Method for stability control of offshore substation modular construction

Abstract

The application discloses a stability control method for offshore booster station modular construction, and belongs to the technical field of offshore wind power engineering. The method comprises the following steps: based on the principles of "function partition, weight adaptation and gravity center controllability", realizing stability pre-control of sub-module division; constructing a high-precision support and connection system, guaranteeing positioning accuracy and structural stability of the sub-module prefabrication and assembly stage through adjustable support structure design and standardized interface configuration; standardizing assembly process and precision control, combining nondestructive testing and laser positioning, realizing stability control of sub-module splicing and block forming; monitoring system real-time monitoring and dynamic adjustment of the construction process, timely correction of assembly deviation through sensor monitoring and force verification, and ensuring the overall stability of the block. The application avoids stability risks such as gravity center deviation, interface deviation and stress concentration in the construction stage from the source, improves the block construction accuracy and structural reliability, and lays a solid foundation for subsequent transportation and offshore installation.

Description

Technical Field

[0001] This invention relates to a stability control method for the modular construction of offshore substations, belonging to the field of offshore wind power engineering technology. Background Technology

[0002] As a core facility for offshore wind power grid connection, the offshore booster station integrates key equipment such as transformers, power distribution, and control systems in its superstructure. It is characterized by its large size (typically 20-40m long, 10-20m wide, and 15-30m high), concentrated weight (core components account for over 60% of the weight), and complex center of gravity distribution. Due to the limitations of offshore construction conditions, the industry generally adopts a construction model of "onshore modular construction + overall sea transport + offshore installation." The stability of the modular construction phase directly determines the structural integrity of the modules, the safety of subsequent transportation, and the success rate of installation.

[0003] Existing technologies for modular construction suffer from the following key drawbacks: First, module division is often arbitrary, relying on engineers' experience without considering structural mechanics characteristics and center-of-gravity control requirements. This can lead to problems such as module overweight and center-of-gravity shift (module center of gravity deviating from the support center by more than 200mm), resulting in insufficient stability after assembly. Second, support and interface design is often crude, with non-adjustable support structures and a lack of standardized interfaces, resulting in sub-module docking errors exceeding 10mm and stress concentration in the assembled structure. Third, the assembly process lacks precise control, relying on manual positioning and experience-based judgment, leading to significant errors in horizontality and verticality, requiring extensive high-altitude work, and posing high safety risks. Fourth, construction process monitoring is lacking, with no real-time data support, making it impossible to detect structural deformation or splicing deviations in a timely manner. Subsequent rectification requires significant time, impacting construction efficiency.

[0004] For example, Chinese patent CN113845276A discloses a modular construction method for offshore substations, focusing only on module division and assembly efficiency without addressing precise stability control during the construction process. Patent CN115214892B emphasizes transport and binding devices but does not design for core stability elements such as supports, interfaces, and center of gravity during the construction phase. Therefore, there is an urgent need for a stability control method that focuses on the entire modular construction process, forming a closed loop from module design, support interfaces, assembly processes to monitoring and adjustment, to solve the problems of low precision, high risk, and low efficiency in existing technologies. Summary of the Invention

[0005] This invention aims to overcome the shortcomings of existing technologies and provide a stability control method for the modular construction of offshore substations. It is applicable to the entire process of onshore modular prefabrication, submodule splicing, and overall block forming of the upper modules (weighing 1000-5000t) of offshore substations. The core solution addresses stability issues such as center of gravity shift, interface deviation, and structural deformation during the construction phase. This provides a high-precision, high-reliability block foundation for subsequent transportation and offshore installation. Through standardized module design, high-precision support interface construction, standardized assembly processes, and collaborative control via real-time monitoring and adjustment, the stability of the entire substation block construction process is controllable, improving block construction accuracy and structural reliability while reducing safety risks and rectification costs.

[0006] The present invention specifically adopts the following technical solution: a stability control method for modular construction of offshore substations, comprising the following steps:

[0007] Step SS1: Standardize module division and design, based on the principles of "functional partitioning, weight adaptation, and controllable center of gravity" to achieve pre-control of the stability of sub-module division;

[0008] Step SS2: Construction of a high-precision support and connection system. Through adjustable support structure design and standardized interface configuration, the positioning accuracy and structural stability of the sub-modules during prefabrication and assembly are ensured.

[0009] Step SS3: Standardize the assembly process and precision control, and combine non-destructive testing and laser positioning to achieve stability control of sub-module splicing and block forming;

[0010] Step SS4: The monitoring system monitors and dynamically adjusts the construction process in real time. Through sensor monitoring and mechanical verification, it corrects assembly deviations in a timely manner to ensure the overall stability of the modules.

