Vertical storage tank digital twin hydraulic synchronous jacking construction method and system

Abstract

The present application relates to the technical field of vertical storage tank construction, in particular to a vertical storage tank digital twin hydraulic synchronous jacking construction method and system, the method constructs a digital twin model consistent with the actual foundation through three-dimensional laser scanning, combines real-time collection of displacement, stress, inclination, wind speed and foundation pressure data and the like from a multi-source heterogeneous sensor network, realizes virtual-real mapping and dynamic updating throughout the construction process, optimizes construction parameters through virtual pre-rehearsal, adopts a progressive closed-loop construction cycle and a double-loop control system, intelligently controls storage tank jacking, attitude regulation, welding and tank dropping. Load distribution is monitored using a foundation pressure sensor array, unevenness is controlled within 1.2, roundness deviation is controlled within ±8mm, and finally an interactive digital twin archive is generated. The present application effectively improves construction precision and safety, realizes intelligent, refined and full-life-cycle digital construction of large storage tanks.

Description

Technical Field

[0001] This invention relates to the field of vertical storage tank construction technology, specifically a digital twin hydraulic synchronous jacking construction method and system for vertical storage tanks. Background Technology

[0002] In the petrochemical and energy storage sectors, the construction of vertical storage tanks is trending towards larger sizes, demanding extremely high levels of construction precision, structural stability, and efficiency. Currently, hydraulic synchronous jacking technology is the mainstream method for the inverted construction of vertical storage tanks, but existing technologies still have many shortcomings and cannot meet the needs of refined and intelligent construction, specifically including: 1. The problem of disconnect between virtual and reality is prominent. Traditional tank foundation modeling relies on design drawings, which deviate significantly from the actual state. There is no full-process virtual pre-construction simulation before construction, which can easily lead to problems such as unreasonable processes and poor connection between procedures.

[0003] 2. Insufficient attitude control precision. During the lifting process, the tank's attitude is prone to deviation due to factors such as hydraulic synchronization and environmental factors. Existing control relies on manual experience or single parameter monitoring, lacking full-dimensional monitoring and simulation optimization, resulting in lag in response, low precision, and potential safety hazards.

[0004] 3. The monitoring and control system is incomplete, the sensor equipment is scattered and cannot achieve full-dimensional data collection; a closed-loop control system has not been built, making it difficult to optimize construction parameters in advance and fine-tune the attitude in real time; the lack of monitoring of the foundation load distribution during the can placement affects the fitting accuracy.

[0005] Digital twin technology offers a solution to the aforementioned pain points, but its application in the hydraulic synchronous jacking construction of vertical storage tanks is still in its initial stage. A complete and feasible construction method and system have not yet been developed, thus failing to fully leverage its technological advantages. Therefore, developing a comprehensive and refined construction method and system based on digital twins has become a pressing technical challenge in this field. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the purpose of this invention is to provide a digital twin-based hydraulic synchronous jacking construction method and system for vertical storage tanks, enabling refined control throughout the entire process.

[0007] The technical solution adopted by this invention to solve its technical problem is: A method for constructing a vertical storage tank using a digital twin hydraulic synchronous jacking system includes the following steps: S1, Digital Twin Foundation Modeling: 3D laser scanning is performed on the completed tank foundation to generate point cloud data, and a digital twin foundation model consistent with the actual foundation spatial form and physical properties is constructed based on the point cloud data. S2, First Ring Physical Installation and Initial Calibration: Complete the installation of the first ring of tank wall panels, and calibrate the installation position and verticality of the first ring of wall panels to form a construction benchmark; S3, Lifting Platform Construction: Construct a lifting platform adapted to the inverted construction of the storage tank. Integrate a multi-source heterogeneous sensor network at preset locations on the lifting platform, the storage tank body, and the storage tank foundation. The multi-source heterogeneous sensor network is used to collect displacement, stress, tilt angle, wind speed, and pressure data. S4, Digital Twin System Activation and Virtual Pre-simulation: Activate the digital twin construction platform, load the tank design model and the digital twin basic model constructed in step S1 into the platform, and conduct multi-physics field coupling simulation of the geometric and mechanical environment for the entire construction process from the installation of the first ring wall panels to the final placement of the tank. Optimize construction process parameters based on the simulation results. S5, based on a progressive closed-loop construction cycle of digital twins: repeatedly execute the lifting, data synchronization evaluation, attitude control, welding and data archiving processes until the tank body reaches the design height; S6, Precise Tank Lowering Guided by Digital Twin: Based on the digital twin model of the digital twin construction platform, multi-physics field coupling simulation of the tank lowering process is carried out to determine the lowering speed and synchronous control strategy of the tank, and guide the hydraulic jacking system to lower the tank synchronously; at the same time, the pressure distribution data of the tank foundation pad layer is collected through a multi-source heterogeneous sensor network and synchronized to the digital twin model. S7, Digital Twin Asset Delivery: Integrates geometric data, mechanical data, environmental data, operation logs and control command data generated throughout the construction process to generate an interactive digital twin archive uniquely bound to the physical storage tank and containing a complete construction history.

