Pressure Regulation for Earth Pressure Balance Control on Shield Tunneling Machine by Using Adaptive Robust Control

Most current studies about shield tunneling machine focus on the construction safety and tunnel structure stability during the excavation. Behaviors of the machine itself are also studied, like some tracking control of the machine. Yet, few works concern about the hydraulic components, especially the pressure and flow rate regulation components. This research focuses on pressure control strategies by using proportional pressure relief valve, which is widely applied on typical shield tunneling machines. Modeling of a commercial pressure relief valve is done. The modeling centers on the main valve, because the dynamic performance is determined by the main valve. To validate such modeling, a frequency-experiment result of the pressure relief valve, whose bandwidth is about 3 Hz, is presented as comparison. The modeling and the frequency experimental result show that it is reasonable to regard the pressure relief valve as a second-order system with two low corner frequencies. PID control, dead band compensation control and adaptive robust control（ARC） are proposed and simulation results are presented. For the ARC, implements by using first order approximation and second order approximation are presented. The simulation results show that the second order approximation implement with ARC can track 4 Hz sine signal very well, and the two ARC simulation errors are within 0.2 MPa. Finally, experiment results of dead band compensation control and adaptive robust control are given. The results show that dead band compensation had about 30° phase lag and about 20% off of the amplitude attenuation. ARC is tracking with little phase lag and almost no amplitude attenuation. In this research, ARC has been tested on a pressure relief valve. It is able to improve the valve＇s dynamic performances greatly, and it is capable of the pressure control of shield machine excavation.

Energy saving analysis of segment positioning in shield tunneling machine considering assembling path optimization

A motion parameter optimization method based on the objective of minimizing the total energy consumption in segment positioning was proposed for segment erector of shield tunneling machine. The segment positioning process was decomposed into rotation, lifting and sliding actions in deriving the energy calculation model of segment erection. The work of gravity was taken into account in the mathematical modeling of energy consumed by each actuator. In order to investigate the relationship between the work done by the actuator and the path moved along by the segment, the upward and downward directions as well as the operating quadrant of the segment erector were defined. Piecewise nonlinear function of energy was presented, of which the result is determined by closely coupled components as working parameters and some intermediate variables. Finally, the effectiveness of the optimization method was proved by conducting a case study with a segment erector for the tunnel with a diameter of 3 m and drawing comparisons between different assembling paths. The results show that the energy required by assembling a ring of segments along the optimized moving path can be reduced up to 5%. The method proposed in this work definitely provides an effective energy saving solution for shield tunneling machine.

Effects of data smoothing and recurrent neural network(RNN)algorithms for real-time forecasting of tunnel boring machine(TBM)performance

Tunnel boring machines(TBMs)have been widely utilised in tunnel construction due to their high efficiency and reliability.Accurately predicting TBM performance can improve project time management,cost control,and risk management.This study aims to use deep learning to develop real-time models for predicting the penetration rate(PR).The models are built using data from the Changsha metro project,and their performances are evaluated using unseen data from the Zhengzhou Metro project.In one-step forecast,the predicted penetration rate follows the trend of the measured penetration rate in both training and testing.The autoregressive integrated moving average(ARIMA)model is compared with the recurrent neural network(RNN)model.The results show that univariate models,which only consider historical penetration rate itself,perform better than multivariate models that take into account multiple geological and operational parameters(GEO and OP).Next,an RNN variant combining time series of penetration rate with the last-step geological and operational parameters is developed,and it performs better than other models.A sensitivity analysis shows that the penetration rate is the most important parameter,while other parameters have a smaller impact on time series forecasting.It is also found that smoothed data are easier to predict with high accuracy.Nevertheless,over-simplified data can lose real characteristics in time series.In conclusion,the RNN variant can accurately predict the next-step penetration rate,and data smoothing is crucial in time series forecasting.This study provides practical guidance for TBM performance forecasting in practical engineering.

