Pile foundation pore-forming quality detection device, assembly installation method and optimization system

Abstract

The invention discloses a pile foundation pore-forming quality detection device, an assembly installation method and an optimization system. Ultrasonic sensors are symmetrically installed on the drill bit portion of the rotary drilling rig, and data collected by the sensors are rapidly sent to an upper computer in a wireless transmission mode when the drill bit is lifted to the ground or a signal transmission area. And the upper computer processes and analyzes the data, and compares the calculated perpendicularity with a preset threshold value. If the perpendicularity exceeds the threshold value range, a prompt is triggered immediately, a constructor is guided to correct deviation in time when digging down again, and dynamic quality control is achieved. System data can be in butt joint with a Beidou digital intelligent construction management platform, and remote monitoring, quality data centralized management and intelligent decision support are achieved.

Description

Technical Field

[0001] This invention relates to the field of pile foundation construction, and in particular to a pile foundation hole formation quality testing device, component installation method and optimization system. Background Technology

[0002] In the infrastructure sector, pile foundations are the core load-bearing structures. The diameter and verticality of the pile hole are key indicators of the hole formation quality. Deviations in these parameters can easily lead to structural safety hazards such as material waste and insufficient bearing capacity. Therefore, hole formation quality testing is of paramount importance.

[0003] Currently, pile foundation borehole quality testing mainly relies on offline methods, which have many drawbacks: manual borehole testing is unsafe, inefficient, and has unstable accuracy; mechanical penetration testing, while avoiding manual risks, is susceptible to data distortion due to impurities, and has a limited measurement range and cannot output data in real time, hindering timely adjustments during construction; early ultrasonic testing, although improving safety and accuracy, still has shortcomings: the transducer frequency is fixed, leading to large measurement errors under complex geological conditions; the communication mode is singular, making data loss easy; and the lack of sound velocity compensation and data fusion algorithms results in poor measurement stability and reliability.

[0004] Furthermore, the existing component installation methods lack a unified standard, with arbitrary location selection and installation methods that do not match the working conditions, further affecting the accuracy of testing.

[0005] In summary, existing detection methods generally suffer from low efficiency, poor safety, insufficient accuracy, or inability to provide real-time data feedback, making it difficult to meet the demands of modern pile foundation construction for efficient and precise control of borehole quality. Therefore, developing a device capable of real-time and accurate detection of pile hole diameter and verticality parameters has become a pressing technical challenge in the field of pile foundation construction. Summary of the Invention

[0006] To solve the above-mentioned technical problems, the present invention provides a pile foundation hole formation quality testing device, including an ultrasonic sensing component, a signal processing module, a wireless transmission module, a host computer system, and a platform docking module;

[0007] The ultrasonic sensing component is fixed to the drill bit of the rotary drilling rig and is used to collect three-dimensional attitude data, spatial position data and depth change data at each depth of the pile hole in real time during the process of the drill bit lifting and unloading soil. It also has a built-in filtering algorithm.

[0008] The signal processing module is electrically connected to the ultrasonic sensing component and is used to process the raw signals collected by the ultrasonic sensing component.

[0009] The wireless transmission module is used to send the processed data to the host computer system when the drill bit is raised to the ground or to an area where the signal can be effectively transmitted.

[0010] The host computer system is used to receive data and perform analysis and processing, calculate the real-time diameter and verticality parameters of the pile hole and compare them with a preset threshold. If the threshold is exceeded, an alarm is triggered.

[0011] The platform docking module is used to establish a communication connection with the Beidou digital construction management platform to complete data uploading, centralized control and sharing.

[0012] Furthermore, the ultrasonic sensing component includes at least two ultrasonic transducers. The ultrasonic transducers are made of piezoelectric ceramic material and have both ultrasonic emission and reflected wave reception functions. When powered on, they generate mechanical vibration to emit ultrasonic waves. When receiving reflected waves, they convert the mechanical vibration into electrical signals. The multiple ultrasonic transducers are evenly distributed along the circumference of the drill bit.

[0013] Furthermore, the ultrasonic frequency emitted by the ultrasonic transducer can be adaptively adjusted within the range of 20kHz-200kHz, and the frequency adjustment is automatically triggered according to the pile hole depth, medium type and detection accuracy requirements.

[0014] Furthermore, the signal processing module includes a signal amplification unit, a filtering unit, and a shaping unit connected in sequence; the signal amplification unit is used to amplify the weak electrical signal output by the ultrasonic transducer; the filtering unit is used to filter out environmental interference signals and equipment noise; and the shaping unit is used to perform waveform normalization processing on the signal to extract the effective reflected signal.

