Technology for a new generation of tunnel boring machines

The challenge is clear: a 30-metre-long tunnel has to be bored with the utmost precision in the shortest possible time. Felix Blanke, a computer science student at the Technical University of Munich, adds: “At the same time, we have to use innovative machine technology to set ourselves apart from the competition.” To achieve this goal, the students also rely on solutions from Balluff.

A key factor for the success of the project is the seamless networking of the individual machine components. IO-Link offers an optimal solution here. This is realized by Balluff components, the IO-Link masters and data cables. 

Communication between the above-ground control system and the sensors and actuators below ground is realized with just a single data cable. “Thanks to IO-Link, we save a considerable amount of wiring work,” explains Jens Zaigler, electrical engineering student at the Technical University of Munich. “As our master can communicate with the same bus system as our frequency inverters, we only need a single data cable from the power pipe to the machine.” 

Thanks to the high resistance of the BNI IO-Link master modules, they are ideal for use in tunnel boring machines. They enable reliable data acquisition and control, even under extreme conditions. In addition, the Balluff Engineering Tool (BET) ensures simple integration and quick adjustments during operation. 

Another advantage is the ability to record error messages and system statuses in real time. This reduces maintenance times and significantly increases the efficiency of the machine. If a component fails, it can be quickly identified and replaced using the Balluff Engineering Tool without having to dismantle the entire machine.

Test phases and preparation for the competition

The intensive development work culminated in comprehensive drilling tests on the TUM campus in Garching. Not only were the individual systems of the new tunnel boring machine tested, but special ground conditions similar to those in Texas were also simulated.

The TU Munich team has been in Texas since the beginning of March, where the final preparations for the competition are taking place. The machine is being finally assembled, final training sessions are being carried out and the control systems are being optimized.

Balluff as a long-term partner for innovations

Balluff regularly supports student projects and innovative research approaches. As a technology leader in the field of industrial automation, it is important to the company to promote young talent and contribute to the further development of new technologies through practical solutions.