A preform of cross arm for repairing broken 10kV line in severe weather and a repairing method

Abstract

This invention relates to the field of power system fault repair technology, and in particular to a prefabricated crossarm component and repair method for 10kV line breakage repair in severe weather. The prefabricated crossarm component includes a prefabricated crossarm, clamp, support insulator, tension clamp, special support iron, parallel groove clamp, and auxiliary splicing components. Through standardized modular design, it is adapted to different tower, conductor, and insulator types. During repair, the type and state of the breakage are first determined by a drone, and after the safety fence is set up in stages, the prefabricated component is adaptively fixed to the lower part of the tower. Through dual-mode tension opening operation, ground-oriented traction and non-destructive splicing are achieved for both fallen and non-fallen line breaks. Finally, after insulation verification, power is restored. This invention eliminates the need for working at height, avoids safety hazards in severe weather, and significantly shortens the repair time by allowing 8 people to work together. The tension opening operation time is ≤0.2 hours. It is adaptable to all types of line breakage scenarios, improves repair quality and efficiency, and reduces the operation threshold and cost.

Description

[0001] This invention relates to the field of power system fault repair technology, and in particular to a pre-constructed crossarm for emergency repair of a 10kV line breakage in severe weather and a repair method. Background Technology

[0002] With economic and social development, electricity users have increasingly higher requirements for power supply reliability. "Uninterrupted power supply is the best service" has become the core service concept of the power industry. However, under severe weather conditions such as strong convection and lightning, 10kV lines are prone to line breakage. Traditional emergency repair methods have significant defects. Currently, emergency repairs require working at heights, which poses safety risks such as falls from heights and lightning strikes in severe weather, leading to frequent work interruptions. According to statistics, from May to September 2024, the duration of work interruptions caused by the inability to work at heights due to severe weather was strongly positively correlated with the time spent on wiring operations, with a correlation coefficient close to 1. For every hour the interruption duration increased, the wiring time increased by an average of 1.34 hours.

[0003] Meanwhile, the tension opening operation process is cumbersome. Traditional pole climbing tension opening operation requires installing hardware and clamps on both sides of the pole and tightening the conductor. Moreover, the number of people working on the pole is limited to 2. The operation takes as long as 3.2-3.7 hours, accounting for more than 86% of the total emergency repair time. The emergency repair process lacks standardization, and the operation time varies greatly depending on the scenario and the skill level of the personnel, resulting in unstable emergency repair efficiency. From May to September 2024, the average emergency repair time for 10kV line breakage faults under severe weather conditions was as long as 4.65 hours, far exceeding the target requirement of 2 hours.

[0004] The above problems seriously affect the reliability of power supply and cause a large number of users to lose power when there is a power outage. Therefore, it is urgent to develop a pre-constructed crossarm for emergency repair of 10kV line breaks in severe weather and an emergency repair method. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a pre-component for emergency repair of a 10kV line breakage in severe weather and an emergency repair method, aiming to solve the technical problems of limited high-altitude operations, long time-consuming tension opening operations, and low repair efficiency and high safety risks caused by non-standard repair procedures in severe weather.

[0006] A prefabricated crossarm component for emergency repair of a 10kV line breakage in severe weather includes a prefabricated crossarm, clamp, bracing, support porcelain insulator, tension porcelain insulator, tension clamp, and parallel groove clamp.

[0007] The clamp is fixedly installed at one end of the prefabricated crossarm. One end of the support iron is obliquely fixedly connected to the lower part of the prefabricated crossarm, and the other end is correspondingly fixedly installed with the clamp. Several crossarm connecting parts are uniformly welded on the prefabricated crossarm along its length. The support porcelain insulator is detachably installed on one of the crossarm connecting parts. The tension porcelain insulators are detachably installed at both ends of the prefabricated crossarm. The tension clamp is detachably installed on the end of the tension porcelain insulator away from the prefabricated crossarm. The parallel groove clamp is used to realize the rapid reconnection of broken conductors.

[0008] Furthermore: the prefabricated crossarm is made of ∠75×8×1500 (375) type angle iron, and the surface of the prefabricated crossarm is provided with anti-slip insulating coating. Its length is designed to be 1500mm according to the spacing of 10kV line conductors.

[0009] Furthermore: the clamp is a nylon elastic band clamp made of high-strength insulating nylon material, with telescopic adjustment function, suitable for tower bodies with a diameter of 300~500mm. A tension sensor is installed on the inner side of the clamp to provide real-time feedback on the fixing tension. The nylon elastic band clamp is also equipped with an electric adjustment module, which realizes adaptive tension adjustment through wireless remote control. The tension threshold is set to 5~8kN.

[0010] Furthermore: the parallel groove clamp is a JBL-50~240 type special-shaped parallel groove clamp, and the post porcelain insulator and tension porcelain insulator are selected as U70B / 255 type disc suspension porcelain insulators;

[0011] Furthermore: the auxiliary connection assembly includes a telescopic insulated operating rod, a two-way guide pulley group, and a locking rod rope. The multi-stage telescopic insulated operating rod has a maximum extension length of ≥8m, an insulation class of 10kV, and a scale marking on the rod body.

[0012] Further: A method for emergency repair of 10kV line crossarm pre-components under severe weather conditions, including the following steps: (1) Intelligent judgment of line breakage status: Using a drone equipped with a visual recognition module to inspect the fault point, through image analysis, distinguishing the line breakage type as a fallen line breakage / a line breakage on the pole that has not fallen, and constructing a judgment formula model to judge the insulator type of the line breakage on the pole as a suspension type / pin type and the residual tension status. The conductor sag angle ≤30° is low tension, 30°~60° is medium tension, and >60° is high tension. Simultaneously record the tower model, conductor specifications and surrounding environment information;

[0013] (2) Graded safety arrangement: Based on the judgment results, the operators shall set up a fence for falling wire breakage within a range of ≥50m, and a fence for non-falling wire breakage on the pole within a range of ≥80m. Each pole shall be guarded by no less than 2 dedicated personnel. Insulation isolation warning shall be set up within 0.7m of the crossarm pre-component installation area. Emergency lighting equipment shall be added at night or in low light conditions, and the lighting brightness shall be ≥500 lux.