[0011] In a preferred embodiment, step SS1 specifically includes:

[0012] Step SS11: Divide the overall module into several sub-modules according to the functions of transformer, power distribution, control and auxiliary functions. The weight of a single sub-module shall be ≤80% of the rated load of the hoisting equipment. The overall dimensions of the assembled sub-modules shall be ≥70% compatible with the effective load-bearing area of ​​the subsequent transport barge deck.

[0013] Step SS12: Perform precise control of the center of gravity. Determine the center of gravity of the sub-module through finite element analysis and weighing method to ensure that the center of gravity offset of a single sub-module is ≤5% of the module side length, and the overlap of the center of gravity projection of the mating surface of adjacent sub-modules is ≥90%, so as to avoid the center of gravity offset after the block is formed.

[0014] Step SS13: Structural strength pre-design. The main structure of the sub-module uses high-strength steel. Finite element analysis verifies that the stress in key parts is ≤ 80% of the allowable stress of the material, ensuring that the structure does not deform during prefabrication and assembly.

[0015] As a preferred embodiment, the finite element analysis in step SS12 specifically includes:

[0016] Step SS121: Establish the 3D geometric model of the submodule, including: building a full-size 3D model in 3D software based on the submodule design drawings;

[0017] Step SS122: Material property definition and mesh generation, including: assigning material values ​​to each component of the submodule; then performing mesh generation, including: using solid elements, using a dense mesh for core heavy components and a sparse mesh for light components, ensuring the accuracy of the center of gravity calculation while balancing computational efficiency;

[0018] Step SS123: The finite element software calculates the total mass and mass moment of the model through integration, and automatically outputs the coordinates of the center of gravity (X, Y, Z). The core formula is as follows:

[0019] Total mass calculation: ;

[0020] in, Let be the density of the i-th component, be the volume of the i-th component, and n be the total number of components;

[0021] The calculation of the center of gravity coordinates takes the X direction as an example; the Y and Z directions are calculated similarly.

[0022] ;

[0023] in, Let X be the centroid of the i-th component. Let the mass of the i-th component be denoted as .

[0024] Boundary conditions: No constraints need to be applied; submit the calculation directly, and the finite element software will output the theoretical coordinates of the submodule's center of gravity. ;

[0025] Step SS124: Simulation result verification, including: comparing the simulated total mass of the submodule with the theoretical mass of the design. The error should be ≤ ±2%. If it exceeds the error range, check whether the geometric dimensions and material density assignments of the three-dimensional geometric model of the submodule are accurate. After correction, recalculate.

[0026] As a preferred embodiment, the weighing method in step SS12 specifically includes the following steps:

[0027] The preparation steps for the crane and weighing equipment include: selecting a high-precision crane with a rated lifting capacity ≥ 1.5 times the weight of the submodule; equipping the crane with a force sensor to collect the lifting force in real time; configuring four high-strength slings of the same length, with shackles installed at both ends of the slings; and preparing a laser level, steel tape measure, and marker as auxiliary tools for lifting point positioning and data measurement.

[0028] The steps for arranging the lifting points and establishing the coordinate system include: arranging four lifting points symmetrically on the top of the submodule to form a rectangular layout: Let the long side of the top plane of the submodule be the X direction and the short side be the Y direction. The four lifting points are located at the four corners of the rectangle, denoted as lifting point 1, lifting point 2, lifting point 3, and lifting point 4. Measure and record the coordinates of the four lifting points: taking the lower left corner of the rectangle, lifting point 1, as the origin O (0,0,H), H as the height of the lifting point (i.e., the height of the top of the submodule from the ground), the coordinates of lifting point 2 are (L,0,H), the coordinates of lifting point 3 are (L,W,H), and the coordinates of lifting point 4 are (0,W,H), where L is the length of the long side of the rectangle and W is the length of the short side. Ensure that the distances from the four lifting points to the edge of the submodule are consistent, and that the angle between the sling and the top plane of the submodule is ≥60°.

[0029] The lifting, weighing, and data acquisition steps include: connecting four slings to the crane hook and the four lifting points of the submodule respectively; installing tension sensors on the slings to monitor the tension of each sling in real time; starting the crane to lift the submodule 100-200mm off the ground and then stopping the lifting; adjusting the crane's posture using a laser level to ensure the submodule is placed horizontally; and recording the measured tension F of the four slings after the submodule has stabilized. 1、 F 2、 F 3、 F4, total weight of submodule F total= The weights of F1+F2+F3+F4 are compared with the theoretical design weights. The error must be ≤±1%. If the error exceeds the range, check whether the sling connection is reliable and whether the sensor is calibrated. Then lift and measure again.

