A method and device for repairing a photovoltaic cement test pile after it is broken

Abstract

The application discloses the photovoltaic cement test pile fracture repair processing method and the repair device in the photovoltaic new energy infrastructure construction and maintenance technical field, including determining the fracture position and defect range of the cement test pile, analyzing the fracture cause of the fracture position, and obtaining the fracture coefficient.The application carries out global scanning on the cement test pile, determines the defect range of the cement test pile, obtains the fracture coefficient through a fracture coefficient evaluation model, further evaluates the fracture damage degree of the cement test pile, further adopts a matched repair device to reinforce the fracture position, adopts a differentiated reinforcement method, avoids excessive reinforcement or insufficient reinforcement, realizes the balance between the structural performance and the economy, the method does not need large hoisting machinery, the wall protection assembly, the hoop positioning mechanism and the pouring device can all adopt small-sized and modular design, and the method is especially suitable for the on-site environment with almost zero mechanical passability after the photovoltaic assembly is installed.

Description

Technical Field

[0001] This invention relates to the field of construction and maintenance technology for photovoltaic new energy infrastructure, specifically a method and device for repairing and treating fractured photovoltaic cement test piles. Background Technology

[0002] In the construction of centralized photovoltaic power plants, cement test piles are widely used as the load-bearing structure of the support foundation. However, due to complex geological conditions, non-standard construction operations, and lax material quality control, test piles may break during use. The high installation density of photovoltaic modules and the generally low height of the support structure make it difficult for large hoisting machinery to enter the site after installation, further limiting the feasibility of large-scale replacement operations.

[0003] When existing cement test piles break, traditional replacement methods usually involve large-scale rework or pile type replacement, which is difficult, time-consuming, costly, and has poor repair results. Summary of the Invention

[0004] The purpose of this invention is to provide a repair method and device for the fracture of photovoltaic cement test piles, so as to solve the problems that the traditional replacement treatment methods mentioned above usually involve large-scale rework or pile type replacement, which are difficult to carry out, have long cycles and high costs.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] In a first aspect, the present invention provides a method for repairing fractured photovoltaic cement test piles, comprising the following steps:

[0007] S1: Determine the fracture location and defect range of the cement test pile, analyze the fracture cause at the fracture location, and obtain the fracture coefficient.

[0008] S2: If the fracture location of the cement test pile is above the ground surface, a repair device is added at the fracture location according to the fracture coefficient. If the fracture location of the cement test pile is within a set depth range below the ground surface, excavate to the fracture surface, remove the defective concrete, clean the fracture location, add a repair device at the fracture location according to the fracture coefficient, and use filling material to pour multiple times to the ground surface height.

[0009] S3: Conduct a static load test on the repaired cement test pile. After confirming that the repaired cement test pile meets the preset requirements, reinstall the photovoltaic bracket and components on the repaired cement test pile.

[0010] As a further aspect of the present invention: S1 includes:

[0011] The cement test pile is scanned in its entirety using ultrasonic testing technology. By analyzing the propagation time and waveform characteristics of the reflected wave, the three-dimensional coordinates of the fracture location of the cement test pile are accurately located, the fracture location of the cement test pile is determined, the direction, length and width of the crack at the fracture location of the cement test pile are obtained, the defect range of the cement test pile is determined, and the fracture cause at the fracture location is obtained by analyzing the three-dimensional coordinates of the fracture location of the cement test pile.

[0012] A fracture coefficient assessment model was established. The three-dimensional coordinates of the fracture location of the cement test pile, the direction, length and width of the crack were input into the fracture coefficient assessment model to obtain the fracture coefficient. The fracture coefficient is used to quantify the severity of fracture damage in the cement test pile.

[0013] As a further aspect of the present invention: In S2, the repair device consists of stirrups and hoops arranged on the outer wall of the cement test pile, with hoops welded onto the stirrups and the hoops installed on the cement test pile, and the stirrups arranged parallel to the axial direction of the cement test pile.

[0014] As a further aspect of the present invention: the method of adding a repair device at the fracture site according to the fracture coefficient includes:

[0015] The fracture coefficient is compared with the preset damage level to obtain moderate or severe damage.

