GB2611850A

GB2611850A - Real-time wear state monitoring device for TBM rotary cutter, and method

Info

Publication number: GB2611850A
Application number: GB2210379.0A
Authority: GB
Inventors: Li Shucai; Xue Yiguo; Gong Huimin; Qiu Daohong; Li Guangkun; Han Min
Original assignee: Shandong University
Current assignee: Shandong University
Priority date: 2019-12-17
Filing date: 2020-12-16
Publication date: 2023-04-19
Anticipated expiration: 2040-12-16
Also published as: CN110987155A; GB2611850B; WO2021121288A1; GB202210379D0; CN110987155B

Abstract

A real-time wear state monitoring device for a TBM rotary cutter and a method. The monitoring device comprises: a data acquisition and sending module (6), a wear sensing module (5), and a processor. The wear sensing module (5) comprises a flat spring (12) and a strain gauge (15). The strain gauge (15) is attached to the flat spring (12). The flat spring (12) has one fixed end and another end pressing on the rotary cutter and forming a curved shape. The end of the flat spring (12) pressing against the rotary cutter receives a force from the rotary cutter and generates vibration. The data acquisition and sending module (6) measures a vibration signal of the flat spring (12) via the strain gauge (15) and sends the signal to the processor. The processor receives vibration data and compares the data against data in a wear state vibration signal database of the rotary cutter, so as to determine a wear state of the rotary cutter. The invention achieves, without changing a structure of a cutter disc (1) or shutting down operations, effective real-time monitoring of various wear modes of a rotary cutter while a TBM is operating, and prevents rock debris adhering to the rotary cutter from impacting monitoring.

Description

REAL-TIME WEAR STATE MONITORING DEVICE FOR TIM ROTARY CUTTER, AND METHOD

TECHNICAL FIELD

The present application relates to a device and method for monitoring a loss state of a TBM hob in real time.

BACKGROUND

The description in this section merely provides background information related to the present application, and does not necessarily constitute the prior art. In recent years, a tunnel boring machine (TBM) has been widely applied in tunnel engineering. As an important component for TBM rock breaking, a loss state of a hub directly influences boring efficiency, construction quality and construction safety, so the loss state of the hob has been one of key points focused by TBM tunnel construction technical personnel during construction. Cr)

The loss state of the hob can be divided into normal loss and abnormal loss. The normal loss refers to gradual abrasion of a cutter ring of the hob until the cutter ring is abraded to an o CO extreme state and cannot be continuously used. The abnormal loss mainly includes cutter ring CO cracking, cutter ring eccentric abrasion, cutter ring disassembly, cutter ring turning and O tipping and other forms.

An inventor finds that at present, in order to monitor the loss state of the hob, domestic and overseas scholars put forward many monitoring means, mainly including a type of method needing to transform the hob and a cutter head structure such as peculiar smell additive adding, hydraulic sensing system adding, coil pre-installing, but the type of method has problems that the hob and the cutter head structure need to be transformed, consequently, the rock breaking capability of the hob is influenced, implementation and popularization are difficult. The other type of method uses sound waves, infrared rays or laser monitoring or other means to directly measure the loss state of the hob, the type of method is likely to be disturbed and influenced by adhering rock residues on the hob and underground water, thereby a measurement result is influenced, and cutter ring turning, cutter ring tipping and other abnormal loss of the hob are difficult to monitor. The above means hardly meet the existing requirement for real-time mastering of the loss state of the TBM hob.

SUMMARY

The present application aims to defects in the prior art, and provides a device and method for monitoring a loss state of a TBM hob in real time, can effectively monitor multiple loss forms of the hob in real time under the work state of a TBM on the basis that a cutter head structure is not changed and shutdown is avoided and avoids influence on monitoring from adhering rock residues on the hob. The present disclosure is simple in structure and easy to install.

