High-altitude mountain photovoltaic assembly type support rapid construction method

Abstract

This invention relates to the field of photovoltaic power generation technology and discloses a rapid construction method for prefabricated photovoltaic supports in high-altitude mountainous areas, aiming to solve problems such as low construction efficiency, high risk of hot work, and poor terrain adaptability of photovoltaic supports in high-altitude mountainous areas. The method includes: collecting terrain data through high-precision measurement and performing angle zoning modeling; designing modular supports based on the zoning data and determining a specification list; completing component prefabrication, machining, and anti-corrosion treatment in the factory; uniquely coding the components and establishing a logical mapping relationship between them and the installation points; accurately distributing materials on-site according to the codes and assembling them using fasteners; and finally, using the adjustment holes between the diagonal braces and clamps to check structural deviations and fine-tune and optimize angles. This application eliminates on-site hot work, greatly reduces construction intensity, improves construction efficiency and safety, and has strong terrain adaptability and structural stability.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic power generation technology, specifically a rapid construction method for photovoltaic prefabricated support structures in high-altitude mountainous areas. Background Technology

[0002] With the continued expansion of the global clean energy industry, the application of photovoltaic power generation in special geographical environments such as high-altitude mountains is increasingly widespread, becoming an important way to optimize the energy structure. As the core supporting structure of a photovoltaic system, the maturity and reliability of its construction technology play a decisive role in ensuring the construction quality and operation and maintenance life of the power station. In extreme natural environments and complex geological conditions, efficient and stable support system construction schemes have become a research hotspot in the field of new energy infrastructure.

[0003] Among these, rapid construction technology for photovoltaic (PV) supports in high-altitude mountainous areas is a key direction for improving the overall efficiency of the project. It primarily transforms complex on-site operations into a combination of factory prefabrication and on-site assembly through standardized design and industrialized production methods. This technological direction focuses on optimizing the physical structure and connection methods of the supports to adapt to irregular mountainous terrain and achieve rapid, stable, and precise installation under harsh climatic conditions.

[0004] Existing technologies, when addressing the challenges of high-altitude mountain construction, are limited by the low flexibility of traditional non-prefabricated structures, still heavily relying on on-site cutting and welding processes. In the high-altitude, low-oxygen environment, excessive manual labor significantly reduces construction efficiency, and the low temperature environment severely affects the mechanical properties and corrosion resistance of welded joints, posing safety hazards. Furthermore, the complex mountain terrain demands extremely high adaptability to the angles of the support structures; traditional solutions struggle to achieve precise component matching without secondary processing, and frequent hot work increases fire prevention pressure in specific areas. Therefore, achieving rapid, hot-work-free assembly and construction of photovoltaic support structures in complex terrain has become a pressing technical challenge in the current photovoltaic engineering field. Summary of the Invention

[0005] The purpose of this invention is to provide a rapid construction method for photovoltaic prefabricated support structures in high-altitude mountainous areas, which can effectively solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas, comprising the following specific steps: Step 1: Topographic data acquisition and angle partitioning modeling. High-precision measuring equipment is used to acquire topographic data of the construction area, extract the slope and azimuth information of each photovoltaic array point, and divide the terrain into multiple different adaptive partitions according to preset angle thresholds. Step 2: Detailed design and specification matching of prefabricated components. Based on the angle data of the adaptive partitions, the support system is modularly designed to determine the required upper column length specifications, front and rear diagonal brace length specifications, and relative position parameters of connecting components for different partitions, forming a standardized component requirement list. Step 3: Factory prefabrication and anti-corrosion treatment of components. According to the component requirement list, the upper column, diagonal beam, front and rear diagonal braces, purlins and fasteners are machined in the prefabrication factory, including cutting, punching and hot-dip galvanizing anti-corrosion treatment, to ensure that all connection parts are matched through the preset bolt holes. Step 4: Reverse marking of construction drawings and material coding. Mark the angle zoning results calculated in Step 1 and the component specification information determined in Step 2 on the construction plan drawings, and give each type of prefabricated component a unique code to establish a logical mapping relationship between component specifications and installation points. Step 5: On-site material entry and precise bulk material installation. According to the logical mapping relationship, the prefabricated components are transported to the corresponding installation area and placed precisely according to the codes marked on the drawings. Then, the upper columns, diagonal beams, front and rear diagonal braces and purlins are bolted together in sequence using fasteners to build a stable support system. Step 6: Structural deviation verification and angle fine-tuning optimization. After the main body of the support is assembled, the inclination angle of the inclined beam is finely adjusted using the adjustment holes between the front and rear diagonal braces and the clamps to compensate for the verticality or height deviations generated during the pile foundation construction, and finally complete the rapid construction of the overall support system.

[0007] Preferably, in step 1, terrain data acquisition employs aerial remote sensing or ground-based laser scanning technology to obtain three-dimensional coordinate point cloud data of the construction area. By triangulating the point cloud data and calculating the normal vector of each grid cell, the local slope of the mountainous terrain can be accurately identified. The angle partitioning divides the terrain into multiple slope intervals, each interval corresponding to a set of preset support structure parameters.

[0008] Preferably, in step 2, the upper support column is designed with various length specifications according to different terrain slopes. In the first preset zone with a gentler slope, the upper support column adopts a single-column structure, and the column length is increased or decreased to adapt to ground undulations. In the second preset zone with a steeper slope, the upper support column adopts a double-column reinforcement structure to improve the lateral stability of the support under complex terrain.