[0008] As a preferred embodiment, a further technical solution of the present invention is: Preferably, step S5, the progressive closed-loop construction cycle based on digital twins, specifically includes the following sub-steps: S51, Solid Lifting Execution: The storage tank is lifted to a preset height using a hydraulic lifting system. After the lifting is completed, the hydraulic lifting system enters a pressure-holding standby state. S52, Real-Virtual Data Synchronization and Status Assessment: Geometric morphology data, structural mechanics data, and construction environment data of the storage tank entity are collected in real time through a multi-source heterogeneous sensor network. Geometric morphology data includes displacement and tilt angle; structural mechanics data includes stress and strain, hydraulic pressure, and foundation pressure; and construction environment data includes wind speed, temperature, and humidity. The collected data is synchronously uploaded to the digital twin construction platform, and the digital twin model is dynamically updated. Based on the updated digital twin model, the geometric and mechanical deviations between the physical entity of the storage tank and the virtual tank model are calculated. Geometric deviation refers to the difference between the actual displacement and tilt angle parameters of the physical entity of the storage tank and the preset displacement and tilt angle parameters of the virtual tank model. Mechanical deviation refers to the difference between the actual stress and strain, hydraulic pressure, and foundation pressure parameters of the physical entity of the storage tank and the preset stress and strain, hydraulic pressure, and foundation pressure parameters of the virtual tank model. S53, Attitude Control Guided by Digital Twin: Based on the digital twin model of the digital twin construction platform, combined with the current displacement and tilt geometry of the tank, stress and strain, hydraulic pressure, foundation pressure and mechanical state, wind speed, temperature and humidity environmental parameters and action parameters of the hydraulic jacking system, multi-physics field coupling simulation prediction of tank attitude adjustment is carried out. The attitude change and stress distribution of the tank under different adjustment schemes are simulated. Based on the simulation prediction results, hydraulic jacking control commands are generated to dynamically adjust the output force and displacement of the hydraulic synchronous jacking actuator, so that the tank body gradually conforms to the optimal attitude preset by the digital twin model. S54, Solid welding operation: Perform wall panel welding operation on the tank body adjusted to the optimal posture. During the welding process, stress and strain data of the tank weld area are continuously collected through a multi-source heterogeneous sensor network. S55, Data Archiving and Preparation for the Next Cycle: The construction parameters, all data collected by the multi-source heterogeneous sensor network, all instructions for tank attitude control, and tank wall welding quality data within this construction cycle are archived into the digital twin model of the digital twin construction platform. This completes the spatiotemporal correlation and storage of various types of data, providing complete data support for the construction operation of the next construction cycle of the tank.

[0009] Preferably, in step S53, different adjustment schemes are generated based on the geometric and mechanical deviation values ​​and distribution locations of the physical entity of the storage tank and the virtual tank model. The digital twin construction platform matches the adjustable force range and adjustable displacement range of each lifting point of the hydraulic jacking system for each deviation value and distribution location, and combines them to form at least two different lifting adjustment schemes. The hydraulic jacking control command is generated by the digital twin construction platform through multi-physics field coupling simulation prediction results. The platform analyzes the simulation prediction results of each adjustment scheme, selects the optimal adjustment scheme that can make the geometric and mechanical deviations of the storage tank converge synchronously to within the preset threshold, and determines the specific force adjustment amount and displacement adjustment amount of the hydraulic synchronous jacking actuator based on the scheme, and generates the corresponding hydraulic jacking control command. The command includes the action sequence, force parameters, and displacement parameters of each lifting point.

[0010] Preferably, in the virtual pre-simulation of step S4 and the attitude control under the guidance of the twin in step S53, the digital twin construction platform realizes the coupled simulation of geometry, mechanics and environment through its integrated virtual simulation engine. The digital twin construction platform uses its built-in virtual tank model as a benchmark. It receives real-time data on displacement, tilt angle, stress and strain, hydraulic pressure, foundation pressure, wind speed, temperature and humidity collected by a multi-source heterogeneous sensor network as feedback. It first obtains the geometric and mechanical deviations between the physical entity of the storage tank and the virtual tank model. Then, combined with real-time environmental parameters, it calculates the deviations through multi-physics coupling simulation to determine the output force adjustment and displacement adjustment of the hydraulic synchronous lifting actuator.

[0011] Preferably, the digital twin model continuously and dynamically evolves throughout the entire construction process from steps S1 to S7. The evolution process is as follows: the digital twin model is an engineering virtual model that integrates the tank foundation, tank structure, construction equipment, and environmental parameters. The data layer includes at least the foundation geometric model, tank material properties, real-time data streams of displacement, tilt angle, stress and strain, hydraulic pressure, foundation pressure, wind speed, temperature and humidity collected by a multi-source heterogeneous sensor network, construction process logs, environmental parameter records, and analysis and decision-making instructions from the digital twin construction platform. The digital twin model receives various types of data from the aforementioned data layer in real time. Combined with the multiphysics coupling simulation results of the digital twin construction platform, it synchronously updates its own geometric parameters, mechanical parameters, and environmental parameters, ensuring that the digital twin model always remains consistent with the actual state of the physical entity of the storage tank, the construction environment, and the construction equipment, thus achieving continuous dynamic evolution throughout the entire construction process.

