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CN113404502B - Device and method for wear monitoring of shield hob based on topography of ballast - Google Patents

Device and method for wear monitoring of shield hob based on topography of ballast Download PDF

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CN113404502B
CN113404502B CN202110685830.2A CN202110685830A CN113404502B CN 113404502 B CN113404502 B CN 113404502B CN 202110685830 A CN202110685830 A CN 202110685830A CN 113404502 B CN113404502 B CN 113404502B
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shield machine
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CN113404502A (en
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夏毅敏
宁波
王丹
苏逢彬
崔建波
刘沛
邓志强
马英博
邓凯
林赉贶
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Chian Railway 14th Bureau Group Corp Tunnel Engineering Co ltd
Central South University
Jinan Rail Transit Group Co Ltd
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Central South University
Jinan Rail Transit Group Co Ltd
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    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21DSHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D9/00Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
    • E21D9/06Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining
    • E21D9/08Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21DSHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
    • E21D9/00Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
    • E21D9/06Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining
    • E21D9/093Control of the driving shield, e.g. of the hydraulic advancing cylinders
    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21FSAFETY DEVICES, TRANSPORT, FILLING-UP, RESCUE, VENTILATION, OR DRAINING IN OR OF MINES OR TUNNELS
    • E21F17/00Methods or devices for use in mines or tunnels, not covered elsewhere
    • E21F17/18Special adaptations of signalling or alarm devices
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/24Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
    • GPHYSICS
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    • G01JMEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J5/00Radiation pyrometry, e.g. infrared or optical thermometry
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract

The invention provides a shield hob abrasion monitoring device and method based on ballast piece morphology, which comprises the following steps: step 1, acquiring a known shield engineering case in a computer and constructing a database; step 2, analyzing the mapping relation between hob structure parameters, engineering geological parameters, shield tunneling parameters, slag sheet morphology parameters and temperature parameters in a database and the abrasion loss of the hob by adopting a GRNN neural network to obtain a mapping relation analysis result; and 3, constructing a hob abrasion prediction system based on the database, the GRNN neural network and the mapping relation analysis result and setting a hob abrasion alarm threshold. According to the method, the abrasion state of the hob can be predicted in real time through actual engineering geological parameters, hob structural parameters, real-time tunneling parameters and slag parameters, an alarm function is provided when the predicted abrasion state of the hob reaches a set threshold value, and accurate prediction of hob abrasion can be improved through closed-loop feedback adaptive adjustment according to different projects.

Description

基于碴片形貌的盾构滚刀磨耗监测装置及方法Device and method for wear monitoring of shield hob based on topography of ballast

技术领域technical field

本发明涉及隧道施工技术领域,特别涉及一种基于碴片形貌的盾构滚刀磨耗监测装置及方法。The invention relates to the technical field of tunnel construction, in particular to a shield hob wear monitoring device and method based on the shape of a ballast piece.

背景技术Background technique

随着国内外隧道掘进机广泛应用,盾构法施工在隧道施工中已经逐渐成为一种主要施工方法。对于盾构法施工而言,盾构滚刀作为主要的破岩工具。适用于各类岩石地层、卵砾石地层及软硬复合地层,在各种掘进机中广泛使用。With the wide application of tunnel boring machines at home and abroad, shield construction has gradually become a main construction method in tunnel construction. For shield construction, shield hob is the main rock breaking tool. It is suitable for various rock formations, pebble gravel formations and soft and hard composite formations, and is widely used in various roadheaders.

由于掘进过程中岩石的不确定性、地层的复杂性,导致刀具受力变化的动态性和刀具磨损形式的不确定性。经长时间切削岩石,滚刀发生非正常磨损或正常磨损到一定程度,就需要更换,由此必然影响盾构掘进效率和施工成本。Due to the uncertainty of the rock and the complexity of the stratum during the excavation process, the dynamics of the force change of the tool and the uncertainty of the tool wear form are caused. After a long time of rock cutting, the hob needs to be replaced due to abnormal wear or normal wear to a certain extent, which will inevitably affect the shield tunneling efficiency and construction cost.

实践表明,岩碴形状尺寸及其粒径分布是复杂围岩条件和机械掘进性能的间接反馈,通过碴片参数和盾构的运行参数可预测刀具磨损状态。目前。仅凭施工人员的经验判断是否需要进仓换刀,判断准确性因人而异,很可能因为判断失误而引发重大事故发生。因此,需要提供一种基于碴片形貌的盾构滚刀磨耗监测方法。Practice has shown that the shape and size of rock ballast and its particle size distribution are indirect feedbacks of complex surrounding rock conditions and mechanical driving performance, and the tool wear state can be predicted through ballast sheet parameters and shield operating parameters. Currently. Judging whether it is necessary to enter the warehouse to change the tool is only based on the experience of the construction personnel. The accuracy of the judgment varies from person to person, and it is likely to cause major accidents due to misjudgment. Therefore, it is necessary to provide a method for monitoring the wear of shield hob based on the topography of the ballast piece.

发明内容SUMMARY OF THE INVENTION

本发明提供了一种基于碴片形貌的盾构滚刀磨耗监测装置及方法,其目的是为了解决传统的施工方法无法精确准确预测当前滚刀的磨耗量,无法满足盾构智能化安全高效掘进的需求的问题。The invention provides a shield hob wear monitoring device and method based on the topography of the ballast piece, the purpose of which is to solve the problem that the traditional construction method cannot accurately and accurately predict the wear amount of the current hob, and cannot meet the requirements of intelligent, safe and efficient shield tunneling. The problem of excavation needs.

为了达到上述目的,本发明的实施例提供了一种基于碴片形貌的盾构滚刀磨耗监测装置,包括:In order to achieve the above object, an embodiment of the present invention provides a shield hob wear monitoring device based on the topography of the ballast piece, including:

数据采集箱,所述数据采集箱设置在盾构机传送带的一侧;a data collection box, the data collection box is arranged on one side of the conveyor belt of the shield machine;

工控机,所述工控机设置在所述数据采集箱的一侧,所述工控机的第一端与所述数据采集箱的第一端电连接,所述工控的第二端与电脑电连接;Industrial computer, the industrial computer is arranged on one side of the data acquisition box, the first end of the industrial computer is electrically connected to the first end of the data acquisition box, and the second end of the industrial computer is electrically connected to the computer ;

桁架,所述桁架的第一端架设在盾构机传送带上,所述桁架的第二端架设在地面上;a truss, the first end of the truss is erected on the conveyor belt of the shield machine, and the second end of the truss is erected on the ground;

照明装置,所述照明装置设置有两个,两个所述照明装置对称设置在所述桁架的两端上,两个所述照明装置均与所述桁架可拆卸连接;a lighting device, there are two lighting devices, the two lighting devices are symmetrically arranged on both ends of the truss, and both the lighting devices are detachably connected to the truss;

摄像机,所述摄像机设置在所述桁架的顶端,所述摄像机与所述桁架可拆卸连接,所述摄像机与所述数据采集箱的第二端电连接;a camera, the camera is arranged on the top of the truss, the camera is detachably connected to the truss, and the camera is electrically connected to the second end of the data acquisition box;

红外测温仪,所述红外测温仪设置在所述桁架的顶端,所述红外测温仪与所述桁架可拆卸连接,所述红外测温仪与所述数据采集箱的第三端电连接。Infrared thermometer, the infrared thermometer is arranged at the top of the truss, the infrared thermometer is detachably connected to the truss, and the infrared thermometer is electrically connected to the third end of the data acquisition box. connect.

