滚刀状态实时诊断技术在超大直径泥水盾构中的应用——以汕头苏埃通道为例

Real-Time Diagnosis Application of Disc Cutter in Super-Large Diameter Slurry Shield:a Case Study on Shantou Su′ai Tunnel

超大直径隧道施工多采用泥水盾构,掘进过程中面临开挖直径大、地质条件复杂、刀具异常损坏严重等问题。为在掘进过程中实时掌握刀具状态,提高人工抽检的准确率,设计一种适用于超大直径泥水盾构的滚刀状态诊断系统,实现滚刀转速、磨损量、温度的实时监测与状态诊断,以及基于滚刀监测数据的掌子面地质分析技术。以汕头苏埃通道为例,详细介绍刀具监测系统的硬件设计与监测原理,并对实际工程中采集到的典型异常数据进行分析,完成滚刀异常状态识别。同时,基于获取的滚刀实时转速数据和刀盘角度数据,探索性地研究掌子面地质实时感知技术,并在苏埃通道西线进行应用,在基岩凸起段取得了良好的效果,为判断基岩侵入掌子面范围、优化掘进参数以及更准确地判断刀具状态提供直接依据。

Slurry shields are often used in the construction of super-large diameter tunnels,but many problems such as a large diameter,complex geological conditions,and serious abnormal cutter damage are encountered in the process of shield tunneling.To monitor the cutter status in real-time and improve the accuracy of manual cutter checking during shield tunneling,a diagnostic system for checking the disc cutter status used in super-large diameter slurry shields is designed;the real-time monitoring and condition diagnosis of the rotation speed,wear,and temperature of cutters as well as the geological analysis technology based on the monitoring data acquired from the cutters are realized.In this article,the hardware design and testing principle of the cutter diagnostic system are described in detail;typical abnormal data collected in the Shantou Su′ai tunnel are analyzed,and the abnormal states of the cutters are identified.Further,based on the real-time rotation speed data of the cutters and the angle data of the cutterhead,the geological real-time sensing technology of the cutter face is investigated and applied in the western line of the Shantou Su′ai tunnel;good results have been obtained in the raised section of bedrock,which provides a direct basis for optimizing the driving parameters and judging the range of the bedrock intrusion face and cutter state accurately.