Development and in-situ application of a real-time cutting tool forces monitoring system in TBM tunnelling

Abstract

In order to determine the operational status of tunnel boring machines (TBMs), a real-time cutting tool force monitoring system is established based on the proposed cutting tool force measurement and calculation method. The monitoring system is composed of strain sensors, a data acquisition module, a data transmission module, and a data analysis module. The sensor layout and the complete monitoring system operating principle are presented. A dynamic rotary rock cutting test was carried out to verify the effectiveness of the proposed cutting tool force measurement method and corresponding monitoring system. Finally, the monitoring system was applied to the ‘Colorful Clouds’-named TBM in the Gaoligongshan Tunnel (China). This monitoring system can provide continuous power supply, unattended automatic operation, and monitor error information feedback, thereby realizing real-time monitoring, remote control, and data sharing. The field monitoring results show that the cutter's maximum peak normal force and maximum peak side force appear every few seconds. Every two normal force peaks mark a complete penetration process. The maximum and minimum normal force peaks are approximately 800 kN and 50 kN, respectively, and the maximum normal force peak is approximately 6–7 times the peak side force. The normal force frequency indicates that the cutter's normal force is concentrated from 0 to 300 kN, accounting for approximately 95% of the overall proportion.