the cutter (1) and the hob (2) are measured according to preset interval time; the wear data acquisition module (5) receives real-time cutter thickness data through the wireless communication module (7) to obtain real-time cutter wear data; the tunneling parameter acquisition module (4) is used for acquiring dynamic tunneling parameters; the data processing module (6) is used for carrying out noise reduction processing on real-time cutter wear data and dynamic tunneling parameters and then transmitting the data to the upper computer (8) for storage and data analysis by the wireless communication module (7) according to a preset interval time; and the remote monitoring module (11) receives real-time tool wear data and data analysis results through the wireless communication module (7).
2. The real-time shield cutter wear monitoring system of claim 1, wherein: the upper computer (8) is composed of a data storage module (9) and a data analysis module (10), the data storage module (9) synchronously stores cutter wear data and dynamic tunneling parameters, regression analysis and wear empirical formula calculation are carried out through the data analysis module (10), and different cutter position wear predicted values and predicted tunneling speed-actual tunneling speed deviation values are obtained.
3. The real-time shield cutter wear monitoring system of claim 2, wherein: the remote monitoring module (11) is composed of a display (12) and a wear warning lamp (13), the display (12) displays real-time cutter wear data, predicted values of wear of different cutter positions and a predicted tunneling speed-actual tunneling speed deviation value graph, and real-time monitoring of cutter wear amount is achieved; when the real-time cutter wear data, the predicted cutter position wear value and the predicted tunneling speed-actual tunneling speed deviation value reach the threshold value, the display (12) and the wear warning lamp (13) simultaneously send out alarm instructions.
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| CN201920662770.0U CN210483736U (en) | 2019-05-09 | 2019-05-09 | Real-time monitoring system for shield cutter abrasion |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110017147A (en) * | 2019-05-09 | 2019-07-16 | 中国电建集团铁路建设有限公司 | A kind of shield cutter abrasion real-time monitoring system and monitoring method |
| CN112761655A (en) * | 2021-02-02 | 2021-05-07 | 西南石油大学 | Simulation system for regulating and controlling mud cake formation of shield cutter head |
| CN113586028A (en) * | 2021-07-21 | 2021-11-02 | 宁夏天地奔牛实业集团有限公司 | Intelligent monitoring system of raise boring machine reaming cutter head based on digital twinning |
-
2019
- 2019-05-09 CN CN201920662770.0U patent/CN210483736U/en active Active
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110017147A (en) * | 2019-05-09 | 2019-07-16 | 中国电建集团铁路建设有限公司 | A kind of shield cutter abrasion real-time monitoring system and monitoring method |
| CN112761655A (en) * | 2021-02-02 | 2021-05-07 | 西南石油大学 | Simulation system for regulating and controlling mud cake formation of shield cutter head |
| CN112761655B (en) * | 2021-02-02 | 2022-03-11 | 西南石油大学 | Simulation system for regulating and controlling mud cake formation of shield cutter head |
| CN113586028A (en) * | 2021-07-21 | 2021-11-02 | 宁夏天地奔牛实业集团有限公司 | Intelligent monitoring system of raise boring machine reaming cutter head based on digital twinning |
| CN113586028B (en) * | 2021-07-21 | 2024-03-29 | 太原理工大学 | Intelligent monitoring system of counter bore cutter head of anti-well drilling machine based on digital twin |
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Address after: 100160 701, 7th floor, building 3, yard 10, Automobile Museum East Road, Fengtai District, Beijing Patentee after: China Power Construction Railway Construction Investment Group Co.,Ltd. Patentee after: CHENGDU HYDROPOWER CONSTRUCTION ENGINEERING CO., LTD., SINOHYDRO BUREAU 7 Co.,Ltd. Patentee after: POWERCHINA CHENGDU CONSTRUCTION INVESTMENT Co.,Ltd. Address before: 100044 1001, 10th floor, building 2, yard 22, Chegongzhuang West Road, Haidian District, Beijing Patentee before: POWERCHINA RAILWAY CONSTRUCTION Co.,Ltd. Patentee before: CHENGDU HYDROPOWER CONSTRUCTION ENGINEERING CO., LTD., SINOHYDRO BUREAU 7 Co.,Ltd. Patentee before: POWERCHINA CHENGDU CONSTRUCTION INVESTMENT Co.,Ltd. |
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