[0009] Preferably, the upper column is made of high-strength carbon structural steel, and its cross-section is circular or square. The top of the upper column is provided with a hinged connector for connection to the inclined beam. The hinged connector includes two parallel clamping plates with coaxial bolt holes for adjusting the rotation of the inclined beam in the vertical plane. The bottom of the upper column precisely matches the connecting sleeve pre-embedded in the pile foundation and is fixed by transversely inserted locking bolts.

[0010] Preferably, the inclined beam is made of C-shaped carbon structural steel. A first connecting hole is provided in the center of the lower surface of the inclined beam for connection to the hinge at the top of the upper column. Second and third connecting holes are provided at both ends of the side of the inclined beam for connection to the upper parts of the front and rear inclined braces, respectively. Multiple fourth connecting holes are evenly distributed along the length of the upper surface of the inclined beam for installing purlin support components.

[0011] Preferably, the front and rear diagonal braces include a front diagonal brace and a rear diagonal brace, both made of C-shaped steel. The lengths of the front and rear diagonal braces are proportioned according to the terrain slope and the height of the upper column in the corresponding zone. The lower ends of the front and rear diagonal braces are connected to the upper column or the exposed part of the pile foundation via diagonal brace clamps. The diagonal brace clamps are provided with elongated oval adjustment holes distributed circumferentially. These adjustment holes are used to absorb the mechanical stress generated by the displacement of the pile foundation during installation and allow for slight compensation of the inclination angle of the diagonal beam.

[0012] Preferably, the purlins are made of continuously arranged C-shaped steel, and their length is pre-set according to the arrangement spacing of the photovoltaic modules. The upper surface of the purlins has pre-drilled module mounting holes, the spacing of which is completely consistent with the mounting holes on the back frame of the photovoltaic modules, ensuring that the modules can be directly fixed by clamps or bolts without the need for secondary drilling on-site. The back of the purlins has mounting holes that mate with purlin brackets, which are fixed to the inclined beams by high-strength bolts.

[0013] Preferably, the fastener system includes hot-dip galvanized high-strength bolts, nuts, spring washers, and flat washers. The fasteners also include column tie rods and column tie rod clamps, with the column tie rods bridging two adjacent upper columns to form a scissor bracing structure, thereby enhancing the lateral force resistance of the support system along the purlin direction. Purlin straight tie rods and purlin diagonal tie rods are also provided between the purlins to maintain a constant spacing between the purlins and improve the torsional stiffness of the overall structure.

[0014] Preferably, the factory prefabrication process in step 3 strictly adheres to the principle of zero hot work. All components are cut using plasma cutting or precision sawing, and holes are opened using CNC punching or drilling. After prefabrication, all components undergo surface treatment in a hot-dip galvanizing bath. The thickness of the galvanized layer must meet predetermined protection standards to resist corrosion of the metal substrate by strong ultraviolet radiation and low-temperature environments in high-altitude areas.

[0015] Preferably, the material coding in step 4 uses barcode or QR code labels, which are affixed to a prominent position on each component. The code contains core information such as the component's model, its assigned zone number, and installation sequence number. Construction personnel can scan the code using a handheld terminal to obtain the component's precise installation coordinates and technical parameters in real time on an electronic map.

[0016] Preferably, the bulk material handling process in step 5 is completed using a small tracked transport vehicle or a cableway transport system. After the components are transferred to the array point, they are assembled in an assembly line manner in the order of first the columns, then the inclined beams, then the inclined braces, and finally the purlins. During the assembly process, all connection nodes are tightened in two stages: initial tightening and final tightening. The final tightening torque must reach a preset torque threshold, and quality inspectors will conduct random checks and mark the connections.

[0017] Preferably, the angle fine-tuning in step 6 is assisted by a laser inclinometer. The construction worker places the laser inclinometer on the surface of the inclined beam and reads the current real-time angle. If the angle deviation exceeds the predetermined allowable range, the bolts on the brace clamp are loosened, and the brace is slid along the elongated adjustment hole, causing the inclined beam to rotate around the hinge axis at the top of the column until the angle reaches the design requirements, after which the bolts are tightened again.

[0018] Preferably, the rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas also includes a set of personnel operation optimization logics tailored to the low-oxygen environment at high altitudes. Since human function declines at high altitudes, this method reduces the physical exertion required for on-site construction by decreasing the weight of individual components and optimizing the grip design of connectors. Simultaneously, the prefabricated process eliminates harmful fumes generated during on-site welding, improving the working environment for construction workers.

[0019] Preferably, the method also involves post-construction maintenance for uneven foundation settlement. When settlement of a certain group of supports is detected, resulting in angular displacement, it is not necessary to dismantle the supports. Instead, recalibration can be performed using the reserved adjustment allowance of the front and rear diagonal braces to restore the supports to their normal operating posture, significantly reducing operation and maintenance costs.

[0020] Preferably, for terrain with a slope within a first specific range, a single-column support structure is adopted, and the slope effect is balanced by adjusting the burial depth or exposed height of the upper column. For terrain with a slope within a second specific range, an asymmetrical double-column support structure is adopted, and the levelness of the support plane is adjusted by configuring columns that are longer in the front and shorter in the back or vice versa.

[0021] Preferably, all bolted connections in the fasteners are equipped with self-locking nuts to prevent bolt loosening due to structural vibration in high-altitude, high-wind environments. All exposed metal connections must be coated with a layer of cold-sprayed zinc paint after final tightening to compensate for mechanical scratches on the galvanized layer that may occur during bolt assembly.

