CN-122016536-A - TBM hob abrasion identification quantitative monitoring system and method based on vibration magnetic induction compounding

CN122016536ACN 122016536 ACN122016536 ACN 122016536ACN-122016536-A

Abstract

The invention discloses a TBM hob abrasion identification quantitative monitoring system and method based on vibration magnetic induction compounding, comprising a hob assembly, a sensing monitoring unit, a data processing module and a terminal early warning platform, wherein the hob assembly comprises a hob box body and a hob, a permanent magnet is arranged on the hob, the sensing monitoring unit comprises a vibration sensor and a magnetic induction monitoring module, the data processing module is respectively and electrically connected with the vibration sensor and the magnetic induction monitoring module and is used for analyzing and processing vibration signals and magnetic induction signals, and the terminal early warning platform is in communication connection with the data processing module and is used for receiving information transmitted by the data processing module and displaying the hob abrasion state and giving early warning. The system and the method integrate vibration and magnetic induction multi-parameter information, overcome the defect that the traditional single parameter monitoring mode is easily interfered by geological mutation, can effectively distinguish abnormal wear modes such as uniform wear and eccentric wear, and improve the accuracy and reliability of monitoring.

Inventors

ZHANG XIAOPING
JIANG QIWU
WANG HAOJIE
LIU QUANSHENG
ZHANG KUNFENG
LI LEI
KANG HAIBO
You Shaoqiang

Assignees

武汉大学

Dates

Publication Date: 20260512
Application Date: 20251229

Claims (10)

1. The TBM hob abrasion identification quantitative monitoring system based on vibration magnetic induction compounding is characterized by comprising hob components, a sensing monitoring unit, a data processing module and a terminal early warning platform; The hob assembly comprises a hob box body, a rotatable hob is arranged in the hob box body, a permanent magnet is arranged on at least one end face of the hob, and the permanent magnet generates a magnetic field signal which changes regularly when the permanent magnet rotates synchronously with the hob; The sensing monitoring unit comprises a vibration sensor and a magnetic induction monitoring module, wherein the vibration sensor is arranged on the inner wall of the hob box body or the hob and is used for collecting vibration signals generated by hob rock breaking, and the magnetic induction monitoring module is arranged on the hob box body, keeps a radial distance with the rotating track of the permanent magnet and is used for monitoring magnetic induction signals generated by the rotation of the permanent magnet; the data processing module is respectively and electrically connected with the vibration sensor and the magnetic induction monitoring module and is used for analyzing and processing the vibration signal and the magnetic induction signal; The terminal early warning platform is in communication connection with the data processing module, receives information transmitted by the data processing module in a wireless communication mode, and is used for displaying the abrasion state of the hob and giving out early warning.
2. The TBM hob abrasion identification quantitative monitoring system based on vibration and magnetic induction combination according to claim 1, wherein the hob is connected with the hob box body through a bearing, the permanent magnets are uniformly distributed on the end face of the hob end in a ring shape, and magnetic poles of adjacent permanent magnets are alternately arranged.
3. The TBM hob abrasion identification quantitative monitoring system based on vibration and magnetic induction combination according to claim 1, wherein the vibration sensor is embedded in the inner wall of the hob box body, and a triaxial acceleration sensor is adopted to capture vibration acceleration signals of the hob in the radial direction, the axial direction and the circumferential direction.
4. The TBM hob abrasion identification quantitative monitoring system based on vibration and magnetic induction compounding according to claim 1, wherein a mounting groove is formed in the hob box body, and the magnetic induction monitoring module is packaged in the mounting groove.
5. The TBM hob abrasion identification quantitative monitoring system based on vibration and magnetic induction compounding according to claim 1, wherein the magnetic induction monitoring module is at least three Hall sensors uniformly arranged along the circumferential direction.
6. The TBM hob abrasion identification quantitative monitoring system based on vibration and magnetic induction compounding is characterized in that the data processing module comprises a signal preprocessing unit, a characteristic extraction unit and an abrasion identification unit, the signal preprocessing unit adopts a wavelet transformation noise reduction algorithm to conduct filtering and noise reduction processing on vibration signals and magnetic induction signals, the characteristic extraction unit is used for extracting characteristic parameters of vibration frequency, vibration amplitude, magnetic field intensity change rate and amplitude from the preprocessed vibration signals and magnetic induction signals to provide data support for the abrasion identification unit, and the abrasion identification unit is used for analyzing and judging the abrasion type and abrasion quantity of the hob, wherein the abrasion type at least comprises uniform abrasion, uneven abrasion, heavy abrasion and tipping abnormal abrasion.
7. The TBM hob abrasion identification quantitative monitoring system based on vibration and magnetic induction combination according to claim 1, wherein the terminal early warning platform adopts an industrial computer or monitoring software to display the abrasion loss, abrasion type, vibration curve and magnetic field change curve of the hob in real time.
8. A TBM hob abrasion identification quantitative monitoring method based on vibration magnetic induction compounding is characterized in that, the method adopts the TBM hob abrasion identification quantitative monitoring system based on vibration magnetic induction compounding according to any one of claims 1 to 7, and comprises the following steps: The system is initialized, namely a debugging monitoring system is installed, the vibration sensor and the magnetic induction monitoring module are calibrated, and the abrasion judgment threshold value and the data acquisition frequency of the hob are set; In the TBM tunneling process, the vibration sensor acquires vibration signals of the hob in real time, and the magnetic induction monitoring module synchronously acquires magnetic induction signals generated by the rotation of the permanent magnet; The data processing module carries out filtering and noise reduction processing on the acquired vibration signals and magnetic induction signals to remove environmental interference and noise; Extracting characteristic parameters such as vibration frequency, vibration amplitude, magnetic field intensity change rate and amplitude from the preprocessed vibration signal and magnetic induction signal; Identifying and quantitatively calculating the abrasion type of the hob and calculating the abrasion quantity of the hob based on a multi-parameter fusion algorithm and the characteristic parameters and the abrasion judging threshold, wherein the identification of the abrasion type is related to the significant change of the vibration amplitude, and the abnormal increase of the vibration amplitude is related to severe abrasion, eccentric abrasion and tipping abnormal abrasion; the state display and early warning, wherein the terminal early warning platform displays the abrasion state, the abrasion type and the abrasion quantity of the hob in real time, when the abrasion quantity exceeds the abrasion judgment threshold or the abnormal abrasion type appears, an early warning signal is sent out, and when the system judges that the severe abrasion or the abnormal abrasion of the hob is required to be replaced, the tool changing suggestion is clearly displayed on the early warning platform.
9. The TBM hob abrasion identification quantitative monitoring method based on vibration and magnetic induction combination according to claim 8, wherein the characteristic parameters and the abrasion judgment threshold value are required to be obtained through deep excavation of big data in different full-face tunnel boring machines and different strata, and new monitoring data are added and updated iteratively continuously along with the advancement of the tunneling process.
10. The TBM hob abrasion identification quantitative monitoring method based on vibration and magnetic induction compounding is characterized in that a wavelet transformation noise reduction algorithm is adopted in signal preprocessing to remove high-frequency noise and low-frequency interference signals, a fusion model based on a BP neural network is adopted in the multi-parameter fusion algorithm, and the fusion model is trained through training samples, so that accurate identification of abrasion types and quantitative calculation of abrasion quantity are realized.

