An underwater automatic pile cutting system and method for pile foundation construction

Abstract

The application belongs to the technical field of pile foundation construction, and discloses an underwater automatic pile cutting system and method for pile foundation construction, which comprises an automatic pile cutting control unit and an automatic pile cutting device; the automatic pile cutting control unit comprises an electrical control module, a sensing module, a rotary drive control module and a feeding drive module, which are arranged at different positions in the automatic pile cutting device; the automatic pile cutting device comprises a pile cutting working platform, a hoisting steel wire rope and a crane. The underwater automatic pile cutting which cannot be visually observed in pile foundation construction is realized through the cooperation of software and hardware, the sinking speed of the cutting device can be accurately measured and controlled in the sinking process of the automatic cutting device through the positioning rope of the crane, the stable operation is ensured, the cutting head of the rotary mechanism is equipped with four circular blades, the rotation speed and the feeding speed of the blades are controlled through a servo motor, and the cutting efficiency and quality of the automatic rotary cutting are ensured.

Description

An underwater automatic pile cutting system and method for pile foundation construction Technical Field

[0001] This invention relates to the field of underwater pile foundation construction technology, specifically to an underwater automatic pile cutting system and method for pile foundation construction. Background Technology

[0002] In current underwater pile foundation construction, the cutting of steel pipe piles is not visible to personnel above the water, making it impossible to directly observe the work. Therefore, divers are required to carry out the cutting work underwater with cutting equipment. While manual cutting of steel pipe piles by divers can generally proceed smoothly in calm weather, it is inefficient and produces inconsistent quality. In rough weather, manual work becomes impossible, delaying the overall project schedule. Even under suitable weather conditions, manual work suffers from numerous technical problems, including short single-operation times, large underwater measurement errors, difficulties in underwater construction, low efficiency, and high costs.

[0003] To address the aforementioned issues, Chinese invention patent application CN112227367A discloses a pile cutting method for a pile cutter. The pile cutter includes a base, a rotating mechanism, a pile cutting mechanism, a pile cutting detection device, and a rotating detection device. A fixing device is provided on the outer wall of the base, and the rotating mechanism is located inside the base. The pile cutting mechanism is located below and connected to the rotating mechanism. The pile cutting detection device performs real-time detection of the steel pile, and the rotating detection device performs real-time detection of the rotation angle of the pile cutting mechanism. Operation is based on the detection results. The pile cutting drive device first drives the pile cutting component to rotate, and then the pile cutting extension device drives the pile cutting component to extend from the pile cutting support to cut the steel pile. The pile cutting component contacts and cuts the steel pile while rotating, avoiding the problem of the pile cutting component contacting the steel pile first and then rotating, which could cause the cutting edge on the steel pile to jam the pile cutting component and lead to damage.

[0004] However, while the aforementioned patented technology can control the underwater pile cutting process, its pile cutting machine has a complex structural design and a cumbersome control process, making automatic control impossible. For example, the provided pile cutting mechanism can only perform rotary cutting, with each rotation angle controlled at 25°. This significantly limits the diameter of the rotary cut, restricting its operation to steel pipe piles of specific diameters and making it unsuitable for cutting steel pipe piles of various sizes. Furthermore, the pile cutting process relies on a separately installed pile cutting detection device, lacks calibration, and has insufficient positioning accuracy. Its operation is also complex, making normal construction impossible in harsh seawater conditions. It cannot operate in bad weather, and even during normal operation, personnel are required underwater to assist with tasks such as measurement. Therefore, the automation level, quality, and efficiency of the patented technology's cutting process and equipment need further improvement to better meet the diverse practical needs of engineering construction. Summary of the Invention

[0005] The purpose of this invention is to provide an underwater automatic pile cutting system and method for pile foundation construction. Through the coordinated use of hardware and software, the automatic pile cutting control unit (as the control component) and the automatic pile cutting device (as the execution component) are simultaneously improved to meet the process requirements of automated control. A combination of hydraulic and electric drive is adopted, enabling automatic detection, control, and operation. Furthermore, it fully utilizes the relatively stable internal environment of the steel pipe pile, allowing for normal construction in harsh seawater environments with adverse weather conditions. By setting up four support devices, and employing techniques such as an electrical control module monitoring hydraulic pressure and servo motor torque, real-time monitoring of the blade torque, and control of the blade's rotation speed and feed rate, the invention ensures high cutting efficiency and quality for steel pipe piles of various sizes under various working conditions, overcoming the shortcomings of existing technologies.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An underwater automatic pile cutting system for pile foundation construction includes an automatic pile cutting control unit as a control part and an automatic pile cutting device as an execution part.

[0008] The automatic pile cutting control unit includes: an electrical control module, a sensing module, a rotary drive control module, and a feed drive module, which are respectively set in different positions within the automatic pile cutting device; the electrical control module includes a PLC controller and an underwater automatic pile cutting control program built into the PLC controller; the sensing module includes position sensors, pressure sensors, torque sensors, etc., and each type of sensor may include multiple sensing modules to accurately sense the corresponding data.