[0016] When the degree of fracture damage is moderate, a first number of stirrups are set at the fracture location of the cement test pile, and stirrup rings are welded at intervals on the stirrups.

[0017] When the fracture damage is severe, a second number of stirrups are installed at the fracture location of the cement test pile, with hoops welded at intervals on the stirrups, wherein the second number is greater than the first number.

[0018] As a further aspect of the present invention: the cleaning of the fracture site includes:

[0019] Non-contact cleaning is performed on the fracture location of the cement test pile, and the non-contact cleaning uses high-pressure airflow or high-pressure water jet to remove waste.

[0020] As a further aspect of the present invention: the method of repeatedly pouring filler material to the ground surface includes:

[0021] The filling material is micro-expansion concrete, which is poured multiple times to the ground level. This includes first pouring to a predetermined depth below the fracture location, compacting it with vibration, and then waiting for it to initially set; then pouring at least one intermediate layer, with each pour being compacted; and finally pouring to the ground level.

[0022] As a further aspect of the present invention: In S3, the static load test includes loading the cement test pile step by step according to the preset graded load until the preset maximum load is reached. After confirming that the repaired cement test pile meets the preset requirements, the photovoltaic bracket and components are reinstalled on the repaired cement test pile. The preset requirement is that the cement test pile does not break at the fracture location after being loaded with the preset maximum load.

[0023] Secondly, the present invention provides a photovoltaic cement test pile fracture repair device, comprising:

[0024] A fixing component, comprising a hoop, the hoop being composed of two semi-circular cylindrical bodies, wherein mounting holes are provided on both sides of the cylindrical bodies and bolts are installed thereon, the hoop being used to fix the concrete test pile;

[0025] A reinforcing component, the reinforcing component comprising a plurality of stirrups, the stirrups being welded to the cylinder.

[0026] As a further aspect of the present invention, the stirrups on the cylinder are distributed in a ring at equal intervals.

[0027] As a further aspect of the present invention: the stirrup is provided with a plurality of reinforcing ribs, which are welded to the outer surface of the stirrup along the radial direction of the stirrup.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] 1. This invention uses a full-area scan of cement test piles to determine the defect range and obtains the fracture coefficient through a fracture coefficient evaluation model. This allows for the assessment of the degree of fracture damage and the application of matching repair devices to reinforce the fractured areas. Differentiated reinforcement methods are employed to avoid over- or under-reinforcement, achieving a balance between structural performance and economy. This method eliminates the need for large hoisting machinery; the retaining wall components, hoop positioning mechanisms, and pouring devices can all be miniaturized and modularized. It is particularly suitable for site environments where mechanical accessibility is almost zero after photovoltaic module installation, avoiding large-scale rework or pile type replacement. This invention only excavates and reinforces the fractured area, resulting in less earthwork, lower material consumption, and lower labor costs, significantly reducing construction delays and economic losses caused by test pile fractures.

[0030] 2. This invention uses high-pressure airflow or water jet to clean the fracture surface, avoiding secondary damage to the surrounding intact structure caused by manual chiseling. It is applicable to test pile cross-sections of different diameters and shapes. The cleaning treatment of the cross-section facilitates the subsequent filling and bonding of micro-expansion concrete. The rapid hardening characteristics of micro-expansion concrete further shorten the curing waiting period, ensuring that the photovoltaic power station is put into operation on schedule or ahead of schedule. Attached Figure Description

[0031] Figure 1This is a schematic diagram of the method flow of the present invention;

[0032] Figure 2 This is a schematic diagram of the overall structure of the repair device of the present invention;

[0033] Figure 3 This is a schematic diagram of the exploded structure of the repair device of the present invention.

[0034] In the diagram: 1. Hoop; 101. Cylinder; 2. Stirrup; 201. Reinforcing bar. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] Example:

[0037] Please see Figure 1 This invention provides a method for repairing fractured photovoltaic cement test piles, comprising the following steps:

[0038] S1: Determine the fracture location and defect range of the cement test pile, analyze the fracture cause at the fracture location, and obtain the fracture coefficient.

