WO2003087537A1

WO2003087537A1 - Disk roller cutter and disk roller cutter monitoring system

Info

Publication number: WO2003087537A1
Application number: PCT/JP2003/004758
Authority: WO
Inventors: Yoshihiro Motonami; Kazuyoshi Oishi
Original assignee: Starloy Corporation; Oishi International Syscom Co., Ltd.
Priority date: 2002-04-17
Filing date: 2003-04-15
Publication date: 2003-10-23
Also published as: AU2003227498A1; JP3919172B2; JP2003307095A; AU2003227498A8

Abstract

A disk roller cutter and a disk roller cutter monitoring system capable of safely and efficiently operating an excavator, the disk roller cutter (1) comprising a sensor (7) for detecting the worn state of a cutter (2), a sensor (8) for detecting the rotating state of the cutter (2), and sensors (12) for detecting a load acting on the rotating shaft (1a) of the cutter (2) from a cutting face in vertical or tilted direction; the disk roller cutter monitoring system wherein output signals from the sensors are taken in an administration computer (36) disposed behind a cutting head and processed by the computer to simultaneously display, on a monitor (40), the worn amount and rotational speed of a disk and the magnitude and direction of the load acting on the rotating shaft, whereby the use state of the disk roller cutter (1) fitted to the cutting head of the excavator can be monitored in real time even during excavation.

Description

Description Disc roller power meter and disc roller power meter monitoring system Technical field

The present invention relates to a disk roller cutter (hereinafter abbreviated as DRC) of a tunnel excavator used for mine excavation and tunnel construction. In addition, the present invention monitors the amount of disk wear, the number of rotations, and the applied load, monitors and evaluates the DRC usage status, and monitors the face condition. About the system. Background art

The life of the DRC of a tunnel machine is deeply related to the amount and manner of wear of the disk during cutting, the rotational state of the disk, and the load acting on the entire DRC. In order to operate the excavator safely and with high cutting efficiency, it is necessary to accurately measure these to accurately grasp the use of DRC and also to accurately grasp the condition of the face.

Conventionally, various methods have been proposed for measuring the amount of wear, the number of rotations, and the magnitude and direction of the applied load. However, neither of these measures is accurate. For example, as a means for measuring the number of rotations of a disk, there is a method of measuring the number of rotations of a cutting head and calculating the number of rotations of the disk from the measurement. Since this method does not directly measure the number of revolutions of the disk, the variation in the number of revolutions is large and accurate data cannot be obtained. Conventionally, the state of wear, rotation, and applied load of a disk has been measured, but no comprehensive processing has been performed by correlating the measured data. For this reason, it is not possible to grasp the usage status of the entire DRC in real time during cutting, nor at the same time to accurately grasp the face condition. In addition, in order to search for the state of the rock in front of the excavator, the state of the rock on the face is examined using ultrasonic waves and electromagnetic waves, and the pressing force of the propulsion cylinder and the torque of the cutting head during cutting. There is known a system that calculates the pressing force acting on the DRC based on such information and obtains the rock strength ahead of the head. However, these also have large measurement errors and do not provide accurate judgment criteria. A system that uses ultrasonic waves requires a large amount of energy to oscillate ultrasonic waves, and the mechanism for transmitting this energy from the rear fixed part of the excavator to the front rotating part is complicated, making it difficult to construct the entire system. There is also. Disclosure of the invention

An object of the present invention is to make it possible to predict a DRC replacement time by accurately grasping the DRC usage status in real time, and to quickly find a factor that may be a problem for excavation, that is, to check the DRC and face condition. It is necessary to understand and respond accurately and to operate the excavator safely and efficiently.

The DRC of the present invention is mounted on a cutting head of an excavator, and detects a wear state of a disk including a steel disk or a cemented carbide chip, a sensor that detects a rotation state of the disk, A sensor for detecting a load acting from the cutting face in a direction perpendicular or inclined to the rotation axis of the DRC.

