CN-122020428-A - Automatic monitoring system for full-water-covered complex and changeable stratum cutter wear

Abstract

The invention discloses a full-water-covered complex and changeable stratum cutter abrasion automatic monitoring system, which belongs to the technical field of shield construction intelligent monitoring and comprises a sensing layer, a transmission layer, a platform layer and an application layer which are sequentially connected, wherein the sensing layer collects multisource data such as cutter operation, cutter head panel abrasion and working condition parameters, the transmission layer carries out edge pretreatment on the data and then transmits the data to the platform layer through an anti-interference double link, the platform layer eliminates interference such as muddy water corrosion, scouring and temperature drift through coupling abrasion calibration, calculates the real cutting abrasion quantity of a cutter, accurately identifies the fault type of the cutter by combining multisource state characteristics, further evaluates the health state of the cutter head by combining the cutter head panel abrasion data, and generates a multiscope linkage control strategy, and the application layer is used for visual display and early warning. The invention effectively overcomes the interference of the full-water-covered severe muddy water environment on the monitoring data, and realizes the high-precision monitoring and intelligent control of the health states of the shield cutter head and the cutter.

Inventors

• ZHANG YANNIAN
• SHEN CHEN
• YANG SHUCUN
• ZHANG HUI
• Cong Keke
• GAO TONGYU
• CHEN MINGCHAO
• QU LINLIN
• GAO YUFEN
• LI JIANAN
• LI MINGXI
• ZHAO MINHANG
• WANG QINGJIE
• HUANG YANZHENG
• ZHANG MINGZHAN
• GU XIAOWEI
• LIU WENLIANG
• LIU CHANG
• MA GUIHONG

Assignees

• 中建七局第六建筑有限公司
• 中国建筑第七工程局有限公司
• 大连交通大学

Dates

Publication Date

20260512

Application Date

20260410

Claims (8)