[0009] The automatic pile cutting device includes: a pile cutting work platform, a lifting wire rope, and a crane;

[0010] The pile cutting platform includes: a frame and a rotary drive chamber, a feed drive chamber, four support and fixing mechanisms, a rotary mechanism, a feed mechanism, a cutting assembly, and a hydraulic drive assembly, which are fixed sequentially on the frame.

[0011] The rotary drive compartment has a built-in rotary drive control module; the feed drive compartment has a built-in feed drive module.

[0012] The four supporting and fixing mechanisms are evenly distributed and fixedly installed on the outside of the frame;

[0013] The slewing mechanism is located below the frame and is connected to the hydraulic drive assembly; the hydraulic drive assembly includes: a hydraulic pump, a hydraulic cylinder, and multiple hydraulic oil pipes;

[0014] The cutting assembly is located at the bottom of the pile cutting platform. The cutting assembly includes: a central fixing component, four cutting units evenly distributed on the outside of the central fixing component, a saw blade telescopic cylinder, a servo motor, and a saw blade connected to the servo motor for transmission.

[0015] The support and fixing mechanism includes: a support and fixing plate and a support cylinder connected to each other, wherein the support cylinder is connected to the hydraulic drive assembly via a hydraulic oil pipe;

[0016] The outer side of the support fixing plate is flat or arc-shaped, and when the fixing plate is in place, it fits against the inner wall of the steel pipe pile.

[0017] The feeding mechanism is located below the rotary mechanism and is connected to the feeding drive chamber via a hydraulic oil pipe.

[0018] Each cutting unit is connected to a central fixed component via a saw blade telescopic cylinder; the feeding mechanism includes a servo motor, which includes a drive shaft, and each cutting unit is movably connected via the drive shaft. Each cutting unit includes a saw blade below it, and the saw blade is fixedly connected to the drive shaft.

[0019] An underwater automatic pile cutting method for pile foundation construction includes the following steps:

[0020] S1. Set up and debug the underwater automatic pile cutting system.

[0021] Set up an underwater automatic pile cutting system for pile foundation construction, and then run and debug the pile cutting work platform: start the pile cutting work platform and check whether the working status of each component is normal, including checking the electrical control module, hydraulic drive assembly, support and fixing mechanism, slewing mechanism, feeding mechanism and cutting assembly; if any component is not normal, perform maintenance and repair to ensure that each component works normally.

[0022] Before the first operation at the new construction site, a trial run of the pre-set operating parameters should be conducted to verify whether the operating parameters meet the expectations. The operating parameters include: saw blade speed, feed rate, cutting angle, and rotational angular velocity.

[0023] S2. Install support fixing plate

[0024] Select a support fixing plate that matches the inner diameter of the steel pipe pile and install the support fixing plate on the support fixing mechanism;

[0025] S3, hoisting and positioning of the pile cutting work platform

[0026] The crane lifts the pile cutting platform above the opening of the steel pipe pile above the water surface, allowing the platform to enter the opening and descend at a constant speed along the inner wall of the pile. The electrical control module controls the length of the lifting wire rope and uses the wire rope fixing components to maintain stability during descent, precisely adjusting the descent position of the pile cutting platform. As the platform gradually approaches the cutting position of the steel pipe pile, the position sensor of the sensing module detects the designated position and simultaneously verifies that the marked wire rope has reached the designated position. When the two positions are consistent, the electrical control module controls the crane to stop descending.

[0027] The electrical control module controls the feeding mechanism and the support cylinder to adjust the position of the support fixing plate. The outer wall of the support fixing plate fits against the inner wall of the steel pipe pile, ensuring that it can be firmly fixed to the inner wall of the steel pipe pile.

[0028] S4, Steel Pipe Pile Feed Cutting

[0029] The electrical control module starts the cutting assembly, controls the servo motor to drive the saw blade to rotate to the specified speed, and then controls the feeding mechanism to feed the cutting assembly into the inner wall of the steel pipe pile, starting to cut the steel pipe pile; the electrical control module monitors the servo motor torque in real time during the cutting process to ensure cutting quality and safety; after the saw blade reaches the designated position, the saw blade cuts through the steel pipe pile; the feeding mechanism stops feeding; the limit bracket maintains the stability of the cutting assembly to prevent collisions and displacement during the cutting process;

[0030] S5, Rotary Cutting of Steel Pipe Piles

[0031] The rotary mechanism starts, which drives the cutting component to make rotary cutting motion along the pipe wall through the connecting shaft until the electrical control module detects that the pipe wall of the steel pipe pile has been completely cut off; after the pipe wall is completely cut off, the rotary mechanism stops, the feeding mechanism feeds in the reverse direction, the cutting component returns to the starting position, and the servo motor stops rotating.

[0032] S6, Steel pipe pile hoisting

[0033] After the pile cutting platform, along with the steel pipe pile, is lifted to the designated vertical position by a crane using wire ropes, the support and fixing mechanism is retracted, and the pile cutting platform is lifted out by the crane. The cut steel pipe pile is then hoisted by the crane in preparation for subsequent processing or transportation.