According to this configuration, accurate measurement data can be obtained by equipping the DRC with a sensor, and there is a correlation by simultaneously measuring the amount of wear and rotation of the disk, the magnitude of applied load, etc. Data will be obtained and DRC usage will be accurately understood. By installing a plurality of DRCs of the present invention on the cutting head, and more preferably by installing them all over the entire cutting head, each of the installation positions, for example, the center side and the peripheral side of the cutting head, is set. It is possible to grasp the condition of the face in the plane of the cutting head from the measured data of the rotation of the disk at each position and the applied load. You.

In the DRC having the above-described configuration, the wear sensor uses a sensor that captures the wear state of the periphery of the disk including the steel disk or the carbide alloy tip as a change in the magnetic field due to the decrease in the magnetic material, and outputs a signal of the displacement. Can be From the detection signal of the wear sensor, wear state measurement data such as the wear location of the disk, the wear amount at that location, and the average wear amount of the entire disk can be obtained. As the rotation sensor, a sensor that detects the passage of a magnet attached to the rotating part of the DRC as a change in the magnetic field and outputs a signal each time the change is detected. Rotation state measurement data such as the number of rotations of the disk can be obtained from the detection signal of the rotation sensor. A stress sensor is used as the load sensor, which is installed on each of the shaft portions that support the left and right ends of the rotating shaft of the DRC. It is configured so that the magnitude and direction of the load acting from the direction or the inclined direction can be measured. The load condition measurement data such as the magnitude and direction of the load acting on the disk can be obtained from the detection signal of the load sensor.

In a preferred embodiment, in the DRC having the above-described configuration, a support base as a load sensor having a built-in stress strain meter is provided in a housing fixed to the cutting head, and the support base supports the left and right shaft portions of the DRC, respectively. A sensor support having an abrasion sensor and a rotation sensor on its upper surface is detachably provided below the support base or the housing.

According to this configuration, the DRC is installed by fixing the left and right shaft portions of the DRC on a support base mounted on or in the housing, and further, a sensor support having a wear sensor and a rotation sensor installed on the upper surface. This is done by attaching the body to the lower part of a support stand or housing opposite the face. Since the load transmitted to the support base via the rotating shaft of the DRC is measured, the load acting on the DRC during cutting can be measured with high accuracy. Inspection and replacement of the sensor can be easily performed by removing the sensor support from the support base for the wear sensor and the rotation sensor, and removing the load sensor from the housing. If the sensor is easy to maintain, the cutter can be mounted in a single part housing or additionally in the power housing. The sensor may be installed on another component that is used.

Mud water may be filled between the excavator bulkhead and the face to prevent the face from collapsing while the face is being cut by the excavator. Therefore, each sensor in the DRC having the above-mentioned structure has a structure having a water pressure resistance of at least 3 bar.

The monitoring system of the present invention includes the DRC having the above-described configuration and a management computer that processes output signals of the sensors, and displays and outputs the state of disk wear, rotation, and applied load simultaneously with excavation of the face. It is characterized by the following.

According to this configuration, by processing the detection signal of one or more DRCs attached to the cutting head, the DRC can be used accurately based on the disk wear, rotation, and load data, which are mutually correlated. By observing the situation, it is possible to manage DRC efficiently. From the data measured by each DRC during cutting, data obtained by accurately exploring the face, such as the condition of the DRC and the cutting head placed on the face, the rock strength of the face, and the presence or absence of cavities (information) From this data, the condition of the face can be grasped and the excavator can be operated efficiently. In a preferred embodiment, in the system configured as described above, each of the wear, rotation, and load data input from the DRC to the management computer and subjected to data processing is displayed as a numerical value, a table, or a graph on a display or a printer. The data can be sent to another computer online from the signal output terminal of the management computer, or the processed data can be sequentially loaded into the internal memory of the management computer and recorded in an external memory such as a CD burning device, or offline. You may be able to get it on your computer.

Further, in the system having the above-described configuration, the detection signal of each sensor is taken into the fixed portion of the excavator via a non-contact signal transmission device installed at the end of the rotation shaft of the excavator located at the center of the cutting head rotation. Alternatively, the signal may be further amplified and input to the management computer.