[0015] Furthermore, the host computer system includes a data processing unit and a display unit; the data processing unit is used to calculate the one-way distance d from the ultrasonic transducer to the wall of the pile hole, and the calculation formula is d=v×t / 2, where v is the corrected sound speed and t is the total propagation time of the ultrasonic wave from transmission to reception;

[0016] The data processing unit is also used to calculate the actual diameter of the pile hole by combining installation parameters. The formula for calculating the pile hole diameter is: In the formula, , These are the distance measurements collected from the borehole wall by the ultrasonic transducers on both sides. The fixed mounting distance between the two sensor transmitting surfaces is equivalent to the outer envelope diameter of the drill bit at the current measurement section;

[0017] The data processing unit eliminates the influence of drill bit tilt through spatial geometric coordinate transformation and calculates the horizontal offset of the pile hole center. The verticality of the pile hole is calculated based on the offset, and the formula for calculating the verticality is: In the formula, This indicates the depth of the current detection point from the orifice. The range of values ​​is ;

[0018] The display unit is used to display pile hole diameter data, verticality data, and alarm information in real time.

[0019] Furthermore, the wireless transmission module supports dual-mode communication of 5G and LoRa. In areas with good signal, it prioritizes the use of 5G communication mode to achieve high-speed data transmission, and automatically switches to LoRa communication mode in areas with weak signal to ensure the continuity of data transmission. It also has the function of resuming data transmission after interruption.

[0020] The present invention also discloses a component installation method, which is applied to the above-mentioned real-time detection device for pile foundation hole formation quality, including installation location selection, installation method matching, environmental adaptation and post-installation debugging steps.

[0021] The installation location should be selected in accordance with the principles of being unobstructed, free from turbulence, and far away from sources of interference.

[0022] The installation method is matched according to the container structure and material type, and the environmental adaptation is designed to protect against working conditions such as temperature, pressure, corrosion, and explosion.

[0023] The post-installation commissioning includes parameter setting, false echo learning, and accuracy calibration to ensure that the ultrasonic signal reaches the level surface without obstruction or interference, reduce the impact of the installation environment on the equipment, and ensure measurement accuracy.

[0024] Furthermore, when selecting the installation location, the distance between the transducer and the tank wall should be ≥ 1 / 6 of the container diameter and not less than 200mm. It should be kept away from internal obstacles such as agitators, heating pipes, and feed inlets, and should avoid areas with excessively high dust concentrations and strong airflow locations above the liquid surface. It should be preferentially installed in areas with stable material level changes, such as the middle of the container.

[0025] Furthermore, the specific installation methods are as follows: For closed containers, top flange installation or threaded installation is used, with the flange specifications matching the container interface, and the transducer axis perpendicular to the level surface with a deviation of ≤3°; for open containers, bracket installation or wall-mounted installation is used, with the bracket height fixed and no obstruction below the transducer; for high-viscosity / easily deposited media scenarios, installation with a purging device is used, with a reserved purging interface and an anti-deposit probe selected; for deep cavity / narrow-mouth containers, extension rod or waveguide installation is used to extend the transducer to the stable area inside the container.

[0026] Furthermore, when adapting to different environments, select a normal temperature probe for ambient temperatures ≤60℃ and a high temperature probe with a heat insulation layer for temperatures >60℃; select a pressure-resistant level gauge with a matching pressure rating for pressurized closed containers; when measuring corrosive media, use corrosion-resistant materials for the probe, flange, and seals; select an explosion-proof level gauge with an explosion-proof rating that meets the requirements for flammable and explosive environments, and ensure that the junction box and cable are sealed.

[0027] Furthermore, during post-installation commissioning, input basic parameters such as transducer installation height, container bottom blind zone, and medium type into the equipment menu; identify and mark false echoes through the equipment's on-site learning function; measure the actual level height using auxiliary tools such as a tape measure and radar level gauge and compare it with the equipment display value. If the error exceeds ±0.5%FS, adjust the sound velocity compensation parameters or installation position.

[0028] The present invention also discloses an optimization system applied to the above-mentioned real-time detection device for pile foundation hole formation quality. The optimization system includes a sound velocity multi-parameter compensation unit, a data fusion processing unit, and a detection angle adaptive adjustment unit.

[0029] The sound velocity multi-parameter compensation unit includes a temperature sensor, an air pressure sensor, and a medium density sensor. By fusing ambient temperature, air pressure, and medium density data, a multi-parameter sound velocity correction model is established to correct the sound velocity parameters.

[0030] The data fusion processing unit performs weighted fusion of signals collected by multiple ultrasonic transducers to reduce single-point measurement errors.

[0031] The adaptive detection angle adjustment unit drives the ultrasonic transducer through a built-in stepper motor, so that the detection angle automatically matches the optimal angle according to the diameter of the pile hole within a preset angle range.

[0032] Furthermore, the sound speed multi-parameter compensation unit has a built-in preset temperature-sound speed, air pressure-sound speed and medium density-sound speed correlation database, which calls the corresponding data in real time to correct the sound speed.

[0033] Furthermore, the data fusion processing unit employs a Kalman filter fusion algorithm to dynamically weight the pile hole diameter data collected by different ultrasonic transducers at the same depth. The weighting coefficients are adjusted in real time according to the signal strength and stability of each transducer.