[0014] (3) Pre-component adaptive installation: The clamp is installed on the tower near the fault point, the electric adjustment module is started by wireless remote control, and the clamp tension is adjusted to the set threshold according to the feedback of the tension sensor. The support iron is installed and reinforced by the locking rope to keep the special crossarm horizontal. Then the support column porcelain bottle is fixed to complete the support system construction.

[0015] (4) Dual-mode tensioning operation:

[0016] ①The drop-type line breakage adopts a ground-coordinated mode, with 8 workers simultaneously completing the installation of tension hardware, installation of tension clamps and tensioning operations;

[0017] ② For wire breaks that have not fallen off the pole, use the auxiliary splicing mode. Assemble the bidirectional guide pulley to the crossarm of the adjacent intact pole using the multi-stage telescopic insulated operating rod. Adjust it to be in the same direction as the conductor traction path and fix it. Insert the insulated rope and use the multi-stage telescopic insulated operating rod to fasten one end of the insulated rope to the broken conductor. Slowly pull the rope to pull the broken conductor to the corresponding tension clamp and support insulator. Temporarily fix it with the operating rod, without finally tightening it.

[0018] (5) Dynamic tension balance splicing: The tension of the conductor is detected by the conductor tension tester. When the tension value exceeds the threshold of 15~20kN, the tensioning tool is adjusted to release the pressure. After the tension is stabilized, the broken conductor is fixed on the porcelain insulator of the support and the tension clamp is tightened. The conductor splicing is completed by using JBL-50~240 type special groove clamp.

[0019] (6) Insulation verification and power restoration: Use an insulation resistance meter to test the insulation performance of the splice. An insulation resistance of ≥100MΩ is considered qualified. Remove safety facilities and auxiliary tools. After powering on, monitor the line operating parameters through the power distribution automation system. After confirming that there are no abnormalities, clean up the work site. For broken lines that have not fallen off the pole, it is necessary to check the status of the insulators by carrying an insulated camera through a multi-level telescopic insulated operating rod. Damaged insulators need to be hooked to the ground for recovery.

[0020] Furthermore, the specific operation steps for the intelligent judgment of the disconnection status are as follows:

[0021] The technical command post issues an inspection order, and the drone operator controls a drone equipped with a visual recognition module to fly to the faulty line area, keeping the altitude controlled at 10-15m above the fault point. The drone takes high-definition images of the broken line and transmits them back in real time. Through the drone image analysis algorithm, the type of broken line is automatically identified as either a falling broken line (the conductor detaches from the tower suspension point and hangs freely) or a non-falling broken line (the conductor is broken but still partially attached to the insulator string). At the same time, the insulator type (suspension / pin type) and residual tension state of the non-falling broken line are determined by the judgment formula model. Parameters such as the height of the broken line point from the ground and the horizontal distance from the tower are measured, and a fault analysis report is generated.

[0022] The specific operational steps of the graded safety arrangement are as follows: the safety monitoring post delineates the safety fence range based on the fault analysis report. For fallen wire breaks, a conventional fence is used. For wire breaks that have not fallen, an outer warning tape is added. A sign that reads "High Voltage Operation, No Entry" is hung on the fence. Two personnel are assigned to each pole to maintain real-time communication using walkie-talkies. Obstacles within a 5m radius around the crossarm pre-component installation point are cleared to ensure that the working space is unobstructed. Emergency lighting equipment is installed at the four corners of the fence at night or in low-light conditions to ensure visibility of the operation.

[0023] The specific steps for the adaptive installation of the prefabricated components are as follows: The prefabricated component installation team carries the crossarm prefabricated components and installation tools to the predetermined installation position, and sets the clamp on the tower at the designated height, 3-4m above the ground. The technical command team starts the electric adjustment module of the clamp through the wireless remote control. The tension sensor provides real-time feedback on the clamping tension data. When the data reaches the 5-8kN threshold, the clamp is locked. Then, the support iron is installed to ensure that the support iron is tightly attached to the tower and reinforced with the locking rope. The prefabricated crossarm is calibrated with a level to ensure that the installation direction of the support insulator is consistent with the direction of the conductor. Then, the support insulator is fixed and the insulation performance is checked.

[0024] Further: (1) Falling-type wire breakage operation: 8 people work together in the tension operation post, 2 people install tension hardware, 2 people install tension clamps, 2 people operate ground tensioning tools, and 2 people pass materials. The operation is carried out simultaneously. Tension hardware and tension porcelain insulators are quickly installed on the prefabricated crossarms on both sides of the breakage point. The tension clamps are fixed to the end of the conductor. The conductor is slowly tightened by the ground tensioning tools. The changes in conductor tension are observed to avoid over-stretching and damaging the conductor.

[0025] (2) Operation of a broken wire that has not fallen off the pole: Pre-treatment of residual tension: If it is under high tension, install and fix the bidirectional guide pulley group at a height of 3-4m below the pole tower below the break point using a multi-stage telescopic insulated operating rod. Adjust the line connecting the two pulleys to be consistent with the traction direction of the conductor and the center to be on the same horizontal plane as the fixed position of the prefabricated crossarm conductor. The operator holds the multi-stage telescopic insulated operating rod and accurately hooks the anti-slip traction hook at the midpoint of the broken conductor. One end of the insulated rope is fixed to the traction hook, and the other end passes through the double pulley group. Two operators work simultaneously. Slowly pull the conductor at a speed of 0.3~0.5m / s. Control the conductor pulling height according to the scale markings on the multi-stage telescopic insulated operating rod, ensuring that the distance between the conductor and the tower is ≥0.7m and the distance from the conductor to the ground is ≥5m. Pull the broken conductor to the corresponding position of the tension clamp and the support insulator on the crossarm pre-component. After the conductor is pulled to the designated position, temporarily fix the broken conductor to the corresponding tension clamp and the support insulator using the multi-stage telescopic insulated operating rod. Do not perform final tightening. Adjust the conductor tension to ensure that the conductor is not excessively slack or stretched.

