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To address issues such as poor real-time performance and high manual inspection costs in monitoring the wear of TBM disc cutters, this study designed and developed a wireless monitoring system based on eddy current sensors. The system utilizes the ZigBee communication protocol for data transmission and storage, and integrates with upper computer software to achieve human-computer interaction functions. Firstly, an eddy current measurement theoretical model for disc cutter wear was established, and the excitation frequency of the eddy current sensor was optimized through finite element simulation. Subsequently, hardware and software designs were completed, and sensor calibration was performed to ensure the measurement accuracy of the monitoring system. During experimental verification, uniform wear experiments and chordal wear experiments were conducted. The results showed that the system's relative error under long-term monitoring was only 4.06%, and it successfully identified chordal wear signal characteristics, verifying the effectiveness and reliability of the monitoring system. This study provides an efficient and accurate solution for real-time monitoring of TBM disc cutter wear, contributing to the improvement of TBM construction intelligence and engineering safety.

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An Optimized Wireless Monitoring System Design for TBM Cutter Wear Detection

  • 会议论文

  • 发表日期：

    2026年

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  • Simian Yang,
  • Songyong Liu,
  • Wenjie Bao,
  • Yan Wang,
  • Haibin Chen,
  • Congcong Gu,
  • Hongxiang Jiang

摘要

To address issues such as poor real-time performance and high manual inspection costs in monitoring the wear of TBM disc cutters, this study designed and developed a wireless monitoring system based on eddy current sensors. The system utilizes the ZigBee communication protocol for data transmission and storage, and integrates with upper computer software to achieve human-computer interaction functions. Firstly, an eddy current measurement theoretical model for disc cutter wear was established, and the excitation frequency of the eddy current sensor was optimized through finite element simulation. Subsequently, hardware and software designs were completed, and sensor calibration was performed to ensure the measurement accuracy of the monitoring system. During experimental verification, uniform wear experiments and chordal wear experiments were conducted. The results showed that the system's relative error under long-term monitoring was only 4.06%, and it successfully identified chordal wear signal characteristics, verifying the effectiveness and reliability of the monitoring system. This study provides an efficient and accurate solution for real-time monitoring of TBM disc cutter wear, contributing to the improvement of TBM construction intelligence and engineering safety.