[0034] The advantages of this invention include at least the following:

[0035] 1. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention, through the coordinated cooperation of hardware and software, simultaneously improves the automatic pile cutting control unit (as the control part) and the automatic pile cutting device (as the execution part) to meet the process requirements of automated control. This enables automatic detection, control, and operation, and fully utilizes the relatively stable internal environment of steel pipe piles, thus allowing normal construction in harsh seawater environments with adverse weather conditions. By setting up four support devices, the electrical control module monitors the hydraulic pressure and servo motor torque, monitors the torque of the cutting blade in real time, and controls the rotation speed and feed speed of the cutting blade, the system ensures cutting efficiency and quality for steel pipe piles of various sizes under various working conditions, and can be widely applied to construction operations under various working conditions and weather conditions.

[0036] 2. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention improves the structure of the pile cutting work platform and, in conjunction with a crane and wire rope, transports the pile cutting work platform to the inside of the steel pipe pile for cutting. The wire rope has the function of a positioning rope, which can achieve accurate measurement during the sinking process of the automatic cutting device. The crane controls the wire rope to realize the sinking adjustment of the pile cutting work platform. The crane can easily control the sinking speed of the cutting device and ensure stable operation.

[0037] 3. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention improves the automation level of the operation through simultaneous improvements in various construction processes and equipment structures, and ensures the efficiency and quality of underwater cutting operations. It mainly includes: four supporting devices, all of which can be pushed outwards and fixed to the inner wall of the steel pipe, forming a stable supporting platform; and a cutting component of a circular rotary mechanism equipped with four circular blades, enabling rotary cutting. Under the control of the electrical control module, the rotation speed and feed speed of the blades are both precise and rapid.

[0038] 4. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention monitor the hydraulic pressure and servo motor torque through the electrical control module, monitor the torque of the blade in real time, and handle abnormal situations such as blade breakage. If an abnormality is encountered, it can be hoisted ashore for inspection in a timely manner. There is no need to set up a separate cutting monitoring device or have personnel assist underwater, and the degree of automation is high.

[0039] 5. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention, by improving the structure, operation mode and steps of the pile cutting work platform, makes full use of the relatively stable internal environment of the steel pipe pile, so that it can carry out normal construction in various harsh seawater environments, and still achieve precise control and high efficiency and high quality; the four circular blades and the rotary cutting mechanism make the pile cutting operation both stable and efficient; this invention utilizes the waterless environment inside the steel pipe pile, which is more suitable for cutting from the inside of the steel pipe pile, reducing the influence of seawater buoyancy and seawater flow, and overcoming many shortcomings of the prior art.

[0040] 6. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention solves a number of technical problems existing in the prior art by improving the pile cutting method and equipment. It can completely avoid personnel from going into the water to participate in the operation (including auxiliary measurement), and also solves the problem that the excessive length of the steel pipe pile area in deep water affects the navigation safety of ships. The cut steel pipe pile can be conveniently, quickly and safely lifted off the water surface for recycling and reuse, saving resources. Attached Figure Description

[0041] Figure 1 is a schematic diagram of the control flow of the underwater automatic pile cutting method according to an embodiment of the present invention;

[0042] Figure 2 is a three-dimensional external structural diagram of the pile cutting platform according to an embodiment of the present invention;

[0043] Figure 3 is a front view of the pile cutting platform after hoisting according to an embodiment of the present invention.

[0044] Figure 4 is a top view of the pile cutting platform after hoisting according to an embodiment of the present invention.

[0045] Figure 5 is a schematic diagram of the left-side structure of the pile cutting platform according to an embodiment of the present invention;

[0046] Figure 6 is a schematic diagram of the pile cutting platform structure from below according to an embodiment of the present invention.

[0047] In the diagram: 1. Pile cutting platform; 2. Steel pipe pile; 3. Lifting wire rope; 4. Wire rope fixing component; 10. Frame; 11. Rotary drive chamber; 12. Feed drive chamber; 13. Support and fixing mechanism; 131. Support and fixing plate; 132. Support cylinder; 14. Rotary mechanism; 15. Feed mechanism; 16. Cutting assembly; 161. Saw blade; 162. Saw blade telescopic cylinder; 17. Hydraulic drive assembly; 18. Limit bracket; 19. Connecting shaft. Detailed Implementation

[0048] The embodiments of the present invention will be described in detail below.

[0049] Example 1

[0050] Referring to Figures 1 to 6, the underwater automatic pile cutting system for pile foundation construction provided in this embodiment of the invention includes an automatic pile cutting control unit as the control part and an automatic pile cutting device as the execution part.

[0051] The automatic pile cutting control unit includes: an electrical control module, a sensing module, a rotary drive control module, and a feed drive module, which are respectively set in different positions within the automatic pile cutting device; the electrical control module includes a PLC controller and a built-in underwater automatic pile cutting control program; the sensing module includes position sensors, pressure sensors, torque sensors, etc., which automatically sense the corresponding data and transmit it to the electrical control module according to the needs of automatic system control for automatic control;

[0052] The automatic pile cutting device includes: a pile cutting work platform 1, a lifting wire rope 3, and a crane;

[0053] The pile cutting platform 1 includes: a frame 10 and a rotary drive chamber 11, a feed drive chamber 12, four support and fixing mechanisms 13, a rotary mechanism 14, a feed mechanism 15, a cutting assembly 16, and a hydraulic drive assembly 17, which are fixed sequentially on the frame 10.