[0012] Preferably, a dual-loop control system is constructed in the progressive closed-loop construction loop of step S5. The dual-loop control system includes an inner loop regulation loop and an outer loop optimization prediction loop. The inner loop control loop calculates the deviation and outputs adjustment commands based on the deviation between the real-time data of displacement, tilt angle, stress and strain, hydraulic pressure and foundation pressure collected by the multi-source heterogeneous sensor network and the preset parameters of the digital twin model. Before the start of each construction cycle, the outer loop optimization prediction loop conducts multi-scheme multi-physics field coupled simulations based on the current geometric and mechanical state of the tank entity and the external environmental conditions such as wind speed, temperature and humidity. Within a cycle of several minutes to several hours, the subsequent jacking speed, welding sequence and jacking pressure holding time process parameters are simulated and optimized in advance to determine the optimal construction parameters for the next construction cycle.

[0013] Preferably, in step S6, a foundation pressure sensor array is pre-embedded in the foundation pad layer of the storage tank to collect pressure data at each monitoring point of the foundation pad layer; the digital twin model calculates the load distribution non-uniformity coefficient based on the pressure data, and ensures that the load distribution non-uniformity coefficient is no greater than 1.2; the roundness deviation of the storage tank entity is controlled within ±8mm throughout the entire construction process.

[0014] Preferably, the interactive digital twin archive generated in step S7 supports time-stamp-based playback of the entire construction process, status tracing of any construction stage, and visualization analysis of key construction parameters; key construction parameters include tank roundness, tank verticality, weld stress, hydraulic jacking force, and load distribution non-uniformity coefficient.

[0015] Preferably, the multi-source heterogeneous sensor network includes displacement sensors, stress-strain sensors, tilt sensors, anemometers, hydraulic pressure sensors, and foundation pressure sensors; wherein, displacement sensors, stress-strain sensors, and tilt sensors are deployed on the tank wall, hydraulic pressure sensors are deployed on the hydraulic jacking platform, foundation pressure sensors are deployed on the concrete ring wall foundation and foundation pad, and anemometers are deployed at construction environment monitoring points.

[0016] The present invention also discloses a digital twin hydraulic synchronous jacking construction system for vertical storage tanks, used to implement the digital twin hydraulic synchronous jacking construction method for vertical storage tanks, including a digital twin construction platform, a multi-source heterogeneous sensor network, and a hydraulic synchronous jacking actuator; The digital twin construction platform is an industrial control computer or a computer; The multi-source heterogeneous sensor network includes displacement sensors, stress-strain sensors, tilt sensors, anemometers, hydraulic pressure sensors, and foundation pressure sensors. Among them, displacement sensors, stress-strain sensors, and tilt sensors are deployed on the tank wall panels, hydraulic pressure sensors are deployed on the hydraulic jacking platform, foundation pressure sensors are deployed on the concrete ring wall foundation and foundation pad, and anemometers are deployed at construction environment monitoring points. The real-time data collected by the multi-source heterogeneous sensor network is uploaded to the digital twin construction platform through a communication interface. The hydraulic synchronous lifting actuator is installed at the bottom of the storage tank and the hydraulic lifting platform, including a hydraulic pump station, a lifting cylinder assembly, and a synchronous controller. The synchronous controller is communicatively connected to the digital twin construction platform and receives control commands issued by the digital twin construction platform. The synchronous controller is electrically connected to the hydraulic pump station and controls the output pressure and flow rate of the hydraulic pump station. The hydraulic pump station is hydraulically connected to the lifting cylinder assembly and provides power to the lifting cylinder assembly. Under the drive of the hydraulic pump station and the control of the synchronous controller, the lifting cylinder assembly realizes synchronous lifting, attitude adjustment, and tank lowering actions.

[0017] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art: 1. This invention constructs a digital twin model that precisely matches the physical tank, foundation, and construction environment, enabling virtual-real mapping and dynamic evolution throughout the entire construction process. Combined with virtual pre-construction simulations and synchronous data updates during construction, it effectively avoids problems such as unreasonable processes and poor workflow connections, breaks down data silos, and provides precise data support for construction decisions.

[0018] 2. Relying on a multi-source heterogeneous sensor network to achieve full-dimensional data acquisition, combined with a dual-loop control system and multi-physics field coupling simulation, the real-time fine-tuning of the tank's attitude and the forward-looking optimization of construction parameters are realized, solving the problems of lag and insufficient accuracy in traditional control, ensuring that indicators such as the roundness and verticality of the storage tank meet the requirements, and reducing structural safety hazards.

[0019] 3. Construct a systematic multi-source heterogeneous sensor network to achieve comprehensive acquisition of geometric, mechanical, hydraulic and environmental data; the dual-loop control system realizes closed-loop operation of "monitoring-analysis-decision-control", accurately monitors the distribution of foundation load during tank lowering, ensures the fitting accuracy between the storage tank and the foundation, and improves the stability of construction quality.

[0020] 4. Generate an interactive digital twin file uniquely bound to the physical storage tank, enabling playback of the entire construction process, status traceability, and parameter visualization analysis. Completely retain historical construction data, providing precise support for subsequent tank operation, maintenance, and risk assessment, and achieving refined management throughout the entire life cycle.

