Segment assembly is one of the principal processes during tunnel construction using a tunnel boring machine (TBM). The segment erector is a robotic manipulator powered by a hydraulic system that assembles prefabricated concrete segments onto the excavated tunnel surface. In the case of a larger diameter, while the segment assembly has a more extensive range of motion, it also demands more control accuracy. However, the single-pump-based hydraulic system fails to meet the dual requirements. Therefore, this paper proposes a novel dual parallel-connected-pump hydraulic system consisting of a small displacement pump and a large displacement pump. On this basis, taking advantage of both the quick response and low dead zone of the small pump and the high flow range of the large pump, a two-level error allocation strategy is constructed to coordinate the two pumps and keep the motion error of segment assembly within a small range. Finally, comparative experiments were conducted, and the results show that the proposed scheme achieves the simultaneous high-level synchronization of the two pumps and high-precision and high-speed motion-tracking performance.

Tunnel boring machine (TBM) hydraulic cylinders operate under pronounced start–stop shocks and load uncertainties, making it difficult to simultaneously achieve smooth start-up and high-precision tracking. This paper proposes a two-phase switching adaptive sliding mode control (ASMC) strategy for TBM hydraulic actuation. Phase I targets a soft start by introducing smooth gating and a ramped start-up mechanism into the sliding surface and equivalent control, thereby suppressing pressure spikes and displacement overshoot induced by oil compressibility and load transients. Phase II targets precise tracking, combining adaptive laws with a forgetting factor design to maintain robustness while reducing chattering and steady-state error. We construct a state-space model that incorporates oil compressibility, internal/external leakage, and pump/valve dynamics, and provide a Lyapunov-based stability analysis proving bounded stability and error convergence under external disturbances. Comparative simulations under representative TBM conditions show that, relative to conventional PID Controller and single ASMC Controller, the proposed method markedly reduces start-up pressure/velocity peaks, overshoot, and settling time, while preserving tracking accuracy and robustness over wide load variations. The results indicate that the strategy can achieve the unity of smooth start and high-precision trajectory of TBM hydraulic cylinder without additional sensing configuration, offering a practical path for high-performance control of TBM hydraulic actuators in complex operating environments.

The thrust system, an important subsystem of a tunnel boring machine (TBM), primarily provides thrust force and adjusts TBM’s attitude in real time. In the tunneling process, only controlling the thrust speed causes pressure oscillations, increases soil deformation, and leads to surface subsidence or upheaval. Conversely, solely relying on pressure control causes fluctuations in speed, making it difficult to ensure that the deviation between the designed tunneling axis (DTA) and the actual tunneling axis (ATA) remains within the permissible range. Due to the increase in geological complexity and higher construction quality standards, primarily relying on single-mode speed or pressure control has become inadequate to meet operational demands. Therefore, to realize higher safety and precise trajectory tracking, it is necessary to ensure speed and pressure compound control for thrust systems. This paper proposes a novel adaptive sliding mode control (ASMC) strategy for thrust systems, which is composed of a proportional pressure relief valve (PPRV) and a proportional flow control valve (PFCV). Firstly, PPRV and PFCV are modeled as a second-order system and an ASMC is employed to control the pressure and speed. Next, to assess the performance of the ASMC controller, simulation experiments were conducted under various conditions, including speed regulation, sudden changed load, and disturbed load. The simulation results indicate that compared to the Proportion–Integral–Differential (PID) controller, the ASMC controller shows almost no overshoot in speed and pressure control during the initial stages, with the response time reduced by approximately 70%. During speed regulation process and sudden changed load process, the response time for both speed and pressure control is shortened by about 80%. In the disturbed load process, the ASMC controller maintains pressure stability. In conclusion, the ASMC controller significantly improves the response speed and stability of the thrust system, exhibiting better control performance under various operating conditions.

Hydraulic thrust cylinders in hard-rock tunnel boring machines (TBMs) often exhibit slow response and sluggish acceleration during start-up, which degrades early-stage tracking performance and limits overall operational accuracy. Most existing studies primarily enhance start-up behavior through advanced control algorithms, yet the achievable improvement is ultimately constrained by the system’s flow–pressure capacity. Meanwhile, reported system-level optimization approaches are either difficult to implement under practical TBM operating conditions or fail to consistently deliver high-accuracy tracking. To address these limitations, this paper proposes a “dual-pump–single-cylinder” control framework for the TBM thrust system, where a large-displacement pump serves as the main supply and a parallel small-displacement pump provides auxiliary flow compensation to mitigate the start-up flow deficit. Building on this architecture, an adaptive compensation algorithm is developed for the auxiliary pump, with its output updated online according to the system’s dynamic states, including displacement error and velocity-related error components. Comparative simulations and test-bench experiments show that, compared with a single-pump scheme, the proposed method notably accelerates cylinder start-up while effectively suppressing overshoot and oscillations, thereby improving both transient smoothness and tracking accuracy. This study provides a feasible and engineering-oriented solution for achieving “rapid and smooth start-up” of TBM hydraulic cylinders.