本发明的实施例还提供了一种基于碴片形貌的盾构滚刀磨耗监测方法,包括:An embodiment of the present invention also provides a method for monitoring the wear of a shield hob based on the topography of a ballast piece, including:

步骤1,获取电脑中已知的盾构工程案例并构建数据库;Step 1: Obtain known shield engineering cases in the computer and build a database;

步骤2,采用GRNN神经网络分析数据库中的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数和温度参数与滚刀磨损量的映射关系,得到映射关系分析结果;Step 2, using the GRNN neural network to analyze the mapping relationship between the hob structure parameters, engineering geological parameters, shield tunneling parameters, ballast piece topography parameters and temperature parameters and the hob wear amount in the database, and obtain the mapping relationship analysis result;

步骤3,基于数据库、GRNN神经网络和映射关系分析结果构建滚刀磨耗预测系统并设定滚刀磨损量报警阈值;Step 3, build a hob wear prediction system based on the database, the GRNN neural network and the analysis results of the mapping relationship, and set an alarm threshold for the hob wear amount;

步骤4,采集当前盾构机施工前的滚刀结构参数和工程地质参数并输入滚刀磨耗预测系统;Step 4, collect the hob structure parameters and engineering geological parameters of the current shield machine before construction, and input the hob wear prediction system;

步骤5,实时采集当前盾构机施工时的盾构掘进参数、碴片形貌参数和温度参数并输入滚刀磨耗预测系统中;Step 5, collecting the shield tunneling parameters, ballast piece topography parameters and temperature parameters during the construction of the current shield machine in real time and inputting them into the hob wear prediction system;

步骤6,滚刀磨耗预测系统根据输入的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数和温度参数进行滚刀磨损量预测并将预测的滚刀磨损量与设定的滚刀磨损量报警阈值进行比较;Step 6, the hob wear prediction system predicts the hob wear amount according to the input hob structure parameters, engineering geological parameters, shield tunneling parameters, ballast piece shape parameters and temperature parameters, and sets the predicted hob wear amount and setting. Compare with the alarm threshold of hob wear amount;

步骤7,当预测的滚刀磨损量超出滚刀磨损量报警阈值时,滚刀磨耗预测系统发出警报,盾构机停止运行,更换滚刀,测量已磨损滚刀的磨损量并输入滚刀磨耗预测系统;Step 7: When the predicted hob wear exceeds the hob wear alarm threshold, the hob wear prediction system will issue an alarm, the shield machine will stop running, replace the hob, measure the wear of the worn hob and input the hob wear forecasting system;

步骤8,根据已磨损滚刀的磨损量和预测的滚刀磨损量采用粒子群优化算法对GRNN神经网络进行自适应优化;Step 8, adopt the particle swarm optimization algorithm to adaptively optimize the GRNN neural network according to the wear amount of the worn hob and the predicted wear amount of the hob;

步骤9,换刀完成后重新启动盾构机,跳转到步骤4继续执行,直到整个盾构工程工作完成,结束监测;Step 9, restart the shield machine after the tool change is completed, jump to step 4 and continue to execute until the entire shield project is completed, and the monitoring ends;

步骤10,当预测的滚刀磨损量未超出滚刀磨损量报警阈值时,跳转到步骤5继续执行,直到整个盾构工程工作完成,结束监测。Step 10, when the predicted hob wear amount does not exceed the hob wear amount alarm threshold, jump to step 5 and continue to execute until the entire shield tunneling work is completed, ending the monitoring.

其中,所述步骤1具体包括:Wherein, the step 1 specifically includes:

盾构工程案例包括多条换刀记录,换刀记录包括滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数、温度参数和滚刀磨损量,其中,滚刀结构参数包括刀刃结构参数、滚刀半径、刀间距和载荷重量,工程地质参数包括岩石力学参数、岩石材料参数、岩石的节理和断层参数和岩性参数,盾构掘进参数包括盾构机的贯入度、盾构机刀盘转速、盾构机推力、盾构机工作转矩、盾构机土仓压力和盾构机推进速度,碴片形貌参数包括碴片粒径分布指标、碴片长短轴比值指标和碴片纹理指标,温度参数包括碴片温度。The shield engineering case includes a number of tool change records. The tool change records include hob structural parameters, engineering geological parameters, shield tunneling parameters, ballast shape parameters, temperature parameters and hob wear. Among them, the hob structural parameters include: Blade structure parameters, hob radius, cutter spacing and load weight, engineering geological parameters include rock mechanics parameters, rock material parameters, rock joint and fault parameters and lithology parameters, shield tunneling parameters include shield machine penetration, Shield machine cutter head speed, shield machine thrust, shield machine working torque, shield machine soil bin pressure and shield machine propulsion speed, ballast piece morphology parameters including ballast piece particle size distribution index, ballast piece length and short axis ratio index and ballast sheet texture index, and temperature parameters include ballast sheet temperature.

其中,所述步骤2具体包括:Wherein, the step 2 specifically includes:

将盾构机的贯入度、推进速度、刀盘转速、盾构机推力、盾构机工作转矩、盾构机土仓压力和滚刀半径作为GRNN神经网络的输入层的7个神经元,将刀具磨损量作为输出层的神经元,构成GRNN神经网络;The penetration, propulsion speed, cutter head rotation speed, thrust of the shield machine, working torque of the shield machine, soil pressure of the shield machine, and radius of the hob are used as the 7 neurons of the input layer of the GRNN neural network. , the tool wear amount is used as the neuron of the output layer to form a GRNN neural network;

将数据库中的数据分为100组,采用随机抽样的方法在100组数据内选取10组数据作为测试集,剩余的90组数据作为训练集;Divide the data in the database into 100 groups, use random sampling to select 10 groups of data from the 100 groups of data as the test set, and the remaining 90 groups of data as the training set;

将训练集随机分为9个单元,每个单元包括10组数据,采用交叉验证法从9个单元中随机选取8个单元作为训练集输入样本,剩余1个单元作为训练集输出样本,并将训练集输入样本数据归一化到[-1,1]之间,在(0,1]内以步长0.01验证搜索,寻找使得预测值与样本值的均方误差最小的光滑因子σ,并记录当前光滑因子对应的最佳输入样本与最佳输出样本;The training set is randomly divided into 9 units, each unit includes 10 sets of data, 8 units are randomly selected from the 9 units as the input sample of the training set by the cross-validation method, and the remaining 1 unit is used as the output sample of the training set. The input sample data of the training set is normalized to between [-1, 1], and the verification search is performed with a step size of 0.01 in (0, 1], and the smooth factor σ that minimizes the mean square error between the predicted value and the sample value is found, and Record the best input sample and the best output sample corresponding to the current smooth factor;

将测试集数据归一化,将获取的光滑因子σ、最佳输入样本和最佳输出样本作为输入变量,构建4层GRNN神经网络,输出层输出刀具磨损量。The test set data is normalized, and the obtained smooth factor σ, the best input sample and the best output sample are used as input variables to build a 4-layer GRNN neural network, and the output layer outputs the tool wear amount.