[0030] The steps for calculating the center of gravity coordinates based on lifting data include: Calculation of the center of gravity plane coordinates (X, Y): using the rectangular plane where the lifting point is located as the reference plane.

[0031] Total weight lifted: ;

[0032] in, ;

[0033] X-coordinate of the lifting center of gravity: ;

[0034] in, These are the X coordinates of the four suspension points, namely 0, L, L, 0;

[0035] Y-coordinate of the lifting center of gravity: ;

[0036] in, These are the Y coordinates of the four suspension points, namely 0, 0, W, and W.

[0037] Z-coordinate of the lifting center of gravity: ;

[0038] in, The height of the lifting points for the two lifting operations. The tensile force measured twice at lifting point 1; L and W are the side lengths of the rectangle at the lifting point.

[0039] In a preferred embodiment, step SS12 further includes: calculating the deviation between the simulated value and the measured value.

[0040] ;

[0041] ;

[0042] ;

[0043] If the deviation is ≤±3mm, the measured value should be used directly. Use the final centroid coordinates; if the deviation is > ±3mm, analyze the cause of the deviation, correct the finite element model and re-simulate until the deviation between the simulated value and the measured value is ≤ ±3mm, and finally output the corrected centroid coordinates.

[0044] In a preferred embodiment, step SS2 specifically includes:

[0045] Step SS21: Submodule support structure design steps, including: setting several adjustable support seats at the bottom of each submodule, the adjustable support seats are made of Q690D high-strength steel, and the top of the adjustable support seats is equipped with wedge-shaped wooden pads with an adjustment stroke of 0~300mm, which are used for level calibration during the prefabrication and assembly stages;

[0046] Step SS22: Positioning accuracy assurance step, including: a positioning plate is set at the bottom of the adjustable support, and the positioning plate has positioning holes that cooperate with the positioning pins of the prefabricated platform to ensure that the prefabricated plane position error of the sub-module is ≤±2mm;

[0047] Step SS23: Standardized connection interface design steps, including: the sub-module mating surface adopts a combination interface of "slot mating + positioning pin", the slot is designed to prevent falling off, and is fixed for secondary fixation with locking bolts, and the positioning pin is a conical pin to ensure the mating accuracy ≤ ±0.5mm;

[0048] Step SS24: Design steps for stress monitoring, including: reserving sensor mounting holes at the interface for stress monitoring of the assembled module.

[0049] In a preferred embodiment, step SS3 specifically includes:

[0050] Step SS31: Quality control of sub-module prefabrication, including: after the prefabrication of a single sub-module is completed in the onshore prefabrication plant, non-destructive testing methods such as ultrasonic testing and radiographic testing are used to ensure structural integrity;

[0051] Step SS32: Precise transfer and positioning steps, including: transferring qualified sub-modules to the final assembly platform, calibrating the spatial position of the sub-modules using a laser positioning device, and automatically adjusting when the deviation exceeds 5mm;

[0052] Step SS33: Levelness and fastening control steps, including: adjusting the levelness of the sub-module through the adjustable support to ensure that the levelness error is ≤0.1mm / m, and using high-strength bolts to complete the splicing and fastening of the sub-module to form an integral block.

[0053] In a preferred embodiment, step SS4 specifically includes:

[0054] Step SS41: Deployment of the monitoring system, including: placing stress sensors at the sub-module docking interfaces and support points, placing MEMS tilt sensors at the four corners of the top of the module, and placing laser displacement sensors at the splicing points to collect stress, attitude, and displacement data in real time.

[0055] Step SS42: Static mechanical verification, including: establishing a three-dimensional model of the overall block using finite element software, inputting material parameters and sub-module connection stiffness, the parameters including density, elastic modulus, and Poisson's ratio, calculating the gravity distribution and support reaction force of the overall block under static state, and verifying that the stress at the support point is ≤ 80% of the allowable stress of the material;

[0056] Step SS43: Abnormal adjustment mechanism, including: when stress exceeds the threshold, level deviation exceeds 0.2mm / m, or displacement exceeds 3mm, the adjustment process is initiated: level is calibrated by adjusting the support base, bolt tightening force is increased, and the sub-module splicing sequence is re-optimized if necessary.

[0057] In a preferred embodiment, the monitoring system transmits data to a local controller via wired connection, generating stress, attitude, and displacement parameter curves in real time. The data storage period is ≥1 year, which is used for construction quality traceability.

[0058] As a preferred embodiment, the dimensions of a single sub-module in step SS1 must meet the following requirements: length ≤ 20m, width ≤ 16m, and height ≤ 12m, to adapt to the site conditions of the land-based prefabrication plant and the operating range of the hoisting equipment.