[0054] The rotary drive chamber 11 has a built-in rotary drive control module; the feed drive chamber 12 has a built-in feed drive module;

[0055] The four supporting and fixing mechanisms 13 are evenly distributed and fixedly installed on the outside of the frame 10;

[0056] The slewing mechanism 14 is located below the frame 10 and is connected to the hydraulic drive assembly 17; the hydraulic drive assembly 17 includes: a hydraulic pump, a hydraulic cylinder, and multiple hydraulic oil pipes;

[0057] The cutting assembly 16 is located at the lower part of the pile cutting work platform 1. The cutting assembly 16 includes a central fixing member, four cutting units evenly distributed on the outside of the central fixing member, a saw blade telescopic cylinder 162, a servo motor, and a saw blade 161 connected to the servo motor for transmission.

[0058] An underwater automatic pile cutting method for pile foundation construction includes the following steps:

[0059] S1. Set up and debug the underwater automatic pile cutting system.

[0060] Set up an underwater automatic pile cutting system for pile foundation construction, and then run and debug the pile cutting work platform: start the pile cutting work platform 1 and check whether the working status of each component is normal, including checking the electrical control module, hydraulic drive assembly 17, support and fixing mechanism 13, slewing mechanism 14, feeding mechanism 15 and cutting assembly 16; if any component is not normal, perform maintenance and repair to ensure that each component works normally.

[0061] Before the first operation at the new construction site, a trial run of the pre-set operating parameters should be conducted to verify whether the operating parameters meet the expectations. The operating parameters include: saw blade speed, feed rate, cutting angle, and rotational angular velocity.

[0062] Before the system starts working, the electrical control module performs a self-test. During the self-test, the main checks are whether the built-in PLC controller and the built-in underwater automatic pile cutting control program of the PLC controller are normal, and whether the connection and communication with each component are normal; whether each moving part is in the starting position; and whether the operating parameter settings of each component meet the working requirements.

[0063] S2. Install support fixing plate

[0064] Select a support fixing plate 131 that matches the inner diameter of the steel pipe pile 2, and install the support fixing plate 131 on the support fixing mechanism 13;

[0065] S3, hoisting and positioning of the pile cutting work platform

[0066] The crane lifts the pile cutting platform to the opening of the steel pipe pile 2 above the water surface, allowing the platform to enter the opening and descend at a constant speed along the inner wall of the pile. The electrical control module controls the length of the lifting wire rope 3 and uses the wire rope fixing parts 4 to maintain stability during descent, precisely adjusting the descent position of the pile cutting platform. The platform gradually reaches the vicinity of the cutting position of the steel pipe pile 2. The position sensor of the sensing module detects the designated position and simultaneously verifies that the marked wire rope 3 has reached the designated position. When the two positions are consistent, the electrical control module controls the crane to stop descending.

[0067] The electrical control module controls the feeding mechanism 15 and the support cylinder 132 to adjust the position of the support fixing plate 131. The outer wall of the support fixing plate 131 fits against the inner wall of the steel pipe pile 2, ensuring that it can be firmly fixed on the inner wall of the steel pipe pile 2.

[0068] The electrical control module automatically controls the maximum hydraulic pressure value according to the preset standard: the standard is the pressure required to support 1.375-2.0 times the weight of the entire machine + 1.0 MPa. When the pressure is exceeded, the relief valve will overflow; all the supporting cylinders 132 are set in parallel to ensure that the hydraulic pressure of each supporting cylinder 132 is consistent.

[0069] The electrical control module also includes a pressure monitoring module, which can sense pressure data and provide it to the electrical control module for pressure holding and pressure replenishment judgment, so as to ensure stable support of the equipment during operation.

[0070] S4, Steel Pipe Pile Feed Cutting

[0071] The electrical control module starts the cutting assembly 16, controls the servo motor to drive the saw blade 161 to rotate to the specified speed, and then controls the feeding mechanism 15 to feed. The cutting assembly 16 advances into the inner wall of the steel pipe pile 2 and begins to cut the steel pipe pile 2. The electrical control module monitors the torque of the servo motor in real time during the cutting process to ensure cutting quality and safety. After the saw blade 161 reaches the specified position, the saw blade 161 cuts through the steel pipe pile 2. The feeding mechanism 15 stops feeding. The cutting assembly 16 is kept stable by the limit bracket to prevent collisions and displacement during the cutting process.

[0072] S5, Rotary Cutting of Steel Pipe Piles

[0073] The rotary mechanism 14 is started, which drives the cutting component 16 to perform rotary cutting motion along the pipe wall through the connecting shaft 19 until the electrical control module detects that the pipe wall of the steel pipe pile 2 has been completely cut off; after the pipe wall is completely cut off, the rotary mechanism 14 stops, the feeding mechanism 15 feeds in the reverse direction, the cutting component 16 returns to the starting position, and the servo motor stops rotating.