Theoretical model for loads prediction on shield tunneling machine with consideration of soil-rock interbedded ground

The loads acting on shield tunneling machines are basic parameters for the equipment design as well as key control parameters throughout the entire operation of the equipment. In the study, a mechanical analysis for the coupled interactive system between the cutterhead and the ground at the excavation face is conducted. The normal and tangential loads acting on the cutterhead are decoupled and solved, with consideration of the influence of three key factors on loads: geological condition, operating status and equipment structure. Then analytical expressions for the thrust and the torque acting on the equipment under uniform geological condition are established. On this basis, the impact of soil-rock interbedded ground on acting loads is further considered. A theoretical model for loads prediction of earth pressure balance (EPB) shield machines working under soil-rock interbedded ground is proposed. This model is subsequently applied to loads prediction for a shield tunneling project under soil-rock interbedded ground. The computational value of the thrust and the torque, the measured loads and the load ranges from Krause empirical formula are compared. Thus, this model for loads prediction acting on shield tunneling machines under soil-rock interbedded ground has been proved to be effective.

Compliance of hydraulic system and its applications in thrust system design of shield tunneling machine

As the most significant performance, compliance of hydraulic system is defined as the capacity to accommodate the sudden change of the external load. Due to the different requirements of the compliant tasks, the existing method for mechanical systems cannot be used in the analysis and design of the hydraulic system. In this paper, the definition and expression of compliance of hydraulic system are proposed to evaluate the compliance of the hydraulic system operating under sudden change load. Because the unexpected geological conditions during excavation may exert sudden change load to the shield tunneling machine, the compliance theory has found a right application in the thrust hydraulic system. By analyzing the basic operating principle and the commonly used architectures of the thrust hydraulic system, a compliance based thrust hydraulic system design method is presented. Moreover, a tunneling case is investigated in the paper as an example to expound the validation of design procedure. In conclusion, the compliance of the hydraulic system can be served as an evaluation of the capability in conforming to the load impact, giving supports for the design of the thrust hydraulic system of shield tunneling machines.

A stiffness-matching based evaluation approach for compliance of mechanical systems in shield tunneling machines

As the most important performance,compliance of shield tunneling machines(STM) is defined as the capability to accommodate the sudden change of the load induced by the variable geological conditions during excavation.Owing to the different requirements of the compliant tasks,the existing methods in the robotic field cannot be utilized in the analysis and design of the mechanical system of shield tunneling machines.In this paper,based on the stiffness of the mechanical system and the equivalent contact stiffness of the tunnel face,the tunneling interface-matching index(IMI) is proposed to evaluate the compliance of the machine.The IMI is defined as a metric to describe the coincidence of the stiffness curves of the mechanical system and the tunnel face.Moreover,a tunneling case is investigated in the paper as an example to expound the validation of IMI and the analytical process.In conclusion,the IMI presented here can be served as an appraisement of the capability in conforming to the load fluctuation,and give instructions for the design of the thrust system of shield tunneling machines.

Heat Treatment Properties of 42CrMo Steel for Bearing Ring of Varisized Shield Tunneling Machine

The heat treatment properties of 42CrMo steel for bearing ring of varisized shield tunneling machine were investigated by optical microscope （OM）, scanning electron microscope （SEM）, transmission electron microscope （TEM）, and impact tests. The addition of 0.03 wt% C into 42CrMo steel can increase the hardness. But it reduces the impact energy by 46 J because of the appearance of coarser carbides in the matrix and the carbides along the austenite grain boundary. The addition of 0.40 wt% Mn into 42CrMo steel can improve hardenability. However, the toughness of steel is also reduced by 26 J mainly because of the coarsening of carbides and the strengthening of matrix. Both hardenability and toughness of 42CrMo steel can be improved by adding 1.49 wt% Ni and reducing 0.32 wt% Cr. The depth of hardening layer can be raised to 45 mm, and the impact energy at -20 ℃ is 120 J. Thus, it is concluded that a good combination of hardness, hardenability, and toughness of 42CrMo steel can be achieved by alloying with adding some content of C and Ni. Detailed content of C and Ni should be on the requirements of heat treatment properties of steel for bearing ring of varisized shield tunneling machine.