[0059] The beneficial effects achieved by this invention are as follows: First, significant effectiveness in pre-construction stability control: Standardized modular division and center-of-gravity control ensure that the center-of-gravity offset of each module is ≤5%, and the interface docking accuracy is improved to ±0.5mm, thus avoiding the risk of subsequent structural instability from the source; Second, dual improvement in assembly accuracy and efficiency: The combination of adjustable support bases and laser positioning technology ensures a levelness error of ≤0.1mm / m, increases splicing efficiency by 40%, and reduces high-altitude work by 60%; Third, significantly enhanced structural reliability: Through finite element pre-verification and real-time stress monitoring, the stress qualification rate of key parts of the modules is 100%, and the structural deformation rate is reduced to below 0.1%; Fourth, closed-loop control throughout the entire process: A complete "design-prefabrication-assembly-monitoring-adjustment" chain is constructed to avoid problems at each stage. Fifth, this invention is applicable to the construction of superstructure modules for offshore substations weighing 1000-5000t. Through full-process stability control, the module docking accuracy is ≥99.5%, the structural stress qualification rate is 100%, and the assembly efficiency is improved by more than 25% compared with traditional methods. Sixth, this invention avoids stability risks such as center of gravity shift, interface deviation, and stress concentration during the construction stage from the source through standardized design, precise calculation, intelligent execution and real-time monitoring of modular construction, improves the module construction accuracy and structural reliability, lays a solid foundation for subsequent transportation and offshore installation, and significantly reduces engineering safety risks and overall costs. Attached Figure Description

[0060] Figure 1 This is a flowchart of the stability control method for the modular construction of offshore substations according to the present invention. Detailed Implementation

[0061] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0062] Implementation Target: The implementation target is the upper module of the offshore substation of a 500MW offshore wind power project. The module has a total weight of 2500t and dimensions of 32m×16m×22m. It contains 4 functional modules: transformer module (weight 800t, dimensions 16m×16m×10m), GIS power distribution module (weight 600t, dimensions 16m×16m×8m), control and protection module (weight 400t, dimensions 8m×16m×8m), and auxiliary equipment module (weight 700t, dimensions 16m×16m×6m).

[0063] Example 1: As Figure 1 As shown, this invention proposes a stability control method for the modular construction of offshore substations, comprising the following steps:

[0064] Step SS1: Standardize module division and design, based on the principles of "functional partitioning, weight adaptation, and controllable center of gravity" to achieve pre-control of the stability of sub-module division;

[0065] Step SS2: Construction of a high-precision support and connection system. Through adjustable support structure design and standardized interface configuration, the positioning accuracy and structural stability of the sub-modules during prefabrication and assembly are ensured.

[0066] Step SS3: Standardize the assembly process and precision control, and combine non-destructive testing and laser positioning to achieve stability control of sub-module splicing and block forming;

[0067] Step SS4: The monitoring system monitors and dynamically adjusts the construction process in real time. Through sensor monitoring and mechanical verification, it corrects assembly deviations in a timely manner to ensure the overall stability of the modules.

[0068] In a preferred embodiment, step SS1 specifically includes:

[0069] Step SS11: Divide the overall module into several sub-modules according to the transformation, power distribution, control and auxiliary functions. The weight of a single sub-module shall be ≤80% of the rated load of the lifting equipment, and the weight of a single module shall be ≤800t (compatible with 1000t lifting equipment). The total size of the assembled sub-modules shall be ≤70% of the effective bearing area of ​​the deck of the subsequent transport barge. For example, the module size corresponding to a 30m×15m deck shall be ≤21m×10.5m.

[0070] Step SS12: Perform precise control of the center of gravity. Determine the center of gravity of the sub-module through finite element analysis and weighing method to ensure that the center of gravity offset of a single sub-module is ≤5% of the module side length. For example, the center of gravity offset of a 10m side length module is ≤500mm. The overlap of the center of gravity projection of the mating surface of adjacent sub-modules is ≥90% to avoid the center of gravity offset after the block is formed.

[0071] Step SS13: Structural strength pre-design. The main structure of the sub-module uses high-strength steel. Finite element analysis verifies that the stress in key parts (corners, interfaces) is ≤ 80% of the allowable stress of the material, ensuring that the structure does not deform during prefabrication and assembly.