[0022] Compared with the prior art, the beneficial effects achieved by the present invention are: 1. This invention provides a rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas. Through a fully modular structural design and factory prefabrication process, it completely eliminates cutting and welding operations at high-altitude construction sites. This improvement not only significantly reduces the efficiency reduction of on-site manual labor caused by the low-oxygen environment at high altitudes, but also fundamentally avoids the fire risks associated with hot work operations in high-fire-resistance areas such as forests and grasslands, greatly enhancing construction safety and environmental friendliness.

[0023] 2. This invention achieves precise matching between support frame specifications and mountainous terrain through high-precision terrain data acquisition and zonal modeling in the early stages. By back-annotating the angle calculation results onto the construction drawings and implementing component coding management, accurate material distribution and rapid positioning and installation are achieved. This digital management method significantly reduces the probability of secondary handling of materials and misuse of specifications on site, increasing construction efficiency by a predetermined percentage compared to traditional non-prefabricated solutions.

[0024] 3. The support structure designed in this invention has strong terrain adaptability and adjustment redundancy. The multi-specification design of the upper column, combined with the reserved adjustment holes of the front and rear diagonal braces, can flexibly cope with the complex and varied angle requirements of mountainous terrain. At the same time, by utilizing the logical relationship between the clamps and the adjustment holes, it can effectively absorb the verticality deviation caused by pile foundation construction, ensure the flatness of the photovoltaic array surface, improve the power generation efficiency of the photovoltaic modules, and enhance the overall appearance of the system.

[0025] 4. The triangular stable structure design and high-strength hot-dip galvanized material adopted in this invention significantly enhance the stability of the support system under extreme climate conditions. Under the strong winds, heavy snow, and freeze-thaw cycles common in high-altitude areas, this support system exhibits excellent fatigue resistance and corrosion resistance, ensuring that the photovoltaic power station does not require large-scale structural maintenance during its operation cycle of more than 20 years, resulting in significant economic benefits.

[0026] 5. This invention reduces reliance on the professional skills of construction personnel through a standardized assembly process. Simple bolt connections replace complex welding processes, making construction organization more flexible, effectively addressing the challenges of labor shortages in high-altitude areas, shortening the overall project construction cycle, and ensuring the rapid commissioning and fulfillment of clean energy projects. Attached Figure Description

[0027] Figure 1 A flowchart of the construction method; Figure 2 This is a data flow diagram illustrating the construction method. Figure 3 A flowchart for determining the prefabricated component requirements list based on terrain data acquisition and angle zoning modeling in the construction method; Figure 4 A flowchart for establishing a logical mapping relationship between component specifications and installation points in the construction method and for carrying out precise on-site bulk material installation; Figure 5 This is a flowchart illustrating the process of using inclined bracing adjustment holes to compensate for pile foundation construction deviations and to fine-tune and optimize the inclination angle of inclined beams in the construction method. Detailed Implementation

[0028] 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.

[0029] Example 1 In the implementation of a rapid construction method for photovoltaic prefabricated supports in high-altitude mountainous areas, the entire process unfolds strictly according to a systematic engineering logic. Step 1, terrain data acquisition and angle zoning modeling, is the foundation of the entire installation project. In this step, a drone equipped with a high-precision lidar sensor is used to conduct aerial surveys of the target high-altitude mountainous area. During flight, the drone emits tens of thousands of laser pulses per second and receives reflected signals to acquire massive amounts of three-dimensional coordinate point cloud data of the construction area. This point cloud data contains detailed elevation information of the ground surface, vegetation cover, and micro-topographic features. After data acquisition, the raw point cloud is imported into a post-processing workstation, where ground filtering algorithms are used to remove non-ground points such as vegetation and buildings, generating a high-precision digital elevation model.

[0030] Based on this, the digital elevation model is triangulated. Specifically, the terrain surface is decomposed into countless tiny triangular grid cells. By calculating the normal vector of each triangular grid cell in three-dimensional space, the local slope of that grid cell relative to the horizontal plane and its azimuth relative to true north are obtained. To achieve standardized supply of support structures, the system performs cluster analysis on tens of thousands of discrete slope data points based on preset angle thresholds. For example, areas with slopes between -15 degrees and -5 degrees are defined as the first adaptive partition, areas between -5 degrees and 5 degrees as the second adaptive partition, areas between 5 degrees and 15 degrees as the third adaptive partition, and so on, until all possible mountain slope ranges are covered. Through this angle-partitioned modeling, the originally continuous and varied mountain terrain is transformed into a finite number of discrete, representative angle intervals, providing a quantitative basis for the standardized production of subsequent support components.

[0031] Step 2, the detailed design and specification matching of prefabricated components, involves customized parameter design based on the terrain zoning results. For each adaptive zone identified in Step 1, designers establish corresponding mechanical models using structural simulation software. In these models, the length of the upper column is precisely calculated based on the average slope of the zone and the minimum ground clearance required by the photovoltaic modules. The specific calculation logic is as follows: in areas with a downward slope, to maintain the predetermined inclination angle of the inclined beam, the length of the upper column needs to increase accordingly with the increase of the slope to compensate for the spatial displacement caused by the ground drop. In the second preset zone with a larger slope, to cope with the strong wind load and possible lateral displacement in high-altitude areas, the upper column is designed as a double-column reinforced structure. This structure, with two parallel columns jointly supporting the inclined beam, significantly improves the torsional stiffness of the system.