其中,所述步骤3具体包括:Wherein, the step 3 specifically includes:

基于GRNN神经网络通过相关性分析采集数据库中工程地质参数、盾构掘进参数、盾构滚刀结构、碴片形貌尺寸和温度参数与刀具磨损量的映射关系,建立滚刀磨耗预测系统:Based on the GRNN neural network, the mapping relationship between the engineering geological parameters, shield tunneling parameters, shield hob structure, ballast shape size and temperature parameters and the tool wear amount in the database is collected through correlation analysis, and the hob wear prediction system is established:

δi=β0p+β1v+β2n+β3F+β4T+β5S+β6L+······+βmXm+C (1)δ i0 p+β 1 v+β 2 n+β 3 F+β 4 T+β 5 S+β 6 L+...+β m X m +C (1)

其中,β0、β1、β2、β3、β4····βm是待估计参数,δi为刀具磨损量,p表示盾构机的贯入度,v表示推进速度,n表示刀盘转速,F表示盾构机推力,T表示盾构机工作转矩,L表示滚刀半径,S表示碴片形貌尺寸,Xm表示其他与刀具磨损量相关的参数,C表示待定常数。Among them, β 0 , β 1 , β 2 , β 3 , β 4 , β m are the parameters to be estimated, δ i is the tool wear amount, p is the penetration degree of the shield machine, v is the propulsion speed, n Indicates the rotation speed of the cutter head, F represents the thrust of the shield machine, T represents the working torque of the shield machine, L represents the radius of the hob, S represents the shape and size of the ballast piece, X m represents other parameters related to the amount of tool wear, and C represents to be determined constant.

其中,所述步骤5具体包括:Wherein, the step 5 specifically includes:

通过盾构机的主控室实时采集当前盾构机施工时的盾构掘进参数并输入滚刀磨耗预测系统,通过摄像机实时拍摄盾构机传送带上碴片的图片并输入电脑中进行碴片形貌尺寸解算,获得碴片形貌参数并输入滚刀磨耗预测系统,通过红外测温仪实时测量盾构机传送带上碴片的温度并输入滚刀磨耗预测系统。The main control room of the shield machine is used to collect the current shield tunneling parameters during the construction of the shield machine in real time and input them into the hob wear prediction system. The shape and size of the ballast piece are calculated, and the shape parameters of the ballast piece are obtained and input into the hob wear prediction system.

其中,所述步骤8具体包括:Wherein, the step 8 specifically includes:

采用粒子群优化算法对CRNN神经网络进行优化:设置粒子群计算参数,设置滚刀磨耗预测系统发出警报时预测的刀具磨损量与已磨损滚刀的磨损量的均方差为适应度函数,将学习样本和例子带入GRNN神经网络,计算适应度值Fi,比较第i个粒子所经过的所有位置的适应度值,确定其最优位置Pbi,比较所有粒子在其最优位置Pbi的适应度值,确定整个种群的最优位置Gb,根据各粒子自身位置和最优粒子位置调整粒子的速度和位置,当达到迭代终止条件时,得到最优位置Gb,采用搜索到的最优位置Gb优化GRNN神经网络。The particle swarm optimization algorithm is used to optimize the CRNN neural network: set the particle swarm calculation parameters, and set the mean square error of the tool wear amount predicted when the hob wear prediction system sends an alarm and the wear amount of the worn hob as the fitness function. The samples and examples are brought into the GRNN neural network, the fitness value F i is calculated, the fitness values of all positions passed by the i-th particle are compared, and the optimal position P bi is determined, and the optimal position P bi of all particles is compared. The fitness value, determine the optimal position G b of the whole population, adjust the speed and position of the particle according to the position of each particle itself and the optimal particle position, when the iteration termination condition is reached, obtain the optimal position G b , use the searched optimal position G b . The optimal location G b optimizes the GRNN neural network.

本发明的上述方案有如下的有益效果:The above-mentioned scheme of the present invention has the following beneficial effects:

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,根据实际的工程地质参数和滚刀结构参数和实时的掘进参数和碴片参数,能够实时预测滚刀的磨损状态,在预测的滚刀的磨损状态达到设定阈值时提供报警功能,并可以根据不同的工程通过闭环反馈自适应调节提高滚刀磨耗的精确预测。The device and method for monitoring the wear of shield hob based on the topography of the ballast piece described in the above-mentioned embodiments of the present invention can predict the rolling cutter in real time according to the actual engineering geological parameters, the structural parameters of the hob cutter and the real-time excavation parameters and the parameters of the ballast piece. The wear state of the cutter provides an alarm function when the predicted wear state of the hob reaches the set threshold, and can improve the accurate prediction of the hob wear through closed-loop feedback adaptive adjustment according to different projects.

附图说明Description of drawings

图1为本发明的流程图;Fig. 1 is the flow chart of the present invention;

图2为本发明的结构示意图;Fig. 2 is the structural representation of the present invention;

图3为本发明的CRNN神经网络示意图;3 is a schematic diagram of a CRNN neural network of the present invention;

图4为本发明的粒子群优化算法的流程图。FIG. 4 is a flowchart of the particle swarm optimization algorithm of the present invention.

【附图标记说明】[Description of reference numerals]

1-盾构机传送带;2-数据采集箱;3-工控机;4-桁架;5-照明装置;6-摄像机;7-红外测温仪。1-shield conveyor belt; 2-data acquisition box; 3-industrial computer; 4-truss; 5-lighting device; 6-camera; 7-infrared thermometer.

具体实施方式Detailed ways

为使本发明要解决的技术问题、技术方案和优点更加清楚,下面将结合附图及具体实施例进行详细描述。In order to make the technical problems, technical solutions and advantages to be solved by the present invention more clear, the following will be described in detail with reference to the accompanying drawings and specific embodiments.

本发明针对现有的施工方法无法精确准确预测当前滚刀的磨耗量,无法满足盾构智能化安全高效掘进的需求的问题,提供了一种基于碴片形貌的盾构滚刀磨耗监测装置及方法。Aiming at the problems that the existing construction method cannot accurately and accurately predict the wear amount of the current hob, and cannot meet the requirements of the shield machine for intelligent, safe and efficient excavation, the invention provides a shield hob wear monitoring device based on the shape of the ballast piece. and methods.

如图1至图4所示,本发明的实施例提供了一种基于碴片形貌的盾构滚刀磨耗监测装置,包括:数据采集箱2,所述数据采集箱2设置在盾构机传送带1的一侧;工控机3,所述工控机3设置在所述数据采集箱2的一侧,所述工控机3的第一端与所述数据采集箱2的第一端电连接,所述工控的第二端与电脑电连接;桁架4,所述桁架4的第一端架设在盾构机传送带1上,所述桁架4的第二端架设在地面上;照明装置5,所述照明装置5设置有两个,两个所述照明装置5对称设置在所述桁架4的两端上,两个所述照明装置5均与所述桁架4可拆卸连接;摄像机6,所述摄像机6设置在所述桁架4的顶端,所述摄像机6与所述桁架4可拆卸连接,所述摄像机6与所述数据采集箱2的第二端电连接;红外测温仪7,所述红外测温仪7设置在所述桁架4的顶端,所述红外测温仪7与所述桁架4可拆卸连接,所述红外测温仪7与所述数据采集箱2的第三端电连接。As shown in FIG. 1 to FIG. 4 , an embodiment of the present invention provides a shield hob wear monitoring device based on the topography of the ballast piece, including: a data collection box 2 , and the data collection box 2 is arranged in the shield machine One side of the conveyor belt 1; the industrial computer 3, the industrial computer 3 is arranged on one side of the data acquisition box 2, and the first end of the industrial computer 3 is electrically connected to the first end of the data acquisition box 2, The second end of the industrial control is electrically connected to the computer; the truss 4, the first end of the truss 4 is erected on the conveyor belt 1 of the shield machine, and the second end of the truss 4 is erected on the ground; the lighting device 5, the There are two lighting devices 5, the two lighting devices 5 are symmetrically arranged on both ends of the truss 4, and both the lighting devices 5 are detachably connected to the truss 4; the camera 6, the The camera 6 is arranged at the top of the truss 4, the camera 6 is detachably connected to the truss 4, and the camera 6 is electrically connected to the second end of the data acquisition box 2; the infrared thermometer 7, the The infrared thermometer 7 is arranged at the top of the truss 4 , the infrared thermometer 7 is detachably connected to the truss 4 , and the infrared thermometer 7 is electrically connected to the third end of the data acquisition box 2 .