[0072] As a preferred embodiment, the finite element analysis in step SS12 specifically includes:

[0073] Step SS121: Establish the three-dimensional geometric model of the submodule, including: based on the submodule design drawings, construct a full-size three-dimensional model in the three-dimensional software, material parameters: Q690D steel elastic modulus 210GPa, Poisson's ratio 0.3;

[0074] Step SS122: Material property definition and mesh generation, including: assigning material values ​​to each component of the submodule; then performing mesh generation, including: using solid elements, using a dense mesh for core heavy components and a sparse mesh for light components, ensuring the accuracy of the center of gravity calculation while balancing computational efficiency;

[0075] Step SS123: The finite element software calculates the total mass and mass moment of the model through integration, and automatically outputs the coordinates of the center of gravity (X, Y, Z). The core formula is as follows:

[0076] Total mass calculation: ;

[0077] in, Let be the density of the i-th component, be the volume of the i-th component, and n be the total number of components;

[0078] The calculation of the center of gravity coordinates takes the X direction as an example; the Y and Z directions are calculated similarly.

[0079] ;

[0080] in, Let X be the centroid of the i-th component. Let the mass of the i-th component be denoted as .

[0081] Boundary conditions: No constraints need to be applied; submit the calculation directly, and the finite element software will output the theoretical coordinates of the submodule's center of gravity. ;

[0082] Step SS124: Simulation result verification, including: comparing the simulated total mass of the submodule with the theoretical mass of the design. The error should be ≤ ±2%. If it exceeds the error range, check whether the geometric dimensions and material density assignments of the three-dimensional geometric model of the submodule are accurate. After correction, recalculate.

[0083] As a preferred embodiment, the weighing method in step SS12 specifically includes the following steps:

[0084] The preparation steps for the crane and weighing equipment include: selecting a high-precision crane with a rated lifting capacity ≥ 1.5 times the weight of the submodule; equipping the crane with a force sensor to collect the lifting force in real time; configuring four high-strength slings of the same length, with shackles installed at both ends of the slings; and preparing a laser level, steel tape measure, and marker as auxiliary tools for lifting point positioning and data measurement.

[0085] The steps for arranging the lifting points and establishing the coordinate system include: arranging four lifting points symmetrically on the top of the submodule to form a rectangular layout: Let the long side of the top plane of the submodule be the X direction and the short side be the Y direction. The four lifting points are located at the four corners of the rectangle, denoted as lifting point 1, lifting point 2, lifting point 3, and lifting point 4. Measure and record the coordinates of the four lifting points: taking the lower left corner of the rectangle, lifting point 1, as the origin O (0,0,H), H as the height of the lifting point (i.e., the height of the top of the submodule from the ground), the coordinates of lifting point 2 are (L,0,H), the coordinates of lifting point 3 are (L,W,H), and the coordinates of lifting point 4 are (0,W,H), where L is the length of the long side of the rectangle and W is the length of the short side. Ensure that the distances from the four lifting points to the edge of the submodule are consistent, and that the angle between the sling and the top plane of the submodule is ≥60°.

[0086] The lifting, weighing, and data acquisition steps include: connecting four slings to the crane hook and the four lifting points of the submodule respectively; installing tension sensors on the slings to monitor the tension of each sling in real time; starting the crane to lift the submodule 100-200mm off the ground and then stopping the lifting; adjusting the crane's posture using a laser level to ensure the submodule is placed horizontally; and recording the measured tension F of the four slings after the submodule has stabilized. 1、 F 2、 F 3、 F4, total weight of submodule F total= The weights of F1+F2+F3+F4 are compared with the theoretical design weights. The error must be ≤±1%. If the error exceeds the range, check whether the sling connection is reliable and whether the sensor is calibrated. Then lift and measure again.

[0087] The steps for calculating the center of gravity coordinates based on lifting data include: Calculation of the center of gravity plane coordinates (X, Y): using the rectangular plane where the lifting point is located as the reference plane.

[0088] Total weight lifted: ;

[0089] in, ;

[0090] X-coordinate of the lifting center of gravity: ;

[0091] in, These are the X coordinates of the four suspension points, namely 0, L, L, 0;

[0092] Y-coordinate of the lifting center of gravity: ;

[0093] in, These are the Y coordinates of the four suspension points, namely 0, 0, W, and W.

[0094] Z-coordinate of the lifting center of gravity: ;

[0095] in, The height of the lifting points for the two lifting operations. The tensile force measured twice at lifting point 1; L and W are the side lengths of the rectangle at the lifting point.

[0096] In a preferred embodiment, step SS12 further includes: calculating the deviation between the simulated value and the measured value.

[0097] ;

[0098] ;

[0099] ;

[0100] If the deviation is ≤±3mm, the measured value should be used directly. Use the final centroid coordinates; if the deviation is > ±3mm, analyze the cause of the deviation, correct the finite element model and re-simulate until the deviation between the simulated value and the measured value is ≤ ±3mm, and finally output the corrected centroid coordinates.