1. 1. The utility model provides a complicated changeable stratum cutter wearing and tearing automatic monitoring system of full water, its characterized in that, including perception layer, transmission layer, platform layer and the application layer of communication connection in proper order, wherein: the sensing layer is used for collecting multi-source state and working condition data under the shield construction fully-covered stratum, wherein the multi-source state and working condition data comprise cutter running state data, cutter head panel abrasion data and working condition parameters; The transmission layer is used for receiving the multisource state and working condition data acquired by the sensing layer, carrying out edge preprocessing on the multisource state and working condition data, and transmitting the preprocessed data to the platform layer through the anti-interference double-link transmission architecture; the platform layer is used for storing, analyzing, deciding and outputting an control instruction to the data uploaded by the transmission layer, and comprises the following steps: The data storage module is used for storing the preprocessed multi-source state and working condition data, the historical wear data and the fault sample data; The coupling abrasion calibration module is used for eliminating interference of muddy water corrosion, sediment flushing and temperature drift in the fully-covered water stratum on abrasion measurement, and calculating to obtain real cutting abrasion loss of the cutter; The multi-source feature fusion fault judging module is used for fusing multi-source state features to identify the fault type of the cutter; the cutter head and cutter cooperative evaluation module is used for evaluating the overall health state of the cutter head by combining the cutter wear state and cutter head panel wear data; The linkage management and control strategy generation module is used for generating a corresponding management and control strategy according to the fault discrimination result and the health state of the cutterhead; The application layer is used for displaying analysis and decision results of the platform layer, and comprises a visual monitoring interface which is used for presenting real-time running state of the cutter, health state of the cutter, fault early warning information and abrasion statistics analysis data.
2. 2. The automatic monitoring system for tool wear of a fully-covered complex and variable stratum according to claim 1, wherein the sensing layer specifically comprises: The cutter multi-parameter sensing unit comprises a sensing component corresponding to each cutter to be monitored, and is used for collecting three cutter running state data of residual thickness, real-time rotating speed and surface temperature of the cutter; The cutter head panel abrasion monitoring unit comprises a plurality of groups of independent continuous detection oil channels which are distributed in different abrasion risk areas of the front panel and the rear panel of the cutter head, wherein the tail end of each group of continuous detection oil channels is provided with a pressure detection assembly which is used for identifying the abrasion position and the abrasion degree of the cutter head panel through abnormal change of the pressure of the oil channels to obtain abrasion data of the cutter head panel; The working condition linkage acquisition unit is used for synchronously acquiring the rotating speed, the torque, the total thrust, the penetration and the muddy water parameters of the cutterhead, wherein the muddy water parameters comprise the conductivity, the pH value, the sand content and the mud flow rate of muddy water.
3. 3. The automatic monitoring system for the abrasion of the fully-covered complex and changeable stratum cutter according to claim 2, wherein the transmission layer comprises an edge pretreatment module, a plurality of cutter disc relay nodes which are distributed at equal intervals along the circumference of the cutter disc, and a receiving terminal which is fixed on the inner wall of a front cabin of the shield body, wherein: The edge preprocessing module is deployed in each cutterhead relay node and performs two-stage processing on the received perception layer original data, wherein the first step is to eliminate abnormal jump values exceeding a preset range, and the second step is to perform average aggregation on high-frequency acquisition data according to fixed sampling intervals so as to reduce invalid data transmission quantity; The transmission layer adopts a two-stage transmission link to realize the transmission of data from the cutterhead to the shield body, wherein the first stage is a magnetic induction near field transmission link from the cutter multi-parameter sensing unit to the cutterhead relay node, each cutter multi-parameter sensing unit and the cutterhead relay node are internally provided with a magnetic induction communication module, the characteristics of alternating magnetic fields penetrating through metal and muddy water are utilized to transmit the data, the second stage is a LoRa spread spectrum transmission link from the cutterhead relay node to the shield body receiving terminal, the cutterhead relay node is internally provided with a LoRa communication module, and signal attenuation caused by metal shielding is counteracted by adopting a spread spectrum modulation mode.
4. 4. The automatic monitoring system for the abrasion of the fully-covered water complex and variable stratum cutter according to claim 3, wherein the process of calculating the real cutting abrasion loss of the cutter by the coupling abrasion calibration module in the platform layer is as follows: S11, obtaining Raw wear thickness difference at time , For the cutter to leave the factory with initial thickness Multi-parameter sensing unit for time cutter collecting a difference value of the residual thickness of the cutter; S12, calculating Real cutting wear of the tool at the moment : ; The definition and calculation modes of each correction term are as follows: (1) Is that The muddy water corrosion abrasion loss accumulated at the moment is calculated by the following formula: ; Wherein, the In order to monitor the corrosion coefficient of the cutter material, the method is pre-calibrated by a soaking test of simulating the mud water working condition of a target stratum in a laboratory, Is that The muddy water corrosion intensity factor at moment is calculated based on muddy water parameters acquired by the working condition linkage acquisition unit: ; Wherein, the Is that The conductivity of the muddy water at the moment, Is that The pH value of the muddy water at the moment; (2) Is that The sediment scour and abrasion quantity accumulated at the moment is calculated as follows: ; Wherein, the The scouring coefficient of the cutter material to be monitored is pre-calibrated by a scouring test of a laboratory simulation target stratum mud working condition, Is that The muddy water scouring intensity factor at moment is calculated based on muddy water parameters acquired by the working condition linkage acquisition unit: ; Wherein, the Is that The mud flow rate at the surface of the cutterhead at the moment, Is that The sand content of the slurry at the moment, Pre-calibrating the sediment hardness coefficient of the target stratum according to project stratum investigation report The nonlinear enhancement item of (2) reflects the rising characteristic of scouring wear under high sand content and is suitable for the characteristic of large sand content fluctuation of the fully-covered water stratum; (3) Is that The temperature drift error at the moment is calculated by the following formula: ; Wherein, the As a temperature drift coefficient of the sensor, Is that The temperature of the surface of the cutter collected by the multi-parameter sensing unit of the cutter at the moment, Reference temperature calibrated for the sensor.