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,所述桁架4用于支撑所述照明装置5、所述摄像机6和所述红外测温仪7,所述照明装置5用于配合所述摄像机6进行图像数据化,所述红外摄像机6用于实时测量碴片温度。In the device and method for monitoring the wear of a shield hob based on the topography of the ballast sheet according to the above embodiments of the present invention, the truss 4 is used to support the lighting device 5 , the camera 6 and the infrared thermometer 7 . , the lighting device 5 is used to cooperate with the camera 6 to perform image dataization, and the infrared camera 6 is used to measure the temperature of the ballast in real time.

本发明的实施例还提供了一种基于碴片形貌的盾构滚刀磨耗监测方法,包括:步骤1,获取电脑中已知的盾构工程案例并构建数据库;步骤2,采用GRNN神经网络分析数据库中的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数和温度参数与滚刀磨损量的映射关系,得到映射关系分析结果;步骤3,基于数据库、GRNN神经网络和映射关系分析结果构建滚刀磨耗预测系统并设定滚刀磨损量报警阈值;步骤4,采集当前盾构机施工前的滚刀结构参数和工程地质参数并输入滚刀磨耗预测系统;步骤5,实时采集当前盾构机施工时的盾构掘进参数、碴片形貌参数和温度参数并输入滚刀磨耗预测系统中;步骤6,滚刀磨耗预测系统根据输入的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数和温度参数进行滚刀磨损量预测并将预测的滚刀磨损量与设定的滚刀磨损量报警阈值进行比较;步骤7,当预测的滚刀磨损量超出滚刀磨损量报警阈值时,滚刀磨耗预测系统发出警报,盾构机停止运行,更换滚刀,测量已磨损滚刀的磨损量并输入滚刀磨耗预测系统;步骤8,根据已磨损滚刀的磨损量和预测的滚刀磨损量采用粒子群优化算法对GRNN神经网络进行自适应优化;步骤9,换刀完成后重新启动盾构机,跳转到步骤4继续执行,直到整个盾构工程工作完成,结束监测;步骤10,当预测的滚刀磨损量未超出滚刀磨损量报警阈值时,跳转到步骤5继续执行,直到整个盾构工程工作完成,结束监测。The embodiment of the present invention also provides a method for monitoring the abrasion of shield hob based on the topography of the ballast piece, including: step 1, obtaining known shield tunneling engineering cases in a computer and building a database; step 2, using a GRNN neural network Analyze the mapping relationship between the hob structure parameters, engineering geological parameters, shield tunneling parameters, ballast sheet topography parameters and temperature parameters in the database and the hob wear amount, and obtain the analysis result of the mapping relationship; step 3, based on the database, GRNN neural network Build a hob wear prediction system with the results of the mapping relationship analysis and set the alarm threshold of the hob wear amount; Step 4, collect the hob structural parameters and engineering geological parameters of the current shield machine before construction and input it into the hob wear prediction system; Step 5 , collect in real time the shield tunneling parameters, ballast shape parameters and temperature parameters during the construction of the current shield machine and input them into the hob wear prediction system; step 6, the hob wear prediction system according to the input hob structure parameters, engineering geological parameters parameters, shield tunneling parameters, ballast shape parameters and temperature parameters to predict the hob wear amount and compare the predicted hob wear amount with the set hob wear amount alarm threshold; Step 7, when the predicted hob wear amount is When the wear amount exceeds the alarm threshold of the hob wear amount, the hob wear prediction system will issue an alarm, the shield machine will stop running, replace the hob, measure the wear amount of the worn hob and input it into the hob wear prediction system; Step 8, according to the The wear amount of the worn hob and the predicted wear amount of the hob are adaptively optimized by the particle swarm optimization algorithm to the GRNN neural network; step 9, restart the shield machine after the tool change is completed, and jump to step 4 to continue execution until the entire The shield tunneling work is completed, and the monitoring is ended; in step 10, when the predicted hob wear amount does not exceed the hob wear amount alarm threshold, jump to step 5 to continue execution until the entire shield tunneling work is completed, ending the monitoring.

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,采用CRNN神经网络分析采集参数与滚刀磨损量的映射关系,根据工程掘进数据及碴片形貌波动变化情况,设定滚刀磨损量报警阈值,提前预测滚刀磨损异常状态特征,精确识别滚刀各种失效情况,如正常磨损、偏磨等;采用神经网络进行预测判断主要过程如下:1.选择神经网络;2.选择学习样本;3.确定输入向量和输出向量;4.设置神经网络参数;5.神经网络学习,构建神经网络模型;6.输入目标对象进行预测判断;使用GRNN神经网络结构,GRNN神经网络结构包括输入层、模式层、求和层和输出层,使用一部分已有数据对GRNN神经网络结构进行训练;输入层的神经元个数为学习样本中输入向量的个数,输入层将多个输入变量输出到模式层,模式层中神经元的个数与学习样本中输入向量的个数相等,模式层中的各神经元对应不同的输入向量,模式层神经元传递函数,如下所示:The device and method for monitoring the wear of shield hob based on the topography of the ballast piece described in the above-mentioned embodiment of the present invention adopts the CRNN neural network to analyze the mapping relationship between the acquisition parameters and the wear amount of the hob, according to the engineering excavation data and the topography of the ballast piece For fluctuations and changes, set the alarm threshold of the hob wear amount, predict the abnormal state characteristics of the hob wear in advance, and accurately identify various failure conditions of the hob, such as normal wear, partial wear, etc. The main process of using neural network for prediction and judgment is as follows: 1 .Select neural network; 2. Select learning samples; 3. Determine input vector and output vector; 4. Set neural network parameters; 5. Neural network learning, build neural network model; 6. Input target object for prediction and judgment; Network structure, GRNN neural network structure includes input layer, pattern layer, summation layer and output layer, using part of existing data to train GRNN neural network structure; the number of neurons in the input layer is the number of input vectors in the learning sample , the input layer outputs multiple input variables to the model layer, the number of neurons in the model layer is equal to the number of input vectors in the learning sample, each neuron in the model layer corresponds to different input vectors, and the neurons in the model layer transmit function as follows:

Figure BDA0003124618950000071
Figure BDA0003124618950000071

其中,Pi表示模式层第i个神经元的输出,X表示学习样本,X=[X1,X2,…,Xn]T,Xa表示学习样本中第a个输入向量,σ表示光滑因子,i表示第i个神经元。Among them, Pi represents the output of the i -th neuron in the pattern layer, X represents the learning sample, X=[X 1 , X 2 ,...,X n ] T , X a represents the a-th input vector in the learning sample, and σ represents Smoothing factor, i represents the ith neuron.