[0034] Furthermore, the adaptive detection angle adjustment unit also includes a distance sensing subunit, which detects the distance between the ultrasonic transducer and the pile hole wall in real time. When the distance changes beyond the preset range, it automatically triggers a detection angle adjustment command.

[0035] This invention offers several technical advantages: First, by employing a multi-transducer layout, multi-parameter sound velocity compensation, and data fusion algorithms, it significantly improves the accuracy of pile hole diameter and verticality detection, ensuring construction quality. Second, it enables real-time data acquisition and intelligent early warning during the drill bit lifting process, promptly identifying quality issues and avoiding rework to reduce costs. Third, with its adaptive frequency adjustment, dual-mode communication, and adaptive detection angle design, it adapts to complex construction environments, enhancing operational flexibility. Fourth, its standardized installation process adapts to diverse working conditions, ensuring stable equipment operation. Fifth, relying on the BeiDou digital platform, it achieves centralized data management, breaking spatial and temporal limitations, improving the digitalization level of construction management, and facilitating efficient progress. Attached Figure Description

[0036] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0037] Figure 1 Block diagram of a real-time monitoring device for pile foundation hole quality;

[0038] Figure 2 Flowchart of component installation method;

[0039] Figure 3 To optimize the system block diagram. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0041] Example 1

[0042] See Figure 1 The present invention provides a pile foundation hole formation quality testing device, including an ultrasonic sensing component, a signal processing module, a wireless transmission module, a host computer system and a platform docking module;

[0043] The ultrasonic sensing component is fixed to the drill bit of the rotary drilling rig and is used to collect three-dimensional attitude data, spatial position data and depth change data at each depth of the pile hole in real time during the process of the drill bit lifting and unloading soil. It also has a built-in filtering algorithm.

[0044] The signal processing module is electrically connected to the ultrasonic sensing component and is used to process the raw signals collected by the ultrasonic sensing component.

[0045] The wireless transmission module is used to send the processed data to the host computer system when the drill bit is raised to the ground or to an area where the signal can be effectively transmitted.

[0046] The host computer system receives data and performs analysis and processing, calculates the real-time diameter and verticality parameters of the pile hole and compares them with a preset threshold. An alarm is triggered when the threshold is exceeded.

[0047] The platform docking module enables communication with the Beidou digital construction management platform, completing data uploading, centralized control and sharing.

[0048] Furthermore, the ultrasonic sensing component includes at least two ultrasonic transducers. The ultrasonic transducers are made of piezoelectric ceramic material and have both ultrasonic emission and reflected wave reception functions. When powered on, they generate mechanical vibration to emit ultrasonic waves. When receiving reflected waves, they convert the mechanical vibration into electrical signals. The multiple ultrasonic transducers are evenly distributed along the circumference of the drill bit.

[0049] Specifically, the preferred number of ultrasonic transducers is 2-4, with the exact number determined based on the designed diameter of the pile hole. Two transducers are used when the diameter is ≤1.5m, three transducers are used when the diameter is >1.5m and ≤3m, and four transducers are used when the diameter is >3m. PZT-5 series piezoelectric ceramics are selected as the piezoelectric ceramic material, with an electromechanical coupling coefficient ≥0.5 and dielectric loss ≤0.03 to ensure energy conversion efficiency. When the transducers are evenly distributed along the circumference of the drill bit, the central angle deviation between two adjacent transducers shall not exceed ±3°, and the emitting surface of the transducer shall be flush with the outer surface of the drill bit with a protrusion of no more than 0.5mm to avoid collision damage during drilling.

[0050] Furthermore, the ultrasonic frequency emitted by the ultrasonic transducer can be adaptively adjusted within the range of 20kHz-200kHz, and the frequency adjustment is automatically triggered according to the pile hole depth, medium type and detection accuracy requirements.

[0051] Specifically, for every 10m increase in pile hole depth, the frequency is adaptively reduced by 10-15kHz. When the depth is ≤30m, the initial frequency is set to 150-200kHz; when the depth is 30-80m, the initial frequency is set to 80-150kHz; and when the depth is >80m, the initial frequency is set to 20-80kHz. When the medium type is cohesive soil, the frequency adjustment is biased towards 50-120kHz; when the medium type is sandy soil, it is biased towards 40-100kHz; and when the medium type is gravelly soil, it is biased towards 20-80kHz. When the detection accuracy requirement is ±0.5cm, the frequency adjustment step is 2kHz; when the accuracy requirement is ±1cm, the adjustment step is 5kHz, ensuring that the frequency is accurately matched with the detection scenario.

[0052] Furthermore, the signal processing module includes a signal amplification unit, a filtering unit, and a shaping unit connected in sequence; the signal amplification unit is used to amplify the weak electrical signal output by the ultrasonic transducer; the filtering unit is used to filter out environmental interference signals and equipment noise; the shaping unit performs waveform normalization processing on the signal to extract the effective reflected signal.