[0032] In this step, the detailed design also includes matching the length specifications of the front and rear diagonal braces. The length ratio of the front to the rear diagonal braces directly determines the tilt angle of the photovoltaic array. By establishing a geometric constraint model, the parameters of the triangular stable structure formed between the inclined beams, the upper column, and the front and rear diagonal braces are determined under a specific slope. For example, when the slope is 15 degrees, the system automatically matches the corresponding standard length rear diagonal brace and the extended front diagonal brace. At the same time, the relative position parameters of the connecting components, such as the fixing height of the diagonal brace clamps on the column and the bolt hole spacing on the inclined beam, are precisely set at this stage. Finally, all design parameters are compiled into a standardized component requirement list, which details the upper column model, diagonal brace specifications, fastener quantity, and coding information required for each section.

[0033] Step 3, the factory prefabrication and anti-corrosion treatment of the components, transforms the detailed design into physical components. After receiving the component requirement list, the prefabrication plant starts the automated production line. The upper column is made of high-strength carbon structural steel tubing, with its cross-section selected as circular or square based on load-bearing requirements. In the machining stage, a CNC plasma cutting machine is used to precisely cut the material to the required length according to the list, with cutting accuracy controlled within ±1 mm. The top of the upper column is fitted with a hinged component using welding or casting. This hinged component consists of two parallel clamping plates with high-precision coaxial bolt holes. The diagonal beams, front and rear diagonal braces, and purlins are all made of C-shaped carbon structural steel. During production, a CNC punching machine pre-punches all connection holes on the web and flanges of the C-shaped steel according to the design model.

[0034] After all components are fabricated, they undergo a uniform hot-dip galvanizing anti-corrosion treatment. The components are immersed in molten zinc at approximately 450 degrees Celsius, forming a uniform, highly adhesive zinc-iron alloy layer and a pure zinc layer on their surface. The thickness of the galvanized layer strictly adheres to industry standards to ensure that the components maintain a rust-free lifespan of over 25 years under conditions of strong ultraviolet radiation, high-frequency freeze-thaw cycles, and potential acid rain in high-altitude areas. After galvanizing, quality inspectors re-inspect the unobstructedness of the bolt holes to ensure unimpeded insertion during on-site assembly. The entire prefabrication process follows a zero-hot work principle, meaning that all cutting, drilling, or welding operations that might be necessary on-site are performed entirely in the factory environment using precision machinery.

[0035] Step 4, reverse marking of construction drawings and material coding, is a crucial digital step in achieving precise construction. The angle attributes of each photovoltaic array point obtained in Step 1 and the component specifications determined in Step 2 are marked on the overall construction plan as digital labels. Each set of bracket installation points has unique coordinates and a corresponding material requirement identifier on the drawing. Simultaneously, each prefabricated component leaving the factory is uniquely coded, typically using weather-resistant barcodes or QR code labels.

[0036] The coding contains a wealth of information, including but not limited to the component's production batch, material properties, zone type (e.g., dedicated to supports in the -15° to -5° range), specific installation point coordinates, and installation sequence number within the overall support system. Establishing a logical mapping between component specifications and installation points means that by scanning the code of any component, the management system can immediately pinpoint its precise location on the construction site. The construction unit then uses the revised drawings to compile material statistics and requisitions, achieving a high degree of synchronization between material flow and construction flow.

[0037] Step 5, the on-site material delivery and precise bulk material installation, demonstrates the high efficiency of prefabricated construction. During the material delivery phase, small tracked transport vehicles or lightweight cableway systems are used to transport bundles of prefabricated components to various array areas. Construction workers use handheld scanning terminals to scan and verify the unloaded materials, accurately placing the corresponding specifications of upper columns, diagonal beams, front and rear diagonal braces, and purlins next to their respective pile foundation locations according to the markings on the drawings. This process completely eliminates repeated handling and wasted labor time caused by confusion in material specifications.

[0038] The installation process follows a streamlined workflow: First, the bottom of the upper column is inserted into the connecting sleeve pre-embedded in the pile foundation, and high-strength locking bolts are used to initially fix the column. Next, the middle hole of the inclined beam is aligned with the hinge at the top of the upper column, and hinge bolts are inserted to allow the inclined beam to rotate around its axis. Then, the front and rear inclined braces are installed, with the upper end connected to the pre-drilled holes on the side of the inclined beam, and the lower end secured to the exposed part of the upper column or pile foundation via brace clamps. Finally, multiple purlins are laid across the multiple sets of inclined beams and fixed using purlin brackets. Throughout the installation process, the connection nodes are tightened in two stages: initial tightening and final tightening. Construction workers first use a regular wrench for initial tightening and positioning to ensure structural formation; after the overall frame is erected, a calibrated torque wrench is used for final tightening to ensure that the tightening torque of each bolt reaches the design threshold, and quality inspectors apply anti-loosening markings to the bolt heads.

[0039] Step 6, structural deviation verification and angle fine-tuning optimization, is the final checkpoint to ensure project quality. Due to the complex geological conditions of high-altitude mountainous areas, verticality deviations or elevation errors are inevitable during pile foundation construction, resulting in slight discrepancies between the initial installed inclined beam angle and the design value. At this point, the adjustment mechanism designed in this invention is used for fine-tuning. Construction personnel place a laser inclinometer horizontally on the flange surface of the inclined beam and read the real-time angle value. If the difference between the reading and the design angle exceeds the preset allowable range (e.g., ±0.5 degrees), compensation is made using the elongated adjustment holes on the lower clamps of the front and rear inclined supports.