Providing the device for monitoring a loss state of a TBM hob in real time is a first purpose of the present application, and a following technical solution is adopted: data collecting and sending modules, loss sensing modules and a processor are included, the loss sensing module includes a spring steel sheet and a strain gage, where the strain gage is pasted and applied to the spring steel sheet, one end of the spring steel sheet is fixed, the other end abuts against the hob to form an arc, and the end, abutting against the hob, of the spring steel sheet is used for generating vibration upon receiving the hob action; the data collecting and sending modules measure and acquire vibration signals of the spring steel sheets through the strain gages and send the vibration signals to the processor, the processor receives vibration data and compares the vibration data with a hob loss state vibration signal database to judge the loss state of the hob.

Furthermore, the loss sensing module further includes a protective casing sleeving outside the spring steel sheet so that the end, abutting against the hob, of the spring steel sheet can be exposed for isolating interference of an external environment on the spring steel sheet.

Furthermore, at least four loss sensing modules are arranged and symmetrically installed on two sides of the hob, and the spring steel sheets on the same side of the hob correspondingly abut against different positions of a hob cutter ring for collecting vibration signals in different positions of the hob cutter ring Furthermore, an end, close to the hob, of the protective casing is provided with a flexible section, an end portion of the flexible section coincides with corresponding hob positions in shape, and a clearance is reserved.

Furthermore, the strain gages are bonded to the spring steel sheets through strain gage adhesive, and at least two strain gages are pasted to each of a front face and a back face of each spring steel sheet.

Furthermore, a hob cleaning module is further included and the hob cleaning module includes a row brush and a residue guide baffle, the row brush is matched with the hob to clean adhering rock residues on the hob, and the residue guide baffle is installed on the row brush and forms an included angle with the hob cutter ring to prevent collision interference on the spring steel sheets from the external environment.

Providing a method for monitoring a loss state of a TBM hob in real time is a second disclosure purpose of the present application, and the method utilizes any above the device for monitoring a loss state of a TBM hob in real time and includes following steps: monitoring target points are selected on parts of the hob to arrange loss sensing modules; the loss sensing modules collect vibration signals during hob boring, and data collecting and sending modules send the vibration signals to a processor; and after receiving the vibration signals, the processor compares the collected vibration signals with a hob loss state vibration signal database to obtain the loss state of the hob at the time to achieve monitoring.

Furthermore, the hob loss state vibration signal database is established by adopting the following process: different monitoring target points are selected on different parts of the hob, and the loss sensing modules with corresponding length are selected according to the actual distance between the cutter head and the cutter ring and the actual distance between the cutter head and a conductor; vibration frequency when multiple sets of TBM cutter heads perform boring is simulated on a vibration test bench, vibration frequency generated by spring steel sheets when the hob is in an abnormal loss form is tested at various monitoring target points, and vibration signals of various monitoring points are recorded; the vibration test bench simulates the vibration frequency when the multiple sets of TBM cutter heads perform boring, a changing process of the vibration frequency generated by the spring steel sheets in a normal loss form are tested at various monitoring target points, and a changing process of the vibration signals of various monitoring points is recorded; and based on above data, the hob loss state vibration signal database is established.

Furthermore, the abnormal loss form of the hob includes but not limited to cutter ring cracking, cutter ring eccentric abrasion, cutter ring disassembly, and cutter ring turning and tipping.

Furthermore, the hob state is monitored in real time, and when it is monitored that the abnormal loss happens to the hob, alarm information is sent.