[0053] Specifically, the signal amplification unit employs a two-stage operational amplifier circuit. The first stage is a low-noise amplification with a gain of 50-100 times, while the second stage is a programmable gain amplification with a gain adjustable from 1 to 10 times. The overall amplification range is 50-1000 times, ensuring that weak electrical signals are effectively amplified without distortion. The filtering unit uses an active bandpass filter with a center frequency consistent with the ultrasonic transducer's operating frequency. The passband width is ±10% of the operating frequency, and the stopband attenuation is ≥60dB, effectively filtering out irrelevant signals such as power frequency interference and mechanical vibration interference. The shaping unit uses a comparator circuit, with the comparison threshold adaptively adjustable according to the signal amplitude, ranging from 0.1-1V. The output signal is a standard square wave with rise and fall times both ≤0.5μs, facilitating subsequent data acquisition and processing.

[0054] Furthermore, the host computer system includes a data processing unit and a display unit; the data processing unit is used to calculate the one-way distance d from the ultrasonic transducer to the wall of the pile hole, and the calculation formula is d=v×t / 2, where v is the corrected sound speed and t is the total propagation time of the ultrasonic wave from transmission to reception;

[0055] The data processing unit is also used to calculate the actual diameter of the pile hole by combining installation parameters. The formula for calculating the pile hole diameter is: In the formula, , These are the distance measurements collected from the borehole wall by the ultrasonic transducers on both sides. The fixed mounting distance between the two sensor transmitting surfaces is equivalent to the outer envelope diameter of the drill bit at the current measurement section;

[0056] The data processing unit is also used to eliminate the influence of drill bit tilt through spatial geometric coordinate transformation and to calculate the horizontal offset of the pile hole center. The verticality of the pile hole is calculated based on the offset, and the formula for calculating the verticality is: In the formula, This indicates the depth of the current detection point from the orifice. The range of values ​​is The display unit displays real-time data on pile hole diameter, verticality, and alarm information.

[0057] Specifically, the calculation of the sound velocity correction value v requires multi-parameter compensation based on ambient temperature, air pressure, and medium density, with a compensation accuracy of ≤±0.3m / s; the acquisition of ultrasonic propagation time t uses a high-precision timing chip, with a timing accuracy of ≤0.1μs, ensuring that the calculation error of the single-journey distance d is ≤±0.2cm; the fixed installation base distance d0 is precisely calibrated before leaving the factory, with a calibration accuracy of ≤±0.1cm, and is recalibrated every 3 months during use; the spatial geometric coordinate transformation uses a Cartesian coordinate system transformation algorithm, and the attitude data collected by the drill bit tilt angle sensor needs to be introduced during the transformation process, with a tilt angle measurement accuracy of ≤±0.1°, ensuring that the horizontal offset calculation error is ≤±0.3cm; the display unit uses a 10-inch high-definition touch screen with a resolution of ≥1920×1080, a data refresh rate of ≥2Hz, a diameter data display accuracy of ±0.1cm, a verticality data display accuracy of ±0.01%, and alarm information is presented in the form of audible and visual alarms with an alarm response time of ≤0.5s.

[0058] Furthermore, the wireless transmission module supports dual-mode communication of 5G and LoRa. In areas with good signal, it prioritizes the use of 5G communication mode to achieve high-speed data transmission, and automatically switches to LoRa communication mode in areas with weak signal to ensure the continuity of data transmission. It also has the function of resuming data transmission after interruption.

[0059] Specifically, in 5G communication mode, the data transmission rate is ≥100Mbps, the transmission latency is ≤50ms, and it supports the simultaneous transmission of real-time detection data, device status data, and alarm information; in LoRa communication mode, the communication distance is ≥3km, the transmission rate can be adaptively adjusted within the range of 1.2-50kbps, and the receiving sensitivity is ≤-148dBm, ensuring stable transmission in areas with severe signal obstruction, such as underground construction; the data interruption resumption function adopts a fragmented storage + verification retransmission mechanism, the data fragment size is 1KB, and each fragment contains a CRC32 check code. When the transmission is interrupted, only the fragments that were not successfully received are retransmitted when reconnecting, and the maximum number of retransmissions is 3. If the retransmission still fails after 3 retransmissions, the anomaly is recorded and reported to the host computer.

[0060] This embodiment enables real-time monitoring of the pile foundation drilling process. A multi-transducer design ensures comprehensive data, and adaptive frequency adjustment adapts to different depths and geological conditions. The signal processing exhibits strong anti-interference capabilities, and dual-mode communication ensures stable data transmission. It can quickly calculate diameter and verticality and generate alarms, enabling centralized control via a management platform, thus improving construction efficiency and quality control.

[0061] Example 2

[0062] See appendix Figure 2 The present invention also discloses a component installation method for the above-mentioned real-time detection device for pile foundation hole formation quality, including installation location selection, installation method matching, environmental adaptation and post-installation debugging steps.

[0063] The installation location should be selected in accordance with the principles of being unobstructed, free from turbulence, and far away from sources of interference.

[0064] The installation method is matched according to the container structure and material type, and the environmental adaptation is designed to protect against working conditions such as temperature, pressure, corrosion, and explosion.