[0101] In a preferred embodiment, step SS2 specifically includes:

[0102] Step SS21: Submodule support structure design steps, including: setting several adjustable support seats (Q690D steel, adjustment stroke 0-300mm) at the bottom of each submodule. The adjustable support seats are made of Q690D high-strength steel, and wedge-shaped wooden pads are configured on the top of the adjustable support seats. The adjustment stroke is 0~300mm, which is used for level calibration during the prefabrication and assembly stages.

[0103] Step SS22: Positioning accuracy assurance step, including: a positioning plate (500mm×500mm×50mm) is set at the bottom of the adjustable support base, and the positioning plate is provided with a Φ50mm positioning hole that cooperates with the positioning pin of the prefabricated platform to ensure that the prefabricated plane position error of the sub-module is ≤±2mm;

[0104] Step SS23: Standardized connection interface design steps, including: the sub-module mating surface adopts a combination interface of "slot mating + positioning pin". The slot is designed to prevent falling off and is fixed for secondary fixation with locking bolts. The positioning pin is a Φ80mm tapered pin (taper 1:50) with a machining accuracy of IT7 grade to ensure that the mating accuracy is ≤±0.5mm.

[0105] Step SS24: Design steps for stress monitoring, including: reserving sensor mounting holes at the interface for stress monitoring of the assembled module.

[0106] In a preferred embodiment, step SS3 specifically includes:

[0107] Step SS31: Quality control of sub-module prefabrication, including: after the prefabrication of a single sub-module is completed in the onshore prefabrication plant, non-destructive testing methods such as ultrasonic testing (weld pass rate ≥99%) and radiographic testing (Level III or above) are used to ensure structural integrity;

[0108] Step SS32: Precise transfer and positioning steps, including: transferring qualified sub-modules to the final assembly platform, calibrating the spatial position of the sub-modules using a laser positioning device, and automatically adjusting when the deviation exceeds 5mm;

[0109] Step SS33: Levelness and fastening control steps, including: adjusting the levelness of the sub-modules using adjustable support seats to ensure that the levelness error is ≤0.1mm / m; using high-strength bolts (M30, preload 200kN) to complete the splicing and fastening of the sub-modules; after splicing, ultrasonic testing shows that the weld pass rate is 100% to form an integral block; after splicing, the overall flatness error of the block must be checked again using a laser positioning instrument to ensure that the verticality error is ≤±0.5mm / m.

[0110] In a preferred embodiment, step SS4 specifically includes:

[0111] Step SS41: Monitoring system deployment, including: placing stress sensors at the submodule docking interfaces and support points, placing MEMS tilt sensors at the four corners of the top of the module, and placing laser displacement sensors at the splicing points to collect stress, attitude, and displacement data in real time; support point stress 180MPa (≤80% of Q690D allowable stress 310MPa = 248MPa); docking interface stress 220MPa (≤310MPa × 1.1 = 341MPa);

[0112] Step SS42: Static mechanical verification, including: establishing a three-dimensional model of the overall block using finite element software, inputting material parameters and sub-module connection stiffness, the parameters including density, elastic modulus, and Poisson's ratio, calculating the gravity distribution and support reaction force of the overall block under static state, and verifying that the stress at the support point is ≤ 80% of the allowable stress of the material;

[0113] Step SS43: Abnormal adjustment mechanism, including: when the stress exceeds the threshold (90% of the material's allowable stress), the levelness deviation exceeds 0.2 mm / m, or the displacement exceeds 3 mm, the adjustment process is initiated: the levelness is calibrated by adjusting the support base, the bolt tightening force is increased, and the sub-module splicing sequence is re-optimized if necessary.

[0114] In a preferred embodiment, the monitoring system transmits data to a local controller via wired connection, generating stress, attitude, and displacement parameter curves in real time. The data storage period is ≥1 year, which is used for construction quality traceability.

[0115] As a preferred embodiment, the dimensions of a single sub-module in step SS1 must meet the following requirements: length ≤ 20m, width ≤ 16m, and height ≤ 12m, to adapt to the site conditions of the land-based prefabrication plant and the operating range of the hoisting equipment.

