Damage State Recognition and Quantification Method for Shield Machine Hob Based on Deep Forest

The damage status of shield machine disc cutters directly impacts the safety and efficiency of tunnelling projects. Current manual inspection methods involve high risks and low efficiency, while existing detection methods suffer from low accuracy and poor real-time performance in complex environments, often lacking quantitative analysis capabilities. To address these issues, this paper proposes an intelligent identification and quantitative assessment method for disc cutter damage based on the Deep Forest (DF) model. First, an eddy current sensor calibration platform was established, and a mapping relationship between output voltage and actual wear was developed through piecewise fitting to achieve precise wear quantification. In the data preprocessing stage, signal quality was improved via filtering, and typical damage features such as edge chipping, cracks, and eccentric wear were extracted using pulse edge detection. These feature segments were then resampled to construct the model training dataset. The DF model utilizes a hierarchical ensemble structure to mine data correlations, enabling accurate identification of four states: normal, edge chipping, eccentric wear, and cracks. Simultaneously, a DF regression model was employed to provide continuous quantitative predictions of damage size. Experimental results show that the classification model achieved accuracies of 98%, 96%, and 96% on the training, validation, and test sets, respectively, with weighted average F1-scores exceeding 0.96. The regression model achieved a coefficient of determination (R²) of 0.9940 and a root mean square error (RMSE) of 0.4051 on the test set. Both models demonstrate excellent performance and generalization, achieving full coverage from "qualitative state identification" to "quantitative wear assessment," thereby providing reliable decision support for cutter maintenance and replacement.