[0065] The post-installation commissioning includes parameter setting, false echo learning, and accuracy calibration to ensure that the ultrasonic signal reaches the level surface without obstruction or interference, reduce the impact of the installation environment on the equipment, and ensure measurement accuracy.

[0066] Furthermore, when selecting the installation location, the distance between the transducer and the tank wall should be ≥ 1 / 6 of the container diameter and not less than 200mm. It should be kept away from internal obstacles such as agitators, heating pipes, and feed inlets, and should avoid areas with excessively high dust concentrations and strong airflow locations above the liquid surface. It should be preferentially installed in areas with stable material level changes, such as the middle of the container.

[0067] Specifically, the distance between the transducer and the tank wall is calculated based on the straight-line distance from the inner surface of the tank wall to the transducer's emission center. When the container diameter is ≤1.2m, the distance should be ≥200mm (≥1 / 6 of the diameter). When the container diameter is >1.2m, the distance should be strictly ≥1 / 6 of the diameter. When away from internal obstacles, the minimum distance from the agitator blades should be ≥1m, and the minimum distance from the heating pipe and feed inlet should be ≥0.8m. The dust concentration should be controlled at ≤10mg / m³, and the strong airflow velocity above the liquid surface should be ≤2m / s. If this cannot be avoided, a windproof and dustproof cover should be installed. It is preferred to install the transducer within ±10cm above the axial centerline of the container. If the container is irregularly shaped, select an area with a level change rate ≤0.1m / min.

[0068] Furthermore, the installation method is as follows: for closed containers, a top flange or threaded installation is used, with the flange specifications matching the container interface, and the transducer axis perpendicular to the material level surface with a deviation of ≤3°; for open containers, a bracket or wall-mounted installation is used, with the bracket height fixed and no obstruction below the transducer; for high-viscosity / easily deposited media scenarios, an installation with a purging device is used, with a purging interface reserved and an anti-deposit probe selected; for deep cavity / narrow-mouth containers, an extension rod or waveguide is used to extend the transducer to a stable area inside the container.

[0069] Specifically, flanges of PN1.6MPa and DN50-DN100 specifications should be used for flange installation of closed containers, and threads of G1 / 2-G1 specifications should be used for thread installation. After installation, an airtightness test must be performed, and the leakage rate should be ≤1×10⁻⁶. -6Pa·m³ / s; The transducer axis verticality deviation is detected using a level, with a detection accuracy of ≤0.1°, ensuring the deviation does not exceed 3°; The mounting height of the open container's support is determined according to the container height, ensuring the transducer emitting surface is ≥0.5m from the highest material level. The support is made of stainless steel with a load-bearing capacity of ≥5kg. The diameter of the wall-mounted fixing bolts is ≥8mm, and the installation strength must meet the vibration resistance level of ≥IP65; For high-viscosity / easily deposited media scenarios, the purging device uses compressed air purging with a purging pressure of 0.3-0.5MPa and a purging flow rate of 5-10L / min. The anti-deposit probe surface is coated with polytetrafluoroethylene with a coating thickness of ≥0.2mm; The extension rod length for deep cavity / narrow-mouth containers is determined according to the container depth, with a maximum length of 5m. The waveguide inner diameter is ≥50mm, the tube wall thickness is ≥3mm, and the bottom of the waveguide is ≥0.3m from the bottom of the container.

[0070] Furthermore, when adapting to the environment, a normal temperature probe should be selected for ambient temperatures ≤60℃, and a high temperature probe should be selected for temperatures >60℃, with a heat insulation layer installed; for pressure-bearing closed containers, a pressure-resistant level gauge with a matching pressure rating should be selected; when measuring corrosive media, the probe, flange, and seals should be made of corrosion-resistant materials; for flammable and explosive environments, an explosion-proof level gauge with an explosion-proof rating that meets the requirements should be selected, and the junction box and cable should be sealed.

[0071] Specifically, the operating temperature range of the ambient temperature probe is -20℃ to 60℃, and the operating temperature range of the high temperature probe is -10℃ to 200℃. The heat insulation layer is made of ceramic fiber with a thickness of ≥20mm and a surface temperature of ≤50℃. The pressure resistance rating of the pressure-resistant level gauge must be 0.5MPa higher than the working pressure of the container, and the maximum pressure resistance is not less than 2.5MPa. In corrosive media scenarios, Hastelloy alloy is used for acidic media, 316L stainless steel is used for alkaline media, and polytetrafluoroethylene is used for highly corrosive media. Flanges and seals are sealed with fluororubber. The explosion-proof level gauge for flammable and explosive environments has an explosion-proof rating of not less than ExdIIBT4. The junction box adopts an explosion-proof design, the cable adopts a flame-retardant cable, and the sealing joint protection rating is ≥IP68 to ensure no spark leakage.