[0040] In practice, loosen the locking bolts on the clamps and slide the diagonal brace along the elongated hole. The displacement of the diagonal brace causes the inclined beam to rotate around the hinge point at the top of the column. By slightly adjusting the support height or angle of the diagonal brace, the tilt angle of the inclined beam can be smoothly changed. This adjustment process requires no cutting or welding; it only relies on the relative displacement of the bolts. Once the value displayed by the laser tilt meter reaches the design target, immediately retighten the clamp bolts. Furthermore, for high-altitude, high-wind environments, after the main support structure is stabilized, install column tie rods and purlin tie rods. The column tie rods bridge adjacent columns to form a scissor brace structure, significantly enhancing the support's resistance to lateral displacement in the direction perpendicular to the inclined beam. The purlin straight and diagonal tie rods ensure the parallelism between the purlins, improving the torsional stability of the entire photovoltaic array.

[0041] In the specific component structure of a rapid installation method for prefabricated photovoltaic support systems in high-altitude mountainous areas, the upper column, as the core load-bearing component, has a wall thickness determined based on load calculations, typically between 4 and 8 millimeters. Its top hinge design considers all-around adjustment needs; the gap between the clamping plates is slightly larger than the width of the inclined beam web, allowing the inclined beam a large degree of rotational freedom in the vertical plane. The fit tolerance between the connecting sleeve and the upper column is controlled within 1 to 2 millimeters, ensuring smooth insertion while eliminating fit gaps through the squeezing action of the transverse bolts, thus enhancing the rigidity of the connection.

[0042] The inclined beam, serving as the main support for the photovoltaic modules, has an optimized cross-sectional height and width to withstand the heavy snow loads characteristic of high-altitude regions. The first connecting hole on the lower surface of the inclined beam mates with the hinged connector of the upper column, while the second and third connecting holes on the side are used to connect the front and rear inclined braces, respectively. These holes are all stamped in the factory using CNC equipment in a single operation, ensuring the precision of the force transmission path. The fourth connecting hole distributed on the upper surface of the inclined beam has a spacing that strictly corresponds to the installation points of the purlin brackets.

[0043] The design of the front and rear diagonal braces fully considers force balance. At the connection points between the front and rear diagonal braces and the inclined beam, a special connecting plate structure is used, which can adapt to the constantly changing angle between the diagonal brace and the inclined beam. The diagonal brace clamp is an important adjustment component of this invention, with its inner diameter precisely matching the outer diameter of the upper column. The adjustment holes on the clamp are not simple circular holes, but elongated slots extending circumferentially or axially. Through this slotted structure, the installation position of the diagonal brace can be continuously adjusted within a certain range, thereby offsetting various spatial coordinate deviations generated during pile foundation construction.

[0044] In the support system, purlins not only serve to fix the components but also bear the responsibility of lateral reinforcement for the overall skin effect. The pre-drilled mounting holes on the upper surface of the purlins are designed with the spacing based on the standardized dimensions of the photovoltaic module back frame. This means that after the modules arrive on site, they can be directly bolted to the purlins through these pre-drilled holes or secured using quick-release clamps, completely eliminating the need for on-site measurement and drilling. To cope with the thermal expansion and contraction of materials due to large temperature differences at high altitudes, appropriate expansion gaps are provided at the connection points between the purlins.

[0045] The fastener system is crucial for ensuring long-term stability. In this embodiment, all bolts used are high-strength hot-dip galvanized bolts of grade 8.8 or higher. To prevent bolt loosening under continuous vibrations caused by strong winds at high altitudes, all nuts are self-locking nuts with nylon rings or equipped with a double-nut structure. The selection criteria for spring washers require that their rebound force after flattening can continuously provide preload. Furthermore, the design of the column tie rod clamps and column tie rods utilizes the geometric stability principle of triangles. The tie rods are fixed to the lower middle part of the column via clamps, forming cross supports that transfer lateral wind loads to the foundation through the tie rods, effectively reducing the bending moment at the bottom of the column.

[0046] To address the issue of reduced efficiency in manual labor due to low oxygen levels at high altitudes, the support components of this invention are designed with lightweight features. By using high-strength steel, the cross-sectional dimensions of the components are reduced while maintaining load-bearing capacity, ensuring that the weight of each component is within a range that can be easily handled by an adult laborer. Furthermore, all gripping parts of the connectors are rounded, facilitating operation by workers wearing thick, cold-weather gloves and reducing physical exertion caused by operational difficulties.

[0047] Regarding construction environment safety, this installation method offers exceptional safety in high-risk mountainous environments such as forests or grasslands, as it eliminates the need for open flame operations throughout the entire process. The absence of welding equipment, gas cylinders, or cutting machines on-site not only eliminates ignition sources but also reduces the frequency of machinery movement across rugged terrain. This prefabricated process generates minimal waste, and all components can be recycled and reused at the end of the power plant's lifespan, meeting the protection requirements for the fragile ecosystems of high-altitude areas.

[0048] Example 2 In another specific application scenario, for a high-altitude mountain photovoltaic project with extremely irregular slopes and localized steep slopes, Example 2 demonstrates the adaptive capability of the present invention under extreme terrain. In step 1, when the terrain scan results show a slope exceeding 30 degrees and reaching the 35-degree range, the system automatically identifies this area as the sixth adaptive zone. For this type of terrain, the detailed design scheme in step 2 automatically switches from a single-column structure to a double-column support structure.

