Method for producing UHPC (Ultra High Performance Concrete) concrete floating body section of floating type wind turbine generator foundation

Abstract

The invention discloses a method for producing UHPC (Ultra High Performance Concrete) floating body sections of a floating type wind turbine generator foundation, which adopts a prefabricated part independent prefabricating production process and produces a plurality of floating body sections according to an interval production mode. And when the independent prefabrication production process of the prefabricated parts is carried out, every two adjacent floating body sections in the produced floating body sections are used as matched sections, and the other floating body sections are produced by adopting a sandwich matching prefabrication production process, so that the production of all the floating body sections is completed. On the premise that the flatness of the end faces of the floating body sections is guaranteed, the whole floating body construction working face can be increased, and the production cycle of all the floating body sections is effectively shortened.

Description

Technical Field

[0001] The invention relates to the technical field of a floating wind turbine foundation buoy, and in particular to a method for producing a UHPC concrete buoy segment of a floating wind turbine foundation. Background Art

[0002] The floating wind turbine foundation ultra-high performance concrete (Uhpc) buoy segment is the structural unit of the floating foundation buoy. Its prefabrication production method is similar to the prefabrication production of segmental beams in bridge engineering. The segmental beam production is divided into two matching methods: short-line matching production and long-line matching production.

[0003] Long-line conventional beams are prefabricated pedestals with the same length as the span. After the bottom formwork on the pedestal is installed, it is generally not adjusted (or adjusted span by span to make it consistent with the prefabricated line shape). Its line shape is the prefabricated line shape of the bridge segment, which takes into account the bridge design line shape and the pre-camber set for construction, deadweight, shrinkage creep and other factors. The side formwork moves on both sides of the pedestal with the manufactured segment. When pouring the next segment, the rear end face of the previous segment serves as the front end formwork of the next segment, and the prefabricated bridge segments are matched on the pedestal piece by piece.

[0004] The short-line method is a method for prefabricating bridge segments on a limited site. This method divides the beam into several segments and uses a set of formwork (one end of which is a fixed end formwork) to prefabricate the segments. Prefabrication starts from the first segment. The first segment is cast between the fixed end formwork and the movable end formwork, and then the segment is moved forward as a matching beam (acting as a movable end formwork) to cast the second segment, which can ensure the matching quality between adjacent segments. Repeat the above process, move the i-th segment forward to cast the i+1-th segment, until all segments are prefabricated.

[0005] However, the end face size of the floating body segment of the floating wind turbine foundation is particularly large (greater than 12m×6m) and the wall thickness is relatively thin (about 0.3m). An annular waterproof sealing groove is arranged on the end face. During assembly, an annular waterproof sealing gasket is installed in the groove to seal and prevent seepage at the joints between the segments. Due to the huge size and thin-walled structure of the end face, good sealing effect is required between the joints after the segment splicing is completed, which makes the end face flatness requirement extremely high; in addition, whether it is the long-line method or the short-line method, there is only one prefabrication production working surface for the entire span floating body, resulting in a long production cycle for the entire span floating body. Summary of the invention

[0006] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a method for producing UHPC concrete buoy segments for the foundation of a floating wind turbine generator set, which can increase the construction working surface of the entire buoy while ensuring the flatness of the end faces of the buoy segments, and effectively shorten the production cycle of all buoy segments.

[0007] The purpose of the present invention is achieved through the following technical solutions: A method for producing UHPC concrete buoy segments of a floating wind turbine foundation, the method adopts an independent prefabrication production process for prefabricated components and produces a plurality of buoy segments in an interval production mode, while the independent prefabrication production process for prefabricated components is being carried out, two adjacent buoy segments among the produced buoy segments are used as matching segments, and a sandwich matching prefabrication production process is adopted to produce the remaining buoy segments, thereby completing the production of all buoy segments.