Description

TBM hob abrasion identification quantitative monitoring system and method based on vibration magnetic induction compounding Technical Field The invention relates to the technical field of intelligent monitoring of hob abrasion of a full-face tunnel boring machine, in particular to a TBM hob abrasion identification and quantitative monitoring system and method based on vibration-magnetic induction composite monitoring. Background In recent years, with the acceleration of infrastructure construction, ultra-long deep buried tunnel engineering has raised higher requirements on the construction efficiency and reliability of a full-face Tunnel Boring Machine (TBM). As a core rock breaking component of the TBM, the disc cutter bears high stress, strong impact and severe friction for a long time under complex geological conditions, and the abrasion state of the disc cutter directly influences the stability of tunneling parameters and the service life of equipment. Researches show that the hob abrasion can obviously increase the thrust requirement of the TBM, and the cutter failure accident caused by abnormal abrasion can further cause huge shutdown maintenance cost, thereby severely restricting the construction progress. Therefore, grasping the abrasion state of the hob in real time has become a key technical bottleneck for guaranteeing the efficient tunneling of the TBM. The conventional hob abrasion monitoring technology has the remarkable limitations that the conventional manual inspection mode needs to carry out the warehouse opening operation under the high-pressure, high-humidity and high-dust face environment, the detection is time-consuming and long, and the serious safety risks such as cutterhead blocking, water burst and mud burst are faced, the indirect monitoring technology such as an odor additive method is remarkably influenced by stratum permeability characteristics, the identification accuracy rate is low and the reliability is insufficient in complex geology such as a water-rich sand layer, and the signal seriously drifts due to the extreme vibration environment in a tool box due to the monitoring scheme based on a pressure sensor, so that the precision requirement of engineering application is difficult to meet. More prominently, most of the existing monitoring means only can realize rough estimation of the abrasion loss, and abnormal abrasion modes such as eccentric abrasion, tipping, bearing clamping and the like cannot be effectively distinguished. Engineering practice shows that abnormal working conditions such as eccentric wear can sharply increase the lateral force of the hob, so that the service life and safety of core components such as a main bearing of a cutterhead are seriously threatened, and the early warning of the high-risk working conditions by the traditional monitoring method is seriously lagged. In addition, the single parameter monitoring mode is easy to be interfered by geological mutation, and in specific stratum such as hard rock, the relation between a vibration signal and the abrasion loss presents strong nonlinearity, so that the error of a monitoring result is larger, and the reliability is not high. In view of the defects of the existing device and method for monitoring the abrasion of the hob of the tunnel boring machine, the accurate and comprehensive identification and judgment of the abrasion information of the hob of the tunnel boring machine are difficult to realize, so that a TBM hob abrasion identification and quantitative monitoring system and method based on vibration-magnetic induction composite monitoring are established, and an intelligent real-time monitoring scheme is provided for the abrasion of the TBM hob. Disclosure of Invention The invention aims to solve the problems in the prior art, provides a TBM hob abrasion identification quantitative monitoring system and method based on vibration magnetic induction compounding, and aims to realize real-time accurate judgment of hob abrasion states through a multi-physical field coupling monitoring technology. In order to achieve the above purpose, the invention adopts the following technical scheme: A TBM hob abrasion identification quantitative monitoring system based on vibration magnetic induction combination comprises a hob assembly, a sensing monitoring unit, a data processing module and a terminal early warning platform; The hob assembly comprises a hob box body, a rotatable hob is arranged in the hob box body, a permanent magnet is arranged on at least one end face of the hob, and the permanent magnet generates a magnetic field signal which changes regularly when the permanent magnet rotates synchronously with the hob; The sensing monitoring unit comprises a vibration sensor and a magnetic induction monitoring module, wherein the vibration sensor is arranged on the inner wall of the hob box body or the hob and is used for collecting vibration signals generated by hob rock breaking, and the magnetic ind