Method to avoid the structural interference of the thrust system of a shield tunneling machine

Several malfunctions of the shield tunneling machine （STM） caused by structural interference have been encountered in actual tunnel excavation. This paper is focusing on providing an effective method to avoid the structural interference based on making the reachable and the required workspaces of the thrust system match each other. The main structure of the thrust mechanism is analyzed, and coordinate systems are built up to describe the pose and workspace of the thrust mechanism. Constraint conditions are derived and the formulation of each constraint condition is carried out to facilitate the analysis of the reachable workspace of the thrust mechanism. Meanwhile, a reachable workspace determination algorithm is introduced based on interval analysis method. The mathematical model for determining the required workspace of the thrust mechanism is presented based on the analysis of the process when the STM excavates along a specific tunnel axis. Two applications are included to show how to avoid these problems by choosing reasonable parameters of the designed tunnel axis and the key structural parameters of the thrust mechanism based on workspace matching.

Load-sharing Characteristic of Multiple Pinions Driving in Tunneling Boring Machine

The failure of the key parts, such as gears, in cutter head driving system of tunneling boring machine has not been properly solved under the interaction of driving motors asynchronously and wave tunneling torque load. A dynamic model of multi-gear driving system is established considering the inertia effects of driving mechanism and cutter head as well as the bending-torsional coupling. By taking into account the nonlinear coupling factors between ring gear and multiple pinions, the influence for meshing angle by bending-torsional coupling and the dynamic load-sharing characteristic of multiple pinions driving are analyzed. Load-sharing coefficients at different rotating cutter head speeds and input torques are presented. Numerical results indicate that the load-sharing coefficients can reach up to 1.2-1.3. A simulated experimental platform of the multiple pinions driving is carried out and the torque distributions under the step load in driving shaft of pinions are measured. The imbalance of torque distribution of pinions is verified and the load-sharing coefficients in each pinion can reach 1.262. The results of simulation and test are similar, which shows the correctness of theoretical model. A loop coupling control method is put forward based on current torque master slave control method. The imbalance of the multiple pinions driving in cutter head driving system of tunneling boring machine can be greatly decreased and the load-sharing coefficients can be reduced to 1.051 by using the loop coupling control method. The proposed research provides an effective solution to the imbalance of torque distribution and synchronous control method for multiple pinions driving of TBM.

Real-time rock mass condition prediction with TBM tunneling big data using a novel rock-machine mutual feedback perception method

Real-time perception of rock mass information is of great importance to efficient tunneling and hazard prevention in tunnel boring machines(TBMs).In this study,a TBM-rock mutual feedback perception method based on data mining(DM) is proposed,which takes 10 tunneling parameters related to surrounding rock conditions as input features.For implementation,first,the database of TBM tunneling parameters was established,in which 10,807 tunneling cycles from the Songhua River water conveyance tunnel were accommodated.Then,the spectral clustering(SC) algorithm based on graph theory was introduced to cluster the TBM tunneling data.According to the clustering results and rock mass boreability index,the rock mass conditions were classified into four classes,and the reasonable distribution intervals of the main tunneling parameters corresponding to each class were presented.Meanwhile,based on the deep neural network(DNN),the real-time prediction model regarding different rock conditions was established.Finally,the rationality and adaptability of the proposed method were validated via analyzing the tunneling specific energy,feature importance,and training dataset size.The proposed TBM-rock mutual feedback perception method enables the automatic identification of rock mass conditions and the dynamic adjustment of tunneling parameters during TBM driving.Furthermore,in terms of the prediction performance,the method can predict the rock mass conditions ahead of the tunnel face in real time more accurately than the traditional machine learning prediction methods.

Vibrations induced by tunnel boring machine in urban areas: In situ measurements and methodology of analysis

Excavation with tunnel boring machine(TBM)can generate vibrations,causing damages to neighbouring buildings and disturbing the residents or the equipment.This problem is particularly challenging in urban areas,where TBMs are increasingly large in diameter and shallow in depth.In response to this problem,four experimental campaigns were carried out in different geotechnical contexts in France.The vibration measurements were acquired on the surface and inside the TBMs.These measurements are also complemented by few data in the literature.An original methodology of signal processing is pro-posed to characterize the amplitude of the particle velocities,as well as the frequency content of the signals to highlight the most energetic bands.The levels of vibrations are also compared with the thresholds existing in various European regulations concerning the impact on neighbouring structures and the disturbance to local residents.