[0021] 5. This invention utilizes a digital twin construction platform, combined with conventional sensing equipment and hydraulic actuators. It features a reasonable structure and convenient operation, and can be directly adapted to existing vertical storage tank hydraulic synchronous jacking construction scenarios. It is easy to promote and apply, significantly improving construction efficiency and reducing construction costs. Attached Figure Description

[0022] Figure 1 This is a flowchart of the construction method for the digital twin hydraulic synchronous jacking of a vertical storage tank in an embodiment of the present invention; Figure 2 This is a flowchart of the progressive closed-loop construction cycle based on digital twins in an embodiment of the present invention; Figure 3 This is a schematic diagram of the distribution of the multi-source heterogeneous sensor network in an embodiment of the present invention; Figure 4 This is a data flow diagram of the dual-loop control system of the progressive closed-loop construction cycle in this embodiment of the invention. Detailed Implementation

[0023] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0024] like Figure 1 , Figure 2 As shown in the figure, this embodiment presents a digital twin hydraulic synchronous jacking construction method for vertical storage tanks, applicable to the inverted construction of vertical cylindrical steel storage tanks with a volume of 5000m³~100000m³, including the following steps: S1, Digital Twin Foundation Modeling: Three-dimensional laser scanning is performed on the completed tank foundation to generate point cloud data, which is then integrated with the BIM design model to establish a digital twin foundation model with a spatial deviation of less than 3mm from the physical foundation. In this embodiment, a FARO Focus Premium X330 3D laser scanner is used for scanning, with a point cloud acquisition resolution of 3mm. The scanned data is imported into Autodesk RecapPro for point cloud processing and noise reduction. GeomagicWrap is used to complete model registration and reconstruction, establishing a digital twin foundation model with a spatial deviation of less than 3mm from the physical foundation. The model also integrates physical property parameters such as foundation concrete strength and subbase compression modulus.

[0025] S2, First Ring Physical Installation and Initial Calibration: Complete the installation of the first ring of tank wall panels. Use a total station (Leica TS60) to calibrate the installation position and verticality of the first ring of wall panels. The verticality deviation is controlled within ≤1mm / m. Use a steel tape measure (1mm accuracy) to check the roundness of the wall panels to form a construction benchmark. The calibration data is uploaded to the digital twin construction platform in real time to complete the initial data entry.

[0026] S3, Lifting Platform Construction: Construct a lifting platform adapted for inverted tank construction. Integrate a multi-source heterogeneous sensor network at predetermined locations on the lifting platform, the tank body, and the tank foundation. This network is used to collect displacement, stress, tilt angle, wind speed, and pressure data. The sensor network uses an RS485 bus for data networking, with a data acquisition frequency set to 10Hz.

[0027] like Figure 3The multi-source heterogeneous sensor network includes displacement sensors, stress-strain sensors, tilt sensors, anemometers, hydraulic pressure sensors, and foundation pressure sensors. Among them, displacement sensors, stress-strain sensors, and tilt sensors are deployed on the tank wall, hydraulic pressure sensors are deployed on the hydraulic jacking platform, foundation pressure sensors are deployed on the concrete ring wall foundation and foundation pad, and anemometers are deployed at construction environment monitoring points.

[0028] In a specific embodiment, a 24-point synchronously controlled hydraulic jacking system can be integrated on the temporary roof, and a sensor network including 24 wire displacement sensors (model WPS-M), 36 foil strain gauges (model BX120-3AA), 12 dual-axis tilt sensors (model SCA100T), 24 pressure sensors (model PT124G-60M), 48 earth pressure cells (model BX200) and 2 ultrasonic anemometers (model WS300) can be deployed. All sensors can centrally acquire and transmit data through a data acquisition instrument (model NICDAQ-9178).

[0029] S4, Digital Twin System Activation and Virtual Pre-simulation: Activate the digital twin construction platform, load the tank design model and the digital twin basic model constructed in step S1 into the platform, input environmental parameters such as material properties and wind load, and conduct multi-physics coupled simulation of the geometric and mechanical environment for the entire construction process from the installation of the first ring wall panels to the final placement of the tank. Based on the simulation results, optimize construction process parameters. For example, optimize the jacking speed (e.g., set at 0.5 m / h), wind-resistant measures for the temporary roof, and the welding sequence of each ring wall panel. Simultaneously, preset mechanical warning thresholds during tank construction, such as wall panel stress not exceeding 200 MPa and foundation pressure not exceeding 0.3 MPa.

[0030] In this embodiment, the digital twin construction platform is built on an industrial control computer (configured with an Intel Xeon E5-2680v4 processor, 64G memory, 2TSSD, model Advantech IPC-610L), and uses commercial CAE software with multi-physics coupling simulation capabilities (such as ANSYS, Abaqus, etc.) or a simulation module based on a finite element analysis engine.

[0031] S5, based on a progressive closed-loop construction cycle of digital twins: repeatedly execute the lifting, data synchronization evaluation, attitude control, welding and data archiving processes until the tank body reaches the design height. It should be noted that the single lifting height is determined according to the wall panel specifications, which is 1.5m~2.0m.

[0032] like Figure 4 Step S5, the progressive closed-loop construction cycle based on digital twins, specifically includes the following sub-steps: S51, Solid Lifting Execution: The storage tank is solidly lifted to the preset height using a hydraulic lifting system. The hydraulic lifting system is powered by a synchronous hydraulic pump station (model ZB4-500), and the lifting cylinders use single-acting hydraulic jacks (model QF100 / 200). During the lifting process, the synchronous controller (model PLC-S7-1500) achieves synchronous control of 24 lifting points, with the synchronization error controlled within ≤2mm. After the lifting is completed, the hydraulic lifting system enters the pressure holding standby state, and the pressure holding pressure is maintained at 90% of the working pressure.