[0116] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0117] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 The computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to operate in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The functions specified in one or more boxes. These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable apparatus for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0118] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A stability control method for modular construction of offshore substations, characterized in that, Includes the following steps: Step SS1: Standardized module partitioning and design, based on the principles of "functional partitioning, weight adaptation, and controllable center of gravity," to achieve pre-control of the stability of sub-module partitioning; Step SS1 specifically includes: Step SS11: Divide the overall module into several sub-modules according to the functions of transformer, power distribution, control and auxiliary functions. The weight of a single sub-module shall be ≤80% of the rated load of the hoisting equipment. The overall dimensions of the assembled sub-modules shall be ≥70% compatible with the effective load-bearing area of ​​the subsequent transport barge deck. Step SS12: Perform precise control of the center of gravity. Determine the center of gravity of the sub-module through finite element analysis and weighing method to ensure that the center of gravity offset of a single sub-module is ≤5% of the module side length, and the overlap of the center of gravity projection of the mating surface of adjacent sub-modules is ≥90%, so as to avoid the center of gravity offset after the block is formed. Step SS13: Structural strength pre-design. The main structure of the sub-module uses high-strength steel. Finite element analysis verifies that the stress in key parts is ≤80% of the allowable stress of the material, ensuring that the structure does not deform during prefabrication and assembly. Step SS2: Construction of a high-precision support and connection system. Through adjustable support structure design and standardized interface configuration, the positioning accuracy and structural stability of the sub-modules during prefabrication and assembly are ensured. Step SS3: Standardize the assembly process and precision control, and combine non-destructive testing and laser positioning to achieve stability control of sub-module splicing and block forming; Step SS4: The monitoring system monitors and dynamically adjusts the construction process in real time. Through sensor monitoring and mechanical verification, it corrects assembly deviations in a timely manner to ensure the overall stability of the modules.

2. The stability control method for modular construction of offshore substations according to claim 1, characterized in that, The finite element analysis in step SS12 specifically includes: Step SS121: Establish the 3D geometric model of the submodule, including: building a full-size 3D model in 3D software based on the submodule design drawings; Step SS122: Material property definition and mesh generation, including: assigning material values ​​to each component of the submodule; then performing mesh generation, including: using solid elements, using a dense mesh for core heavy components and a sparse mesh for light components, ensuring the accuracy of the center of gravity calculation while balancing computational efficiency; Step SS123: The finite element software calculates the total mass and mass moment of the model through integration, and automatically outputs the coordinates of the center of gravity (X, Y, Z). The core formula is as follows: Total mass calculation: ; in, Let be the density of the i-th component, be the volume of the i-th component, and n be the total number of components; The calculation of the center of gravity coordinates takes the X direction as an example; the Y and Z directions are calculated similarly. ； in, Let X be the centroid coordinate of the i-th component. Let the mass of the i-th component be denoted as . Boundary conditions: No constraints need to be applied; submit the calculation directly, and the finite element software will output the theoretical coordinates of the submodule's center of gravity. ; Step SS124: Simulation result verification, including: comparing the simulated total mass of the submodule with the theoretical mass of the design. The error should be ≤ ±2%. If it exceeds the error range, check whether the geometric dimensions and material density assignments of the three-dimensional geometric model of the submodule are accurate. After correction, recalculate.

3. The stability control method for modular construction of offshore substations according to claim 1, characterized in that, The weighing method in step SS12 specifically includes the following steps: The preparation steps for the crane and weighing equipment include: selecting a high-precision crane with a rated lifting capacity ≥ 1.5 times the weight of the submodule; equipping the crane with a force sensor to collect the lifting force in real time; configuring 4 high-strength slings of the same length, with shackles installed at both ends of the slings; and preparing a laser level, steel tape measure, and marker as auxiliary tools for lifting point positioning and data measurement. The steps for arranging the lifting points and establishing the coordinate system include: arranging four lifting points symmetrically on the top of the submodule to form a rectangular layout: Let the long side of the top plane of the submodule be the X direction and the short side be the Y direction. The four lifting points are located at the four corners of the rectangle, denoted as lifting point 1, lifting point 2, lifting point 3, and lifting point 4. Measure and record the coordinates of the four lifting points: taking lifting point 1 at the lower left corner of the rectangle as the origin O(0,0,H), H as the height of the lifting point (i.e., the height of the top of the submodule from the ground), the coordinates of lifting point 2 are (L,0,H), the coordinates of lifting point 3 are (L,W,H), and the coordinates of lifting point 4 are (0,W,H), where L is the length of the long side of the rectangle and W is the length of the short side. Ensure that the distances from the four lifting points to the edge of the submodule are consistent, and that the angle between the sling and the top plane of the submodule is ≥60°. The lifting, weighing, and data acquisition steps include: connecting four slings to the crane hook and the four lifting points of the submodule respectively; installing tension sensors on the slings to monitor the tension of each sling in real time; starting the crane to lift the submodule 100-200mm off the ground and then stopping the lifting; adjusting the crane's posture using a laser level to ensure the submodule is placed horizontally; and recording the measured tension F of the four slings after the submodule has stabilized. 1、 F 2、 F 3、 F4, total weight of submodule F total= The weights of F1+F2+F3+F4 are compared with the theoretical design weights. The error must be ≤±1%. If the error exceeds the range, check whether the sling connection is reliable and whether the sensor is calibrated. Then lift and measure again. The steps for calculating the center of gravity coordinates based on lifting data include: Calculation of the center of gravity plane coordinates (X, Y): using the rectangular plane where the lifting point is located as the reference plane. Total weight lifted: ; in, ; X-coordinate of the lifting center of gravity: ; in, These are the X coordinates of the four suspension points, namely 0, L, L, 0; Y-coordinate of the lifting center of gravity: ; in, These are the Y coordinates of the four suspension points, namely 0, 0, W, and W. Z-coordinate of the lifting center of gravity: ; in, The height of the lifting points for the two lifting operations. The tensile force measured twice at lifting point 1; L and W are the side lengths of the rectangle at the lifting point.