[0049] This double-column structure consists of a front column and a rear column forming a robust support frame. The front column is shorter, and the rear column is longer; their precise length ratio compensates for the difference in ground level, keeping the top of the support level. Due to the extremely steep terrain, the design length of the rear diagonal brace was significantly extended, and its angle with the ground was optimized to ensure that the resultant force is perpendicular to the center of the pile foundation.

[0050] In step 3, for this reinforced support, the factory prefabricated C-shaped steel components with higher specifications and increased wall thickness. Simultaneously, to cope with the enormous sliding force brought about by the steep slope, additional reinforcing ribs and multi-point locking diagonal bracing clamps were added to the fastener system. The adjustment holes on the clamps are designed as multi-dimensional composite slots, allowing the diagonal bracing to be corrected in both vertical and horizontal dimensions to address the more difficult-to-control angular deviations during steep slope pile foundation construction.

[0051] In step 5, the on-site installation phase, the steep slope significantly increased the difficulty of conventional manual handling. At this point, leveraging the material coding and installation point mapping established in step 4, the construction team employed a precise cableway transportation system. Each bundle of components marked with a specific code was directly lowered to the corresponding installation platform via the cableway. During installation, workers first constructed a portal frame consisting of double columns and horizontal tie rods, a frame possessing strong self-stability even before the installation of the inclined beams.

[0052] The optimization process in step 6 is particularly important in this embodiment. Due to the significant shift in the center of gravity of the steep slope support, a laser inclinometer is used for multi-point sampling. This not only verifies the north-south tilt angle of the inclined beams but also monitors the east-west horizontality of multiple parallel inclined beams. By adjusting the elongated hole positions, six degrees of freedom fine-tuning of the spatial attitude of the inclined beams is achieved. This precise angle correction ensures that even on a rugged 35-degree slope, the photovoltaic modules maintain a uniform arrangement, maximizing the light-receiving area and effectively dispersing the impact of wind loads on individual columns.

[0053] Furthermore, for this extreme terrain, the fasteners' surface treatment includes not only hot-dip galvanizing but also an additional layer of composite ceramic coating, enhancing the components' resistance to fretting wear under complex stress conditions. After final tightening, all bolted connections are coated with anti-loosening paint and fitted with dedicated anti-loosening caps to prevent structural instability caused by human factors or extreme animal activity during long-term operation.

[0054] Example 3 In the context of large-scale, cross-regional high-altitude mountain photovoltaic projects, Example 3 illustrates the implementation details of the present invention in terms of information management and full-cycle maintenance. The terrain data collected in step 1 is not only used for zoning but also integrated into a digital twin construction management platform. This platform is interconnected in real time with the material coding system in step 4.

[0055] Once the on-site assembly of loose materials begins in step 5, after each support frame is assembled, construction workers scan the QR code on the support column using a handheld device. The system automatically records the installation completion time, installers, torque value used, and final check angle for that support frame. This data is uploaded to the cloud server in real time, allowing managers to monitor the construction progress and quality compliance rate of the entire site from the command center.

[0056] Regarding the deviation verification mentioned in step 6, this embodiment introduces augmented reality navigation technology. Construction workers wear smart terminals, and after identifying the pile foundation number through a camera, the augmented reality interface directly overlays the theoretical support model onto the field of view. Workers only need to manually adjust the bolt positions on the diagonal brace clamps according to the visual deviation to make the physical components coincide with the virtual model, greatly improving the speed and accuracy of fine-tuning and optimization.

[0057] This embodiment also defines in detail the post-maintenance logic for uneven foundation settlement. In high-altitude areas, repeated freeze-thaw cycles of the permafrost layer may cause slight displacement or settlement of the pile foundation after several years of operation. The monitoring system acquires the angular offset data of the support through a sensor array. When the offset triggers the warning value, maintenance personnel do not need to carry heavy cutting or welding tools. They only need to carry a torque wrench and a laser inclinometer. After arriving at the site, they loosen the inclined brace clamp adjustment bolts described in Embodiment 1, use the elongated oval adjustment holes reserved in this invention to readjust the inclined beam posture to the design position, and then tighten it again. This "reversible" adjustment capability based on the prefabricated structure enables the photovoltaic power station to have a lifetime geometric posture correction function, significantly reducing the structural maintenance costs during the 25-year operation period of the power station.

[0058] Furthermore, Example 3 describes the surface repair process for the components. During installation, even if localized scratches occur to the galvanized layer due to mechanical impact, the construction personnel immediately initiate a "cold spray zinc" repair procedure. Using a special coating rich in zinc powder, multiple layers are sprayed onto the scratched area, ensuring that the zinc content in the dried paint film reaches over 90%. This on-site repair method, combined with the factory prefabrication process, forms a closed loop, ensuring that no exposed metal point becomes a starting point for corrosion, even in harsh high-altitude environments.

[0059] Regarding the details of the fasteners, Example 3 uses a torque bolt with intelligent sensing function. The head of this bolt integrates a tiny color-changing washer. When the tightening torque reaches the design value, the washer changes from white to green under pressure. Quality inspectors can complete the quality inspection simply by observing the color from a distance. This greatly improves the efficiency and reliability of acceptance in environments such as high altitude, low oxygen, and extreme cold, where prolonged precision work is not suitable.