[0033] S52, Real-Virtual Data Synchronization and Status Assessment: Geometric morphology data, structural mechanics data, and construction environment data of the storage tank are collected in real time through a multi-source heterogeneous sensor network. Geometric morphology data includes displacement and tilt angle; structural mechanics data includes stress and strain, hydraulic pressure, and foundation pressure; and construction environment data includes wind speed, temperature, and humidity. Temperature and humidity are collected using a temperature and humidity sensor (model DHT22, accuracy ±0.5℃, ±2%RH). The collected data is synchronously uploaded to the digital twin construction platform via industrial Ethernet (Profinet protocol) and the digital twin model is dynamically updated. Based on the updated digital twin model, the geometric and mechanical deviations between the physical storage tank and the virtual tank model are calculated. Geometric deviation refers to the difference between the actual displacement and tilt angle parameters of the physical storage tank and the preset displacement and tilt angle parameters of the virtual tank model; mechanical deviation refers to the difference between the actual stress and strain, hydraulic pressure, and foundation pressure parameters of the physical storage tank and the preset stress and strain, hydraulic pressure, and foundation pressure parameters of the virtual tank model.

[0034] The basic pressure parameters are measured by a basic pressure sensor array embedded in the foundation pad of the storage tank. The digital twin model calculates the load distribution non-uniformity coefficient based on the pressure data using the area weighting method, and ensures that the load distribution non-uniformity coefficient is no greater than 1.2. The roundness deviation of the storage tank is controlled within ±8mm throughout the entire construction process.

[0035] S53, Attitude Control Guided by Digital Twin: Based on the digital twin model built on the digital twin construction platform, combined with the current displacement, tilt angle geometry, stress and strain, hydraulic pressure, foundation pressure mechanical state, wind speed, temperature and humidity environmental parameters, and the action parameters of the hydraulic jacking system, multi-physics coupling simulation prediction of tank attitude adjustment is carried out. The simulation simulates the attitude change and stress distribution of the tank under different adjustment schemes. The simulation prediction time does not exceed 5 minutes. Based on the simulation prediction results, hydraulic jacking control commands are generated and sent to the synchronous controller through a wireless data transmission module (model LoRaSX1278, transmission distance 1km). The output force and displacement of the hydraulic synchronous jacking actuator are dynamically adjusted with an adjustment accuracy of 0.1mm, so that the tank gradually conforms to the optimal attitude preset by the digital twin model.

[0036] Different adjustment schemes are generated based on the geometric and mechanical deviations and their distribution locations between the physical tank and the virtual tank model. The digital twin construction platform matches the adjustable force range (0~100t) and adjustable displacement range (0~200mm) of each lifting point in the hydraulic jacking system for each deviation value and distribution location, forming at least two different lifting adjustment schemes. The hydraulic jacking control commands are generated by the digital twin construction platform through multi-physics field coupling simulation prediction results. The platform analyzes the simulation prediction results of each adjustment scheme, selecting the optimal adjustment scheme that allows the geometric and mechanical deviations of the tank to converge synchronously to within a preset threshold. Based on this scheme, the specific force and displacement adjustment amounts of the hydraulic synchronous jacking actuator are determined, generating corresponding hydraulic jacking control commands. These commands include the action sequence, force parameters, and displacement parameters of each lifting point. For example, when the tank's roundness deviation exceeds the standard by 10mm, the platform can quickly simulate different force adjustment schemes for different lifting points and issue the optimal adjustment command. The single attitude adjustment time does not exceed 10 minutes, and the roundness deviation converges to within ±8mm after adjustment.

[0037] Figure 4 In this context, the decision algorithm is a general term for the algorithms integrated within the digital twin construction platform, including deviation calculation, scheme optimization, control command generation, parameter optimization, and index determination. It corresponds to all decision and control functions in this invention, such as geometric / mechanical deviation calculation, optimal adjustment scheme screening, dual-loop control logic, and load non-uniformity coefficient calculation.

[0038] S54, Solid Welding Operation: Perform wall panel welding on the tank body adjusted to the optimal posture. The welding adopts gas metal arc welding (Welding machine model Panasonic YD-500GR), the welding current is set to 200~250A, the voltage is 24~28V, and the welding speed is 15~20cm / min. During the welding process, stress and strain data of the tank weld area are continuously collected through a multi-source heterogeneous sensor network to monitor the welding residual stress in real time. If the residual stress exceeds 250MPa, welding is stopped immediately and stress relief measures are taken.

[0039] S55, Data Archiving and Preparation for the Next Cycle: The construction parameters, all data collected from the multi-source heterogeneous sensor network, all instructions for tank attitude control, and tank wall welding quality data (including weld non-destructive testing data, tested using an ultrasonic flaw detector (model Shanchao CTS-22)) within this construction cycle are uniformly archived into the digital twin model of the digital twin construction platform. This completes the spatiotemporal correlation and storage of various types of data, providing complete data support for the construction operation of the next construction cycle of the tank.

[0040] A dual-loop control system is constructed within the progressive closed-loop construction cycle. This system comprises an inner-loop control loop and an outer-loop optimization and prediction loop. The inner-loop control loop calculates the deviation between real-time data on displacement, tilt angle, stress-strain, hydraulic pressure, and foundation pressure collected by a multi-source heterogeneous sensor network and preset parameters of a digital twin model. It then uses a PID control algorithm to output adjustment commands. Before each construction cycle begins, the outer-loop optimization and prediction loop conducts multi-scheme, multi-physics field coupled simulations based on the current geometric and mechanical state of the tank and external environmental conditions such as wind speed, temperature, and humidity. Within a period ranging from several minutes to several hours, it simulates and optimizes the subsequent jacking speed, welding sequence, and jacking and pressure holding time process parameters in advance to determine the optimal construction parameters for the next construction cycle.