[0008] Furthermore, for a total of an odd number of 2n+1 floating body segments, the 1st, 3rd, 5th..., 2n-1th and 2n+1th floating body segments are produced by an independent prefabrication production process of prefabricated components, and the adjacent floating body segments among the produced 1st, 3rd, 5th..., 2n-1th and 2n+1th floating body segments are used as matching segments, and the remaining floating body segments are produced by a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

[0009] Furthermore, for a total of an even number of 2n floating body segments, the 1st, 3rd, 5th..., 2n-3rd and 2n floating body segments are produced by an independent prefabrication production process of prefabricated components, and the adjacent floating body segments among the produced 1st, 3rd, 5th..., 2n-3rd and 2n floating body segments are used as matching segments, and the remaining floating body segments are produced by a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

[0010] Furthermore, the prefabricated component independent prefabrication production process comprises the steps of: S1.1. Cast an independent prefabricated pedestal on the ground; S1.2. Lay the first bottom mold of a single floating body segment on an independent prefabricated pedestal and level it; S1.3, setting a first fixed end mold at one end of the first bottom mold and adjusting the end surface flatness; S1.4, tie the steel bar skeleton into shape as a whole, and hoist it onto the first bottom form; S1.5. Arrange a first movable end mold at the other end of the first bottom mold and adjust the end surface flatness; S1.6. Install the first outer mold, fix the prestressed corrugated pipe to the first movable end mold and the steel frame, and close the installed first outer mold and the first movable end mold; S1.7, operate the first hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment to be prefabricated, adjust the axis position, and open the first hydraulic inner mold; S1.8, pouring concrete with the cooperation of the first bottom mold, the first fixed end mold, the first movable end mold, the first outer mold and the first hydraulic inner mold to obtain an independently prefabricated floating body segment; S1.9, maintaining the floating body segment obtained by independent prefabrication, and dismantling the first movable end mold, the first outer mold and the first hydraulic inner mold; S1.10. A plurality of control points for matching segment reset adjustment are set on the top plate of the floating body segment; S1.11. Hoist and store the floating body segments, and execute steps S1.4 to S1.10 repeatedly until the independent prefabrication of other floating body segments is completed.

[0011] Furthermore, a steel truss is provided on the rear side of the first movable end mold, and a plurality of adjusting screw rods are connected between the steel truss and the first movable end mold, and the end surface flatness of the first movable end mold can be adjusted by adjusting the length of the adjusting screw rods.

[0012] Furthermore, the multiple control points include two axis control points set by total station in the middle of the top plate of the floating segment, and four elevation control points respectively set at preset positions of the top plate, and the elevations of the four elevation control points are pre-collected using a precision level.

[0013] Further, the sandwich matching prefabrication production process includes the steps of: S2.1, pouring sandwich matching prefabricated pedestal on the ground; S2.2, lay the second bottom mold on the sandwich matching pedestal and level it; S2.3. Bottom mold trolleys are respectively arranged on both sides of the second bottom mold for resetting and adjusting the matching segments during the sandwich matching prefabrication production process; S2.4. Hoist two adjacent floating body segments as matching segments onto the bottom mold trolley and perform reset adjustment; S2.5, tie the steel bar skeleton into shape as a whole and hoist it onto the second bottom form; S2.6, install the second outer mold, fix the prestressed corrugated pipe on the matching segment and the steel skeleton, and close the mold of the installed second outer mold; S2.7, operate the second hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment to be prefabricated between the two matching segments, adjust the axis position, and open the second hydraulic inner mold; S2.8, pouring concrete with the cooperation of the second bottom mold, the second outer mold and the second hydraulic inner mold to obtain a floating body segment prefabricated by sandwich matching; S2.9, maintain the floating body segment prefabricated by sandwich matching, and remove the second outer mold and the second hydraulic inner mold; S2.10, separate the sandwich-matched prefabricated floating body segments and matching segments, hoist and store them, and repeat steps S2.3 to S2.10 until the sandwich-matched prefabrication production of other floating body segments is completed.

[0014] Furthermore, in step S2.4, two adjacent floating body segments are hoisted onto the bottom mold trolley as matching segments and reset and adjusted, and the axes of the two matching segments and the axis of the second bottom mold of the floating body segment to be prefabricated are adjusted to a straight line through a total station, and according to the elevations of the elevation control points on the two matching segments collected in advance during the independent prefabrication production process of prefabricated components, the two matching segments are adjusted to a horizontal state after casting using the independent prefabrication production process of prefabricated components using a precision level.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects: 1. The present invention adopts the prefabrication of prefabricated components independently combined with the sandwich matching prefabrication production method, which can continuously increase the working surface of prefabrication production, shorten the production cycle of all floating body segments, and greatly improve the progress of prefabrication production.