[0039] The cement test pile is scanned in its entirety using ultrasonic testing technology. By analyzing the propagation time and waveform characteristics of the reflected wave, the three-dimensional coordinates of the fracture location of the cement test pile are accurately located, the fracture location of the cement test pile is determined, the direction, length and width of the crack at the fracture location of the cement test pile are obtained, the defect range of the cement test pile is determined, and the fracture cause at the fracture location is obtained by analyzing the three-dimensional coordinates of the fracture location of the cement test pile.

[0040] A fracture coefficient assessment model was established. The three-dimensional coordinates of the fracture location of the cement test pile, the direction, length and width of the crack were input into the fracture coefficient assessment model to obtain the fracture coefficient. The fracture coefficient is used to quantify the severity of the fracture damage of the cement test pile.

[0041] Specifically, a fracture coefficient evaluation model is established, and the establishment process is as follows:

[0042] First, historical fracture data of photovoltaic cement test piles under different working conditions were collected, including parameters such as the three-dimensional coordinates of the fracture location, the direction, length, width of the crack, and the corresponding actual damage degree. A training dataset was constructed. Then, an appropriate machine learning algorithm, such as support vector machine or neural network, was selected. The three-dimensional coordinates of the fracture location, the direction, length, and width of the crack were used as input features, and the actual damage degree was used as the output label to train the model. During the training process, the model parameters, such as the learning rate and the number of hidden layer nodes, were continuously adjusted to improve the prediction accuracy of the model. Finally, the trained model was validated using a test dataset. When the prediction error of the model was within the preset range, the model was determined as the final fracture coefficient evaluation model.

[0043] S2: If the fracture location of the cement test pile is above the ground surface, a repair device is added at the fracture location according to the fracture coefficient. If the fracture location of the cement test pile is within a set depth range below the ground surface, excavate to the fracture surface, remove the defective concrete, clean the fracture location, add a repair device at the fracture location according to the fracture coefficient, and pour the filler material multiple times to the ground surface height.

[0044] The repair device consists of stirrups and hoops arranged on the outer wall of the cement test pile. Hoops are welded onto the stirrups and the hoops are installed on the cement test pile. The stirrups are arranged parallel to the axial direction of the cement test pile.

[0045] S3: Conduct a static load test on the repaired cement test pile. After confirming that the repaired cement test pile meets the preset requirements, reinstall the photovoltaic bracket and components on the repaired cement test pile.

[0046] Specifically, this invention performs a full-area scan of cement test piles to determine the defect range, obtains the fracture coefficient through a fracture coefficient evaluation model, and then assesses the degree of fracture damage. A matching repair device is then used to reinforce the fracture location, employing differentiated reinforcement methods to avoid over- or under-reinforcement, achieving a balance between structural performance and economy. This method eliminates the need for large hoisting machinery; the retaining wall components, hoop positioning mechanisms, and pouring devices can all be miniaturized and modularized. It is particularly suitable for on-site environments where mechanical accessibility is almost zero after photovoltaic module installation, avoiding large-scale rework or pile type replacement. This invention only excavates and reinforces the fractured area, resulting in less earthwork, lower material consumption, and lower labor costs, significantly reducing construction delays and economic losses caused by test pile fractures.

[0047] This invention uses high-pressure airflow or water jet to clean the fracture surface, avoiding secondary damage to the surrounding intact structure caused by manual chiseling. It is applicable to test pile cross-sections of different diameters and shapes. The cleaning treatment of the cross-section facilitates the subsequent filling and bonding of micro-expansion concrete. The rapid hardening characteristics of micro-expansion concrete further shorten the curing waiting period, ensuring that the photovoltaic power station is put into operation on schedule or ahead of schedule.

[0048] In this embodiment, a repair device is added at the fracture site according to the fracture coefficient, including:

[0049] The fracture coefficient is compared with the preset damage level to obtain moderate or severe damage.

[0050] When the degree of fracture damage is moderate, a first number of stirrups are set at the fracture location of the cement test pile, and stirrup rings are welded at intervals on the stirrups.

[0051] When the fracture damage is severe, a second number of stirrups are installed at the fracture location of the cement test pile, with hoops welded at intervals on the stirrups, wherein the second number is greater than the first number.