[0074] The cutting head of the rotary mechanism 14 is equipped with four symmetrical circular blades. The rotation speed and feed speed of the blades are controlled by a servo motor, which can ensure the cutting efficiency and quality of automatic rotary cutting.

[0075] S6, Steel pipe pile hoisting

[0076] After the pile cutting platform 1 and the steel pipe pile 2 are hoisted to the designated vertical position by the crane using wire rope, the support and fixing mechanism 13 is retracted, and the pile cutting platform 1 is hoisted out by the crane; the cut steel pipe pile 2 is then hoisted by the crane in preparation for subsequent processing or transportation.

[0077] The underwater automatic pile cutting system and method for pile foundation construction provided in this invention, through the coordinated use of hardware and software, simultaneously improves the automatic pile cutting control unit (as the control part) and the automatic pile cutting device (as the execution part) to meet the process requirements of automated control. This enables automatic detection, control, and operation, and fully utilizes the relatively stable internal environment of steel pipe piles, allowing for normal construction in harsh seawater environments with adverse weather conditions. By setting up four support devices, the electrical control module monitors the hydraulic pressure and servo motor torque, monitors the torque of the cutting blade in real time, and controls the rotation speed and feed speed of the cutting blade, the system ensures cutting efficiency and quality for steel pipe piles of various sizes under various working conditions, and can be widely applied to construction operations under various working conditions and weather conditions.

[0078] Example 2

[0079] Referring to Figures 1 to 6, the underwater automatic pile cutting system for pile foundation construction provided in this embodiment of the invention is an optimization based on Embodiment 1.

[0080] Referring to Figures 2 to 6, the support and fixing mechanism 13 includes: a support and fixing plate 131 and a support cylinder 132 connected to each other. The support cylinder 132 is connected to the hydraulic drive assembly 17 through a hydraulic oil pipe.

[0081] The outer side of the support fixing plate 131 is a plane or an arc. When the fixing plate 131 is in place, it fits against the inner wall of the steel pipe pile 2.

[0082] The feeding mechanism 15 is located below the rotary mechanism 14, and the feeding mechanism 15 is connected to the feeding drive chamber 12 via a hydraulic oil pipe.

[0083] Each cutting unit is connected to the central fixed part through a saw blade telescopic cylinder 162; the feeding mechanism 15 includes a servo motor, the servo motor includes a drive shaft, each cutting unit is movably connected through the drive shaft, and each cutting unit includes a saw blade 161 below it, the saw blade 161 is fixedly connected to the drive shaft.

[0084] The pile cutting platform 1 also includes: a connecting shaft 19; one end of the connecting shaft 19 is fixedly connected to the central fixing member, and the other end is movably connected to the rotary mechanism 14;

[0085] The cutting assembly 16 further includes: four limiting brackets 18, each of which is fixedly disposed between the four cutting units;

[0086] The electrical control module is sealed and installed on the pile cutting platform 1; the electrical control module is electrically connected to the hydraulic drive assembly 17;

[0087] The multiple steel wire ropes 3 are evenly arranged and fixed on the outside of the frame 10 respectively; multiple steel wire rope fixing parts 4 are arranged between the multiple steel wire ropes 3, which can prevent the steel wires from getting tangled and ensure even stress distribution during hoisting; the crane is movably connected to the multiple steel wire ropes 3.

[0088] In other preferred embodiments, the frame 10 can be adjusted according to the shape of the steel pipe pile 2; for example, if the steel pipe pile is cylindrical, the frame 10 is set as a circular frame; if the steel pipe pile 2 is square, the frame 10 is set as a square frame, to adapt to different situations.

[0089] In other preferred embodiments, the plurality of lifting wire ropes 3 are evenly arranged into four ropes, which are respectively fixed on the outside of the frame 10; four wire rope fixing members 4 are arranged in sequence between the plurality of wire ropes 3, which can prevent the wires from getting tangled and ensure even stress distribution during hoisting.

[0090] Example 3

[0091] Referring to Figures 1 to 6, the underwater automatic pile cutting method for pile foundation construction provided in this embodiment uses the aforementioned underwater automatic pile cutting system and is an optimization based on the above embodiments 1-2. Step S1 also includes a step in which the electrical control module performs a self-test on the system.

[0092] During the self-test of the electrical control module, the main checks are whether the built-in PLC controller and the built-in underwater automatic pile cutting control program of the PLC controller are normal, whether the connection and communication with each component are normal, whether the preset parameters are complete, whether each moving part is in the starting position, and whether the operating parameter settings of each component meet the working requirements, so that the whole system is ready. If any part is not perfect, the self-test program will prompt the staff to handle it, and the system will be restarted after the problem is resolved.