[0026] The specific steps for the tension dynamic balance splicing are as follows: The conductor tension data is detected by a conductor tension detector. When the tension value exceeds the threshold of 15~20kN, the technical command post instructs the tension operation post to adjust the tensioning tool to release pressure. After the tension stabilizes, three layers of insulating tape are wrapped around the contact point between the broken conductor and the prefabricated crossarm. An insulating isolation pad is installed at the position adjacent to the conductor and the tower. After completion, the conductor tension is detected again to ensure that the tension fluctuation is ≤±1kN. Then, the broken conductor is fixed on the porcelain insulator of the support post and the tension clamp is tightened. The splicing operation post installs the special-shaped parallel groove clamp at the fixed position of the broken conductor and fixes it to ensure that the parallel groove clamp is in full contact with the broken conductor. At the same time, the splicing part is visually inspected to ensure that there are no problems such as conductor damage or insulation layer damage.

[0027] The specific steps for insulation verification and power restoration are as follows: The reconnection operator uses an insulation resistance meter to test the insulation performance of the reconnection point and the line. When the insulation resistance is ≥100MΩ, the insulation is confirmed to be qualified. For non-fallen broken lines on the pole, an additional multi-level telescopic insulated operating pole with an insulated camera is used to check whether there are cracks or damage on the surface of the insulator. If there is damage, it is hooked to the ground and retrieved using an insulated hook. The safety monitoring station removes the safety fence and warning signs. The technical command station issues the closing command. The voltage and current parameters of the line are monitored through the power distribution automation system. After observing for 15 minutes without any abnormalities, the power restoration is confirmed to be successful. Tools and waste at the work site are cleaned up. Auxiliary tools are retrieved in the order of "heavy first, light second; far first, near third". After all tools are retrieved, the insulation performance is retested. The emergency repair record is filled out and the line equipment file is updated simultaneously.

[0028] Furthermore: the judgment formula model includes:

[0029] Formula for determining insulator type:

[0030]

[0031] in, These are the structural characteristic coefficients of the insulator string. This represents the measured spacing between individual insulator plates. This is the measured total length of the insulator string. When, it is determined to be a suspension insulator, when At that time, it was determined to be a pin-type insulator;

[0032] Formula for calculating residual tension:

[0033]

[0034] Among them, The residual tension of the conductor. Mass per unit length of conductor It is the acceleration due to gravity. The horizontal distance between the suspension points on both sides of the break point. This is the measured value of the conductor sag. The angle of the conductor's sag. correspond For low tension, correspond For medium tension, correspond It is for high tension.

[0035] The present invention has the following beneficial effects:

[0036] 1. Significantly improve emergency repair efficiency: By using crossarm prefabrication, the operation is transformed from working at height to working on the ground. Combined with standardized ground tensioning procedures, the average repair time and wiring operation time for 10kV line breakage faults under severe weather conditions are significantly reduced. At the same time, the safety hazards of falling from height and lightning strikes during working at height under severe weather conditions are completely avoided. Through the selection of insulation materials and the installation of safety fences, the safety of the operation is further improved, ensuring the safety of front-line workers.

[0037] 2. Wide applicability: Nylon elastic band clamps can be adapted to various types of poles and towers, and special-shaped parallel groove clamps cover the mainstream conductor specifications of 10kV lines, making them suitable for emergency repairs in complex scenarios such as densely populated areas, near water bodies, and at night.

[0038] 3. Breaking through the limitations of traditional emergency repair scenarios and expanding the scope of application: By adding auxiliary connection components consisting of telescopic insulated operating rods, anti-slip insulated traction hooks, and bidirectional guide pulley groups, and combining insulator structural feature identification and residual tension state judgment, ground-based emergency repair of non-fallen wires on poles can be achieved for the first time without climbing, solving the defect of existing technologies that can only handle fallen wires in severe weather.

[0039] 4. Reduced operational threshold and cost: The crossarm pre-components are assembled with standardized hardware, which is reusable and easy to maintain. The electric adjustment module and wireless remote control design reduce the intensity of personnel operation. The emergency repair process is standardized and the steps are clear, which reduces the dependence on the skill level of the operators. Both new and old employees can get started quickly. The solution is compatible with the 10kV line specifications in most parts of the country and can be applied without major modifications, making it suitable for large-scale promotion in the power grid industry.

[0040] 5. A dual-mode tension-resistant operation process is adopted. For dropped wire breakage, 8 people work together on the ground to reduce tool transfer and waiting time. For wire breakage on the pole that has not fallen, the operation rhythm is optimized by adjusting the tension step by step and controlling the traction speed to avoid ineffective work. Attached Figure Description

[0041] Figure 1 A flowchart of a method for emergency repair of a 10kV power line breakage in severe weather;

[0042] Figure 2 A schematic diagram of the installation structure of a crossarm prefabricated component for emergency repair of a 10kV line breakage in severe weather.

[0043] Figure 3 A schematic diagram of the overall structure of a crossarm pre-component for emergency repair of a 10kV power line breakage under severe weather conditions;

[0044] Figure 4 A schematic diagram of the crossarm pre-component for emergency repair of a 10kV power line breakage under severe weather conditions from another perspective.

[0045] Figure 5 This is an enlarged view of part A in section 3;

[0046] Figure 6 for Figure 2 Enlarged view of section B in the middle.

[0047] The following are the reference numerals in the attached diagram: 1. Precast crossarm; 2. Clamp; 3. Support iron; 4. Support porcelain insulator; 5. Tension porcelain insulator; 6. Tension clamp; 7. Parallel groove clamp; 8. Crossarm connecting piece. Detailed Implementation

[0048] The present invention will be further described in detail below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0049] Please see the appendix Figure 1 The present invention provides an embodiment 1: a method for emergency repair of a 10kV line breakage in severe weather, including the following specific implementation steps:

[0050] (1) Intelligent judgment of line breakage status: The drone equipped with a visual recognition module is used to inspect the fault point. Through image analysis, the line breakage type is distinguished as a fallen line breakage / a line breakage on the pole that has not fallen. A judgment formula model is constructed to determine the insulator type of the line breakage on the pole as a suspension type / pin type and the residual tension status. The conductor sag angle ≤30° is low tension, 30°~60° is medium tension, and >60° is high tension. The pole tower model, conductor specifications and surrounding environment information are recorded simultaneously.