[0016] 2. In the independent prefabrication production process of prefabricated components, the present invention can well ensure the extremely high flatness requirements of the end faces of the floating body segments by arranging a fixed end mold and a movable end mold with adjustable flatness on an independent prefabrication pedestal, and the independent prefabrication pedestal is flexibly arranged, occupies a small space and has low cost.

[0017] 3. The present invention uses independently prefabricated floating body segments as matching segments and adopts sandwich matching to prefabricate the remaining floating body segments, thereby ensuring smooth assembly lines of the floating body segments while improving the prefabrication production progress. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 Flow chart of the independent prefabrication production process for prefabricated components.

[0019] Figure 2 A schematic diagram for adjusting the flatness of the end face of the first movable end mold.

[0020] Figure 3 Schematic diagram of arranging control points on the top plate.

[0021] Figure 4 Flow chart of the production process for sandwich matching prefabrication.

[0022] Figure 5 This is a schematic diagram of the installation of the second hydraulic inner mold.

[0023] Figure 6 This is a schematic diagram of the structure of the prefabricated floating body segment using sandwich matching. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0025] The present embodiment provides a method for producing UHPC concrete float segments for the foundation of a floating wind turbine. The method adopts an independent prefabrication production process for prefabricated components and produces a plurality of float segments in an interval production mode. While the independent prefabrication production process for prefabricated components is being carried out, two adjacent float segments among the produced float segments are used as matching segments, and the remaining float segments are produced using a sandwich matching prefabrication production process, thereby completing the production of all float segments.

[0026] Specifically, for a total of an odd number of 2n+1 floating body segments, the 1st, 3rd, 5th..., 2n-1th and 2n+1th floating body segments are produced by an independent prefabrication production process of prefabricated components, and the adjacent floating body segments among the produced 1st, 3rd, 5th..., 2n-1th and 2n+1th floating body segments are used as matching segments, and the remaining floating body segments are produced by a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

[0027] For a total of an even number of 2n floating body segments, the 1st, 3rd, 5th..., 2n-3rd and 2n floating body segments are produced by an independent prefabrication production process of prefabricated components, and the adjacent floating body segments among the produced 1st, 3rd, 5th..., 2n-3rd and 2n floating body segments are used as matching segments, and the remaining floating body segments are produced by a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

[0028] like Figure 1 As shown, the independent prefabrication production process of prefabricated components includes the following steps: S1.1. Cast an independent prefabricated pedestal on the ground; S1.2. Lay the first bottom mold of a single floating body segment on an independent prefabricated pedestal and level it; S1.3, setting a first fixed end mold at one end of the first bottom mold and adjusting the end surface flatness; S1.4, tie the steel bar skeleton into shape as a whole, and hoist it onto the first bottom form; S1.5, set a first moving end mold at the other end of the first bottom mold, such as Figure 2As shown, a steel truss 8 is provided at the rear side of the first movable end mold 7, and a plurality of adjusting screw rods 9 are connected between the steel truss 8 and the first movable end mold 7, and the end surface flatness of the first movable end mold can be adjusted by adjusting the length of the adjusting screw rods; S1.6. Install the first outer mold, fix the prestressed corrugated pipe to the first movable end mold and the steel frame, and close the installed first outer mold and the first movable end mold; S1.7, operate the first hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment to be prefabricated, adjust the axis position, and open the first hydraulic inner mold; S1.8, pouring concrete with the cooperation of the first bottom mold, the first fixed end mold, the first movable end mold, the first outer mold and the first hydraulic inner mold to obtain an independently prefabricated floating body segment; S1.9, maintaining the floating body segment obtained by independent prefabrication, and dismantling the first movable end mold, the first outer mold and the first hydraulic inner mold; S1.10, six control points for matching segment reset adjustment are set on the top plate of the floating body segment, wherein the multiple control points include two axis control points 5 set by total station in the middle of the top plate of the floating body segment, and four elevation control points 6 respectively set at preset positions of the top plate, such as Figure 3 As shown, this embodiment can be set at the four corners of the top plate between the two webs, and the elevations of the four elevation control points can be collected in advance using a precision level.