Compared with the prior art, the present application has the following advantages and beneficial effects: (1) multiple loss forms of the hob can be effectively monitored in real time under the work state of a TBM on the basis that a cutter head structure is not changed and shutdown is avoided, influence on monitoring from adhering rock residues on the hob is avoided due to arrangement of the hob cleaning module, an effective shelter space is provided for the loss sensing modules, and the monitoring precision of the loss state of the hob is further improved; (2) the spring steel sheets are utilized for collecting the vibration signals when the hob works, and compared with traditional transformation on the hob and the cutter head, work information of the hob can be effectively collected under the situation that the work state of the hob and the cutter head is not influenced, the hob can be conveniently installed on an existing TBNI cutter head, and accordingly higher applicability is achieved; and in addition, the vibration signals are adopted for reflecting work conditions of the hob, and compared with other optical monitoring manners, the contact type spring steel sheets are adopted for acquiring the vibration signals so that attachments of the hob can be prevented from influencing a monitoring result; (3) the spring steel sheets are curved in an initial state, can abut against the hob and sense vibration information of the hob in a direct contact manner, on one hand, a certain reserved allowance can be provided, and the spring steel sheets can be still kept to make contact with the hob when the hob is normally abraded to enlarge the distance between the cutter ring and the cutter head; and on the other hand, certain abutting force is provided so that an end portion can be closely attached to the hob, and contact is kept all the time to acquire a vibration state; (4) the symmetrically-arranged loss sensing modules are adopted so that deformation of the cutter ring in a left direction and a right direction can be detected, and data deviation caused by using the single-side loss sensing module for acquiring data is avoided; and in addition, due to symmetrical arrangement, vibration data are collected, meanwhile, data on two sides of the same position can be subjected to complementary analysis, data analysis accuracy is guaranteed, and accordingly, loss situations of the hob can be more comprehensively reflected; and (5) by adopting configuration of fit of casing bodies and the flexible sections, the spring steel sheet collecting process is protected, and external disturbance is avoided; and by means of the flexible sections, collisions on the casing bodies when the cutter ring deforms are avoided, the flexible sections can absorb the collisions, damage to the spring steel sheets and the strain gages due collisions on the rigidity protective casing bodies is avoided, and accordingly normal running of the casing bodies, the spring steel sheets and the strain gages is effectively protected.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings constituting a part of the present application are used for providing further understanding for the present application. Exemplary embodiments of the present application and descriptions thereof are used for explaining the present application and do not constitute any inappropriate limitation to the present application.

FIG. 1 is a schematic structural diagram of a monitoring device in an Embodiment 1 of the present application; FIG. 2 is a top view of the monitoring device in the Embodiment 1 of the present application; FIG. 3 is a side view of the monitoring device in the Embodiment 1 of the present application; FIG. 4 is a schematic structural diagram of a loss sensing module in the Embodiment 1 of the present application; FIG. 5 is a side view of the loss sensing module in the Embodiment 1 of the present application; FIG. 6 is a schematic diagram of fit of a spring steel sheet and a strain gage in the Embodiment 1 of the present application; and FIG. 7 is a side view after the spring steel sheet and the strain gage in the Embodiment 1 of the present application are matched.

1 denotes cutter head, 2 denotes hob cutter ring, 3 denotes hob body, 4 denotes hob shaft, 5 denotes loss sensing module, 6 denotes data collecting and sending module, 7 denotes data receiving module, 8 denotes PC, 9 denotes row brush, 10 denotes residue guide baffle, 11 denotes row brush bristle, 12 denotes spring steel sheet, 13 denotes flexible section, 14 denotes protective casing body and 15 denotes strain gage.

DETAILED DESCRIPTION

It should be noted that the following detailed descriptions are all exemplary and are intended to provide a further understanding of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art to which the present application belongs.

It should be noted that terms used herein are only for describing specific implementations and are not intended to limit exemplary implementations according to the present application. As used herein, the singular form is intended to include the plural form, unless the context clearly indicates otherwise. In addition, it should further be understood that terms "comprise" and/or "include" used in this specification indicate that there are features, steps, operations, devices, components, and/or combinations thereof For convenience of description, the words "above", and "below" appearing in this application only indicate directions consistent with those of the accompanying drawings, are not intended to limit the structure, and are used only for ease and brevity of illustration and description, rather than indicating or implying that the mentioned device or element needs to have a particular orientation or needs to be constructed and operated in a particular orientation. Therefore, such terms should not be construed as a limitation on the present application.