[0051] The technical command post issues an inspection order, and the drone operator controls a drone equipped with a visual recognition module to fly to the faulty line area, keeping the altitude controlled at 10-15m above the fault point. The drone takes high-definition images of the broken line and transmits them back in real time. Through the drone image analysis algorithm, the type of broken line is automatically identified as either a falling broken line (the conductor detaches from the tower suspension point and hangs freely) or a non-falling broken line (the conductor is broken but still partially attached to the insulator string). At the same time, the insulator type (suspension / pin type) and residual tension state of the non-falling broken line are determined by the judgment formula model. Parameters such as the height of the broken line point from the ground and the horizontal distance from the tower are measured, and a fault analysis report is generated.

[0052] The judgment formula model includes:

[0053] Formula for determining insulator type:

[0054]

[0055] Where is the structural characteristic coefficient of the insulator string, is the measured value of the spacing between individual insulator pieces, and is the measured value of the total length of the insulator string. When , it is determined to be a suspension insulator; when , it is determined to be a pin insulator.

[0056] Formula for calculating residual tension:

[0057]

[0058] Among them, The residual tension of the conductor. Mass per unit length of conductor It is the acceleration due to gravity. The horizontal distance between the suspension points on both sides of the break point. This is the measured value of the conductor sag. The angle of the conductor's sag. correspond For low tension, correspond For medium tension, correspond It is for high tension.

[0059] (2) Graded safety arrangement: Based on the judgment results, the operators shall set up a fence for falling wire breakage within a range of ≥50m, and a fence for non-falling wire breakage on the pole within a range of ≥80m. Each pole shall be guarded by no less than 2 dedicated personnel. Insulation isolation warning shall be set up within 0.7m of the crossarm pre-component installation area. Emergency lighting equipment shall be added at night or in low light conditions, and the lighting brightness shall be ≥500 lux.

[0060] The safety monitoring post delineates the safety fence area based on the fault analysis report. For dropped wire breaks, a conventional fence is used. For wire breaks that have not fallen, an outer warning tape is added. A sign that reads "High Voltage Operation, No Entry" is hung on the fence. Two personnel are assigned to each pole to maintain real-time communication using walkie-talkies. Obstacles within a 5-meter radius around the crossarm pre-component installation point are cleared to ensure an unobstructed working space. Emergency lighting equipment is installed at the four corners of the fence at night or in low-light conditions to ensure visibility of the operation.

[0061] (3) Pre-component adaptive installation: The clamp 2 is set on the tower near the fault point. The electric adjustment module is started by wireless remote control. According to the feedback of the tension sensor, the tension of the clamp 2 is adjusted to the set threshold. The special support iron 3 is installed and reinforced by the locking rope to keep the special crossarm horizontal. Then the support column porcelain bottle 4 is fixed to complete the support system construction.

[0062] The prefabricated component installation team, carrying the crossarm prefabricated components and installation tools, arrives at the designated installation position and sets the clamp 2 at the specified height on the tower, 3-4m above the ground. The technical command team starts the electric adjustment module of clamp 2 via wireless remote control. The tension sensor provides real-time feedback on the clamping tension data. When the data reaches the 5-8kN threshold, clamp 2 is locked. Then, the support iron is installed to ensure that the support iron fits tightly against the tower and is reinforced with locking ropes. The prefabricated crossarm 1 is calibrated with a level to ensure that the installation direction of the support insulator 4 is consistent with the direction of the conductor. Then, the support insulator 4 is fixed and the insulation performance is checked.

[0063] (4) Dual-mode tensioning operation:

[0064] ① The drop-type line breakage adopts a ground-coordinated mode, with 8 workers simultaneously completing the installation of tension hardware, installation of tension clamp 6, and tensioning operation;

[0065] Eight people work together at the tension operation station, with two people installing tension hardware, two people installing tension clamps 6, two people operating ground tensioning tools, and two people passing materials. They carry out the work simultaneously, quickly installing tension hardware and tension porcelain insulators 5 on the prefabricated crossarms 1 on both sides of the break point, fixing the tension clamps 6 to the end of the conductor, and slowly tightening the conductor using ground tensioning tools, observing changes in conductor tension, and avoiding over-stretching to avoid damaging the conductor.

[0066] ② For wire breaks that have not fallen off the pole, use the auxiliary splicing mode. Assemble the bidirectional guide pulley to the crossarm of the adjacent intact pole tower using the multi-stage telescopic insulated operating rod. Adjust it to be in the same direction as the conductor traction path and fix it. Insert the insulated rope and use the multi-stage telescopic insulated operating rod to fasten one end of the insulated rope to the broken conductor. Slowly pull the rope to pull the broken conductor to the corresponding tension clamp 6 and the support porcelain insulator 4. Temporarily fix it with the operating rod, without finally tightening it.

[0067] Residual tension pretreatment: If under high tension, install and fix the bidirectional guide pulley block 3-4m below the break point on the tower using a multi-stage telescopic insulated operating rod. Adjust the line connecting the two pulleys to align with the conductor traction direction and ensure its center is on the same horizontal plane as the fixed position of the precast crossarm 1 conductor. The operator holds the multi-stage telescopic insulated operating rod and precisely hooks the anti-slip traction hook onto the midpoint of the broken conductor. One end of the insulated rope is fixed to the traction hook, and the other end passes through the double pulley block. Two operators simultaneously and slowly pull the conductor, controlling the speed. The speed is set to 0.3~0.5m / s. The conductor traction height is controlled according to the scale markings on the multi-stage telescopic insulating operating rod to ensure that the distance between the conductor and the tower is ≥0.7m and the distance between the conductor and the ground is ≥5m. The broken conductor is pulled to the corresponding position of the tension clamp 6 and the support porcelain insulator 4 of the crossarm pre-component. After the conductor is pulled to the designated position, the broken conductor is temporarily fixed to the corresponding tension clamp 6 and the support porcelain insulator 4 with the cooperation of the multi-stage telescopic insulating operating rod. No final tightening is performed. The conductor tension is adjusted to ensure that the conductor is not excessively slack or stretched.