[0041] S6, Precise Tank Lowering Guided by Digital Twin: Multi-physics coupling simulation of the tank lowering process is conducted using a digital twin model built on a digital twin platform. This determines the lowering speed and synchronization control strategy, for example, setting the lowering speed to 0.3 m / h and controlling the synchronization error to ≤1 mm. This guides the hydraulic jacking system to synchronously lower the tank body through staged pressure relief. Simultaneously, pressure distribution data of the tank foundation pad layer is collected through a multi-source heterogeneous sensor network and synchronized to the digital twin model. In a specific embodiment, the unevenness coefficient of the foundation load distribution after the tank is in place can reach 1.15.

[0042] S7, Digital Twin Asset Delivery: Integrates geometric data, mechanical data, environmental data, operation logs and control command data generated throughout the construction process, builds a visual interactive interface using the Unity3D engine, and generates an interactive digital twin file that is uniquely bound to the physical storage tank (bound to the storage tank equipment number and QR code) and contains a complete construction history. The file is stored in FBX format and supports access from multiple terminals (computers, tablets, mobile phones).

[0043] Interactive digital twin archives support time-stamped playback of the entire construction process, status tracing at any construction stage, and visual analysis of key construction parameters; key construction parameters include tank roundness, tank verticality, weld stress, hydraulic jacking force, and load distribution non-uniformity coefficient.

[0044] In the virtual pre-simulation of step S4 and the attitude control under the guidance of the digital twin in step S53, the digital twin construction platform realizes the coupling simulation of geometry, mechanics, and environment through its integrated virtual simulation engine. The digital twin construction platform uses its built-in virtual tank model as a reference and receives real-time data on displacement, tilt angle, stress and strain, hydraulic pressure, foundation pressure, wind speed, temperature and humidity collected by a multi-source heterogeneous sensor network as feedback. First, it obtains the geometric and mechanical deviations between the physical entity of the storage tank and the virtual tank model by fitting and calculating the least squares method. Then, combined with real-time environmental parameters, it solves and calculates the deviations through multi-physics coupling simulation to determine the output force adjustment and displacement adjustment of the hydraulic synchronous lifting actuator.

[0045] The digital twin model continuously and dynamically evolves throughout the entire construction process from steps S1 to S7. The evolution process is as follows: The digital twin model is an engineering virtual model that integrates the tank foundation, tank structure, construction equipment, and environmental parameters. The data layer includes at least the foundation geometric model, tank material properties, real-time data streams of displacement, tilt angle, stress and strain, hydraulic pressure, foundation pressure, wind speed, temperature and humidity collected by a multi-source heterogeneous sensor network, construction process logs, environmental parameter records, and analysis and decision-making instructions from the digital twin construction platform.

[0046] The digital twin model uses a real-time simulation engine to achieve data-driven dynamic updates. It receives various types of data from the aforementioned data layers in real time and combines them with the multi-physics coupling simulation results of the digital twin construction platform. It uses parametric modeling to synchronously update its own geometric parameters, mechanical parameters, and environmental parameters, so that the digital twin model always keeps in line with the actual state of the physical entity of the storage tank, the construction environment, and the construction equipment, and achieves continuous dynamic evolution throughout the entire construction process.

[0047] This invention also discloses a digital twin hydraulic synchronous jacking construction system for vertical storage tanks, used to implement a digital twin hydraulic synchronous jacking construction method for vertical storage tanks. The system includes a digital twin construction platform, a multi-source heterogeneous sensor network, and a hydraulic synchronous jacking actuator. The digital twin construction platform is an industrial control computer or a computer. The multi-source heterogeneous sensor network includes displacement sensors, stress-strain sensors, tilt sensors, anemometers, hydraulic pressure sensors, and foundation pressure sensors. The displacement sensors, stress-strain sensors, and tilt sensors are installed on the tank wall panels, the hydraulic pressure sensors are installed on the hydraulic jacking platform, and the foundation pressure sensors are installed on the concrete ring wall foundation and foundation pad. Anemometers are deployed at construction environment monitoring points; real-time data collected by a multi-source heterogeneous sensor network is uploaded to the digital twin construction platform via a communication interface; a hydraulic synchronous lifting actuator is deployed at the bottom of the storage tank and the hydraulic lifting platform, including a hydraulic pump station, a lifting cylinder assembly, and a synchronous controller; the synchronous controller is communicatively connected to the digital twin construction platform and receives control commands issued by the platform; the synchronous controller is electrically connected to the hydraulic pump station and controls its output pressure and flow rate; the hydraulic pump station is hydraulically connected to the lifting cylinder assembly, providing power to the assembly; under the drive of the hydraulic pump station and the control of the synchronous controller, the lifting cylinder assembly achieves synchronous lifting, attitude adjustment, and tank lowering actions.