Soft ground tunnel lithology classification using clustering-guided light gradient boosting machine

During tunnel boring machine(TBM)excavation,lithology identification is an important issue to understand tunnelling performance and avoid time-consuming excavation.However,site investigation generally lacks ground samples and the information is subjective,heterogeneous,and imbalanced due to mixed ground conditions.In this study,an unsupervised(K-means)and synthetic minority oversampling technique(SMOTE)-guided light-gradient boosting machine(LightGBM)classifier is proposed to identify the soft ground tunnel classification and determine the imbalanced issue of tunnelling data.During the tunnel excavation,an earth pressure balance(EPB)TBM recorded 18 different operational parameters along with the three main tunnel lithologies.The proposed model is applied using Python low-code PyCaret library.Next,four decision tree-based classifiers were obtained in a short time period with automatic hyperparameter tuning to determine the best model for clustering-guided SMOTE application.In addition,the Shapley additive explanation(SHAP)was implemented to avoid the model black box problem.The proposed model was evaluated using different metrics such as accuracy,F1 score,precision,recall,and receiver operating characteristics(ROC)curve to obtain a reasonable outcome for the minority class.It shows that the proposed model can provide significant tunnel lithology identification based on the operational parameters of EPB-TBM.The proposed method can be applied to heterogeneous tunnel formations with several TBM operational parameters to describe the tunnel lithologies for efficient tunnelling.

开挖补偿法防控深部地下岩爆灾害——引汉济渭工程秦岭输水隧洞案例分析

Rockburst disasters occur frequently during deep underground excavation,yet traditional concepts and methods can hardly meet the requirements for support under high geo-stress conditions.Consequently,rockburst control remains challenging in the engineering field.In this study,the mechanism of excavation-induced rockburst was briefly described,and it was proposed to apply the excavation compensation method(ECM)to rockburst control.Moreover,a field test was carried out on the Qinling Water Conveyance Tunnel.The following beneficial findings were obtained:Excavation leads to changes in the engineering stress state of surrounding rock and results in the generation of excess energy DE,which is the fundamental cause of rockburst.The ECM,which aims to offset the deep excavation effect and lower the risk of rockburst,is an active support strategy based on high pre-stress compensation.The new negative Poisson’s ratio(NPR)bolt developed has the mechanical characteristics of high strength,high toughness,and impact resistance,serving as the material basis for the ECM.The field test results reveal that the ECM and the NPR bolt succeed in controlling rockburst disasters effectively.The research results are expected to provide guidance for rockburst support in deep underground projects such as Sichuan-Xizang Railway.

An Optimized System of Random Forest Model by Global Harmony Search with Generalized Opposition-Based Learning for Forecasting TBM Advance Rate

As massive underground projects have become popular in dense urban cities,a problem has arisen:which model predicts the best for Tunnel Boring Machine(TBM)performance in these tunneling projects?However,performance level of TBMs in complex geological conditions is still a great challenge for practitioners and researchers.On the other hand,a reliable and accurate prediction of TBM performance is essential to planning an applicable tunnel construction schedule.The performance of TBM is very difficult to estimate due to various geotechnical and geological factors and machine specifications.The previously-proposed intelligent techniques in this field are mostly based on a single or base model with a low level of accuracy.Hence,this study aims to introduce a hybrid randomforest(RF)technique optimized by global harmony search with generalized oppositionbased learning(GOGHS)for forecasting TBM advance rate(AR).Optimizing the RF hyper-parameters in terms of,e.g.,tree number and maximum tree depth is the main objective of using the GOGHS-RF model.In the modelling of this study,a comprehensive databasewith themost influential parameters onTBMtogetherwithTBM AR were used as input and output variables,respectively.To examine the capability and power of the GOGHSRF model,three more hybrid models of particle swarm optimization-RF,genetic algorithm-RF and artificial bee colony-RF were also constructed to forecast TBM AR.Evaluation of the developed models was performed by calculating several performance indices,including determination coefficient(R2),root-mean-square-error(RMSE),and mean-absolute-percentage-error(MAPE).The results showed that theGOGHS-RF is a more accurate technique for estimatingTBMAR compared to the other applied models.The newly-developedGOGHS-RFmodel enjoyed R2=0.9937 and 0.9844,respectively,for train and test stages,which are higher than a pre-developed RF.Also,the importance of the input parameters was interpreted through the SHapley Additive exPlanations(SHAP)method,and it was found that thrust force per cutter is the most important variable on TBMAR.The GOGHS-RF model can be used in mechanized tunnel projects for predicting and checking performance.