[0093] Example 4

[0094] Referring to Figures 1 to 6, the underwater automatic pile cutting method for pile foundation construction provided in this embodiment uses the aforementioned underwater automatic pile cutting system and is an optimization based on the above embodiments 1-3. The feed cutting in step S4 further includes the following steps:

[0095] S4-1, Torque Judgment: The servo motor, which serves as the power source, has a maximum output torque. During equipment operation, the torque sensor in the sensing module controls the output torque and makes a judgment on the operating status: when the monitored output torque is ≤80% of the maximum output torque, it is automatically judged that the equipment is working normally; when the monitored output torque is ≥85%, it is automatically judged that the equipment operating condition may be abnormal, the system alarm is activated, and the staff is prompted to follow up and determine whether to stop the equipment operation; when the monitored output torque is ≥95%, it is automatically judged that the equipment operating condition is absolutely abnormal, the system automatically stops working, and returns to the starting position.

[0096] S4-2. Cutting Speed ​​Control: The electrical control module sets the feed speed based on the cutting depth of the material and the size of the saw blade. During the cutting process, it automatically adjusts the saw blade speed to control the cutting speed: if the torque value is less than 50% of the maximum output torque, the feed speed is automatically increased to improve the cutting speed; conversely, if the torque value is greater than 80% of the maximum output torque, the feed speed is automatically decreased to reduce the cutting speed. Since the cutting speed is achieved by the interaction of the feed speed and the saw blade speed, the electrical control module can achieve precise control of the cutting speed by adjusting the saw blade speed.

[0097] Example 5

[0098] Referring to Figures 1 to 6, the underwater automatic pile cutting method for pile foundation construction provided in this embodiment uses the aforementioned underwater automatic pile cutting system and is an optimization based on the above embodiments 1-4. The specific process of step S5, in which the electrical control module detects that the pipe wall has been completely cut, is as follows:

[0099] S5-1, Preset rotation angle

[0100] The PLC controller calculates the rotation angle during cutting based on the wall thickness and diameter of the steel pipe pile 2 to be cut, ensuring that the wall of the steel pipe pile 2 is completely cut off.

[0101] S5-2, Judgment of Steel Pipe Pile Cutting

[0102] Before the steel pipe pile is cut, the torque values ​​of the slewing mechanism 14 and the cutting component 16 are within a certain range of fluctuation. When the electrical control module detects that the torque value is lower than the value and tends to 0, and the torque duration is more than 3 seconds, it determines that the steel pipe pile has been cut.

[0103] During the cutting process of the steel pipe pile 2, vibration and humming sound are generated. After the electrical control module completes step S5-2, the cutting component 16 is disengaged from the steel pipe pile 2. If the vibration and humming sound are detected to be eliminated at this time, it is further determined that the steel pipe pile has been cut, which can avoid misjudgment.

[0104] In summary, the embodiments of the present invention, through improvements to the structure of the pile-cutting platform and the coordination of a crane and wire rope, achieve harmonious integration of equipment and construction methods. With the cooperation of hardware and software, the pile-cutting platform is automatically transported to the interior of the steel pipe pile for cutting. The wire rope also has an auxiliary measurement function for positioning the rope length, enabling precise measurement of the cutting position during the descent of the automatic cutting device. The crane controls the wire rope to adjust the descent of the pile-cutting platform, and can precisely control the descent speed and position of the cutting device, ensuring stable and accurate operation.

[0105] The underwater automatic pile cutting system and method for pile foundation construction provided by this invention improves the automation level of the operation through simultaneous improvements in various construction processes and equipment structures, ensuring both efficiency and quality of underwater cutting operations. It mainly includes: four support devices, each capable of being pushed outwards and fixed to the inner wall of a steel pipe, forming a stable support platform; and a cutting component for a circular rotary mechanism equipped with four circular blades for rotary cutting. Under the control of the electrical control module, the rotation speed and feed speed of the blades are both precise and rapid. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention monitors the hydraulic pressure and servo motor torque through the electrical control module, monitors the blade torque in real time, and handles abnormalities such as blade breakage. In case of an anomaly, it can be promptly hoisted ashore for inspection, eliminating the need for a separate cutting monitoring device and underwater personnel assistance, resulting in a high degree of automation. The underwater automatic pile cutting system and method for pile foundation construction provided by this invention improves the structure, operation mode, and steps of the pile cutting platform, making full use of the relatively stable internal environment of the steel pipe pile. This allows for normal construction in various harsh seawater environments while still achieving precise control and high efficiency and quality. The four circular blades, combined with the rotating cutting mechanism, make the pile cutting operation both stable and efficient. This invention utilizes the waterless environment inside the steel pipe pile, making it more suitable for cutting from the inside of the steel pipe pile, reducing the influence of seawater buoyancy and seawater flow, and overcoming many shortcomings of the prior art.

[0106] The above are merely specific embodiments of the present invention and are not intended to limit the scope of protection of the present invention; any substitutions and improvements made without departing from the concept of the present invention shall fall within the scope of protection of the present invention.