[0048] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A method for constructing a vertical storage tank using digital twin hydraulic synchronous jacking, characterized in that: Includes the following steps: S1, Digital Twin Foundation Modeling: 3D laser scanning is performed on the completed tank foundation to generate point cloud data, and a digital twin foundation model consistent with the actual foundation spatial form and physical properties is constructed based on the point cloud data. S2, First Ring Physical Installation and Initial Calibration: Complete the installation of the first ring of tank wall panels, and calibrate the installation position and verticality of the first ring of wall panels to form a construction benchmark; S3, Lifting Platform Construction: Construct a lifting platform adapted to the inverted construction of the storage tank. Integrate a multi-source heterogeneous sensor network at preset locations on the lifting platform, the storage tank body, and the storage tank foundation. The multi-source heterogeneous sensor network is used to collect displacement, stress, tilt angle, wind speed, and pressure data. S4, Digital Twin System Activation and Virtual Pre-simulation: Activate the digital twin construction platform, load the tank design model and the digital twin basic model constructed in step S1 into the platform, and conduct multi-physics field coupling simulation of the geometric and mechanical environment for the entire construction process from the installation of the first ring wall panels to the final placement of the tank. Optimize construction process parameters based on the simulation results. S5, based on a progressive closed-loop construction cycle of digital twins: repeatedly execute the lifting, data synchronization evaluation, attitude control, welding and data archiving processes until the tank body reaches the design height; S6, Precise Tank Lowering Guided by Digital Twin: Based on the digital twin model of the digital twin construction platform, multi-physics field coupling simulation of the tank lowering process is carried out to determine the lowering speed and synchronous control strategy of the tank, and guide the hydraulic jacking system to lower the tank synchronously; at the same time, the pressure distribution data of the tank foundation pad layer is collected through a multi-source heterogeneous sensor network and synchronized to the digital twin model. S7, Digital Twin Asset Delivery: Integrates geometric data, mechanical data, environmental data, operation logs and control command data generated throughout the construction process to generate an interactive digital twin archive uniquely bound to the physical storage tank and containing a complete construction history.

2. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 1, characterized in that, Step S5, the progressive closed-loop construction cycle based on digital twins, specifically includes the following sub-steps: S51, Solid Lifting Execution: The storage tank is lifted to a preset height using a hydraulic lifting system. After the lifting is completed, the hydraulic lifting system enters a pressure-holding standby state. S52, Real-Virtual Data Synchronization and Status Assessment: Geometric morphology data, structural mechanics data, and construction environment data of the storage tank entity are collected in real time through a multi-source heterogeneous sensor network. Geometric morphology data includes displacement and tilt angle; structural mechanics data includes stress and strain, hydraulic pressure, and foundation pressure; and construction environment data includes wind speed, temperature, and humidity. The collected data is synchronously uploaded to the digital twin construction platform, and the digital twin model is dynamically updated. Based on the updated digital twin model, the geometric and mechanical deviations between the physical entity of the storage tank and the virtual tank model are calculated. Geometric deviation refers to the difference between the actual displacement and tilt angle parameters of the physical entity of the storage tank and the preset displacement and tilt angle parameters of the virtual tank model. Mechanical deviation refers to the difference between the actual stress and strain, hydraulic pressure, and foundation pressure parameters of the physical entity of the storage tank and the preset stress and strain, hydraulic pressure, and foundation pressure parameters of the virtual tank model. S53, Attitude Control Guided by Digital Twin: Based on the digital twin model of the digital twin construction platform, combined with the current displacement and tilt geometry of the tank, stress and strain, hydraulic pressure, foundation pressure and mechanical state, wind speed, temperature and humidity environmental parameters and action parameters of the hydraulic jacking system, multi-physics field coupling simulation prediction of tank attitude adjustment is carried out. The attitude change and stress distribution of the tank under different adjustment schemes are simulated. Based on the simulation prediction results, hydraulic jacking control commands are generated to dynamically adjust the output force and displacement of the hydraulic synchronous jacking actuator, so that the tank body gradually conforms to the optimal attitude preset by the digital twin model. S54, Solid welding operation: Perform wall panel welding operation on the tank body adjusted to the optimal posture. During the welding process, stress and strain data of the tank weld area are continuously collected through a multi-source heterogeneous sensor network. S55, Data Archiving and Preparation for the Next Cycle: The construction parameters, all data collected by the multi-source heterogeneous sensor network, all instructions for tank attitude control, and tank wall welding quality data within this construction cycle are archived into the digital twin model of the digital twin construction platform. This completes the spatiotemporal correlation and storage of various types of data, providing complete data support for the construction operation of the next construction cycle of the tank.

3. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 2, characterized in that: In step S53, different adjustment schemes are generated based on the geometric and mechanical deviation values ​​and distribution locations of the physical entity of the storage tank and the virtual tank model. The digital twin construction platform matches the adjustable force range and adjustable displacement range of each lifting point of the hydraulic jacking system for each deviation value and distribution location, and combines them to form at least two different lifting adjustment schemes. The hydraulic jacking control command is generated by the digital twin construction platform through multi-physics field coupling simulation prediction results. The platform analyzes the simulation prediction results of each adjustment scheme, selects the optimal adjustment scheme that can make the geometric and mechanical deviations of the storage tank converge synchronously to within the preset threshold, and determines the specific force adjustment amount and displacement adjustment amount of the hydraulic synchronous jacking actuator based on the scheme, and generates the corresponding hydraulic jacking control command. The command includes the action sequence, force parameters, and displacement parameters of each lifting point.

4. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 2, characterized in that: In the virtual pre-simulation of step S4 and the attitude control under the guidance of the digital twin in step S53, the digital twin construction platform realizes the coupled simulation of geometry, mechanics and environment through its integrated virtual simulation engine. The digital twin construction platform uses its built-in virtual tank model as a benchmark. It receives real-time data on displacement, tilt angle, stress and strain, hydraulic pressure, foundation pressure, wind speed, temperature and humidity collected by a multi-source heterogeneous sensor network as feedback. It first obtains the geometric and mechanical deviations between the physical entity of the storage tank and the virtual tank model. Then, combined with real-time environmental parameters, it calculates the deviations through multi-physics coupling simulation to determine the output force adjustment and displacement adjustment of the hydraulic synchronous lifting actuator.

5. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 1, characterized in that, The digital twin model continuously and dynamically evolves throughout the entire construction process from steps S1 to S7. The evolution process is as follows: The digital twin model is an engineering virtual model that integrates the tank foundation, tank structure, construction equipment, and environmental parameters. The data layer includes at least the foundation geometric model, tank material properties, real-time data streams of displacement, tilt angle, stress and strain, hydraulic pressure, foundation pressure, wind speed, temperature and humidity collected by a multi-source heterogeneous sensor network, construction process logs, environmental parameter records, and analysis and decision-making instructions from the digital twin construction platform. The digital twin model receives various types of data from the aforementioned data layer in real time. Combined with the multiphysics coupling simulation results of the digital twin construction platform, it synchronously updates its own geometric parameters, mechanical parameters, and environmental parameters, ensuring that the digital twin model always remains consistent with the actual state of the physical entity of the storage tank, the construction environment, and the construction equipment, thus achieving continuous dynamic evolution throughout the entire construction process.

6. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 1, characterized in that: In step S5, a dual-loop control system is constructed in the progressive closed-loop construction cycle. The dual-loop control system includes an inner loop regulation loop and an outer loop optimization prediction loop. The inner loop control loop calculates the deviation and outputs adjustment commands based on the deviation between the real-time data of displacement, tilt angle, stress and strain, hydraulic pressure and foundation pressure collected by the multi-source heterogeneous sensor network and the preset parameters of the digital twin model. Before the start of each construction cycle, the outer loop optimization prediction loop conducts multi-scheme multi-physics field coupled simulations based on the current geometric and mechanical state of the tank entity and the external environmental conditions such as wind speed, temperature and humidity. Within a cycle of several minutes to several hours, the subsequent jacking speed, welding sequence and jacking pressure holding time process parameters are simulated and optimized in advance to determine the optimal construction parameters for the next construction cycle.

7. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 1, characterized in that: In step S6, a foundation pressure sensor array is pre-embedded in the foundation cushion layer of the storage tank to collect pressure data at each monitoring point of the foundation cushion layer. The digital twin model calculates the load distribution non-uniformity coefficient based on pressure data, and ensures that the load distribution non-uniformity coefficient is no greater than 1.2; the roundness deviation of the tank body is controlled within ±8mm throughout the entire construction process.

8. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 1, characterized in that: The interactive digital twin archive generated in step S7 supports time-stamp-based playback of the entire construction process, status tracing at any construction stage, and visualization analysis of key construction parameters. Key construction parameters include tank roundness, tank verticality, weld stress, hydraulic jacking force, and load distribution non-uniformity coefficient.

9. The vertical storage tank digital twin hydraulic synchronous jacking construction method according to claim 1, characterized in that: The multi-source heterogeneous sensor network includes displacement sensors, stress-strain sensors, tilt sensors, anemometers, hydraulic pressure sensors, and foundation pressure sensors. Among them, displacement sensors, stress-strain sensors, and tilt sensors are deployed on the tank wall panels, hydraulic pressure sensors are deployed on the hydraulic jacking platform, foundation pressure sensors are deployed on the concrete ring wall foundation and foundation pad, and anemometers are deployed at construction environment monitoring points.

10. A digital twin hydraulic synchronous jacking construction system for a vertical storage tank, used to implement the digital twin hydraulic synchronous jacking construction method for a vertical storage tank as described in any one of claims 1 to 9, characterized in that: This includes a digital twin construction platform, a multi-source heterogeneous sensor network, and a hydraulic synchronous lifting actuator; The digital twin construction platform is an industrial control computer or a computer; The multi-source heterogeneous sensor network includes displacement sensors, stress-strain sensors, tilt sensors, anemometers, hydraulic pressure sensors, and foundation pressure sensors. Among them, displacement sensors, stress-strain sensors, and tilt sensors are deployed on the tank wall panels, hydraulic pressure sensors are deployed on the hydraulic jacking platform, foundation pressure sensors are deployed on the concrete ring wall foundation and foundation pad, and anemometers are deployed at construction environment monitoring points. The real-time data collected by the multi-source heterogeneous sensor network is uploaded to the digital twin construction platform through a communication interface. The hydraulic synchronous lifting actuator is installed at the bottom of the storage tank and on the hydraulic lifting platform. It includes a hydraulic pump station, a lifting cylinder assembly, and a synchronous controller. The synchronous controller is communicatively connected to the digital twin construction platform, receiving control commands from it. It is also electrically connected to the hydraulic pump station, controlling its output pressure and flow rate. The hydraulic pump station is hydraulically connected to the lifting cylinder assembly, providing power to it. Under the drive of the hydraulic pump station and the control of the synchronous controller, the lifting cylinder assembly achieves synchronous lifting, attitude adjustment, and tank lowering actions.

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