[0060] Through the detailed description of the above embodiments, it is clear how this invention, through a technical approach of "lean prefabrication in factories, rapid on-site assembly, precise digital matching, and flexible multi-dimensional fine-tuning," has completely transformed the construction mode of photovoltaic support systems in high-altitude mountainous areas. Each step is interconnected, constructing a complete, closed-loop industrialized construction system from data collection at the source to post-construction maintenance.

[0061] In this construction method, every component of the support system, from the massive top column to the tiny spring pads, fulfills a clearly defined functional responsibility. The top column adapts to the terrain with different length specifications and provides stable vertical support; the diagonal beams, acting as a framework, ensure geometric accuracy during installation through pre-drilled holes; the front and rear diagonal braces utilize the principle of triangular stability and the elongated hole adjustment mechanism to perfectly accommodate construction errors; and the purlins, through precise mapping with the module mounting holes, enable "instant mounting and locking" of the photovoltaic modules. All fasteners, including diagonal brace clamps, column tie rods, and purlin tie rods, intertwine to form a high-strength load-bearing network.

[0062] Throughout the process, digitized material codes and reverse markings on construction drawings acted as a "navigator" guiding the construction flow. This not only solved the persistent problems of chaotic material storage and incorrect requisition in high-altitude areas, but also provided the most basic digital foundation for subsequent asset management and operation. The application of this method makes it possible to construct high-standard, high-quality photovoltaic power plants in extreme environments characterized by high altitude, oxygen deficiency, low temperatures, and immense forest fire prevention pressure. It not only significantly improves construction speed and reduces ineffective waste of manpower and machinery, but more importantly, through structural redundancy design and flexible adjustment mechanisms, it endows the photovoltaic support system with exceptional resilience to cope with complex mountainous environments, ensuring the long-term safe and stable operation of clean energy facilities under extreme geographical and climatic conditions.

[0063] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas, characterized in that, Includes the following steps: Step 1: Topographic data acquisition and angle partitioning modeling. Topographic data of the construction area is acquired through measuring equipment, the slope and azimuth information of the photovoltaic array points are extracted, and the terrain is divided into multiple adaptive partitions according to preset angle thresholds. Step 2: Detailed design and specification matching of components. Based on the angle data of the adaptive partitions, the support system is modularly designed to determine the required upper column length specifications, front and rear diagonal brace length specifications, and relative position parameters of connecting components for different partitions, forming a standardized component requirement list. Step 3: Factory prefabrication and anti-corrosion treatment of components. According to the component requirement list, the upper column, diagonal beam, front and rear diagonal braces, purlins and fasteners are machined and anti-corrosion treated in the prefabrication factory to ensure that the connection parts are matched through the preset bolt holes. Step 4: Reverse marking of construction drawings and material coding. Mark the angle zoning results and component specification information on the construction plan drawings, assign unique codes to prefabricated components, and establish a logical mapping relationship between component specifications and installation points. Step 5: On-site material entry and precise bulk material installation. Prefabricated components are transported to the corresponding installation area according to the logical mapping relationship, placed according to the code, and the upper column, diagonal beam, front and rear diagonal braces and purlins are bolted together with fasteners. Step six: Structural deviation verification and angle fine-tuning optimization. After the main body of the support is assembled, the inclination angle of the inclined beam is adjusted through the adjustment holes between the front and rear inclined braces and the clamps to compensate for the deviations in the pile foundation construction.

2. The rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas according to claim 1, characterized in that, The terrain data acquisition in step one is performed by aerial remote sensing through a flight platform equipped with a lidar sensor or by ground-based laser scanning equipment; the three-dimensional coordinate point cloud data of the construction area is obtained, and the three-dimensional coordinate point cloud data contains fine elevation information and micro-topographic features of the ground surface; Ground filtering is performed on the three-dimensional coordinate point cloud data to remove interference points and generate a digital elevation model. The digital elevation model is then triangulated into multiple triangular grid cells, and the local slope of each grid cell relative to the horizontal plane and its azimuth relative to a specific orientation are determined by calculating the normal vector of each triangular grid cell in three-dimensional space. The collected slope data is then clustered according to a preset angle threshold, and regions with slopes in different intervals are defined as corresponding adaptive partitions. Preset support structure parameters are matched for each type of adaptive partition.

3. The rapid construction method for high-altitude mountain photovoltaic prefabricated support according to claim 1, characterized in that, In step two, the upper columns are designed with various length specifications according to the differences in terrain slope. In adaptive zones where the slope is less than a preset first threshold, the upper columns adopt a single-column structure, adapting to ground undulations by changing the column length. In adaptive zones where the slope is greater than a preset second threshold, the upper columns adopt a double-column reinforced structure, using two parallel columns to support the inclined beam to improve the system's torsional stiffness. For each adaptive zone, the length of the upper columns is calculated using a structural simulation model, and the length is determined based on the average slope of the zone and the required ground clearance of the photovoltaic modules. In areas with a downward slope, the length of the upper columns is increased to compensate for the displacement caused by ground subsidence. A geometric constraint model is established to determine the parameters of the triangular stable structure formed by the inclined beam, upper columns, and front and rear inclined braces, matching the lengths of the front and rear inclined braces under specific slopes.