[0029] S1.11. Hoist and store the floating body segments, and execute steps S1.4 to S1.10 repeatedly until the independent prefabrication of other floating body segments is completed.

[0030] like Figures 4 to 5 As shown, the sandwich matching prefabrication production process includes the steps of: S2.1, pouring a sandwich matching prefabricated pedestal 1 on the ground; S2.2, lay the second bottom mold 2 on the sandwich matching pedestal and level it; S2.3. A bottom mold trolley 3 is respectively arranged on both sides of the second bottom mold for resetting and adjusting the matching segments during the sandwich matching prefabrication production process; S2.4. Hoist two adjacent floating body segments as matching segments (such as matching beam 1 and matching beam 3) onto the bottom mold trolley and perform reset adjustment. Specifically, hoist two adjacent floating body segments as matching segments onto the bottom mold trolley and perform reset adjustment. Use a total station to adjust the axes of the two matching segments and the axis of the second bottom mold of the floating body segment to be prefabricated to a straight line. According to the elevations of the elevation control points on the two matching segments collected in advance during the independent prefabrication production process of prefabricated components, use a precision level to adjust the two matching segments to a horizontal state after casting using the independent prefabrication production process of prefabricated components; S2.5, tie the steel bar skeleton into shape as a whole and hoist it onto the second bottom form; S2.6, install the second outer mold, fix the prestressed corrugated pipe on the matching segment and the steel skeleton, and close the mold of the installed second outer mold; S2.7, operate the second hydraulic inner mold 4 to move to the specified position of the inner cavity of the floating body segment to be prefabricated (such as the beam 2 to be cast) between the two matching segments, adjust the axis position, and open the second hydraulic inner mold; S2.8, pouring concrete with the cooperation of the second bottom mold, the second outer mold and the second hydraulic inner mold to obtain a floating body segment prefabricated by sandwich matching; S2.9, maintain the floating body segment prefabricated by sandwich matching, and remove the second outer mold and the second hydraulic inner mold; S2.10, separate the sandwich-matched prefabricated floating body segments and matching segments, hoist and store them, and repeat steps S2.3 to S2.10 until the sandwich-matched prefabrication production of other floating body segments is completed.

[0031] The above is only a preferred embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solution and invention concept of the present invention within the scope disclosed by the present invention, which shall fall within the protection scope of the present invention.

Claims

1. A method for producing UHPC concrete floating body segments for floating wind turbine foundation, characterized in that: The method adopts an independent prefabrication production process for prefabricated components and produces multiple floating body segments in an interval production mode. While the independent prefabrication production process for prefabricated components is being carried out, two adjacent floating body segments among the produced floating body segments are used as matching segments, and the remaining floating body segments are produced using a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

2. The method for producing UHPC concrete buoy segments for floating wind turbine foundation according to claim 1, characterized in that: For a total of an odd number of 2n+1 floating body segments, the 1st, 3rd, 5th ..., 2n-1th and 2n+1th floating body segments are produced by an independent prefabrication production process of prefabricated components, and the adjacent floating body segments among the produced 1st, 3rd, 5th ..., 2n-1th and 2n+1th floating body segments are used as matching segments, and the remaining floating body segments are produced by a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

3. The method for producing UHPC concrete buoy segments for floating wind turbine foundation according to claim 1, characterized in that: For a total of an even number of 2n floating body segments, the 1st, 3rd, 5th..., 2n-3rd and 2n floating body segments are produced by an independent prefabrication production process of prefabricated components, and the adjacent floating body segments among the produced 1st, 3rd, 5th..., 2n-3rd and 2n floating body segments are used as matching segments, and the remaining floating body segments are produced by a sandwich matching prefabrication production process, thereby completing the production of all floating body segments.

4. The method for producing a UHPC concrete floating body segment for a floating wind turbine foundation according to any one of claims 1 to 3, characterized in that: The independent prefabrication production process of prefabricated components comprises the steps of: S1.