According to this configuration, the signal line of each sensor passes through the rotation shaft of the excavator, and It is connected to the movable part of the non-contact signal device that rotates integrally with the rotating shaft. The output signal of each sensor is transmitted to the fixed part of the non-contact signaling device via the movable part, the signal is amplified and input to the management computer. Thus, the use of the non-contact signal transmission device makes it possible to easily construct the entire system.

In the system having the above-described configuration, a shielded cable that cuts off the influence of electromagnetic waves from a motor or the like disposed inside and outside the excavator is used as a signal transmission path from each sensor to the management computer. As described above, the components that make up the sensor of the excavator to the non-contact signal transmission device have a structure that can operate normally even under water pressure of 3 bar or more.

For example, if the diameter of the cutting head of an excavator is 1 Om, and the cutting head makes one revolution in 15 seconds to excavate the face, the cutting head was mounted near the outer periphery of the cutting head. The rotation speed of the DRC is about 2 m / s, and if sensor detection signals are collected at intervals of seconds, the data collection interval becomes too large for the DRC's travel distance and rotation speed, and the DRC's Precise measurement data cannot be obtained. Therefore, in the system having the above configuration, the detection signal of each sensor is 0.0

It is configured to collect and process at intervals of about 1 second (100 Hz). In order to obtain more accurate data, further reducing the collection interval is performed appropriately according to the diameter of the cutting head and its rotation speed.

Further, the system having the above-mentioned configuration includes means for detecting the wear, rotation and load acting on the DRC, which are attached to the cutting head of the excavator, means for detecting the rotation angle of the cutting head, and cutting head. And a means for displaying and outputting the wear and rotation of the DRC and the displacement of the load corresponding to the rotation angle of the drive.

According to this configuration, the data detected by each of the detecting means is processed, and the data is simultaneously displayed on the display display or the like while having a correlation with the rotation angle of the cutting head. It is possible to clearly determine the situation of the DRC of the location. In addition, from the situation of such DRC, it is possible to accurately determine the situation of the face facing the DRC. It becomes possible to separate. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a diagram showing a DRC according to the present invention with a part thereof broken away.

FIG. 2 is a diagram showing a configuration of a monitoring system according to the present invention. FIG. 3 is an example of a display screen when data processed by the monitoring system according to the present invention is output to a display monitor. BEST MODE FOR CARRYING OUT THE INVENTION

FIG. 1 shows a DRC of the present invention. In the drawing, reference numeral 1 denotes a DRC, 2 denotes a cutter, 4 denotes a cutter support, and 5 denotes a housing. As shown in the figure, the DRC 1 includes a cutter 2 and a cutter support 4 that rotatably supports the cutter 2.

The cutter 2 has a disk 3a made of steel or a steel disk with a cemented carbide chip arranged around the periphery of the disk, and a hub 3 rotatably supported at both left and right ends by shaft portions la and la. It is configured to be fitted integrally on the outer circumference of b. The force cutter 2 may be formed by integrally molding the disk 3a and the hap 3b.

The cutter support section 4 includes support housings 6 and 6 to which the left and right shaft sections 1 a and 1 a for supporting the cutter 1 are fixed in a housing 5 fixed to the cutting head. It comprises a wear sensor 7 for detecting the state, a rotation sensor 8 for detecting the rotation state of the disk 3a, and a load sensor 12 for detecting a load acting on the cutter 2 from the cutting face.

The wear sensor 7 is a sensor that detects displacement of a magnetic field caused by a decrease in mass due to wear or cracks of the outer circumference of the disk 3a formed of a magnetized substance, converts this into an electric signal, and outputs a signal. And is located in the lower center of the housing 5 close to the periphery of the disk 3a. The rotation sensor 8 is a sensor that detects a magnetic field generated by a magnet 9 attached to the outer peripheral surface of the hub 3 b every time the power meter 2 rotates, converts this to an electric signal, and outputs a signal. Outer peripheral surface It is installed at the lower part of the housing 5 so as to be close to. Both sensors are fixed to the upper surface of a sensor support 11 that is horizontally mounted between the support frames 6 and 6 at the lower portion of the housing 5 and attached to the support frames with screws 10. Both sensors are removed from the support base 6 together with the sensor support 11 by loosening the screw 10 so that maintenance such as inspection and replacement can be easily performed.

