China develops ‘brain’ for tunneling machine

The new operating system was designed by experts at Hunan University in cooperation with China Railway Construction Heavy Industry Company. The research team on January 25 commented that this is an important step forward in automating tunnel construction and preventing risks.

Tunnel boring machines (TBMs) are giant pieces of equipment essential for the underground tunnel construction process. Unlike machines that operate on the ground, TBMs are in direct contact with surrounding soil and rock when operating, so they are very sensitive to geological conditions. In complex environments, humans often have difficulty adjusting machine settings. This can lead to dangerous situations such as ground collapse, excessive subsidence, and even loss of equipment control.

To solve the challenge, Professor Chen Renpeng from Hunan University and his colleagues developed an operating system that helps tunneling machines “read” the ground, predict risks and make precise adjustments on their own. The system acts as a real-time monitor during the tunnel construction process. It continuously collects data from the TBM’s sensors, analyzes geological conditions and automatically recommends optimal digging parameters.

“With this ‘smart brain’, we can accurately predict ground settlement and the machine’s posture, helping to avoid risks such as surface collapse. It also warns when the machine is at risk of getting stuck and makes smart decisions so that the tunneling process goes smoothly and effectively,” said Professor Zhang Chao, a member of the research team.

The new operating system was deployed on an ultra-large diameter TBM in a Shanghai subway project and showed impressive results. According to the research team, the support system makes operating decisions with over 90% accuracy, while keeping tunneling deviation within 30 mm, far exceeding the accuracy of manual control. In another project in Guangzhou, the system helped increase error diagnosis and maintenance efficiency by 20%, increase equipment utilization efficiency by 12% and increase monthly progress by 5%.

The China Road and Transport Association evaluates this as an important technology to promote the development of the industry. Professor Chen said that the research team will continue to perfect the technology and expand its application to more complex projects, including river crossing tunnels and undersea tunnels, supporting underground infrastructure in China to develop safer and smarter.