Just as introductions in the background art, in order to monitor the loss state of the hob in the prior art, domestic and overseas scholars put forward many monitoring means, mainly including a type of method needing to transform the hob and a cutter head structure such as peculiar smell additive adding, hydraulic sensing system adding, coil pre-installing, but the type of method has problems that the hob and the cutter head structure need to be transformed, consequently, the rock breaking capability of the hob is influenced, implementation and popularization are difficult. The other type of method uses sound waves, infrared rays or laser monitoring or other means to directly measure the loss state of the hob, the type of method is likely to be disturbed and influenced by adhering rock residues on the hob and underground water, thereby a measurement result is influenced, and cutter ring turning, cutter ring tipping and other abnormal loss of the hob are difficult to monitor. The above means hardly meet the existing requirement for real-time mastering of the loss state of the TBM hob. For the above technical problems, the present application provides a device and method for monitoring a loss state of a TBM hob in real time.

Example 1

In a typical embodiment mode of the present application, as shown in FIG. 1-FIG. 7, a device for monitoring a loss state of a TBM hob in real time is provided.

Loss sensing modules 5, data collecting and sending modules 6, a processor and a hob cleaning module are included. The loss sensing module 5 includes a protective casing, a spring steel sheet 12 and a semiconductor self-compensating strain gage 15. The data collecting and sending module 6 includes a data collecting circuit, a single chip microcomputer and a wireless signal sending device. The data collecting circuit converts resistance changes of the semiconductor self-compensating strain gage 15 into voltage changes, and voltage signals are processed by the single chip microcomputer and converted into digital signals to be sent by the wireless signal sending device. The processor includes a data receiving module 7 and further includes a wireless signal receiving device, a single chip microcomputer and a personal computer (PC) 8. After the wireless signal receiving device receives the signals sent by the wireless signal sending device and the signals are processed by the single chip microcomputer, vibration signals of the spring steel sheets 12 are displayed on the PC 8 in real time. The hob cleaning module includes a row brush 9 and a residue guide baffle 10.

Multiple loss forms of the hob can be effectively monitored in real time under the work state of a TBM on the basis that a cutter head structure is not changed and shutdown is avoided. Influence on monitoring from adhering rock residues on the hob is avoided due to arrangement of the hob cleaning module. An effective shelter space is provided for the loss sensing modules. The monitoring precision of the loss state of the hob is further improved.

A hob shaft 4 is arranged in a middle of the hob. A hob body 3 and a hob cutter ring 2 are sequentially arranged outwards in the radial direction. At least four loss sensing modules 5 are arranged and symmetrically installed on parts, on two sides of the hob cutter ring 2 of a cutter head, at least two loss sensing modules 5 on the same side correspondingly abut against different positions of the cutter ring 2. The loss sensing modules 5 are connected to the data collecting and sending modules 6 through wires.

The spring steel sheets are utilized for collecting vibration signals when the hob works. Compared with traditional transformation on the hob and the cutter head, work information of the hob can be effectively collected under the situation that the work state of the hob and the cutter head is not influenced, the hob can be conveniently installed on an existing TBM cutter head, and accordingly higher applicability is achieved. In addition, the vibration signals are adopted for reflecting work conditions of the hob. Compared with other optical monitoring manners, the contact type spring steel sheets are adopted for acquiring the vibration signals so that attachments of the hob can be prevented from influencing a monitoring result.

The symmetrically-arranged loss sensing modules are adopted so that deformation of the cutter ring in a left direction and a right direction can be detected, and data deviation caused by using the single-side loss sensing module for acquiring data is avoided. In addition, due to symmetrical arrangement, vibration data are collected. Meanwhile, data on two sides of the same position can be subjected to complementary analysis, data analysis accuracy is guaranteed. Accordingly, loss situations of the hob can be more comprehensively reflected.

The protective casing is in a horn shape and includes a flexible rubber opening end 13 and a stainless steel casing body 14. The total length of the protective casing is equal to the distance between the cutter head 1 and a corresponding monitoring point of the hob cutter ring 2. Rubber materials are adopted in a flexible section to form the flexible rubber opening end 13. Radian of the flexible rubber opening end coincides with radian at a corresponding monitoring position of the cutter ring 2. A certain clearance is reserved.