The load sensor 12 consists of a stress-strain meter that detects the expansion and contraction of the structure and outputs a signal, and the inside of the support bases 6 and 6 that abut and support the right and left shafts 1 &, 1 a of 0〇1 It is provided so that the state of expansion and contraction inside both support bases 6 is detected, and the magnitude and direction of the load acting on cutter 2 are detected from the respective detection signals. In other words, the support bases 6 and 6 with the built-in stress strain gauge have the function of the load sensor 12.

More specifically, the support pedestal 6 is provided with a pair of convex steps at corresponding positions on the upper and lower surfaces thereof, and a convex step on the upper surface is joined to the lower surface of the shaft portion 1a. It is installed so that the part is supported. Therefore, when a load is applied to the cutter 2, the load is transmitted intensively between the upper and lower convex portions via the joint surface, and the stress acting inside the support base 6 can be accurately measured by the load sensor 12. It has become.

The support base 6 is integrally attached to the shaft portion 1a with screws 13 and further fixed between the housing 5 with screws 14 so that these screws can be loosened for easy removal. You can do it. In addition, a sleeve 15 is inserted between the screw 14 and the housing 5 in order to suppress a change in the pretension due to the tightening force of the screw due to loosening of each of the above-mentioned screw cutters or a bite of each other. It is provided so that the change in pretension can be absorbed by the elasticity of the sleeve 15 and the change in load can be accurately measured.

Further, a metal plate is inserted between a lower portion of the support base 6 and an inner surface of the housing 5 to absorb a shift due to a difference in shape of a joint surface between the support base 6 and the housing 5. As a result, the support base 6 is stably supported on the housing 5 內, and the load measurement with reproducibility can be performed. A signal cable (not shown) connected to each of these sensors is drawn into the protection section in the cutting head through the sensor support 11 to protect it from external impact such as cutting rock. Also, each sensor and signal cable must be at least

It is designed to operate normally even at a water pressure of 3 bar or more.

FIG. 2 shows the configuration of the monitoring system of the present invention. In the figure, reference numeral 20 denotes an excavator, 21 denotes a cutting head which is a rotating part of the excavator, 22 denotes a fixed part of the excavator, and 23 denotes a center of rotation of the cutting head 21. A rotating shaft 24, a partition wall separating the fixed part 22 and the cutting head 21 and a management computer 36 are provided. During excavation of the face by the excavator 20, muddy water is filled at a pressure of about 3 bar between the face and the bulkhead 24 of the excavator 20 in order to prevent the face from collapsing. In the figure, a plurality of DRCs 1 having the above-mentioned configuration are attached to a cutting head 21, and signal cables 25 of the respective sensors installed on the respective support portions 4 are respectively drawn into the cutting head 21. Each signal cable 25 is connected, if necessary, via an extension cable 26 and a repeater 27, passes through the rotary shaft 23, and rotates inside the fixed part 22 of the excavator. It is connected to the non-contact signal transmission device 28 installed at the end of the shaft 23.

The non-contact signal transmitting device 28 includes a signal amplifier 29 and a rotating ring 30 that rotate integrally with the rotating shaft 23, and a fixed portion 22 facing the rotating ring 30 and opening an appropriate space. And a fixing ring 31 fixed therein. Signals input to the device from each signal cable 25 and extension cable 26 are arranged and amplified as transmission data in a signal amplifier 29, and then transmitted from the rotating ring 30 to the fixed ring 31 for cutting. Even when the head 21 is rotating, the sensor detection signal is taken into the fixed part 22 of the excavator 20 in a non-contact manner even when the head 21 is rotating. The driving current of the sensor is transmitted from the fixed ring 31 to the rotating ring 30 so as to be supplied to each sensor on the surface of the cutting head.

The non-contact signal transmission device 28 has a built-in sensor (not shown) for detecting the position of the rotating part in both rings 30 and 31, and the rotation angle of the cutting head 21. And a detection signal are output together with the sensor detection signal received by the fixed ring 31. Then, the output signal of the non-contact signal transmission device 28 is input to the management computer 36 via the signal cable 32. If there is a distance from the non-contact signal transmission device 28 to the installation position of the management computer 36, the signal is appropriately and appropriately increased via the repeater 33, the extension cable 34, and the signal amplifier 35. It is then transmitted to the management computer 36.