4. The rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas according to claim 1, characterized in that, In step three, the upper column is made of high-strength carbon structural steel pipe with a circular or square cross-section. The top of the upper column is equipped with a hinge for connecting the inclined beam. The hinge includes two parallel clamping plates with coaxial bolt holes to allow for rotational adjustment of the inclined beam in the vertical plane. The bottom of the upper column matches the connecting sleeve embedded in the pile foundation and is fixed by transversely inserted locking bolts. The inclined beam, front brace, rear brace, and purlins are all made of C-shaped carbon structural steel. In the component processing stage, CNC plasma cutting equipment is used to cut the material to the required length according to the component demand list, and CNC punching equipment is used to punch connecting holes on the web and flanges of the C-shaped steel. After prefabrication, the components undergo hot-dip galvanizing treatment, immersing them in zinc liquid at a predetermined melting temperature to form a protective layer on the component surface. At the assembly site, areas with mechanical scratches are coated with cold-sprayed zinc paint, and the dry film of the cold-sprayed zinc paint reaches a preset zinc content.

5. The rapid construction method for high-altitude mountain photovoltaic prefabricated support according to claim 1, characterized in that, In step four, the material code is affixed to the predetermined position of the component using a weather-resistant coding label. The material code includes the component's production batch, material properties, zone type, installation point coordinates, and installation sequence number within the overall support system. The angle attributes and corresponding component specifications of each photovoltaic array point are marked on the construction plan drawing in the form of digital labels, so that each set of support installation points has corresponding coordinates and material requirement identifiers on the drawing. By scanning the code on the component with a handheld terminal, the management system points to the installation position of the component on the construction site, realizing synchronous management of material flow and construction flow.

6. The rapid construction method for high-altitude mountain photovoltaic prefabricated support according to claim 1, characterized in that, In step five, the material dismantling process of the components is completed using small tracked transport equipment or cableway transport system. The installation process follows a streamlined assembly sequence: first, the upper column; then, the diagonal beams; next, the front and rear diagonal braces; and finally, the purlins. Specific assembly steps include: first, inserting the bottom of the upper column into the pile foundation connecting sleeve and inserting locking bolts; then, aligning the middle hole of the diagonal beam with the hinge at the top of the upper column and inserting hinge bolts; subsequently, installing the front and rear diagonal braces, with the upper ends connected to the pre-drilled holes on the side of the diagonal beams, and the lower ends fitted onto the exposed parts of the upper column or pile foundation using diagonal brace clamps; finally, placing the purlins across multiple sets of diagonal beams and securing them with purlin support components. During assembly, the connection nodes undergo two stages: initial tightening and final tightening. In the final tightening process, a torque-controlled tool is used to ensure the tightening torque reaches the preset torque threshold, and anti-loosening markings are applied to the bolt heads.

7. A rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas according to claim 6, characterized in that, The diagonal brace clamp has elongated or axially extending adjustment holes, which are used to absorb mechanical stress generated by pile displacement during installation. The connection between the front and rear diagonal braces and the inclined beam adopts a connecting plate structure, which adapts to changes in the angle between the diagonal brace and the inclined beam. The lower surface of the inclined beam has a first connecting hole in the middle, which is used to cooperate with the hinge at the top of the upper column. The two ends of the side of the inclined beam have a second connecting hole and a third connecting hole, respectively, for connecting the front and rear diagonal braces. The upper surface of the inclined beam has multiple fourth connecting holes distributed along its length, which are used to install the purlin support components. The upper surface of the purlin has pre-drilled component mounting holes, the spacing of which is consistent with the back frame mounting holes of the photovoltaic module, so that the photovoltaic module is directly fixed to the purlin with fasteners.

8. A rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas according to claim 1, characterized in that, The angle fine-tuning process in step six is ​​assisted by a laser tilting device. The laser tilting device is placed on the surface of the inclined beam, and the real-time angle value is read. When the deviation between the real-time angle value and the design angle exceeds the preset allowable range, the locking bolts on the inclined brace clamp are loosened, and the inclined brace is slid along the direction of the elongated adjustment hole. The displacement of the inclined brace causes the inclined beam to rotate around the hinge at the top of the column, thereby adjusting the tilt angle of the inclined beam. When the value displayed by the laser tilting device reaches the design target, the locking bolts on the inclined brace clamp are tightened again. To address the angular deviation caused by uneven foundation settlement, the angle data of the support is monitored periodically, and the attitude of the inclined beam is recalibrated using the elongated adjustment hole to restore the operating attitude of the support.

9. A rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas according to claim 1, characterized in that, The fasteners include hot-dip galvanized bolts, nuts, spring washers, and flat washers; the nuts employ a self-locking structure to prevent loosening due to vibration in high-altitude windy environments; the fasteners also include column tie rods and column tie rod clamps, the column tie rods bridging two adjacent upper columns to form a scissor bracing structure to enhance the lateral force resistance of the support system along the purlin direction; purlin straight tie rods and purlin diagonal tie rods are provided between the purlins to maintain the spacing between the purlins and improve the torsional stiffness of the structure; after all bolted connections are finally tightened, protective coating is applied to the exposed metal connection parts.

10. A rapid construction method for prefabricated photovoltaic support structures in high-altitude mountainous areas according to claim 1, characterized in that, For terrain with a slope within the first specific range, a single-column support structure is adopted, and the slope effect is balanced by adjusting the burial depth or exposed height of the upper column. For terrain with a slope within the second specific range, an asymmetrical double-column support structure is adopted, and the levelness of the support plane is adjusted by the length difference between the front and rear columns. During construction, augmented reality technology is used to overlay the theoretical support model onto the actual pile foundation location. Construction workers adjust the position of the diagonal bracing clamps in the elongated adjustment holes according to visual deviation, so that the physical components coincide with the virtual model.

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