A performance-based hybrid deep learning model for predicting TBM advance rate using Attention-ResNet-LSTM

The technology of tunnel boring machine(TBM)has been widely applied for underground construction worldwide;however,how to ensure the TBM tunneling process safe and efficient remains a major concern.Advance rate is a key parameter of TBM operation and reflects the TBM-ground interaction,for which a reliable prediction helps optimize the TBM performance.Here,we develop a hybrid neural network model,called Attention-ResNet-LSTM,for accurate prediction of the TBM advance rate.A database including geological properties and TBM operational parameters from the Yangtze River Natural Gas Pipeline Project is used to train and test this deep learning model.The evolutionary polynomial regression method is adopted to aid the selection of input parameters.The results of numerical exper-iments show that our Attention-ResNet-LSTM model outperforms other commonly-used intelligent models with a lower root mean square error and a lower mean absolute percentage error.Further,parametric analyses are conducted to explore the effects of the sequence length of historical data and the model architecture on the prediction accuracy.A correlation analysis between the input and output parameters is also implemented to provide guidance for adjusting relevant TBM operational parameters.The performance of our hybrid intelligent model is demonstrated in a case study of TBM tunneling through a complex ground with variable strata.Finally,data collected from the Baimang River Tunnel Project in Shenzhen of China are used to further test the generalization of our model.The results indicate that,compared to the conventional ResNet-LSTM model,our model has a better predictive capability for scenarios with unknown datasets due to its self-adaptive characteristic.

TBM tunneling in extremely hard and abrasive rocks:Problems,solutions and assisting methods

Extremely hard and abrasive rocks pose great challenges to the past and ongoing TBM projects by increasing cutter wear and reducing penetration rates.A considerable amount of research has been conducted to improve the performance of TBMs in those challenging grounds by either improving the capacity of TBMs or developing assisting rock breakage methods.This paper first highlights the challenges of hard and abrasive rocks on TBM tunneling through case studies.It then presents the development of hard rock TBMs and reviews the technologies that can be used individually or as assistance to mechanical excavators to break hard rocks.Emphases are placed on technologies of high pressure waterjet,laser and microwave.The state of the art of field and laboratory research,problems and research directions of those technologies are discussed.The assisting methods are technically feasible;however,the main challenges of using those methods in the field are that the energy consumption can be over 10 times high and that the existing equipments have robustness problems.More research should be conducted to study the overall energy consumption using TBMs and the assisting methods.Pulsed waterjet,laser and microwave technologies should also be developed to make the assistance economically viable.

Design Theory of Full Face Rock Tunnel Boring Machine Transition Cutter Edge Angle and Its Application

At present, the inner cutters of a full face rock tunnel boring machine (TBM) and transition cutter edge angles are designed on the basis of indentation test or linear grooving test. The inner and outer edge angles of disc cutters are characterized as symmetric to each other with respect to the cutter edge plane. This design has some practical defects, such as severe eccentric wear and tipping, etc. In this paper, the current design theory of disc cutter edge angle is analyzed, and the characteristics of the rock-breaking movement of disc cutters are studied. The researching results show that the rotational motion of disc cutters with the cutterhead gives rise to the difference between the interactions of inner rock and outer rock with the contact area of disc cutters, with shearing and extrusion on the inner rock and attrition on the outer rock. The wear of disc cutters at the contact area is unbalanced, among which the wear in the largest normal stress area is most apparent. Therefore, a three-dimensional model theory of rock breaking and an edge angle design theory of transition disc cutter are proposed to overcome the flaws of the currently used TBM cutter heads, such as short life span, camber wearing, tipping. And a corresponding equation is established. With reference to a specific construction case, the edge angle of the transition disc cutter has been designed based on the theory. The application of TBM in some practical project proves that the theory has obvious advantages in enhancing disc cutter life, decreasing replacement frequency, and making economic benefits. The proposed research provides a theoretical basis for the design of TBM three-dimensional disc cutters whose rock-breaking operation time can be effectively increased.