求和层中使用两种类型对模式层各神经元的输出进行求和:The summation layer uses two types to sum the outputs of the neurons in the pattern layer:

一类的计算方式为:A class of calculations are:

Figure BDA0003124618950000072
Figure BDA0003124618950000072

对模式层的各神经元输出进行算术求和,模式层与各神经元的连接权值为1,求和层神经元传递函数,如下所示:The output of each neuron in the pattern layer is arithmetically summed, the connection weight between the pattern layer and each neuron is 1, and the summation layer neuron transfer function is as follows:

Figure BDA0003124618950000073
Figure BDA0003124618950000073

二类的计算方式为:The calculation method of the second category is:

Figure BDA0003124618950000074
Figure BDA0003124618950000074

对模式层的各神经元进行加权求和,模式层中第i个神经元与求和层中第j个分子求和神经元之间的连接权值为第i个输出样本Yi中的第i个元素,求和层神经元传递函数,如下所示:The weighted summation is performed on each neuron in the pattern layer, and the connection weight between the ith neuron in the pattern layer and the jth molecular summation neuron in the summation layer is the ith in the ith output sample Yi. i elements, the summation layer neuron transfer function is as follows:

Figure BDA0003124618950000075
Figure BDA0003124618950000075

输出层中的神经元数目等于学习样本中输出向量的维数k,各神经元将求和层的输出相除,神经元j的输出,如下所示:The number of neurons in the output layer is equal to the dimension k of the output vector in the learning sample. Each neuron divides the output of the summation layer, and the output of neuron j is as follows:

Figure BDA0003124618950000076
Figure BDA0003124618950000076

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,施工前将工程地质、滚刀结构及刀盘结构等参数输入系统作为已知参数,并在施工过程中实时监测盾构机掘进参数及碴片形貌参数并输入系统,预测滚刀的实时磨损量,当滚刀磨损量达到设定的滚刀磨损量报警阈值时报警提示换刀,停机后工人进仓换刀并测量刀具当前磨损状态及磨损量,将结果输入滚刀磨耗预测系统中,进行滚刀磨耗预测系统的反馈自适应调节,保持在当前工程高预测精度条件下,提高滚刀磨耗预测系统预测的鲁棒性,在每次换刀后重复该循环。In the device and method for monitoring the abrasion of shield hob based on the topography of the ballast piece described in the above-mentioned embodiments of the present invention, parameters such as engineering geology, hob structure and cutter head structure are input into the system as known parameters before construction, and the parameters are input during construction. During the process, real-time monitoring of the tunneling parameters of the shield machine and the shape parameters of the ballast piece are input into the system to predict the real-time wear amount of the hob. The worker enters the warehouse to change the tool and measures the current wear status and wear amount of the tool, and inputs the result into the hob wear prediction system to carry out the feedback adaptive adjustment of the hob wear prediction system, so as to maintain the high prediction accuracy of the current project and improve the hob Robustness of wear prediction system predictions, repeating the cycle after each tool change.

其中,所述步骤1具体包括:盾构工程案例包括多条换刀记录,换刀记录包括滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数、温度参数和滚刀磨损量,其中,滚刀结构参数包括刀刃结构参数、滚刀半径、刀间距和载荷重量,工程地质参数包括岩石力学参数、岩石材料参数、岩石的节理和断层参数和岩性参数,盾构掘进参数包括盾构机的贯入度、盾构机刀盘转速、盾构机推力、盾构机工作转矩、盾构机土仓压力和盾构机推进速度,碴片形貌参数包括碴片粒径分布指标、碴片长短轴比值指标和碴片纹理指标,温度参数包括碴片温度。Wherein, the step 1 specifically includes: the shield engineering case includes a plurality of tool change records, and the tool change records include hob structural parameters, engineering geological parameters, shield tunneling parameters, ballast blade morphology parameters, temperature parameters, and hob wear. Among them, the hob structure parameters include blade edge structure parameters, hob radius, cutter spacing and load weight, engineering geological parameters include rock mechanics parameters, rock material parameters, rock joints and fault parameters and lithology parameters, shield tunneling parameters Including the penetration of the shield machine, the rotation speed of the cutter head of the shield machine, the thrust of the shield machine, the working torque of the shield machine, the pressure of the soil silo of the shield machine and the propulsion speed of the shield machine, and the shape parameters of the ballast piece include the ballast piece. The diameter distribution index, the ratio of the long and the short axis of the ballast piece and the texture index of the ballast piece, and the temperature parameters include the temperature of the ballast piece.

其中,所述步骤2具体包括:将盾构机的贯入度、推进速度、刀盘转速、盾构机推力、盾构机工作转矩、盾构机土仓压力和滚刀半径作为GRNN神经网络的输入层的7个神经元,将刀具磨损量作为输出层的神经元,构成GRNN神经网络;Wherein, the step 2 specifically includes: using the penetration of the shield machine, the propulsion speed, the rotational speed of the cutter head, the thrust of the shield machine, the working torque of the shield machine, the pressure of the soil bin of the shield machine and the radius of the hob as the GRNN nerve The 7 neurons in the input layer of the network use the tool wear amount as the neurons in the output layer to form a GRNN neural network;

将数据库中的数据分为100组,采用随机抽样的方法在100组数据内选取10组数据作为测试集,剩余的90组数据作为训练集;Divide the data in the database into 100 groups, use random sampling to select 10 groups of data from the 100 groups of data as the test set, and the remaining 90 groups of data as the training set;

将训练集随机分为9个单元,每个单元包括10组数据,采用交叉验证法从9个单元中随机选取8个单元作为训练集输入样本,剩余1个单元作为训练集输出样本,并将训练集输入样本数据归一化到[-1,1]之间,在(0,1]内以步长0.01验证搜索,寻找使得预测值与样本值的均方误差最小的光滑因子σ,并记录当前光滑因子对应的最佳输入样本与最佳输出样本;The training set is randomly divided into 9 units, each unit includes 10 sets of data, 8 units are randomly selected from the 9 units as the input sample of the training set by the cross-validation method, and the remaining 1 unit is used as the output sample of the training set. The input sample data of the training set is normalized to between [-1, 1], and the verification search is performed with a step size of 0.01 in (0, 1], and the smooth factor σ that minimizes the mean square error between the predicted value and the sample value is found, and Record the best input sample and the best output sample corresponding to the current smooth factor;

将测试集数据归一化,将获取的光滑因子σ、最佳输入样本和最佳输出样本作为输入变量,构建4层GRNN神经网络,输出层输出刀具磨损量。The test set data is normalized, and the obtained smooth factor σ, the best input sample and the best output sample are used as input variables to build a 4-layer GRNN neural network, and the output layer outputs the tool wear amount.

其中,所述步骤3具体包括:基于GRNN神经网络通过相关性分析采集数据库中工程地质参数、盾构掘进参数、盾构滚刀结构、碴片形貌尺寸和温度参数与刀具磨损量的映射关系,建立滚刀磨耗预测系统:Wherein, the step 3 specifically includes: collecting the engineering geological parameters, shield tunneling parameters, shield hob structure, ballast topography size and temperature parameters and the mapping relationship between the tool wear amount and the tool wear amount in the database through correlation analysis based on the GRNN neural network , to establish a hob wear prediction system:

δi=β0p+β1v+β2n+β3F+β4T+β5S+β6L+······+βmXm+C (1)δ i0 p+β 1 v+β 2 n+β 3 F+β 4 T+β 5 S+β 6 L+...+β m X m +C (1)

其中,β0、β1、β2、β3、β4····βm是待估计参数,δi为刀具磨损量,p表示盾构机的贯入度,v表示推进速度,n表示刀盘转速,F表示盾构机推力,T表示盾构机工作转矩,L表示滚刀半径,S表示碴片形貌尺寸,Xm表示其他与刀具磨损量相关的参数,C表示待定常数。Among them, β 0 , β 1 , β 2 , β 3 , β 4 , β m are the parameters to be estimated, δ i is the tool wear amount, p is the penetration degree of the shield machine, v is the propulsion speed, n Indicates the rotation speed of the cutter head, F represents the thrust of the shield machine, T represents the working torque of the shield machine, L represents the radius of the hob, S represents the shape and size of the ballast piece, X m represents other parameters related to the amount of tool wear, and C represents to be determined constant.