[0072] Furthermore, during the post-installation commissioning, basic parameters such as transducer installation height, container bottom blind zone, and medium type are input into the equipment menu; false echoes are identified and marked through the equipment's on-site learning function; the actual material level height is measured using auxiliary tools such as a tape measure and radar level gauge and compared with the value displayed on the equipment. If the error exceeds ±0.5%FS, the sound velocity compensation parameters or installation position are adjusted.

[0073] Specifically, the transducer installation height input accuracy should be ≤ ±1cm, the container bottom blind zone should be set to 0.2-0.5m, and the medium type should be selected from 20 common media preset by the equipment according to the actual working conditions. If no matching medium is available, the medium sound velocity parameter can be customized. The false echo learning process requires the acquisition of at least 5 sets of echo signals at different material level heights, with a learning time ≥ 30s. Marked false echoes will be automatically masked in subsequent measurements. When measuring the actual material level height, the measurement accuracy of the measuring tape should be ≤ ±1mm, and the measurement accuracy of the radar level gauge should be ≤ ±0.2%FS. When comparing, 3 different material level height points should be selected for measurement, and each point should be measured 3 times and the average value should be taken. If the error exceeds ±0.5%FS, the sound velocity compensation parameter should be adjusted first, with an adjustment step size of 0.1m / s. If the requirements are still not met after adjustment, the installation position should be readjusted until the error meets the standard.

[0074] This embodiment clarifies the installation site selection, method, environmental adaptation, and commissioning specifications, adapting to different pile hole sizes and working conditions. Through precise installation parameters and commissioning procedures, detection errors caused by installation deviations are avoided, ensuring stable transmission of sensor signals. This improves the ease of installation and adaptability of the device, laying the foundation for accurate detection and reducing construction and commissioning costs.

[0075] Example 3

[0076] See appendix Figure 3 The present invention also discloses an optimization system applied to the above-mentioned real-time detection device for pile foundation hole formation quality. The optimization system includes a sound velocity multi-parameter compensation unit, a data fusion processing unit, and a detection angle adaptive adjustment unit.

[0077] The sound velocity multi-parameter compensation unit includes a temperature sensor, an air pressure sensor, and a medium density sensor. By fusing ambient temperature, air pressure, and medium density data, a multi-parameter sound velocity correction model is established to correct the sound velocity parameters.

[0078] The data fusion processing unit performs weighted fusion of signals collected by multiple ultrasonic transducers to reduce single-point measurement errors.

[0079] The adaptive detection angle adjustment unit drives the ultrasonic transducer through a built-in stepper motor, so that the detection angle automatically matches the optimal angle according to the diameter of the pile hole within a preset angle range.

[0080] Furthermore, the sound speed multi-parameter compensation unit has a built-in preset temperature-sound speed, air pressure-sound speed and medium density-sound speed correlation database, which calls the corresponding data in real time to correct the sound speed.

[0081] Specifically, the temperature-velocity of sound correlation database covers a temperature range of -40℃ to 120℃, with a temperature interval of 1℃, and the corresponding velocity of sound data accuracy is ≤±0.1m / s; the air pressure-velocity of sound correlation database covers an air pressure range of 80kPa to 120kPa, with an air pressure interval of 1kPa, and the corresponding velocity of sound data accuracy is ≤±0.2m / s; the medium density-velocity of sound correlation database covers a density range of 0.8g / cm³ to 2.5g / cm³, with a density interval of 0.01g / cm³, and the corresponding velocity of sound data accuracy is ≤±0.3m / s. The database supports online updates every 3 months and can obtain the latest correlation data through a wireless transmission module to ensure the accuracy of the velocity of sound correction.

[0082] Furthermore, the data fusion processing unit employs a Kalman filter fusion algorithm to dynamically weight the pile hole diameter data collected by different ultrasonic transducers at the same depth. The weighting coefficients are adjusted in real time according to the signal strength and stability of each transducer.

[0083] Specifically, the noise variance of the state equation in the Kalman filter fusion algorithm is set to 0.01, while the noise variance of the observation equation is dynamically adjusted based on the signal strength: 0.005 when the signal strength is ≥80dB, 0.01 when the signal strength is 60-80dB, and 0.02 when the signal strength is <60dB. In the dynamic weighted calculation, the signal strength weight accounts for 60%, and the stability weight accounts for 40%. Signal stability is evaluated using the standard deviation of five consecutive measurement data: 0.4 when the standard deviation is ≤0.1cm, 0.2 when the standard deviation is 0.1-0.3cm, and 0.1 when the standard deviation is >0.3cm. The diameter data error after fusion is ≤±0.3cm, ensuring a significant improvement in measurement accuracy.

[0084] Furthermore, the adaptive detection angle adjustment unit also includes a distance sensing subunit, which detects the distance between the ultrasonic transducer and the borehole wall in real time. When the distance changes beyond a preset range, it automatically triggers a detection angle adjustment command. Preferably, the preset angle range is 10°-30°.