[0068] (5) Dynamic tension balance splicing: The tension of the conductor is detected by the conductor tension tester. When the tension value exceeds the threshold of 15~20kN, the tensioning tool is adjusted to release the pressure. After the tension is stabilized, the broken conductor is fixed on the support porcelain insulator 4 and the tension clamp 6 is tightened. The conductor splicing is completed by using JBL-50~240 type special groove clamp 7.

[0069] The conductor tension data is detected by a conductor tension tester. When the tension value exceeds the threshold of 15~20kN, the technical command post instructs the tension operation post to adjust the tensioning tool to release pressure. After the tension stabilizes, three layers of insulating tape are wrapped around the contact point between the broken conductor and the precast crossarm 1. An insulating isolation pad is installed at the position adjacent to the conductor and the tower. After completion, the conductor tension is detected again to ensure that the tension fluctuation is ≤±1kN. Then, the broken conductor is fixed on the porcelain insulator 4 of the support post, and the tension clamp 6 is tightened. The splicing operation post installs the special-shaped parallel groove clamp 7 at the fixed position of the broken conductor and fixes it to ensure that the parallel groove clamp 7 is in full contact with the broken conductor. At the same time, the splicing part is visually inspected to ensure that there are no problems such as conductor damage or insulation layer damage.

[0070] (6) Insulation verification and power restoration: Use an insulation resistance meter to test the insulation performance of the splice. An insulation resistance ≥100MΩ is considered qualified. Remove safety facilities and auxiliary tools. After closing the switch and energizing, monitor the line operating parameters through the power distribution automation system. After confirming that there are no abnormalities, clean up the work site. For non-fallen wires on the pole, it is necessary to check the status of the insulators using a multi-level telescopic insulated operating rod with an insulated camera. Damaged insulators need to be hooked to the ground for recovery.

[0071] The reconnection work station uses an insulation resistance meter to test the insulation performance of the reconnection point and the line. When the insulation resistance is ≥100MΩ, the insulation is confirmed to be qualified. For non-fallen broken lines on the pole, an insulated camera is used to check the surface of the insulator for cracks or damage through a multi-stage telescopic insulated operating pole. If damage is found, it is retrieved to the ground using an insulated hook. The safety monitoring station removes the safety fence and warning signs. The technical command station issues the closing command and monitors the line voltage and current parameters through the power distribution automation system. After observing for 15 minutes without any abnormalities, the power restoration is confirmed to be successful. Tools and waste are cleaned up at the work site. Auxiliary tools are retrieved in the order of "heavy first, light second; far first, near third". After all tools are retrieved, the insulation performance is retested. The emergency repair record is filled out and the line equipment file is updated simultaneously.

[0072] In the aforementioned series of operations, auxiliary connection components, including telescopic insulated operating rods, anti-slip insulated traction hooks, and bidirectional guide pulley groups, work together. Combined with insulator structural feature identification and residual tension state judgment, ground-based emergency repair of non-fallen wires on poles was achieved for the first time without climbing. This solves the problem that existing technologies can only handle fallen wires in severe weather. The crossarm pre-components are assembled with standardized hardware, are reusable and easy to maintain. The electric adjustment module and wireless remote control design reduce the intensity of personnel operation. The repair process is standardized and the steps are clear, reducing the reliance on the skill level of the operators. Both new and old employees can quickly get started. The solution is compatible with 10kV line specifications in most parts of the country and can be applied without major modifications, making it suitable for large-scale promotion in the power grid industry.

[0073] Please see Figure 2-6 The present invention provides an embodiment 2: a prefabricated crossarm component for emergency repair of 10kV line breakage in severe weather, including a prefabricated crossarm 1, a clamp 2, a special support iron 3, a support porcelain insulator 4, a tension porcelain insulator 5, a tension clamp 6, and a parallel groove clamp 7.

[0074] The clamp 2 is fixedly installed at one end of the prefabricated crossarm 1. One end of the special support iron 3 is inclinedly fixedly connected to the lower part of the prefabricated crossarm 1, and the other end is correspondingly fixedly installed with the clamp 2. Several crossarm connecting parts 8 are uniformly welded on the prefabricated crossarm 1 along its length direction. The support porcelain insulator 4 is detachably installed on a certain crossarm connecting part 8. The tension porcelain insulator 5 is detachably installed at both ends of the prefabricated crossarm 1. The tension clamp 6 is detachably installed on the end of the tension porcelain insulator 5 away from the prefabricated crossarm 1. The parallel groove clamp 7 is used to realize the rapid reconnection of broken wires.

[0075] The prefabricated crossarm 1 is made of angle iron of type ∠75×8×1500 (375), and the surface of the prefabricated crossarm 1 is provided with anti-slip insulating coating. Its length is designed to be 1500mm according to the spacing of 10kV line conductors.

[0076] The clamp 2 is a nylon elastic band clamp 2, made of high-strength insulating nylon material, with telescopic adjustment function, and is suitable for tower bodies with a diameter of 300~500mm. A tension sensor is installed on the inner side of the clamp 2 to provide real-time feedback on the fixing tension. The nylon elastic band clamp 2 is also equipped with an electric adjustment module, which realizes adaptive tension adjustment through wireless remote control. The tension threshold is set to 5~8kN.

[0077] The parallel groove clamp 7 is a JBL-50~240 type special-shaped parallel groove clamp 7, and the support porcelain insulator 4 and tension porcelain insulator 5 are U70B / 255 type disc suspension porcelain insulators.

[0078] It also includes an auxiliary connection assembly, which includes a telescopic insulated operating rod, a two-way guide pulley block, and a locking rope. The multi-stage telescopic insulated operating rod has a maximum extension length of ≥8m, an insulation class of 10kV, and a scale marking on the rod body.