其中,所述步骤5具体包括:通过盾构机的主控室实时采集当前盾构机施工时的盾构掘进参数并输入滚刀磨耗预测系统,通过摄像机6实时拍摄盾构机传送带1上碴片的图片并输入电脑中进行碴片形貌尺寸解算,获得碴片形貌参数并输入滚刀磨耗预测系统,通过红外测温仪7实时测量盾构机传送带1上碴片的温度并输入滚刀磨耗预测系统。Wherein, the step 5 specifically includes: collecting the current shield tunneling parameters during the construction of the shield tunneling machine in real time through the main control room of the shield tunneling machine and inputting them into the hob wear prediction system; The picture of the ballast chip is input into the computer to calculate the shape and size of the ballast chip, the shape parameters of the ballast chip are obtained and input into the hob wear prediction system, and the temperature of the ballast chip on the conveyor belt 1 of the shield machine is measured in real time through the infrared thermometer 7 and input Hob wear prediction system.

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,所述摄像机6、所述红外测温仪7、所述数据采集箱2和所述工控机3连接通过数据线将图像数据与温度数据传输并存储至电脑内的所述滚刀磨耗预测系统中,通过所述滚刀磨耗预测系统,实时分析当前滚刀磨损情况。The device and method for monitoring the wear of shield hob based on the topography of the ballast sheet according to the above embodiments of the present invention, the camera 6 , the infrared thermometer 7 , the data collection box 2 and the industrial computer 3 The connection transmits and stores the image data and temperature data to the hob wear prediction system in the computer through the data line, and analyzes the current hob wear condition in real time through the hob wear prediction system.

其中,所述步骤8具体包括:采用粒子群优化算法对CRNN神经网络进行优化:设置粒子群计算参数,设置滚刀磨耗预测系统发出警报时预测的刀具磨损量与已磨损滚刀的磨损量的均方差为适应度函数,将学习样本和例子带入GRNN神经网络,计算适应度值Fi,比较第i个粒子所经过的所有位置的适应度值,确定其最优位置Pbi,比较所有粒子在其最优位置Pbi的适应度值,确定整个种群的最优位置Gb,根据各粒子自身位置和最优粒子位置调整粒子的速度和位置,当达到迭代终止条件时,得到最优位置Gb,采用搜索到的最优位置Gb优化GRNN神经网络。Wherein, the step 8 specifically includes: using the particle swarm optimization algorithm to optimize the CRNN neural network: setting the particle swarm calculation parameters, setting the tool wear amount predicted when the hob wear prediction system issues an alarm and the wear amount of the worn hob. The mean square error is the fitness function, and the learning samples and examples are brought into the GRNN neural network to calculate the fitness value F i , compare the fitness values of all positions passed by the ith particle, determine its optimal position P bi , compare all The fitness value of the particle at its optimal position P bi determines the optimal position G b of the entire population, and adjusts the speed and position of the particle according to the position of each particle and the optimal particle position. When the iteration termination condition is reached, the optimal position is obtained. Position G b , using the searched optimal position G b to optimize the GRNN neural network.

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,盾构机施工前,在所述盾构机传送带1上搭建所述盾构滚刀磨耗监测装置,通过人工采集当前盾构机的滚刀结构参数和工程地质参数并输入所述滚刀磨耗预测系统,盾构机运行时,通过盾构滚刀磨耗监测装置实时获取盾构机运行过程中的碴片形貌参数和温度参数输入并存储到所述滚刀磨耗预测系统,具体为通过所述摄像机6实时拍摄所述盾构机传送带1上碴片的图片并输入电脑中进行碴片形貌尺寸解算,获得碴片形貌参数输入并存储到所述滚刀磨耗预测系统,通过所述红外测温仪7实时测量所述盾构机传送带1上碴片的温度输入并存储到所述滚刀磨耗预测系统;通过盾构机的主控室实时采集当前盾构机施工时的盾构掘进参数输入并存储到所述滚刀磨耗预测系统;所述滚刀磨耗预测系统根据输入的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数、温度参数和已有的映射关系分析结果输出当前输入参数对应的滚刀磨损量,判断输出的滚刀磨损量是否超过设定的滚刀磨损量报警阈值,当输出的滚刀磨损量未超过设定的滚刀磨损量报警阈值时,继续下一组参数的滚刀磨损量预测;当输出的滚刀磨损量超过设定的滚刀磨损量报警阈值时,发出警报,停止运行盾构机,工作人员对盾构机的滚刀进行更换,测量当前已磨损滚刀的滚刀磨损量并输入所述滚刀磨耗预测系统进行存储,将当前已磨损滚刀的滚刀磨损量和预测的滚刀磨损量的协方差作为粒子群优化算法的适应度函数寻找最优光滑因子,根据最优光滑因子优化CRNN神经网络,启动盾构机,继续下一组参数的滚刀磨损量预测,直到整个盾构工程工作完成,结束监测。For the shield machine tool wear monitoring device and method based on the topography of the ballast piece according to the above-mentioned embodiments of the present invention, the shield machine tool wear monitoring device is built on the shield machine conveyor belt 1 before the shield machine is constructed. , By manually collecting the hob structural parameters and engineering geological parameters of the current shield machine and inputting the hob wear prediction system, when the shield machine is running, the shield machine hob wear monitoring device is used to obtain real-time information on the shield machine during operation. The shape parameters and temperature parameters of the ballast piece are input and stored in the hob wear prediction system. Specifically, the camera 6 is used to take a picture of the ballast piece on the conveyor belt 1 of the shield machine in real time and input it into a computer to carry out the shape of the ballast piece. Calculate the size, obtain the input of ballast piece morphology parameters and store it in the hob wear prediction system, measure the temperature input of the ballast piece on the shield machine conveyor belt 1 in real time by the infrared thermometer 7 and store it in the The hob wear prediction system; the shield tunneling parameters input during the current shield machine construction are collected in real time through the main control room of the shield machine and stored in the hob wear prediction system; the hob wear prediction system is based on the input rolling The tool structure parameters, engineering geological parameters, shield tunneling parameters, ballast sheet shape parameters, temperature parameters and the analysis results of the existing mapping relationship output the hob wear amount corresponding to the current input parameters, and judge whether the output hob wear amount exceeds the set value. Set the hob wear amount alarm threshold, when the output hob wear amount does not exceed the set hob wear amount alarm threshold, continue to predict the hob wear amount of the next group of parameters; when the output hob wear amount exceeds the set hob wear amount When the hob wear amount alarm threshold is set, an alarm will be issued, the shield machine will be stopped, the staff will replace the hob of the shield machine, measure the hob wear amount of the currently worn hob and input the hob wear prediction The system stores and uses the covariance of the hob wear amount of the currently worn hob and the predicted hob wear amount as the fitness function of the particle swarm optimization algorithm to find the optimal smooth factor, and optimizes the CRNN neural network according to the optimal smooth factor. Start the shield machine and continue to predict the hob wear amount of the next set of parameters until the entire shield engineering work is completed and the monitoring is ended.