1. Cast an independent prefabricated pedestal on the ground; S1.

2. Lay the first bottom mold of a single floating body segment on an independent prefabricated pedestal and level it; S1.3, setting a first fixed end mold at one end of the first bottom mold and adjusting the end surface flatness; S1.4, tie the steel bar skeleton into shape as a whole, and hoist it onto the first bottom form; S1.

5. Arrange a first movable end mold at the other end of the first bottom mold and adjust the end surface flatness; S1.

6. Install the first outer mold, fix the prestressed corrugated pipe to the first movable end mold and the steel frame, and close the installed first outer mold and the first movable end mold; S1.7, operate the first hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment to be prefabricated, adjust the axis position, and open the first hydraulic inner mold; S1.8, pouring concrete with the cooperation of the first bottom mold, the first fixed end mold, the first movable end mold, the first outer mold and the first hydraulic inner mold to obtain an independently prefabricated floating body segment; S1.9, maintaining the floating body segment obtained by independent prefabrication, and dismantling the first movable end mold, the first outer mold and the first hydraulic inner mold; S1.

10. A plurality of control points for matching segment reset adjustment are set on the top plate of the floating body segment; S1.

11. Hoist and store the floating body segments, and execute steps S1.4 to S1.10 repeatedly until the independent prefabrication of other floating body segments is completed.

5. The method for producing UHPC concrete buoy segments for floating wind turbine foundation according to claim 4, characterized in that: A steel truss is arranged at the rear side of the first movable end mold, and a plurality of adjusting screw rods are connected between the steel truss and the first movable end mold. The end surface flatness of the first movable end mold can be adjusted by adjusting the length of the adjusting screw rods.

6. The method for producing UHPC concrete buoy segments for floating wind turbine foundation according to claim 4, characterized in that: The multiple control points include two axis control points set by total station in the middle of the top plate of the floating body segment, and four elevation control points respectively set at preset positions of the top plate. The elevations of the four elevation control points are pre-collected using a precision level.

7. The method for producing UHPC concrete buoy segments for floating wind turbine foundation according to claims 1 to 3, characterized in that: The sandwich matching prefabrication production process comprises the steps of: S2.1, pouring sandwich matching prefabricated pedestal on the ground; S2.2, lay the second bottom mold on the sandwich matching pedestal and level it; S2.

3. Bottom mold trolleys are respectively arranged on both sides of the second bottom mold for resetting and adjusting the matching segments during the sandwich matching prefabrication production process; S2.

4. Hoist two adjacent floating body segments as matching segments onto the bottom mold trolley and perform reset adjustment; S2.5, tie the steel bar skeleton into shape as a whole and hoist it onto the second bottom form; S2.6, install the second outer mold, fix the prestressed corrugated pipe on the matching segment and the steel skeleton, and close the mold of the installed second outer mold; S2.7, operate the second hydraulic inner mold to move to the specified position of the inner cavity of the floating body segment to be prefabricated between the two matching segments, adjust the axis position, and open the second hydraulic inner mold; S2.8, pouring concrete with the cooperation of the second bottom mold, the second outer mold and the second hydraulic inner mold to obtain a floating body segment prefabricated by sandwich matching; S2.9, maintain the floating body segment prefabricated by sandwich matching, and remove the second outer mold and the second hydraulic inner mold; S2.10, separate the sandwich-matched prefabricated floating body segments and matching segments, hoist and store them, and repeat steps S2.3 to S2.10 until the sandwich-matched prefabrication production of other floating body segments is completed.

8. The method for producing UHPC concrete buoy segments for floating wind turbine foundation according to claim 7, characterized in that: In step S2.4, two adjacent floating body segments are hoisted onto the bottom mold trolley as matching segments and reset and adjusted. The axes of the two matching segments and the axis of the second bottom mold of the floating body segment to be prefabricated are adjusted to a straight line through a total station. According to the elevations of the elevation control points on the two matching segments collected in advance during the independent prefabrication production process of prefabricated components, the two matching segments are adjusted to a horizontal state after casting using the independent prefabrication production process of prefabricated components using a precision level.

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