Claims

1. An underwater automatic pile cutting system for pile foundation construction, characterized in that, It includes an automatic pile cutting control unit as the control part and an automatic pile cutting device as the execution part; The automatic pile cutting control unit includes: an electrical control module, a sensing module, a rotary drive control module, and a feed drive module, which are respectively set in different positions within the automatic pile cutting device; the electrical control module includes a PLC controller and an underwater automatic pile cutting control program built into the PLC controller; the sensing module includes a position sensor, a pressure sensor, and a torque sensor; the automatic pile cutting device includes: a pile cutting work platform (1), a lifting wire rope (3), and a crane; the pile cutting work platform (1) includes: a frame (10) and components sequentially fixed to the machine. The frame (10) includes a rotary drive chamber (11), a feed drive chamber (12), four support and fixing mechanisms (13), a rotary mechanism (14), a feed mechanism (15), a cutting assembly (16), and a hydraulic drive assembly (17). The rotary drive chamber (11) contains a rotary drive control module. The feed drive chamber (12) contains a feed drive module. The four support and fixing mechanisms (13) are evenly distributed and fixedly installed on the outside of the frame (10). The rotary mechanism (14) is located below the frame (10). The hydraulic drive assembly (17) is connected; the hydraulic drive assembly (17) includes: a hydraulic pump, a hydraulic cylinder, and multiple hydraulic oil pipes; the cutting component (16) is located at the lower part of the pile cutting work platform (1), the cutting component (16) includes a central fixing part, four cutting units evenly distributed on the outside of the central fixing part, a saw blade telescopic cylinder (162), a servo motor and a saw blade (161) connected to the servo motor; the support fixing mechanism (13) includes: a support fixing plate (131) and a support cylinder (132) connected to each other, the support... The cylinder (132) is connected to the hydraulic drive assembly (17) via a hydraulic oil pipe; the outer side of the support fixing plate (131) is a plane or an arc, and when the support fixing plate (131) is in place, it fits against the inner wall of the steel pipe pile (2); each of the cutting units is connected to the central fixing part via a saw blade telescopic cylinder (162); the feeding mechanism (15) includes a servo motor, the servo motor includes a transmission shaft, each of the cutting units is movably connected via the transmission shaft, and each cutting unit includes a saw blade (161) below it, and the saw blade (161) is fixedly connected to the transmission shaft.

2. The underwater automatic pile cutting system for pile foundation construction as described in claim 1, characterized in that, The feeding mechanism (15) is located below the rotary mechanism (14), and the feeding mechanism (15) is connected to the feeding drive chamber (12) via a hydraulic oil pipe.

3. The underwater automatic pile cutting system for pile foundation construction as described in claim 1, characterized in that, The pile cutting platform (1) further includes: a connecting shaft (19); one end of the connecting shaft (19) is fixedly connected to the central fixing member, and the other end is movably connected to the rotary mechanism (14); the cutting assembly (16) further includes: four limiting brackets (18), each limiting bracket (18) is fixedly installed between the four cutting units; the electrical control module is sealed in the pile cutting platform (1); the electrical control module is electrically connected to the hydraulic drive assembly (17); multiple lifting wire ropes (3) are evenly arranged and fixed on the outside of the frame (10); multiple wire rope fixing parts (4) are arranged between the multiple lifting wire ropes (3), and the multiple wire rope fixing parts (4) can prevent the wire from getting tangled and the force is evenly distributed during hoisting; the crane is movably connected to the multiple lifting wire ropes (3).

4. An underwater automatic pile cutting method for pile foundation construction, characterized in that, The process includes the following steps: S1. Set up and debug the underwater automatic pile cutting system for pile foundation construction. Then, run and debug the pile cutting platform: Start the pile cutting platform (1) and check whether the working status of each component is normal, including checking the electrical control module, hydraulic drive assembly (17), support fixing mechanism (13), slewing mechanism (14), feeding mechanism (15) and cutting assembly (16); if any component is not normal, perform maintenance and repair to ensure that each component works normally. Before the first operation at the new construction site, a trial run of the pre-set operating parameters should be conducted to verify whether the operating parameters meet the expectations. The operating parameters include: saw blade speed, feed rate, cutting angle, and rotational angular velocity; S2, Set a support fixing plate, select a support fixing plate (131) that matches the inner diameter of the steel pipe pile (2), and install the support fixing plate (131) on the support fixing mechanism (13); S3, The pile cutting platform hoisting and positioning crane hoists the pile cutting platform to the opening of the steel pipe pile (2) above the water surface, so that the pile cutting platform enters the opening of the steel pipe pile (2) and descends at a uniform speed along the inner wall of the steel pipe pile (2). The electrical control module controls the length of the lifting wire rope (3) and uses the wire rope fixing part (4) during the descent process. The system maintains stability to precisely adjust the descent position of the pile cutting platform, gradually bringing it closer to the cutting position of the steel pipe pile (2). The position sensor of the sensing module detects the designated position, and at the same time, the hoisting wire rope (3) marked by the verification reaches the designated position. When the two positions are consistent, the electrical control module controls the crane to stop descending. The electrical control module controls the feeding mechanism (15) and the support cylinder (132) to adjust the position of the support fixing plate (131). The outer wall of the support fixing plate (131) fits against the inner wall of the steel pipe pile (2), ensuring that it can be firmly fixed to the inner wall of the steel pipe pile (2). S4, Steel pipe pile feeding and cutting electrical control module The block starts the cutting assembly (16), controls the servo motor to drive the saw blade (161) to rotate and reach the specified speed, and then controls the feeding mechanism (15) to feed. The cutting assembly (16) moves towards the inner wall of the steel pipe pile (2) and begins to cut the steel pipe pile (2). The electrical control module monitors the torque of the servo motor in real time during the cutting process to ensure cutting quality and safety. After the saw blade (161) reaches the specified position, the saw blade (161) cuts through the steel pipe pile (2). The feeding mechanism (15) stops feeding. The cutting assembly (16) is kept stable by the limit bracket to prevent collision and displacement during the cutting process. S5, the steel pipe pile rotary cutting rotary mechanism (14) starts, and its... The cutting assembly (16) is driven by the connecting shaft (19) to make a rotary cutting motion along the pipe wall until the electrical control module detects that the pipe wall of the steel pipe pile (2) has been completely cut off. After the pipe wall is completely cut off, the rotary mechanism (14) stops, the feeding mechanism (15) feeds in the opposite direction, the cutting assembly (16) returns to the starting position, and the servo motor stops rotating. S6, Steel pipe pile hoisting: The pile cutting platform (1) and the steel pipe pile (2) are hoisted to the designated vertical position by the crane using wire rope. The support fixing mechanism (13) is then retracted, and the pile cutting platform (1) is hoisted out by the crane. The cut steel pipe pile (2) is hoisted by the crane and prepared for subsequent processing or transportation.