本发明的上述实施例所述的基于碴片形貌的盾构滚刀磨耗监测装置及方法,通过采集实际的工程地质参数和滚刀结构参数和实时的掘进参数和碴片参数输入滚刀磨耗预测系统,滚刀磨耗预测系统能够实时预测滚刀的磨损状态,滚刀磨耗预测系统在预测的滚刀的磨损状态达到设定滚刀磨损量报警阈值时提供报警功能,在滚刀磨耗预测系统报警时,根据预测的滚刀磨损量和实际的滚刀磨损量采用粒子群优化算法优化GRNN神经网络参数进行优化,减少人为因素对神经网络设计的影响,将GRNN神经网络适应性改进,在原有映射关系的基础上,增加自适应改进算法,在保持高预测精度条件下,提高滚刀磨耗预测的鲁棒性,使所述基于碴片形貌的盾构滚刀磨耗监测装置及方法可以根据不同的工程通过闭环反馈自适应调节提高滚刀磨耗的精确预测。The device and method for monitoring the wear of shield hob based on the topography of the ballast piece described in the above-mentioned embodiments of the present invention input the wear of the hob by collecting actual engineering geological parameters, structural parameters of the hob and real-time excavation parameters and parameters of the ballast piece. Prediction system, the hob wear prediction system can predict the wear state of the hob in real time. The hob wear prediction system provides an alarm function when the predicted wear state of the hob reaches the set alarm threshold of the hob wear amount. When an alarm occurs, the particle swarm optimization algorithm is used to optimize the parameters of the GRNN neural network according to the predicted and actual hob wear, so as to reduce the influence of human factors on the neural network design, and improve the adaptability of the GRNN neural network. On the basis of the mapping relationship, an adaptive improvement algorithm is added to improve the robustness of the hob wear prediction under the condition of maintaining high prediction accuracy, so that the shield hob wear monitoring device and method based on the topography of the ballast piece can be based on Different projects improve accurate prediction of hob wear through closed-loop feedback adaptive adjustment.

以上所述是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明所述原理的前提下,还可以作出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。The above are the preferred embodiments of the present invention. It should be pointed out that for those skilled in the art, without departing from the principles of the present invention, several improvements and modifications can be made. It should be regarded as the protection scope of the present invention.

Claims (6)