[0052] Specifically, the fracture coefficient is compared with the preset damage level. The preset damage level includes: when the fracture coefficient is within the preset moderate damage threshold range, it is judged as moderate damage; when the fracture coefficient is within the preset severe damage threshold range or exceeds the upper limit of the range, it is judged as severe damage. For example, when the fracture coefficient is between 0.3 and 0.5 (moderate damage), an additional ring hoop is added at intervals of 15-20cm on the outside of the stirrup. The hoop is made of HRB400 grade steel bar with a diameter of 12mm and is fixed to the stirrup by double-sided welding. The welding length is not less than 5 times the diameter of the steel bar. When the fracture coefficient is greater than 0.5 (severe damage), in addition to setting the above-mentioned hoop, the stirrups within a range of 1.5 times the pile diameter above and below the fracture location need to be densified to 1 / 2 of the original spacing. Different damage levels correspond to different repair strategies to achieve accurate, efficient and economical repair.

[0053] In this embodiment, cleaning the fracture site includes:

[0054] Non-contact cleaning was carried out on the fractured locations of the cement test piles. The non-contact cleaning method used high-pressure airflow or high-pressure water jet to remove debris.

[0055] Specifically, an adjustable-pressure cleaning device is used, with a pressure range set between 0.8 and 1.5 MPa. During cleaning, the nozzle is kept 30-50 cm away from the fracture surface and moved at a uniform speed along the circumference of the fracture surface at a 45° angle to ensure that concrete residue, dust, oil, and other impurities within a 50 cm radius of the fracture surface are thoroughly removed. During the cleaning process, a dust collection device installed on the cleaning device simultaneously removes the raised debris to avoid secondary pollution. After cleaning, a high-definition endoscope is used to inspect the fracture surface. Only after confirming that there are no visible impurities on the surface and that fresh concrete structure is exposed can the next repair process begin.

[0056] In this embodiment, the filling material is poured multiple times to the ground level, including:

[0057] The filling material is micro-expansion concrete, which is poured multiple times to the ground level. This includes first pouring to a predetermined depth below the fracture location, compacting it with vibration, and then waiting for it to set initially; then pouring at least one intermediate layer, with each layer being vibrated after each pour; and finally pouring to the ground level.

[0058] Specifically, during the first pour, the micro-expansion concrete is filled to 20-30cm below the fracture site and thoroughly vibrated with a vibrator to ensure a tight bond between the concrete and the inner wall of the test pile, avoiding voids or honeycomb structures. After the initial setting of the first pour (usually 2-3 hours), a second pour is made, filling to 10-15cm below the ground surface and compacting again. During the final pour, the micro-expansion concrete is slowly injected to be level with the ground surface. During the pouring process, it is necessary to observe whether shrinkage cracks appear on the concrete surface. If so, add material and smooth it out in time. The water-cement ratio of the micro-expansion concrete for each pour is controlled between 0.42 and 0.45, and the slump is maintained at 180±20mm to ensure the filling effect and repair strength.

[0059] In this embodiment, in S3, the static load test includes loading the cement test pile step by step according to the preset graded load until the preset maximum load is reached. After confirming that the repaired cement test pile meets the preset requirements, the photovoltaic bracket and components are reinstalled on the repaired cement test pile. The preset requirement is that the cement test pile does not break at the fracture location after being loaded with the preset maximum load.

[0060] Specifically, the static load test uses graded loads starting at 10% of the estimated ultimate bearing capacity of the test pile, with each subsequent load increasing by 10%. Each load level must be maintained for one hour, during which the settlement at the top of the test pile is monitored in real-time using a dial gauge. The next load level can only be applied when two consecutive settlement levels are less than 0.1 mm / h. If, during loading, the settlement of the test pile suddenly increases and exceeds 20 mm, or if the load does not reach the preset maximum load but the settlement continues to increase, the test pile is deemed not to meet the preset requirements and must be repaired. The preset maximum load needs to be determined based on the design bearing capacity of the test pile and the strength grade of the repaired concrete, typically taken as 1.5 times the design bearing capacity. Furthermore, it is crucial to ensure uniform load application during loading to avoid secondary damage to the test pile caused by impact loads.