4. The stability control method for modular construction of offshore substations according to claim 3, characterized in that, Step SS12 further includes: calculating the deviation between the simulation value and the measured value. ； ； ； If the deviation ≤ 3mm, using actual measured value directly. As the final centroid coordinates; if the deviation > 3mm, analyze the cause of the deviation, correct the finite element model and resimulate until the deviation between the simulated value and the measured value is ≤ 3mm, and finally output the corrected center of gravity coordinates.

5. The stability control method for modular construction of offshore substations according to claim 1, characterized in that, Step SS2 specifically includes: Step SS21: Submodule support structure design steps, including: setting several adjustable support seats at the bottom of each submodule, the adjustable support seats are made of Q690D high-strength steel, and the top of the adjustable support seats is equipped with wedge-shaped wooden pads with an adjustment stroke of 0~300mm, which are used for level calibration during the prefabrication and assembly stages; Step SS22: Positioning accuracy assurance step, including: a positioning plate is set at the bottom of the adjustable support, and the positioning plate has positioning holes that cooperate with the positioning pins of the prefabricated platform to ensure that the prefabricated plane position error of the sub-module is ≤±2mm; Step SS23: Standardized connection interface design steps, including: the sub-module mating surface adopts a combination interface of "slot mating + positioning pin", the slot is designed to prevent falling off, and is fixed for secondary fixation with locking bolts, and the positioning pin is a conical pin to ensure the mating accuracy ≤ ±0.5mm; Step SS24: Design steps for stress monitoring, including: reserving sensor mounting holes at the interface for stress monitoring of the assembled module.

6. The stability control method for modular construction of offshore substations according to claim 1, characterized in that, Step SS3 specifically includes: Step SS31: Quality control of sub-module prefabrication, including: after the prefabrication of a single sub-module is completed in the onshore prefabrication plant, non-destructive testing methods such as ultrasonic testing and radiographic testing are used to ensure structural integrity; Step SS32: Precise transfer and positioning steps, including: transferring qualified sub-modules to the final assembly platform, calibrating the spatial position of the sub-modules using a laser positioning device, and automatically adjusting when the deviation exceeds 5mm; Step SS33: Levelness and fastening control steps, including: adjusting the levelness of the sub-module through the adjustable support to ensure that the levelness error is ≤0.1mm / m, and using high-strength bolts to complete the splicing and fastening of the sub-module to form an integral block.

7. The stability control method for modular construction of offshore substations according to claim 1, characterized in that, Step SS4 specifically includes: Step SS41: Deployment of the monitoring system, including: placing stress sensors at the sub-module docking interfaces and support points, placing MEMS tilt sensors at the four corners of the top of the module, and placing laser displacement sensors at the splicing points to collect stress, attitude, and displacement data in real time; Step SS42: Static mechanical verification, including: establishing a three-dimensional model of the overall block using finite element software, inputting material parameters and sub-module connection stiffness, the parameters including density, elastic modulus, and Poisson's ratio, calculating the gravity distribution and support reaction force of the overall block under static state, and verifying that the stress at the support point is ≤ 80% of the allowable stress of the material; Step SS43: Abnormal adjustment mechanism, including: when stress exceeds the threshold, level deviation exceeds 0.2mm / m, or displacement exceeds 3mm, the adjustment process is initiated: level is calibrated by adjusting the adjustable support, bolt tightening force is increased, and the sub-module splicing sequence is re-optimized if necessary.

8. The stability control method for modular construction of offshore substations according to claim 7, characterized in that, The data from the monitoring system is transmitted to the local controller via wired transmission, generating stress, attitude, and displacement parameter curves in real time. The data storage period is ≥1 year, which is used for construction quality traceability.

9. The stability control method for modular construction of offshore substations according to claim 1, characterized in that, In step SS1, the dimensions of a single sub-module must meet the following requirements: length ≤ 20m, width ≤ 16m, and height ≤ 12m, to adapt to the site conditions of the land-based prefabrication plant and the operating range of the hoisting equipment.

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