[0079] Through the specific operational steps in Example 1, combined with the crossarm pre-component in the example, the transformation of crossarm pre-component aerial work to ground work is realized. Combined with the standardized ground tensioning process, the average repair time and wiring operation time of 10kV line breakage faults under severe weather conditions are significantly reduced. At the same time, the safety hazards of falling from heights and lightning strikes during aerial work under severe weather conditions are completely avoided. Through the selection of insulation materials and the setting of safety fences, the safety of the operation is further improved, and the life safety of front-line workers is protected. Meanwhile, the nylon elastic band clamp 2 can be adapted to various types of towers, and the special-shaped parallel groove clamp 7 covers the mainstream conductor specifications of 10kV lines, which is suitable for emergency repairs in complex scenarios such as densely populated areas, near water bodies, and at night.

[0080] An embodiment 3 provided by the present invention:

[0081] I. Fault Background

[0082] At 2:00 PM on June 15, 2025, Huarong District, Ezhou City, experienced severe convective thunderstorms. A 10kV Hua18 switch Miaoling branch line suffered a non-falling wire breakage on a conductor pole due to a lightning strike. The fault point was located on concrete tower No. 12 (380mm in diameter), with conductor type LGJ-120 / 20. The broken wire was attached to a suspension insulator string, with a sag angle of 45° (medium tension). The surrounding area was a water feature, with obstructed visibility and muddy ground.

[0083] II. Emergency Repair Preparation

[0084] An 8-person emergency repair team was formed, with roles assigned as drone operator, safety supervisor, 2 pre-component installation personnel, 2 tensioning personnel, splicing personnel, and technical commander. All members were equipped with insulated gloves, insulated boots, and special insulated shawls for rainy days.

[0085] Carry the optimized crossarm pre-components (including a ∠75×8×1500 special crossarm, U70B / 255 type support porcelain insulator, JBL-120 type special grooved clamp, nylon elastic band clamp) and auxiliary splicing components (8m telescopic insulated operating rod, anti-slip insulated traction hook, bidirectional guide pulley block), and calibrate tension sensors, insulation resistance meters and other equipment.

[0086] III. Emergency Repair Implementation (Total Time: 1.32 hours)

[0087] Line breakage status assessment (10 minutes): The drone ascends to a position 12m above the fault point, captures high-definition images and transmits them back, identifies the line breakage type as pole-mounted and not fallen, determines that the insulator is suspended and under medium tension, generates three-dimensional coordinates of the fault, and determines that the pre-component installation position is 3.5m above the ground.

[0088] Tiered safety setup (15 minutes): The safety monitoring post marks an 80m safety fence, adds an outer warning tape, installs emergency lighting equipment (600 lux brightness) at the four corners of the fence, assigns two dedicated personnel to guard the pole, and clears obstacles within 5m around the installation point.

[0089] Pre-component installation (20 minutes): The installation team will attach the nylon elastic band clamps to the tower, and the technical command team will start the electric adjustment module via wireless remote control. After the tension sensor reports that the actual tension reaches 6.5kN (threshold 5~8kN), it will be locked. The support iron will be installed and reinforced by cross-locking ropes. The level instrument will be used to calibrate the horizontality error of the crossarm to ≤±1°, and the porcelain insulator of the support column will be fixed.

[0090] Tensioning operation (35 minutes): Using the telescopic insulated operating rod, hook the anti-slip traction hook to the midpoint of the broken wire. Install guide pulley blocks near the end of the precast crossarm and 3.5m from the tower. Two people pull in a directional manner at a speed of 0.4m / s, keeping the distance between the conductor and the tower at 0.8m and the distance between the conductor and the ground at 5.2m. Pull the broken conductor to the corresponding position of the tension clamp and the support insulator of the crossarm precast component. After the conductor is pulled to the designated position, use the multi-stage telescopic insulated operating rod to temporarily fix the broken conductor to the corresponding tension clamp and the support insulator without final tightening.

[0091] Dynamic tension splicing (18 minutes): The conductor tension detector monitors the tension in real time and keeps it stable at 18kN. The splicing operator fixes the conductor to the support porcelain insulator, tightens it with a torque of 30N·m and grooves the wire clamp. The pressure sensor shows a clamping pressure of 2.5kN. Three layers of insulating tape are wrapped around the contact point between the conductor and the crossarm, and a 300×200mm insulating isolation pad is installed.

[0092] Insulation verification and power restoration (19 minutes): The insulation resistance was tested with a 2500V insulation resistance meter and found to be 120MΩ (≥100MΩ is acceptable). The insulators were checked for damage by a camera carried by the insulated operating rod. After the safety facilities were removed, the circuit was closed and power was restored. The power distribution automation system monitored for 15 minutes and found no abnormalities.

[0093] IV. Repair Results

[0094] This emergency repair was 3.33 hours shorter than traditional pole climbing operations, with the tensioning operation taking only 0.22 hours and the wiring operation taking only 0.3 hours. This significantly reduced the risks of operating in water areas, and the number of users affected by power outages during the fault was reduced by 71% compared to similar faults in the past, fully meeting the company's requirement that "power restoration time should not exceed 2 hours".

[0095] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A pre-constructed crossarm component for emergency repair of a 10kV power line breakage during severe weather, characterized in that: Including prefabricated crossarm (1), clamp (2), support iron (3), support porcelain insulator (4), tension porcelain insulator (5), tension clamp (6) and parallel groove clamp (7); The clamp (2) is fixedly installed at one end of the prefabricated crossarm (1). One end of the support iron (3) is inclinedly fixedly connected to the lower part of the prefabricated crossarm (1), and the other end is fixedly installed with the clamp (2). Several crossarm connecting parts (8) are uniformly welded on the prefabricated crossarm (1) along its length direction. The support porcelain insulator (4) is detachably installed on a certain crossarm connecting part (8). The tension porcelain insulator (5) is detachably installed at both ends of the prefabricated crossarm (1). The tension clamp (6) is detachably installed on the end of the tension porcelain insulator (5) away from the prefabricated crossarm (1). The parallel groove clamp (7) is used to realize the rapid reconnection of broken conductors.