[0085] Specifically, the distance sensing subunit uses an infrared ranging sensor with a ranging range of 0.5-5m, a ranging accuracy of ≤±0.2cm, and a sampling frequency of ≥10Hz. It provides real-time feedback of the distance data between the transducer and the borehole wall. The preset distance range is determined based on the design diameter of the pile hole and is ±10% of the design diameter. When the detection distance exceeds this range, the stepper motor is triggered. The stepper motor has a step angle of 1.8°, an angle adjustment accuracy of ≤0.1°, and an adjustment speed of 5° / s. During the adjustment process, the echo signal intensity is collected every 1° adjustment. When the signal intensity reaches the maximum value and the stability meets the requirements, the adjustment is stopped and the current detection angle is locked to ensure that the transducer always detects at the optimal angle.

[0086] This embodiment offers the following advantages: multi-parameter compensation corrects sound velocity, improving ranging accuracy; Kalman filtering and data fusion reduce single-point errors; adaptive adjustment of the detection angle ensures signal strength. Multi-unit collaborative optimization of detection accuracy adapts to complex pile hole environments, reduces the impact of environmental and equipment factors on detection results, and meets the requirements of high-level engineering quality testing.

[0087] It is understood that the system and units provided in this embodiment can also be used to implement the steps in the methods provided in other embodiments of the present invention.

[0088] The present invention also provides a computer device. The computer device is manifested in the form of a general-purpose computing device. The components of the computer device may include, but are not limited to: one or more processors or processing units, system memory, and buses connecting different system components.

[0089] Computer devices typically include a variety of computer system-readable media. These media can be any available media that can be accessed by a computer device, including volatile and non-volatile media, and removable and non-removable media.

[0090] The system memory may include a computer system readable medium in the form of volatile memory, and the memory may include at least one program product having a set (e.g., at least one) of program modules configured to perform the functions of the embodiments of the present invention.

[0091] The processing unit executes various functional applications and data processing by running programs stored in the system memory, such as implementing the methods provided in other embodiments of the present invention.

[0092] The present invention also provides a storage medium containing computer-executable instructions and storing a computer program thereon, which, when executed by a processor, implements the methods provided in other embodiments of the present invention.

[0093] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A device for testing the quality of pile foundation drilling, characterized in that, It includes ultrasonic sensing components, signal processing modules, wireless transmission modules, host computer systems, and platform interface modules; The ultrasonic sensing component is fixed to the drill bit of the rotary drilling rig and is used to collect three-dimensional attitude data, spatial position data and depth change data at each depth of the pile hole in real time during the process of the drill bit lifting and unloading soil. It also has a built-in filtering algorithm. The signal processing module is electrically connected to the ultrasonic sensing component and is used to process the raw signals collected by the ultrasonic sensing component. The wireless transmission module is used to send the processed data to the host computer system when the drill bit is raised to the ground or to an area where the signal can be effectively transmitted. The host computer system is used to receive data and perform analysis and processing, calculate the real-time diameter and verticality parameters of the pile hole and compare them with a preset threshold. If the threshold is exceeded, an alarm is triggered. The platform docking module is used to establish a communication connection with the Beidou digital construction management platform to complete data uploading, centralized control and sharing.

2. The pile foundation borehole quality testing device according to claim 1, characterized in that, The ultrasonic sensing component includes at least two ultrasonic transducers. The ultrasonic transducers are made of piezoelectric ceramic material and have both ultrasonic emission and reflected wave reception functions. When powered on, they generate mechanical vibration to emit ultrasonic waves. When receiving reflected waves, they convert the mechanical vibration into electrical signals. The multiple ultrasonic transducers are evenly distributed along the circumference of the drill bit.

3. The pile foundation hole formation quality testing device according to claim 2, characterized in that, The ultrasonic transducer emits ultrasonic frequencies that can be adaptively adjusted within the range of 20kHz-200kHz. The frequency adjustment is automatically triggered based on the pile hole depth, medium type, and detection accuracy requirements.

4. The pile foundation hole formation quality testing device according to claim 1, characterized in that, The signal processing module includes a signal amplification unit, a filtering unit, and a shaping unit connected in sequence. The signal amplification unit is used to amplify the weak electrical signal output by the ultrasonic transducer. The filtering unit is used to filter out environmental interference signals and equipment noise. The shaping unit is used to perform waveform normalization on the signal to extract the effective reflected signal.

5. The pile foundation borehole quality testing device according to claim 1, characterized in that, The host computer system includes a data processing unit and a display unit; the data processing unit is used to calculate the one-way distance d from the ultrasonic transducer to the wall of the pile hole, and the calculation formula is d=v×t / 2, where v is the corrected sound speed and t is the total propagation time of the ultrasonic wave from transmission to reception; The data processing unit is also used to calculate the actual diameter of the pile hole by combining installation parameters. The formula for calculating the pile hole diameter is: In the formula, , These are the distance measurements collected from the borehole wall by the ultrasonic transducers on both sides. The fixed mounting distance between the two sensor transmitting surfaces is equivalent to the outer envelope diameter of the drill bit at the current measurement section; The data processing unit is also used to eliminate the influence of drill bit tilt through spatial geometric coordinate transformation and to calculate the horizontal offset of the pile hole center. The verticality of the pile hole is calculated based on the offset, and the formula for calculating the verticality is: In the formula, This indicates the depth of the current detection point from the orifice. The range of values ​​is ; The display unit is used to display pile hole diameter data, verticality data, and alarm information in real time.