[0061] Please see Figure 2 and Figure 3 This invention provides a device for repairing fractures in photovoltaic cement test piles, comprising:

[0062] The fixing component includes a hoop 1, which is composed of two semi-circular cylindrical bodies 101. The cylindrical bodies 101 have mounting holes on both sides and are fitted with bolts. The hoop 1 is used to fix the cement test pile.

[0063] The reinforcing component includes several stirrups 2, which are welded to the cylinder 101.

[0064] Specifically, the stirrups 2 are made of high-strength threaded steel, and their diameter is determined according to the diameter and fracture coefficient of the cement test pile, usually not less than 12mm. The spacing of the stirrups 2 is set to 150-200mm to ensure that a uniform and continuous circumferential constraint force is provided at the fracture point of the test pile. The hoop 1 is a circular structure, which is formed by joining two arc-shaped cylinders 101. The thickness of the cylinder 101 is not less than 8mm, and the inner wall conforms to the curvature of the outer wall of the test pile. The inner diameter of the hoop 1 matches the outer diameter of the cement test pile. The two arc-shaped cylinders 101 are connected by bolt assemblies. For fastening connections, 8.8 grade high-strength bolts are used, with no less than 4 bolts per hoop 1, evenly distributed along the circumference. During the welding process between the hoop 2 and the hoop 1, double-sided fillet welds are used, with the weld height not less than 0.7 times the diameter of the hoop 2. After welding, the weld must be non-destructively inspected to ensure that there are no welding defects such as porosity or slag inclusions, so that the hoop 1 and the hoop 2 form a stable reinforcement area. This reinforcement area can effectively wrap the fractured part of the test pile and a certain range extending above and below it, forming a solid overall frame.

[0065] In this embodiment, the stirrups 2 on the cylinder 101 are distributed in a ring at equal intervals.

[0066] Specifically, the stirrups 2 are evenly arranged along the circumference of the hoop 1, and the central angles between adjacent stirrups 2 are equal to ensure the uniform transmission of reinforcement force. The length of the stirrups 2 should be determined according to the reinforcement range required for the vertical extension of the fractured part of the test pile. Its two ends are welded and fixed to the upper and lower hoop 1 respectively, so as to connect multiple hoop 1 into a whole and form a three-dimensional surrounding reinforcement structure for the fractured area of ​​the test pile.

[0067] In this embodiment, a plurality of reinforcing ribs 201 are provided on the stirrup 2, and the reinforcing ribs 201 are welded to the outer surface of the stirrup along the radial direction of the stirrup.

[0068] Specifically, the reinforcing rib 201 is made of the same material as the stirrup 2, with a diameter not less than 0.8 times the diameter of the stirrup 2. Its length is determined based on the diameter of the stirrup 2 and the required structural strength enhancement, generally 3 to 5 times the diameter of the stirrup 2. These reinforcing ribs 201 are evenly distributed along the axial direction on the outer surface of each stirrup 2, with the distance between adjacent reinforcing ribs 201 not exceeding 10 times the diameter of the stirrup 2. Each stirrup 2 has at least 3 reinforcing ribs 201 to ensure uniform distribution of support and reinforcement. The welding of the reinforcing ribs 201 to the stirrup 2 also uses double-sided fillet welds, with a weld height not less than 0.7 times the diameter of the reinforcing rib 201. Non-destructive testing is also required after welding. By setting the reinforcing bar 201, the bending and torsional resistance of the stirrup 2 itself can be significantly improved, thereby enhancing the overall stiffness and bearing capacity of the entire three-dimensional surrounding reinforcement structure. This effectively prevents the stirrup 2 from deforming or becoming unstable when the test pile is subjected to stress after repair, further ensuring the reinforcement effect of the repair device on the fracture area of ​​the test pile.