By adopting configuration of fit of casing bodies and the flexible sections, the spring steel sheet collecting process is protected, and external disturbance is avoided. By means of the flexible sections, collisions on the casing bodies when the cutter ring deforms are avoided. The flexible sections can absorb the collisions. Damage to the spring steel sheets and the strain gages due collisions on the rigidity protective casing bodies is avoided. Accordingly normal running of the casing bodies, the spring steel sheets and the strain gages is effectively protected.

The length of the spring steel sheets 12 is larger than the total length of the protective casings by 2-5 cm, parts between the cutter head 1 and the hob cutter ring 2 are curved. Under the situation that the hob encounters various losses of the cutter ring 2 in the rotation process, the spring steel sheets 12 can generate vibration with corresponding characteristic frequency.

The spring steel sheets 12 are arranged in protective casing inner cavities. At least two semiconductor self-compensating strain gages 15 are pasted to each of a front face and a back face of the spring steel sheet 12. The semiconductor self-compensating strain gages 15 and the spring steel sheet 12 are bonded through strain gage adhesive, and surfaces of the spring steel sheet 12 are cured.

The spring steel sheets are curved in an initial state, can abut against the hob and sense vibration information of the hob in a direct contact manner, on one hand, a certain reserved allowance can be provided, and the spring steel sheets can be still kept to make contact with the hob when the hob is normally abraded to enlarge the distance between the cutter ring and the cutter head. On the other hand, certain abutting force is provided so that an end portion can be closely attached to the hob, and contact is kept all the time to acquire a vibration state.

Bristles of the row brush 9 of the hob cleaning module are flexible bristles 11, the bristles 11 are different in length, the length of various parts of bristles 11 is equal to the distance between the row brush 9 and the hob body 3 and the distance between the row brush 9 and the cutter ring 2. The row brush 9 is connected to the residue guide baffle 10. A certain angle is formed between the residue guide baffle 10 and the cutter ring 2 to provide the shelter space for the loss sensing modules 5.

Example 2

In another typical example of the present application, a method for monitoring a loss state of a TBM hob in real time is provided and utilizes any above the device for monitoring the loss state of the TBM hob in real time.

Monitoring target points are selected on parts of the hob to arrange loss sensing modules. the loss sensing modules collect vibration signals during hob boring, and data collecting and sending modules send the vibration signals to a processor, and After receiving the vibration signals, the processor compares the collected vibration signals with a hob loss state vibration signal database to obtain the loss state of the hob at the time to achieve monitoring.

Furthermore, the hob loss state vibration signal database is established by adopting the following process: Different monitoring target points are selected on different parts of the hob, and the loss sensing modules with corresponding length are selected according to the actual distance between the cutter head and the cutter ring and the actual distance between the cutter head and a conductor.

vibration frequency when multiple sets of TBM cutter heads perform boring is simulated on a vibration test bench, vibration frequency generated by spring steel sheets when the hob is in an abnormal loss form is tested at various monitoring target points, and vibration signals of various monitoring points are recorded; the vibration test bench simulates the vibration frequency when the multiple sets of TBM cutter heads perform boring, a changing process of the vibration frequency generated by the spring steel sheets in a normal loss form are tested at various monitoring target points, and a changing process of the vibration signals of various monitoring points is recorded; and based on above data, the hob loss state vibration signal database is established.

Furthermore, the abnormal loss form of the hob includes but not limited to cutter ring cracking, cutter ring eccentric abrasion, cutter ring disassembly, and cutter ring turning and tipping Furthermore, the hob state is monitored in real time, and when it is monitored that the abnormal loss happens to the hob, alarm information is sent.

The above descriptions are merely preferred embodiments of the present application and are not intended to limit the present application. For a person skilled in the art, the present application may have various modifications and changes. Any modification, equivalent replacement, or improvement made without departing from the spirit and principle of the present application shall fall within the protection scope of the present application.