6. The pile foundation hole formation quality testing device according to claim 1, characterized in that, The wireless transmission module supports dual-mode communication of 5G and LoRa. In areas with good signal, it prioritizes 5G communication mode to achieve high-speed data transmission, and automatically switches to LoRa communication mode in areas with weak signal to ensure data transmission continuity. It also has the function of resuming data transmission after interruption.

7. A component installation method, applied to the pile foundation borehole quality testing device as described in any one of claims 1-6, characterized in that, This includes selecting the installation location, matching the installation method, adapting to the environment, and post-installation debugging steps; The installation location should be selected in accordance with the principles of being unobstructed, free from turbulence, and far away from sources of interference. The installation method is matched according to the container structure and material type, and the environmental adaptation is designed to protect against temperature, pressure, corrosion and explosion-proof conditions. The post-installation commissioning includes parameter setting, false echo learning, and accuracy calibration to ensure that the ultrasonic signal reaches the level surface without obstruction or interference, reduce the impact of the installation environment on the equipment, and ensure measurement accuracy.

8. The component installation method according to claim 7, characterized in that, When selecting the installation location, the distance between the transducer and the tank wall should be ≥ 1 / 6 of the container diameter and not less than 200mm. It should be kept away from the agitator, heating pipe, and internal obstacles of the feed inlet, and should avoid areas with excessive dust concentration and strong airflow above the liquid surface. It should be installed in the middle of the container in an area where the material level changes steadily.

9. The component installation method according to claim 8, characterized in that, The specific installation methods are as follows: For closed containers, top flange installation or threaded installation is adopted, with the flange specifications matching the container interface, and the transducer axis perpendicular to the level surface with a deviation of ≤3°; for open containers, bracket installation or wall-mounted installation is adopted, with the bracket height fixed and no obstruction below the transducer; for high-viscosity / easily deposited media scenarios, installation with a purging device is adopted, with a purging interface reserved and an anti-deposit probe selected; for deep cavity / narrow mouth containers, extension rod or waveguide installation is adopted, extending the transducer to the stable area inside the container.

10. The component installation method according to claim 8, characterized in that, When adapting to the environment, select a normal temperature probe for ambient temperatures ≤60℃ and a high temperature probe with a heat insulation layer for ambient temperatures >60℃; select a pressure-resistant level gauge with a matching pressure rating for pressurized closed containers; when measuring corrosive media, use corrosion-resistant materials for the probe, flange, and seals; select an explosion-proof level gauge with an explosion-proof rating that meets the requirements for flammable and explosive environments, and ensure that the junction box and cable are sealed.

11. The component installation method according to claim 7, characterized in that, During the post-installation commissioning, input the transducer installation height, container bottom blind zone, and medium type basic parameters into the equipment menu; identify and mark false echoes through the equipment's on-site learning function; measure the actual level height using a tape measure and radar level gauge and compare it with the equipment display value. If the error exceeds ±0.5%FS, adjust the sound velocity compensation parameters or installation position.

12. An optimization system, applied to the pile foundation borehole quality testing device as described in any one of claims 1-6, characterized in that, The optimization system includes a sound velocity multi-parameter compensation unit, a data fusion processing unit, and a detection angle adaptive adjustment unit. The sound velocity multi-parameter compensation unit includes a temperature sensor, an air pressure sensor, and a medium density sensor. The sound velocity multi-parameter compensation unit is used to establish a multi-parameter sound velocity correction model to correct the sound velocity parameters by fusing ambient temperature, air pressure, and medium density data. The data fusion processing unit is used to perform weighted fusion of signals collected by multiple ultrasonic transducers to reduce single-point measurement errors. The adaptive detection angle adjustment unit is used to drive the ultrasonic transducer through a built-in stepper motor, so that the detection angle automatically matches the optimal angle according to the diameter of the pile hole within a preset angle range.

13. The optimization system according to claim 12, characterized in that, The sound velocity multi-parameter compensation unit has a built-in preset temperature-sound velocity, air pressure-sound velocity, and medium density-sound velocity correlation database, and calls the corresponding data in real time to correct the sound velocity.

14. The optimization system according to claim 12, characterized in that, The data fusion processing unit uses a Kalman filter fusion algorithm to dynamically weight the pile hole diameter data at the same depth collected by different ultrasonic transducers. The weighting coefficients are adjusted in real time according to the signal strength and stability of each transducer.

15. The optimization system according to claim 14, characterized in that, The adaptive detection angle adjustment unit also includes a distance sensing subunit, which detects the distance between the ultrasonic transducer and the hole wall in real time. When the distance changes beyond the preset range, it automatically triggers the detection angle adjustment command.

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