5. 5. The automatic monitoring system for tool wear of a fully-covered complex and variable stratum according to claim 4, wherein the step of executing the multi-source feature fusion fault discrimination module in the platform layer comprises: s21, setting 4 types of fully-covered water ground high-incidence tool faults to be identified, and constructing an identification frame: wherein Representing a normal wear and tear of the article, Represents a bias-wear and is used to determine, Representing a stall in the vehicle and, Representing tipping or breakage; S22, extracting characteristic values of 4 independent evidences, including: a. evidence 1 corresponding to wear characteristics, characteristic values are ring average change rates of real cutting wear The calculation formula is as follows: ; Wherein, the Is continuous The true cutting wear increment of the individual ripper rings, The number of loops for continuous tunneling; b. evidence body 2, corresponding rotation speed characteristics, wherein the characteristic value is a matching coefficient of the rotation speed of the cutter and the rotation speed of the cutter head The calculation formula is as follows: ; Wherein, the The real-time rotating speed of the cutter is adopted, The real-time rotating speed of the cutterhead is set; c. evidence body 3, corresponding to the temperature characteristics, wherein the characteristic value is the temperature difference value between the cutter and the cutter head panel The calculation formula is as follows: ; Wherein, the For the temperature of the surface of the tool, The temperature of the corresponding area of the cutterhead; d. Evidence body 4, corresponding to the characteristics of the tunneling parameters, wherein the characteristic value is the deviation degree of the tunneling coupling factor The calculation formula is as follows: ; Wherein, the In order to actually tunnel the coupling factor, For the torque of the cutter head, As a result of the total thrust force, In order to achieve the degree of penetration, Pre-calibrating standard tunneling coupling factors under the corresponding tunneling working conditions of the target stratum by using current tunneling data or the historical samples of the same stratum; s23, calculating basic probability distribution of each evidence body, wherein the formula is as follows: ; Wherein, the Is the first The characteristic value of the individual evidence body, Respectively corresponding to the 4 types of evidence bodies, 、 Is the first The evidence body corresponds to the first The characteristic mean value and the characteristic standard deviation of the similar faults are obtained through the pre-training of the historical fault samples of the target stratum, Respectively corresponding to the faults of the 4 types of cutters, Is the first Dynamic confidence weights of individual evidence bodies satisfy The calculation formula is Wherein Setting initial weight for pre-calibration according to the historical fault recognition accuracy, For the dynamic confidence coefficient, the dynamic confidence coefficient is inversely related to the fluctuation coefficient of the last 10 groups of sampling data of the corresponding evidence body, and the more stable the data is, the higher the weight is; S24, fusing 4 types of evidence by adopting an improved D-S evidence combination rule, wherein the fusion formula is as follows: ; Wherein, the For evidence conflict coefficients, the calculation formula is: ; the value range is 0-1, and the larger the value is, the higher the conflict degree among multiple evidences is represented; In order to conflict with the adjustment factor, The higher the collision coefficient The closer to 1, the influence of conflict evidence on the fusion result is automatically reduced; S25, judging faults, if the probability of a certain type of faults after fusion is high Greater than the decision threshold And judging that the cutter has corresponding type faults.
6. 6. The system for automatically monitoring the wear of a complex and variable formation tool with full water according to claim 5, wherein the step of executing the cutterhead tool collaborative assessment module in the platform layer comprises: S31, dividing the cutter disc into 3 general function areas according to the radial radius of the cutter disc, wherein the general function areas comprise a central area, a main cutting area and an edge gage area, and the radial radius of the central area Corresponding to the low abrasion zone, the main cutting zone Corresponding to the middle and high abrasion areas and the edge gage area Corresponding to the eccentric wear high-incidence high-wear area, 、 The partition limit value is preset according to the radius of the cutter head; s32, calculating the abrasion deviation degree of the cutters in each functional area, wherein the calculation formula is as follows: ; Wherein, the Is the average value of the real cutting wear amounts of all normal tools in the current functional area, The average value of the real cutting abrasion quantity of all normal cutters of the whole cutter head, A value of greater than 0 represents that the zone wear is faster than the average level of the cutterhead, and the greater the value, the higher the degree of abnormality; s33, calculating panel abrasion coefficients of all the functional areas, namely obtaining rated pressure of the continuous detection oil duct Real-time pressure of oil duct When meeting the following requirements When the continuous detection oil duct in the area is judged to be broken due to panel abrasion, the panel abrasion coefficient is marked Otherwise ; S34, quantitatively evaluating the health state of the region by three characteristics of abnormal cutter abrasion of the linkage region, cutter panel abrasion and local cutter failure, and calculating the health degree score of each functional region, wherein the calculation formula is as follows: ; Wherein, the As the weight of the wear of the tool, For the panel wear weight, satisfy ; For the regional fault penalty coefficient, every 1 fault cutter exists in the corresponding functional region, An increase of 0.1, up to 0.3; Scoring the health degree of the functional area, wherein the higher the value is, the better the health state of the area is represented; and S35, taking the minimum value of the health degree scores of all the functional areas as the overall health degree of the cutterhead, and dividing risk levels according to a fixed threshold value, wherein the health degree is higher than 0.8 and marked as a normal state, the health degree is between 0.5 and 0.8 and marked as an early warning state, and the health degree is lower than 0.5 and marked as a high risk state.
7. 7. The automatic monitoring system for the cutter wear of the fully-covered water complex and changeable stratum is characterized in that a linkage management and control strategy generation module in a platform layer divides three different scenes, including a single cutter scattered fault scene, a multi-cutter batch wear fault scene and a cutter head high risk scene, and generates different management and control strategies according to the different scenes.
8. 8. The automatic monitoring system for the abrasion of the full-water-covered complex and variable stratum cutters is characterized in that the judging condition of a single cutter scattered fault scene is that the number of the full cutter failed cutters is lower than a preset number, the health degree of all functional areas is higher than 0.8, and the condition of oil duct breakage is continuously detected by a cutter-free panel; The judging condition of the multi-tool batch abrasion fault scene is that the number of fault tools in the same functional area is higher than a preset number, or the health degree of any functional area is in an early warning area of 0.5-0.8, and no oil duct rupture condition of a cutter disc panel exists; The judging condition of the cutter head high risk scene is that the health degree of any functional area is lower than 0.5 or the cutter head abrasion condition of continuously detecting oil duct breakage exists, and the generating strategy comprises immediately outputting an emergency stop instruction and pushing the emergency stop instruction to operation and maintenance personnel.