[0069] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for repairing and treating fractured photovoltaic cement test piles, characterized in that, Includes the following steps: S1: Determine the fracture location and defect range of the cement test pile, analyze the fracture cause at the fracture location, and obtain the fracture coefficient. S2: If the fracture location of the cement test pile is above the ground surface, a repair device is added at the fracture location according to the fracture coefficient. If the fracture location of the cement test pile is within a set depth range below the ground surface, excavate to the fracture surface, remove the defective concrete, clean the fracture location, add a repair device at the fracture location according to the fracture coefficient, and use filling material to pour multiple times to the ground surface height. S3: Conduct a static load test on the repaired cement test pile. After confirming that the repaired cement test pile meets the preset requirements, reinstall the photovoltaic bracket and components on the repaired cement test pile.

2. The repair and treatment method for fractured photovoltaic cement test piles according to claim 1, characterized in that, S1 includes: The cement test pile is scanned in its entirety using ultrasonic testing technology. By analyzing the propagation time and waveform characteristics of the reflected wave, the three-dimensional coordinates of the fracture location of the cement test pile are accurately located. The fracture location of the cement test pile is determined, and the direction, length and width of the crack at the fracture location are obtained to determine the defect range of the cement test pile. The cause of the fracture is obtained by analyzing the three-dimensional coordinates of the fracture location. A fracture coefficient assessment model was established. The three-dimensional coordinates of the fracture location of the cement test pile, the direction, length and width of the crack were input into the fracture coefficient assessment model to obtain the fracture coefficient. The fracture coefficient is used to quantify the severity of fracture damage in the cement test pile.

3. The repair and treatment method for fractured photovoltaic cement test piles according to claim 2, characterized in that, In S2, the repair device consists of stirrups and hoops arranged on the outer wall of the cement test pile. Hoops are welded onto the stirrups, and the hoops are installed on the cement test pile. The stirrups are arranged parallel to the axial direction of the cement test pile.

4. The repair and treatment method for fractured photovoltaic cement test piles according to claim 3, characterized in that, The method of adding a repair device at the fracture site according to the fracture coefficient includes: The fracture coefficient is compared with the preset damage level to obtain moderate or severe damage. When the degree of fracture damage is moderate, a first number of stirrups are set at the fracture location of the cement test pile, and stirrup rings are welded at intervals on the stirrups. When the fracture damage is severe, a second number of stirrups are installed at the fracture location of the cement test pile, with hoops welded at intervals on the stirrups, wherein the second number is greater than the first number.

5. The repair and treatment method for fractured photovoltaic cement test piles according to claim 4, characterized in that, The cleaning of the fracture site includes: Non-contact cleaning is performed on the fracture location of the cement test pile, and the non-contact cleaning uses high-pressure airflow or high-pressure water jet to remove waste.

6. The repair treatment method for fractured photovoltaic cement test piles according to claim 5, characterized in that, The method of pouring filler material multiple times to the ground level includes: The filling material is micro-expansion concrete, which is poured multiple times to the ground level. This includes first pouring to a predetermined depth below the fracture location, compacting it with vibration, and then waiting for it to initially set; then pouring at least one intermediate layer, with each pour being compacted; and finally pouring to the ground level.

7. The repair and treatment method for fractured photovoltaic cement test piles according to claim 6, characterized in that, In S3, the static load test includes loading the cement test pile step by step according to the preset graded load until the preset maximum load is reached. After confirming that the repaired cement test pile meets the preset requirements, the photovoltaic bracket and components are reinstalled on the repaired cement test pile. The preset requirement is that the cement test pile does not break at the fracture location after being loaded with the preset maximum load.

8. A photovoltaic cement test pile fracture repair device, applied to the repair treatment method for photovoltaic cement test pile fracture as described in any one of claims 1-7, characterized in that, include: A fixing component, comprising a hoop, the hoop being composed of two semi-circular cylindrical bodies, wherein mounting holes are provided on both sides of the cylindrical bodies and bolts are installed thereon, the hoop being used to fix the concrete test pile; A reinforcing component, the reinforcing component comprising a plurality of stirrups, the stirrups being welded to the cylinder.

9. The photovoltaic cement test pile fracture repair device according to claim 8, characterized in that, The stirrups on the cylinder are distributed in a ring at equal intervals.

10. The photovoltaic cement test pile fracture repair device according to claim 8, characterized in that, The stirrup is provided with several reinforcing ribs, which are welded to the outer surface of the stirrup along the radial direction.

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