Real-Time Multi-Step Prediction Method of TBM Cutterhead Torque Based on Fusion Signal Decomposition Mechanism and Physical Constraints

The cutterhead torque of a full-face tunnel boring machine (TBM) is a pivotal parameter that characterises the rock-machine interaction. Its dynamic prediction is of considerable significance to achieve intelligent regulation of the boring parameters and enhance the construction efficiency and safety. In order to achieve high-precision time series prediction of cutterhead torque under complex geological conditions, this study proposes an intelligent prediction method (VBGAP) that integrates signal decomposition mechanism and physical constraints. At the data preprocessing level, a multi-step data cleaning process is designed. This process comprises the following steps: the processing of invalid values, the detection of outliers, and normalisation. The non-smooth torque time-series signal is decomposed by variational mode decomposition (VMD) into narrow-band sub-signals that serve as a data-driven, frequency-specific input for subsequent modelling, and a hybrid deep learning model based on Bi-GRU and self-attention mechanism is built for each sub-signal. Finally, the prediction results of each component are linearly superimposed to achieve signal reconstruction. Concurrently, a novel modal energy conservation loss function is proposed, with the objective of effectively constraining the information entropy decay in the decomposition-reconstruction process. The validity of the proposed method is supported by empirical evidence from a real tunnel project dataset in Northeast China, which demonstrates an average accuracy of over 90% in a multi-step prediction task with a time step of 30 s. This suggests that the proposed method exhibits superior adaptability and prediction accuracy in comparison to existing mainstream deep learning models. The findings of the research provide novel concepts and methodologies for the intelligent regulation of TBM boring parameters.