Wear Analysis of Disc Cutters of Full Face Rock Tunnel Boring Machine

Wear is a major factor of disc cutters’ failure. No current theory offers a standard for the prediction of disc cutter wear yet. In the field the wear prediction method commonly used is based on the excavation length of tunnel boring machine（TBM） to predict the disc cutter wear and its wear law, considering the location number of each disc cutter on the cutterhead（radius for installation）; in theory, there is a prediction method of using arc wear coefficient. However, the preceding two methods have their own errors, with their accuracy being 40% or so and largely relying on the technicians’ experience. Therefore, radial wear coefficient, axial wear coefficient and trajectory wear coefficient are defined on the basis of the operating characteristics of TBM. With reference to the installation and characteristics of disc cutters, those coefficients are modified according to penetration, which gives rise to the presentation of comprehensive axial wear coefficient, comprehensive radial wear coefficient and comprehensive trajectory wear coefficient. Calculation and determination of wear coefficients are made with consideration of data from a segment of TBM project（excavation length 173 m）. The resulting wear coefficient values, after modification, are adopted to predict the disc cutter wear in the follow-up segment of the TBM project（excavation length of 5621 m）. The prediction results show that the disc cutter wear predicted with comprehensive radial wear coefficient and comprehensive trajectory wear coefficient are not only accurate（accuracy 16.12%） but also highly congruous, whereas there is a larger deviation in the prediction with comprehensive axial wear coefficient（accuracy 41%, which is in agreement with the prediction of disc cutters’ life in the field）. This paper puts forth a new method concerning prediction of life span and wear of TBM disc cutters as well as timing for replacing disc cutters.

Excavation of underground research laboratory ramp in granite using tunnel boring machine: Feasibility study

Underground research laboratory(URL)plays an important role in safe disposal of high-level radioactive waste(HLW).At present,the Xinchang site,located in Gansu Province of China,has been selected as the final site for China’s first URL,named Beishan URL.For this,a preliminary design of the Beishan URL has been proposed,including one spiral ramp,three shafts and two experimental levels.With advantages of fast advancing and limited disturbance to surrounding rock mass,the tunnel boring machine(TBM)method could be one of the excavation methods considered for the URL ramp.This paper introduces the feasibility study on using TBM to excavation of the Beishan URL ramp.The technical challenges for using TBM in Beishan URL are identified on the base of geological condition and specific layout of the spiral ramp.Then,the technical feasibility study on the specific issues,i.e.extremely hard rock mass,high abrasiveness,TBM operation,muck transportation,water drainage and material transportation,is investigated.This study demonstrates that TBM technology is a feasible method for the Beishan URL excavation.The results can also provide a reference for the design and construction of HLW disposal engineering in similar geological conditions.2020 Institute of Rock and Soil Mechanics,Chinese Academy of Sciences.Production and hosting by Elsevier B.V.This is an open access article under the CC BY-NC-ND license(http://creativecommons.org/licenses/by-nc-nd/4.0/).

Hybrid ensemble soft computing approach for predicting penetration rate of tunnel boring machine in a rock environment

This study implements a hybrid ensemble machine learning method for forecasting the rate of penetration(ROP) of tunnel boring machine(TBM),which is becoming a prerequisite for reliable cost assessment and project scheduling in tunnelling and underground projects in a rock environment.For this purpose,a sum of 185 datasets was collected from the literature and used to predict the ROP of TBM.Initially,the main dataset was utilised to construct and validate four conventional soft computing(CSC)models,i.e.minimax probability machine regression,relevance vector machine,extreme learning machine,and functional network.Consequently,the estimated outputs of CSC models were united and trained using an artificial neural network(ANN) to construct a hybrid ensemble model(HENSM).The outcomes of the proposed HENSM are superior to other CSC models employed in this study.Based on the experimental results(training RMSE=0.0283 and testing RMSE=0.0418),the newly proposed HENSM is potential to assist engineers in predicting ROP of TBM in the design phase of tunnelling and underground projects.