2. The pre-constructed crossarm for emergency repair of a 10kV line breakage in severe weather as described in claim 1, characterized in that, The prefabricated crossarm (1) is made of angle iron of type ∠75×8×1500 (375), and the surface of the prefabricated crossarm (1) is provided with anti-slip insulating coating. Its length is designed to be 1500mm according to the spacing of 10kV line conductors.

3. The pre-constructed crossarm for emergency repair of a 10kV line breakage in severe weather as described in claim 1, characterized in that, The clamp (2) is a nylon elastic band clamp (2), made of high-strength insulating nylon material, with telescopic adjustment function, and is suitable for tower bodies with a diameter of 300~500mm. A tension sensor is installed on the inner side of the clamp (2) to provide real-time feedback on the fixing tension. The nylon elastic band clamp (2) is equipped with an electric adjustment module, which realizes adaptive tension adjustment through wireless remote control. The tension threshold is set to 5~8kN.

4. The pre-constructed crossarm for emergency repair of a 10kV line breakage in severe weather as described in claim 1, characterized in that, The parallel groove clamp (7) is a JBL-50~240 type special-shaped parallel groove clamp (7), and the support porcelain insulator (4) and tension porcelain insulator (5) are U70B / 255 type disc suspension porcelain insulators.

5. A pre-constructed crossarm for emergency repair of a 10kV line breakage in severe weather as described in claim 1, characterized in that, It also includes an auxiliary connection assembly, which includes a telescopic insulated operating rod, a two-way guide pulley block, and a locking rope. The multi-stage telescopic insulated operating rod has a maximum extension length of ≥8m, an insulation class of 10kV, and a scale marking on the rod body.

6. A method for emergency repair of a 10kV line breakage under severe weather conditions based on the crossarm pre-construction element described in claim 1, characterized in that, Includes the following steps: (1) Intelligent judgment of line breakage status: The drone equipped with a visual recognition module is used to inspect the fault point. Through image analysis, the line breakage type is distinguished as a fallen line breakage / a line breakage on the pole that has not fallen. A judgment formula model is constructed to determine the insulator type of the line breakage on the pole as a suspension type / pin type and the residual tension status. The conductor sag angle ≤30° is low tension, 30°~60° is medium tension, and >60° is high tension. The pole tower model, conductor specifications and surrounding environment information are recorded simultaneously. (2) Graded safety arrangement: Based on the judgment results, the operators set up a fence for falling wire breakage within a range of ≥50m, and a fence for non-falling wire breakage on the pole within a range of ≥80m. Each pole is assigned a dedicated person to guard it. Insulation isolation warnings are set up within 0.7m of the crossarm pre-component installation area. Emergency lighting equipment is added at night or in low light conditions, and the lighting brightness is ≥500 lux. (3) Pre-component adaptive installation: The clamp (2) is fitted onto the tower near the fault point. The electric adjustment module is started by wireless remote control. According to the feedback of the tension sensor, the tension of the clamp (2) is adjusted to the set threshold. The support iron (3) is installed and reinforced by the locking rope to keep the prefabricated crossarm (1) horizontal. Then the support column porcelain bottle (4) is fixed to complete the support system construction. (4) Dual-mode tensioning operation: ①The drop-type line breakage adopts the ground coordination mode, with 8 operators simultaneously completing the installation of tension hardware, installation of tension clamps (6) and tensioning operation; ② When the broken wire on the pole is not dropped, the auxiliary splicing mode is activated. The bidirectional guide pulley is assembled to the crossarm of the adjacent intact pole tower through the multi-level telescopic insulating operating rod. It is adjusted to be in the same direction as the traction path of the broken wire and fixed. The insulating rope is inserted, and one end of the insulating rope is fastened to the broken wire with the multi-level telescopic insulating operating rod. The rope is slowly pulled to pull the broken wire to the corresponding tension clamp (6) and the support porcelain insulator (4). It is temporarily fixed with the help of the multi-level telescopic insulating operating rod and is not finally tightened. (5) Dynamic tension balance splicing: The tension of the broken conductor is detected by the conductor tension tester. When the tension value exceeds the threshold of 15~20kN, the tensioning tool is adjusted to release the pressure. After the tension is stabilized, the broken conductor is fixed on the support porcelain insulator (4) and the tension clamp (6) is tightened. The conductor splicing is completed by using JBL-50~240 type special groove clamp (7). (6) Insulation verification and power restoration: Use an insulation resistance meter to test the insulation performance of the splice. An insulation resistance of ≥100MΩ is considered qualified. Remove safety facilities and auxiliary tools. After powering on, monitor the line operating parameters through the power distribution automation system. After confirming that there are no abnormalities, clean up the work site. For broken lines that have not fallen off the pole, it is necessary to check the status of the insulators by carrying an insulated camera through a multi-level telescopic insulated operating rod. Damaged insulators need to be hooked to the ground for recovery.