1.一种基于碴片形貌的盾构滚刀磨耗监测方法,应用于一种基于碴片形貌的盾构滚刀磨耗监测装置,包括:数据采集箱,所述数据采集箱设置在盾构机传送带的一侧;工控机,所述工控机设置在所述数据采集箱的一侧,所述工控机的第一端与所述数据采集箱的第一端电连接,所述工控的第二端与电脑电连接;桁架,所述桁架的第一端架设在盾构机传送带上,所述桁架的第二端架设在地面上;照明装置,所述照明装置设置有两个,两个所述照明装置对称设置在所述桁架的两端上,两个所述照明装置均与所述桁架可拆卸连接;摄像机,所述摄像机设置在所述桁架的顶端,所述摄像机与所述桁架可拆卸连接,所述摄像机与所述数据采集箱的第二端电连接;红外测温仪,所述红外测温仪设置在所述桁架的顶端,所述红外测温仪与所述桁架可拆卸连接,所述红外测温仪与所述数据采集箱的第三端电连接,其特征在于,包括:1. A method for monitoring the wear of shield hob based on the topography of the ballast piece, applied to a device for monitoring the wear of a shield machine hob based on the topography of the ballast piece, comprising: a data acquisition box, the data acquisition box is arranged on the shield. One side of the conveyor belt of the mechanism; an industrial computer, the industrial computer is arranged on one side of the data acquisition box, the first end of the industrial computer is electrically connected to the first end of the data acquisition box, and the industrial computer is connected to the first end of the data acquisition box. The second end is electrically connected to the computer; the truss, the first end of the truss is erected on the conveyor belt of the shield machine, the second end of the truss is erected on the ground; the lighting device, the lighting device is provided with two, two Each of the lighting devices is symmetrically arranged on both ends of the truss, and both of the lighting devices are detachably connected to the truss; a camera, the camera is arranged on the top of the truss, and the camera is connected to the truss. The truss is detachably connected, and the camera is electrically connected to the second end of the data acquisition box; an infrared thermometer is arranged at the top of the truss, and the infrared thermometer is connected to the truss. Detachable connection, the infrared thermometer is electrically connected to the third end of the data acquisition box, characterized in that it includes: 步骤1,获取电脑中已知的盾构工程案例并构建数据库;Step 1: Obtain known shield engineering cases in the computer and build a database; 步骤2,采用GRNN神经网络分析数据库中的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数和温度参数与滚刀磨损量的映射关系,得到映射关系分析结果;Step 2, using the GRNN neural network to analyze the mapping relationship between the hob structure parameters, engineering geological parameters, shield tunneling parameters, ballast piece topography parameters and temperature parameters and the hob wear amount in the database, and obtain the mapping relationship analysis result; 步骤3,基于数据库、GRNN神经网络和映射关系分析结果构建滚刀磨耗预测系统并设定滚刀磨损量报警阈值;Step 3, build a hob wear prediction system based on the database, the GRNN neural network and the analysis results of the mapping relationship, and set an alarm threshold for the hob wear amount; 步骤4,采集当前盾构机施工前的滚刀结构参数和工程地质参数并输入滚刀磨耗预测系统;Step 4, collect the hob structure parameters and engineering geological parameters of the current shield machine before construction, and input the hob wear prediction system; 步骤5,实时采集当前盾构机施工时的盾构掘进参数、碴片形貌参数和温度参数并输入滚刀磨耗预测系统中;Step 5, collecting the shield tunneling parameters, ballast piece topography parameters and temperature parameters during the construction of the current shield machine in real time and inputting them into the hob wear prediction system; 步骤6,滚刀磨耗预测系统根据输入的滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数和温度参数进行滚刀磨损量预测并将预测的滚刀磨损量与设定的滚刀磨损量报警阈值进行比较;Step 6, the hob wear prediction system predicts the hob wear amount according to the input hob structure parameters, engineering geological parameters, shield tunneling parameters, ballast piece shape parameters and temperature parameters, and sets the predicted hob wear amount and setting. Compare with the alarm threshold of hob wear amount; 步骤7,当预测的滚刀磨损量超出滚刀磨损量报警阈值时,滚刀磨耗预测系统发出警报,盾构机停止运行,更换滚刀,测量已磨损滚刀的磨损量并输入滚刀磨耗预测系统;Step 7: When the predicted hob wear exceeds the hob wear alarm threshold, the hob wear prediction system will issue an alarm, the shield machine will stop running, replace the hob, measure the wear of the worn hob and input the hob wear forecasting system; 步骤8,根据已磨损滚刀的磨损量和预测的滚刀磨损量采用粒子群优化算法对GRNN神经网络进行自适应优化;Step 8, adopt the particle swarm optimization algorithm to adaptively optimize the GRNN neural network according to the wear amount of the worn hob and the predicted wear amount of the hob; 步骤9,换刀完成后重新启动盾构机,跳转到步骤4继续执行,直到整个盾构工程工作完成,结束监测;Step 9, restart the shield machine after the tool change is completed, jump to step 4 and continue to execute until the entire shield project is completed, and the monitoring ends; 步骤10,当预测的滚刀磨损量未超出滚刀磨损量报警阈值时,跳转到步骤5继续执行,直到整个盾构工程工作完成,结束监测。Step 10, when the predicted hob wear amount does not exceed the hob wear amount alarm threshold, jump to step 5 and continue to execute until the entire shield tunneling work is completed, ending the monitoring. 2.根据权利要求1所述的基于碴片形貌的盾构滚刀磨耗监测方法,其特征在于,所述步骤1具体包括:2. The method for monitoring the abrasion of shield hob based on the topography of the ballast piece according to claim 1, wherein the step 1 specifically comprises: 盾构工程案例包括多条换刀记录,换刀记录包括滚刀结构参数、工程地质参数、盾构掘进参数、碴片形貌参数、温度参数和滚刀磨损量,其中,滚刀结构参数包括刀刃结构参数、滚刀半径、刀间距和载荷重量,工程地质参数包括岩石力学参数、岩石材料参数、岩石的节理和断层参数和岩性参数,盾构掘进参数包括盾构机的贯入度、盾构机刀盘转速、盾构机推力、盾构机工作转矩、盾构机土仓压力和盾构机推进速度,碴片形貌参数包括碴片粒径分布指标、碴片长短轴比值指标和碴片纹理指标,温度参数包括碴片温度。The shield engineering case includes a number of tool change records. The tool change records include hob structural parameters, engineering geological parameters, shield tunneling parameters, ballast shape parameters, temperature parameters and hob wear. Among them, the hob structural parameters include: Blade structure parameters, hob radius, cutter spacing and load weight, engineering geological parameters include rock mechanics parameters, rock material parameters, rock joint and fault parameters and lithology parameters, shield tunneling parameters include shield machine penetration, Shield machine cutter head speed, shield machine thrust, shield machine working torque, shield machine soil bin pressure and shield machine propulsion speed, ballast piece morphology parameters including ballast piece particle size distribution index, ballast piece length and short axis ratio index and ballast sheet texture index, and temperature parameters include ballast sheet temperature. 3.根据权利要求2所述的基于碴片形貌的盾构滚刀磨耗监测方法,其特征在于,所述步骤2具体包括:3. The method for monitoring the abrasion of shield hob based on the topography of the ballast piece according to claim 2, wherein the step 2 specifically comprises: 将盾构机的贯入度、推进速度、刀盘转速、盾构机推力、盾构机工作转矩、盾构机土仓压力和滚刀半径作为GRNN神经网络的输入层的7个神经元,将刀具磨损量作为输出层的神经元,构成GRNN神经网络;The penetration, propulsion speed, cutter head rotation speed, thrust of the shield machine, working torque of the shield machine, soil pressure of the shield machine, and radius of the hob are used as the 7 neurons of the input layer of the GRNN neural network. , the tool wear amount is used as the neuron of the output layer to form a GRNN neural network; 将数据库中的数据分为100组,采用随机抽样的方法在100组数据内选取10组数据作为测试集,剩余的90组数据作为训练集;Divide the data in the database into 100 groups, use random sampling to select 10 groups of data from the 100 groups of data as the test set, and the remaining 90 groups of data as the training set; 将训练集随机分为9个单元,每个单元包括10组数据,采用交叉验证法从9个单元中随机选取8个单元作为训练集输入样本,剩余1个单元作为训练集输出样本,并将训练集输入样本数据归一化到[-1,1]之间,在(0,1]内以步长0.01验证搜索,寻找使得预测值与样本值的均方误差最小的光滑因子σ,并记录当前光滑因子对应的最佳输入样本与最佳输出样本;The training set is randomly divided into 9 units, each unit includes 10 sets of data, 8 units are randomly selected from the 9 units as the input sample of the training set by the cross-validation method, and the remaining 1 unit is used as the output sample of the training set. The input sample data of the training set is normalized to between [-1, 1], and the verification search is performed with a step size of 0.01 in (0, 1], and the smooth factor σ that minimizes the mean square error between the predicted value and the sample value is found, and Record the best input sample and the best output sample corresponding to the current smooth factor; 将测试集数据归一化,将获取的光滑因子σ、最佳输入样本和最佳输出样本作为输入变量,构建4层GRNN神经网络,输出层输出刀具磨损量。The test set data is normalized, and the obtained smooth factor σ, the best input sample and the best output sample are used as input variables to build a 4-layer GRNN neural network, and the output layer outputs the tool wear amount. 4.根据权利要求3所述的基于碴片形貌的盾构滚刀磨耗监测方法,其特征在于,所述步骤3具体包括:4. The method for monitoring the abrasion of shield hob based on the topography of the ballast piece according to claim 3, wherein the step 3 specifically comprises: 基于GRNN神经网络通过相关性分析采集数据库中工程地质参数、盾构掘进参数、盾构滚刀结构、碴片形貌尺寸和温度参数与刀具磨损量的映射关系,建立滚刀磨耗预测系统:Based on the GRNN neural network, the mapping relationship between the engineering geological parameters, shield tunneling parameters, shield hob structure, ballast shape size and temperature parameters and the tool wear amount in the database is collected through correlation analysis, and the hob wear prediction system is established: δi=β0p+β1v+β2n+β3F+β4T+β5S+β6L+······+βmXm+C (1)δ i0 p+β 1 v+β 2 n+β 3 F+β 4 T+β 5 S+β 6 L+...+β m X m +C (1) 其中,β0、β1、β2、β3、β4····βm是待估计参数,δi为刀具磨损量,p表示盾构机的贯入度,v表示推进速度,n表示刀盘转速,F表示盾构机推力,T表示盾构机工作转矩,L表示滚刀半径,S表示碴片形貌尺寸,Xm表示其他与刀具磨损量相关的参数,C表示待定常数。Among them, β 0 , β 1 , β 2 , β 3 , β 4 , β m are the parameters to be estimated, δ i is the tool wear amount, p is the penetration degree of the shield machine, v is the propulsion speed, n Indicates the rotation speed of the cutter head, F represents the thrust of the shield machine, T represents the working torque of the shield machine, L represents the radius of the hob, S represents the shape and size of the ballast piece, X m represents other parameters related to the amount of tool wear, and C represents to be determined constant. 5.根据权利要求4所述的基于碴片形貌的盾构滚刀磨耗监测方法,其特征在于,所述步骤5具体包括:5. The method for monitoring the abrasion of shield hob based on the topography of the ballast piece according to claim 4, wherein the step 5 specifically comprises: 通过盾构机的主控室实时采集当前盾构机施工时的盾构掘进参数并输入滚刀磨耗预测系统,通过摄像机实时拍摄盾构机传送带上碴片的图片并输入电脑中进行碴片形貌尺寸解算,获得碴片形貌参数并输入滚刀磨耗预测系统,通过红外测温仪实时测量盾构机传送带上碴片的温度并输入滚刀磨耗预测系统。The main control room of the shield machine is used to collect the current shield tunneling parameters during the construction of the shield machine in real time and input them into the hob wear prediction system. The shape and size of the ballast piece are calculated, and the shape parameters of the ballast piece are obtained and input into the hob wear prediction system. 6.根据权利要求5所述的基于碴片形貌的盾构滚刀磨耗监测方法,其特征在于,所述步骤8具体包括:6. The method for monitoring the abrasion of shield hob based on the topography of the ballast piece according to claim 5, wherein the step 8 specifically comprises: 采用粒子群优化算法对CRNN神经网络进行优化:设置粒子群计算参数,设置滚刀磨耗预测系统发出警报时预测的刀具磨损量与已磨损滚刀的磨损量的均方差为适应度函数,将学习样本和例子带入GRNN神经网络,计算适应度值Fi,比较第i个粒子所经过的所有位置的适应度值,确定其最优位置Pbi,比较所有粒子在其最优位置Pbi的适应度值,确定整个种群的最优位置Gb,根据各粒子自身位置和最优粒子位置调整粒子的速度和位置,当达到迭代终止条件时,得到最优位置Gb,采用搜索到的最优位置Gb优化GRNN神经网络。The particle swarm optimization algorithm is used to optimize the CRNN neural network: set the particle swarm calculation parameters, and set the mean square error of the tool wear amount predicted when the hob wear prediction system sends an alarm and the wear amount of the worn hob as the fitness function. The samples and examples are brought into the GRNN neural network, the fitness value F i is calculated, the fitness values of all positions passed by the i-th particle are compared, and the optimal position P bi is determined, and the optimal position P bi of all particles is compared. The fitness value, determine the optimal position G b of the whole population, adjust the speed and position of the particle according to the position of each particle itself and the optimal particle position, when the iteration termination condition is reached, obtain the optimal position G b , use the searched optimal position G b . The optimal location G b optimizes the GRNN neural network.
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