The management computer 36 is a data processing means for analyzing signals and performing arithmetic processing, a data input means such as a keyboard or a mouse, a display output means such as a display or a printer for displaying processed data, and a memory for storing data. And processing means such as signal input / output means.

The management computer 36 shown in FIG. 2 shows a form in which each of these processing means is stored in a console box 37 together with the signal amplifier 35, and in this embodiment, the processing means is inputted from the signal amplifier 35. An analysis unit 38 for analyzing and processing each signal to be processed, a keyboard and mouse 39, a display moeta 40, and an arithmetic unit 41 having a storage unit.

The data processing in the management computer 36 is performed by the operation unit 41 controlling the operation of each processing unit according to the operation program stored in the operation unit 41, and the data is transmitted to the keyboard and mouse 39 or the console box 37. Based on the processing instruction signal input from the provided switches 42 and 43, the data is sequentially taken in from the analysis unit 38 to the calculation unit 41 and processed, and the processing result is displayed and output on the display monitor 40. At the same time, the information is stored in the storage unit. The measurement data of each sensor is set to be collected at 0.01 second intervals.

The processing unit 41 also has an external input / output interface, sends the processed data to a CD burning device, creates a CD on which the processed data is recorded, and imports the processed data to another computer 44 offline. , Can be processed. A data output terminal is provided in the arithmetic section 41, and connected online with another computer 44 through this terminal, and the data detected and processed by each of the sensors is processed. Data may be output.

Each component constituting a signal transmission path from each of the sensors to the non-contact signal transmission device 28 is provided with a pressure-resistant seal so as to operate normally under a water pressure of at least 3 bar. In addition, as for each signal cable connecting each sensor to the management computer 36, it is preferable to use a shielded cable for removing the influence of an external electromagnetic field.

FIG. 3 shows an example of a display screen when the detection signal of each sensor is processed by the management computer 36 and the processed data is displayed on the display monitor 40. This screen is displayed by selecting and selecting the DRC 1 whose rotation status is to be displayed by operating the switch 42 or 43 provided on the console box 37.The number and position of the corresponding DRC 1 are displayed in the screen. Information such as the amount of wear, the number of rotations, and the load acting on the face is displayed.

In the figure, reference numeral 50 denotes a selected DRC 1 number display portion, and 51 denotes a position of the corresponding DRC 1 with respect to the face. In the display section 51, the entire circular display panel represents a face, and the position of the DRC 1 that is sequentially displaced with respect to the face as the cutting head 21 rotates is indicated by an arrow 52 in the display panel. It is specified and displayed at the tip. In addition, when the cutting head 21 is stopped, the arrow 52 is set to make one rotation in the display panel in 36 seconds. Reference numeral 53 denotes a display section of the wear state of the disk 3a obtained by processing the detection signal of the wear sensor 7 of the corresponding DRC 1, and the display section displays the average value of the wear amount of the entire circumference of the disk in mm. A display section 53a for displaying the unit number and a display section 53b for displaying the degree of wear in three colors of green, yellow and red are arranged. Based on the difference between the average value of the wear amount and the preset wear amount, the color-coded display section 53 b shows green as a safety zone when the wear is small and a caution zone when the wear has advanced. When the wear reaches the use limit of the disc 3a, yellow is displayed as danger, and the operator who looks at the screen can intuitively know and judge the degree of wear of the disc 3a. Has become.