7. The method for emergency repair of a 10kV line breakage under severe weather conditions using a crossarm pre-construction as described in claim 6, characterized in that... The specific steps for intelligently determining the disconnection status are as follows: The technical command post issues an inspection order, and the drone operator controls a drone equipped with a visual recognition module to fly to the faulty line area, keeping the altitude controlled at 10-15m above the fault point. The drone takes high-definition images of the broken line and transmits them back in real time. Through the drone image analysis algorithm, the type of broken line is automatically identified as either a falling broken line (the conductor detaches from the tower suspension point and hangs freely) or a non-falling broken line (the conductor is broken but still partially attached to the insulator string). At the same time, the insulator type (suspension / pin type) and residual tension state of the non-falling broken line are determined by the judgment formula model. Parameters such as the height of the broken line point from the ground and the horizontal distance from the tower are measured, and a fault analysis report is generated. The specific operational steps of the graded safety arrangement are as follows: the safety monitoring post delineates the safety fence range based on the fault analysis report. For fallen wire breaks, a conventional fence is used. For wire breaks that have not fallen, an outer warning tape is added. A sign that reads "High Voltage Operation, No Entry" is hung on the fence. Two personnel are assigned to each pole to maintain real-time communication using walkie-talkies. Obstacles within a 5m radius around the crossarm pre-component installation point are cleared to ensure that the working space is unobstructed. Emergency lighting equipment is installed at the four corners of the fence at night or in low-light conditions to ensure visibility of the operation. The specific operation steps for the adaptive installation of the pre-component are as follows: The pre-component installation post carries the crossarm pre-component and installation tools to the predetermined installation position, and puts the clamp (2) on the tower at the specified height, 3~4m from the ground. The technical command post starts the electric adjustment module of the clamp (2) through the wireless remote control. The tension sensor provides real-time feedback of the clamping tension data. When the data reaches the threshold of 5~8kN, the clamp (2) is locked. Then the support iron (3) is installed so that the support iron is tightly attached to the tower and reinforced with the locking rope. The prefabricated crossarm (1) is calibrated with a level to ensure that the installation direction of the support porcelain insulator (4) is consistent with the direction of the broken conductor. Then the support porcelain insulator (4) is fixed and the insulation performance is checked.

8. The method for emergency repair of a 10kV line breakage under severe weather conditions using a crossarm pre-construction as described in claim 6, characterized in that... The specific operating steps for the dual-mode tension-bearing operation are as follows: (1) Drop-type wire breakage operation: 8 people work together at the tension operation station, 2 people install tension hardware, 2 people install tension clamps (6), 2 people operate ground tensioning tools, and 2 people pass materials. The operation is carried out simultaneously. Tension hardware and tension porcelain insulators (5) are quickly installed on the prefabricated crossarms (1) on both sides of the breakage point. The tension clamps (6) are fixed to the end of the broken wire. The wire is slowly tightened by the ground tensioning tools. The changes in wire tension are observed to avoid over-stretching and damaging the wire. (2) Operation of wire breakage without falling off the pole: Residual tension pretreatment: If it is in a high tension state, install and fix the bidirectional guide pulley group at a height of 3~4m below the pole tower below the breakage point through the multi-stage telescopic insulated operating rod, and adjust the connection line of the two pulleys to be consistent with the traction direction of the conductor and the center to be on the same horizontal plane as the prefabricated crossarm (1) The conductor fixing position is on the same horizontal plane. The operator holds the multi-stage telescopic insulated operating rod and accurately hooks the anti-slip traction hook at the midpoint of the broken conductor. One end of the insulating rope is fixed to the traction hook, and the other end passes through the double pulley group. Two operators pull slowly and synchronously. The speed is controlled at 0.3~0.5m / s. The conductor traction height is controlled according to the scale markings of the multi-level telescopic insulating operating rod to ensure that the distance between the conductor and the tower is ≥0.7m and the distance between the conductor and the ground is ≥5m. The broken conductor is pulled to the corresponding position of the tension clamp (6) and the support porcelain insulator (4) of the crossarm pre-component. After the conductor is pulled to the designated position, the broken conductor is temporarily fixed to the corresponding tension clamp (6) and the support porcelain insulator (4) through the cooperation of the multi-level telescopic insulating operating rod. No final tightening is performed. The conductor tension is adjusted to ensure that the conductor is not excessively loose or stretched.

9. The method for emergency repair of a 10kV line breakage under severe weather conditions using a crossarm pre-construction as described in claim 6, characterized in that... The specific operation steps of the tension dynamic balance continuation are as follows: the tension data of the conductor is detected by the conductor tension detector. When the tension value exceeds the threshold of 15~20kN, the technical command post instructs the tension operation post to adjust the tensioning tool to release pressure. After the tension is stable, three layers of insulating tape are wrapped around the contact point between the broken conductor and the prefabricated crossarm (1). An insulating isolation pad is installed at the position adjacent to the conductor and the tower. After completion, the conductor tension is detected again to ensure that the tension fluctuation is ≤±1kN. Then the broken conductor is fixed on the support porcelain insulator (4) and the tension clamp (6) is tightened. The continuation operation post installs the special-shaped parallel groove clamp (7) at the fixed position of the broken conductor and fixes it to ensure that the parallel groove clamp (7) is in full contact with the broken conductor. At the same time, the continuation part is visually inspected to ensure that there are no problems such as conductor damage or insulation layer damage. The specific steps for insulation verification and power restoration are as follows: The reconnection operator uses an insulation resistance meter to test the insulation performance of the reconnection point and the line. When the insulation resistance is ≥100MΩ, the insulation is confirmed to be qualified. For non-fallen broken lines on the pole, an insulated camera is used to check the surface of the insulator for cracks or damage via a multi-stage telescopic insulated operating pole. If damage is found, it is retrieved to the ground using an insulated hook. The safety monitoring station removes the safety fence and warning signs. The technical command station issues the closing command. The voltage and current parameters of the line are monitored through the distribution automation system. After observing for 15 minutes without any abnormalities, the power restoration is confirmed to be successful. Tools and waste at the work site are cleaned up. Auxiliary tools are retrieved in the order of "heavy first, light second; far first, near third". After all tools are retrieved, the insulation performance is retested. The emergency repair record is filled out and the line equipment file is updated simultaneously.

10. The method for emergency repair of a 10kV line breakage under severe weather conditions using a crossarm pre-construction as described in claim 6, characterized in that... The judgment formula model includes: Formula for determining insulator type: in, These are the structural characteristic coefficients of the insulator string. This represents the measured spacing between individual insulator plates. This is the measured total length of the insulator string. When, it is determined to be a suspension insulator, when At that time, it was determined to be a pin-type insulator; Formula for calculating residual tension: Among them, The residual tension of the conductor. Mass per unit length of conductor It is the acceleration due to gravity. The horizontal distance between the suspension points on both sides of the break point. This is the measured value of the conductor sag. The angle of the conductor's sag. correspond For low tension, correspond For medium tension, correspond It is for high tension.

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