5. The underwater automatic pile cutting method for pile foundation construction as described in claim 4, characterized in that, Step S1 further includes the following steps: electrical control module self-test. During the electrical control module self-test, the main checks are whether the built-in PLC controller and the built-in underwater automatic pile cutting control program of the PLC controller are normal, and whether the connection and communication with each component are normal; whether each moving component is in the starting position; and whether the operating parameter settings of each component meet the working requirements.

6. The underwater automatic pile cutting method for pile foundation construction as described in claim 4, characterized in that, Step S3 further includes the following steps: The electrical control module automatically controls the maximum hydraulic pressure value according to the preset: the standard is set to the pressure required to support 1.375-2.0 times the weight of the entire machine + 1.0 MPa. When the pressure is exceeded, the overflow valve will overflow; each of the support cylinders (132) is set to a parallel structure to ensure that the hydraulic pressure of each support cylinder (132) is consistent; the electrical control module also includes a pressure monitoring module, which can sense the pressure data and provide it to the electrical control module for pressure holding and pressure replenishment judgment to ensure stable support of the equipment during operation.

7. The underwater automatic pile cutting method for pile foundation construction as described in claim 4, characterized in that, The feed cutting in step S4 further includes the following steps: S4-1, Torque Judgment: The servo motor, as the power source, has a maximum output torque. During equipment operation, the output torque is controlled by the torque sensor in the sensing module, and a working condition judgment is made: When the monitored output torque is ≤80% of the maximum output torque, it is automatically judged that the equipment is working normally; when the monitored output torque is ≥85%, it is automatically judged that the equipment working condition may be abnormal, the system alarm is activated, and the operator is prompted to track and determine whether to terminate the equipment operation; when the monitored output torque is ≥95%, it is automatically judged that the equipment working condition is absolutely abnormal, the system automatically terminates the operation, and... Return to the starting position; S4-2, Control of cutting speed: The electrical control module sets the feed speed according to the cutting depth of the material and the size of the saw blade. During the cutting process, it automatically adjusts the saw blade speed to control the cutting speed: if the torque value is less than 50% of the maximum output torque, the feed speed is automatically increased to increase the cutting speed; conversely, if the torque value is greater than 80% of the maximum output torque, the feed speed is automatically decreased to reduce the cutting speed. Since the cutting speed is achieved by the interaction of the feed speed and the saw blade speed, the electrical control module can control the cutting speed by adjusting the saw blade speed.

8. The underwater automatic pile cutting method for pile foundation construction as described in claim 4, characterized in that, The steps in step S5 where the electrical control module detects that the pipe wall has been completely cut are as follows: S5-1, Preset rotation angle: The PLC controller calculates the rotation angle during cutting based on the pipe wall thickness and diameter of the steel pipe pile (2) to be cut, ensuring that the pipe wall of the steel pipe pile (2) is completely cut; S5-2, Steel pipe pile cutting judgment: Before the steel pipe pile is cut, the torque values ​​of the rotation mechanism (14) and the cutting component (16) are within a certain fluctuation range. When the electrical control module detects that the torque value is lower than the value and tends to 0, and the torque duration is more than 3 seconds, it is determined that the steel pipe pile has been cut; During the pipe wall cutting process of the steel pipe pile (2) to be cut, vibration and humming are generated; After the electrical control module completes step S5-2, the cutting component (16) is disengaged from the steel pipe pile (2). If the vibration and humming are detected to be eliminated at this time, it is further determined that the steel pipe pile has been cut.

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