Symbols 5 and 4 indicate the detection signal of the wear sensor 7 and the rotation sensor 8 of the corresponding DRC 1. This is a display section that continuously displays the disk wear state and the rotation state obtained by processing the detection signal in accordance with the rotation angle of the cutting head 21. The horizontal axis indicates the rotation angle (0 to 360 degrees) when the cutting head 21 rotates toward the face, and the vertical axis indicates the amount of disk wear. The wear value on the outer circumference of the disk corresponding to each rotation angle is continuously displayed by the output line 54a, and is arranged along with the output line 54a every time the cutter 1-2 rotates. The pulse signal output to the disk 3a is continuously displayed by the output line 54b, and the two output lines displayed in this manner allow the operator viewing the screen to determine which part of the disk 3a is missing. Alternatively, it is possible to determine whether uneven wear has occurred and, at the same time, determine whether or not the force cutter 2 has slipped against the face and has caused irregular rotation. During cutting, the set value of the rotation speed of the cutter 2 obtained by the calculation formula is displayed on the display unit 55, and the measured value of the measured rotation speed of the cutter 2 is displayed on the display unit 56. Similarly, the measured value of the rotation speed of the cutting head 21 measured is displayed on the display unit 57.

Reference numeral 58 indicates the state of the load acting on the cutter 2 obtained by processing the detection signal of the load sensor 12 provided on the left and right shaft support portions of the corresponding DRC 1 and the cutting head 2 1 This is a display unit that continuously displays the image according to the rotation angle. This display section is composed of a graph in which the horizontal axis indicates the rotation angle when the cutting head 21 rotates, and the vertical axis indicates the magnitude of the load acting on the force cutter 2. Changes in the load measured by the load sensors 12 and 12 in the gantry 6 and 6 are displayed separately on the continuous output lines 58a and 58a, respectively, and at the same time each time the cutting head 21 rotates The pulse signal to be output is also output and displayed side by side with the load output line on the output line 58b. The display sections 59 and 60 are correction bars for calibrating the display zeros of the load sensors 12 and 12.

In this way, information such as the amount and location of wear of the disc 3a of the DRC 1 and the number of rotations of the cutter 2 and the magnitude and direction of the applied load are simultaneously displayed and output. Can be properly monitored. To face The position of the DRC 1 and the rotation angle of the cutting head 21 with respect to the face are also displayed and output.For example, if there are cavities or high-strength rock in the face, the information on the rotation and load is used. It will be possible to grasp the position of the tunnel and excavate the tunnel efficiently.

It should be noted that the configuration of the illustrated DRC and its supporting base, the configuration of the monitoring system, and the layout of the data display screen are merely examples, and the present invention can be configured in various other forms.

Claims

The scope of the claims

1. A disk roller cutter attached to a cutting head of an excavator, a sensor for detecting a worn state of a disk including a steel disk or a cemented carbide chip, and a sensor for detecting a rotating state of the disk. And a sensor for detecting a load acting on the cutting face in a direction perpendicular or inclined to the rotation axis of the disc roller force cutter.

2. A support base as a load sensor with a built-in stress strain gauge is provided in the housing fixed to the cutting head. The support base supports the left and right shafts of the disc roller force meter, and the support base or housing. 2. The disc roller force meter according to claim 1, wherein a sensor support having a wear sensor and a rotation sensor installed on its upper surface is detachably provided at a lower portion of the disc roller force meter.

3. The disk roller cutter according to claim 1, wherein each of the sensors has a water pressure resistance of at least 3 bar.

4. A disc roller cutter according to any one of claims 1 to 3, and a management computer for processing output signals of the respective sensors of the disc roller force meter, the disc being worn, rotating, and the state of a load applied. A disc roller cutter-monitoring system characterized in that the display is output simultaneously with the excavation of the face.

5. The detection signal of each sensor is taken into the fixed part of the excavator via the non-contact signal transmission device installed at the end of the rotating shaft of the excavator located at the center of the cutting head rotation, and further amplified. 5. The disc roller cutter monitoring system according to claim 4, wherein the disc roller cutter monitoring system is configured to be input to a management computer.

6. The disk roller cutter monitoring system according to claim 4, wherein the detection signal of each sensor is collected and processed at an interval of about 0.01 second.

7-mounted on the cutting head of the machine Means for detecting wear and rotation and the load acting on the disc roller cutter, means for detecting the rotation angle of the cutting head, and the wear, rotation and load displacement of the disc roller force meter corresponding to the rotation angle of the cutting head 7. The disk roller one-way motering system according to claim 4, further comprising means for displaying and outputting the respective values.