Claims

CLAIMSWhat is claimed is: 1. A device for monitoring a loss state of a TBM hob in real time, comprising data collecting and sending modules, loss sensing modules arid a processor, wherein the loss sensing module comprises a spring steel sheet and a strain gage, the strain gage is pasted and applied to the spring steel sheet, one end of the spring steel sheet is fixed, the other end abuts against the hob to form an arc, and the end, abutting against the hob, of the spring steel sheet is used for generating vibration upon receiving the hob action; and the data collecting and sending modules measure and acquire vibration signals of the spring steel sheets through the strain gages and send the vibration signals to the processor, the processor receives vibration data and compares the vibration data with a hob loss state vibration signal database to judge the loss state of the hob.
2. The device for monitoring a loss state of a TBM hob in real time according to claim 1, wherein the loss sensing module fiirther comprises a protective casing sleeving outside the spring steel sheet so that the end, abutting against the hob, of the spring steel sheet can be exposed for isolating interference of an external environment on the spring steel sheet.
3. The device for monitoring a loss state of a TBM hob in real time according to claim 2, wherein at least four loss sensing modules are arranged and symmetrically installed on two sides of the hob, and the spring steel sheets on the same side of the hob correspondingly abut against different positions of a hob cutter ring for collecting vibration signals in different positions of the hob cutter ring.
4. The device for monitoring a loss state of a TBM hob in real time according to claim 3, wherein an end, close to the hob, of the protective casing is provided with a flexible section, an end portion of the flexible section coincides with corresponding hob positions in shape, and a clearance is reserved.
5. The device for monitoring a loss state of a TBM hob in real time according to claim 1, wherein the strain gages are bonded to the spring steel sheets through strain gage adhesive, and at least two strain gages are pasted to each of a front face and a back face of each spring steel sheet.
6. The device for monitoring a loss state of a TBM hob in real time according to claim 1, further comprising a hob cleaning module, wherein the hob cleaning module comprises a row brush and a residue guide baffle, the row brush is matched with the hob to clean adhering rock residues on the hob, and the residue guide baffle is installed on the row brush and forms an included angle with a hob cutter ring to prevent collision interference on the spring steel sheets from the external environment.
7. A method for monitoring a loss state of a TBM hob in real time, wherein the method utilizes the device for monitoring a loss state of a TBM hob in real time according to any of claims 1-6 and comprises: monitoring target points are selected on parts of the hob to arrange loss sensing modules; the loss sensing modules collect vibration signals during hob boring, and data collecting and sending modules send the vibration signals to a processor; and after receiving the vibration signals, the processor compares the collected vibration signals with a hob loss state vibration signal database to obtain the loss state of the hob at the time to achieve monitoring.
8. The method for monitoring a loss state of a TBM hob in real time according to claim 7, wherein the hob loss state vibration signal database is established by adopting the following process: different monitoring target points are selected on different parts of the hob, and the loss sensing modules with corresponding length are selected according to the actual distance between the cutter head and the cutter ring and the actual distance between the cutter head and a conductor; vibration frequency when multiple sets of TBM cutter heads perform boring is simulated on a vibration test bench, vibration frequency generated by spring steel sheets when the hob is in an abnormal loss form is tested at various monitoring target points, and vibration signals of various monitoring points are recorded; the vibration test bench simulates the vibration frequency when the multiple sets of TBM cutter heads perform boring, a changing process of the vibration frequency generated by the spring steel sheets in a normal loss form are tested at various monitoring target points, and a changing process of the vibration signals of various monitoring points is recorded; and based on above data, the hob loss state vibration signal database is established.
9. The method for monitoring a loss state of a TBM hob in real time according to claim 8, wherein the abnormal loss form of the hob comprises but not limited to cutter ring cracking, cutter ring eccentric abrasion, cutter ring disassembly, and cutter ring turning and tipping.
10. The method for monitoring a loss state of a TBM hob in real time according to claim 7, wherein the hob state is monitored in real time, and when it is monitored that the abnormal loss happens to the hob, alarm information is sent.