Description

Automatic monitoring system for full-water-covered complex and changeable stratum cutter wear Technical Field The invention belongs to the technical field of intelligent monitoring of shield construction and intelligent construction of tunnels, and particularly relates to an automatic monitoring system for cutter wear of a fully-covered complex and changeable stratum. Background The shield construction is a core construction method for underground space development, wherein a fully-covered water complex and changeable stratum is a typical high-risk working condition of the shield construction, the stratum has the characteristics of high water pressure, strong corrosion, uneven hardness, karst/boulder development and the like, a shield cutter head cutter is subjected to coupling action of hard rock impact, muddy water corrosion, sediment flushing, the abrasion rate is 3-5 times that of a common stratum, faults such as eccentric wear, tipping and fracture are easy to occur, and manual opening inspection under the high water pressure environment has extremely high water flushing and collapse risks, so that the operation cost is high and the efficiency is low, and therefore, the automatic cutter abrasion monitoring technology is needed to realize the state sensing of the cutter without opening a bin. The existing shield cutter wear monitoring technology collects thickness data by arranging a wear sensor on a cutter, and transmits the thickness data to the ground for analysis through wireless or wired transmission, so that the open bin detection frequency is reduced to a certain extent, but the following defects are still exposed when the shield cutter wear monitoring technology faces to a fully-covered complex and changeable stratum: firstly, transmission stability is poor, and the blade disc is inside to be in the dynamic rotation environment of strong metal shielding, high pressure muddy water parcel, and traditional communication mode extremely easily leads to data loss because of signal attenuation. Second, environmental interference is severe and the actual wear amount is distorted by calculation. In the fully-covered stratum, a shield machine cutterhead is soaked in a high-pressure muddy water environment for a long time, the abrasion loss is usually obtained by directly subtracting the actually measured residual thickness from the original thickness of a cutter in a simple calculation mode, the thickness loss and the measurement error caused by muddy water chemical corrosion, silt scouring and temperature drift of the fully-covered stratum are not considered, the real effective abrasion generated by cutting operation of the cutter cannot be distinguished from the ineffective thickness loss caused by environmental factors, and the monitoring data are seriously distorted due to the abrasion measurement error, so that the cutting life of the cutter cannot be truly reflected. Third, the diagnostic dimension is single, lacking multi-source coordination and linkage management. Most of the existing monitoring systems only stay on a single data display level for measuring abrasion, whether a cutter is normally and uniformly abraded or suddenly faults such as eccentric abrasion, stalling or tipping occur cannot be accurately distinguished, in addition, the cutter abrasion, the abrasion of a cutter head panel and the shield tunneling working condition are usually fractured, a health evaluation model of a global visual angle is lacked, and a targeted tunneling parameter adjustment and cutter changing management and control strategy cannot be automatically generated according to different scenes. In view of the foregoing, there is a need for an automatic tool wear monitoring system that can overcome muddy water corrosion and erosion interference, realize stable data transmission, and perform fault accurate discrimination and linkage management by combining multiple source features. Disclosure of Invention In order to solve the problems in the background art, the invention provides an automatic monitoring system for the abrasion of a fully-covered water complex and changeable stratum cutter, which aims to solve the core technical problems of high signal attenuation packet loss rate, high abrasion quantity calculation distortion, high failure misjudgment and omission rate caused by single diagnosis dimension, lack of global cooperative management and control capability and the like caused by the single diagnosis dimension under the condition of strong metal shielding of the fully-covered water stratum and high signal attenuation packet loss rate of high-pressure muddy water package, and realize the joint optimization of the data transmission reliability, abrasion measurement precision, failure recognition accuracy and full-scene operation and maintenance management and control efficiency of cutter abrasion monitoring by constructing a dual-link anti-interference transmission mechanism, a muddy water corrosion-scouring