A cantilevered pump pipe droop compensation welding method and design for electric pole pumping

Abstract

The application provides a cantilever type pump pipe droop compensation welding method for electric pole pumping and design, relates to the technical field of concrete pump pipe welding, and realizes real-time measurement of droop height through an integrated laser ranging sensor system, and sends data to a central monitoring platform for analysis through wireless transmission, adjusts the angle and length by adding a telescopic buffer sleeve made of high-elastic polymer and embedding a spiral spring mechanism, the technical scheme effectively solves the problem that the steel reinforcement frame stand circle is contacted and worn due to the gravity droop of the cantilever type pump pipe in the background technology through the integrated laser ranging sensor system and the closed loop monitoring frame. The scheme is installed with high-precision infrared laser sensors at the cantilever end (12-18 meters key point) of the pump pipe, combines ZigBee wireless transmission and statistical analysis (such as moving average and trend analysis) of the central monitoring platform, realizes real-time measurement of droop height and dynamic adjustment of the best working height.

Description

Technical Field

[0001] This invention relates to the field of concrete pump pipe welding technology, specifically to a welding method and design for compensating sag of cantilever pump pipes used in electric pole pumping. Background Technology

[0002] In the production of concrete utility poles, cantilever pump pipes, as key equipment for conveying concrete, are widely used to pump concrete into molds to form the pole structure. However, the design and use of existing cantilever pump pipes have significant problems, mainly stemming from the physical characteristics of the pump pipe itself and the working environment. Pump pipes typically employ a cantilever structure, with a length of 12 to 18 meters from the support point, a diameter of 108 millimeters, and are mostly made of steel, thus possessing a certain weight. Under its own gravity, the pump pipe inevitably sags naturally, especially in long-distance cantilever configurations, and this sag intensifies with prolonged use.

[0003] In existing technologies, pump pipe sagging has led to a series of serious consequences in actual production. First, when the pump pipe enters the production mold, its natural sagging causes the top of the pipe to directly contact the bottom reinforcing steel support ring inside the mold, resulting in friction with the stressed reinforcing steel. Prolonged contact and sliding cause wear on the steel surface, and a sharp angle gradually forms at the bottom of the pump pipe, further exacerbating the wear. Second, the pump pipe vibrates due to internal pressure during pumping, especially when concrete is flowing, and the pump pipe outlet may directly impact the reinforcing steel frame. This vibration and impact not only causes the support ring to fall off, compromising the stability of the reinforcing steel frame, but may also pose a risk of breakage to the stressed reinforcing steel (such as 7.0 mm diameter prestressed main bars) after a sharp angle appears in the pump pipe. Once the reinforcing steel breaks, fragments may be ejected, causing injury to operators and severely damaging the mechanical properties of the pole.

[0004] Furthermore, existing technologies lack effective sagging compensation and stiffness enhancement measures. The height and changes in pump pipe sagging are not monitored in real time, and there is a lack of dynamic adjustment mechanisms, resulting in the inability to detect and correct sagging problems in a timely manner. The optimized design of the pump pipe inlet is insufficient, failing to effectively buffer the impact of vibrations, and the steel reinforcement welding process does not adequately consider stiffness enhancement, causing the pump pipe to be unable to maintain a stable working state during long-term use. Existing maintenance methods rely heavily on manual inspection and periodic replacement, lacking data-driven preventive maintenance strategies, making it difficult to predict the critical points of pump pipe wear and steel reinforcement damage. As a result, damaged poles often have to be disposed of as scrap, which not only increases production costs but also threatens production safety and efficiency. Summary of the Invention

[0005] Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this invention provides a welding method and design for compensating sag of cantilever pump pipes used in electric pole pumping, thus solving the problems of existing technologies.

[0007] Technical solution

[0008] To achieve the above objectives, the present invention provides the following technical solution: a digital pricing method for agricultural product transactions based on a neural network model, comprising the following steps:

[0009] S1. Monitoring steps for pump pipe sag height parameters: The sag height is measured in real time through an integrated laser rangefinder sensor system, and the data is transmitted wirelessly to the central monitoring platform for analysis.

[0010] S2, the optimized design steps for the pump inlet involve adjusting the angle and length by adding a stretchable buffer sleeve made of highly elastic polymer and embedding a helical spring mechanism;

[0011] S3. The pump pipe is reinforced with steel bars in a continuous spiral structure by welding carbon fiber reinforced steel bars along the pump pipe axis.

[0012] Preferably, the monitoring step of the S1 pump pipe sag height parameter further includes developing a closed-loop monitoring framework integrating IoT data acquisition, installing multi-sensor arrays at key nodes of the pump pipe to collect production data, recording historical databases through a cloud platform and analyzing data patterns using statistical analysis methods, setting the optimal working height of the pump pipe, dynamically calculating the pump pipe replacement frequency using the sag height as the core monitoring parameter, and including an acoustic detection device and a visual inspection system to monitor microcracks in the pump pipe and welded structure, and setting detection thresholds through production data recording and experimental verification.

[0013] Preferably, the optimization design steps of the S2 pump inlet further include introducing an adaptive buffer nozzle system, designing a multi-layer composite structure at the pump inlet end including an outer high-wear-resistant polymer sheath and a built-in adjustable hydraulic buffer mechanism, determining the pump inlet design parameters based on production data records and laboratory experiments, setting the optimal working height of the pump pipe, feeding back the sag height monitoring data to the nozzle control module to achieve automatic compensation, and including a modular installation interface to support quick replacement and angle adjustment, with interface parameters determined through production data records and simulation experiments.

[0014] Preferably, the steel bar welding step of the S3 pump pipe further includes implementing parametric laser-assisted composite welding technology, using high-strength alloy steel bars to form a variable density grid structure along the pump pipe axis, determining the welding method through production data recording and control experiments, setting the optimal working height of the pump pipe, integrating the sag height as a monitoring parameter into the welding optimization model to calculate the pump pipe replacement frequency, and including laser-assisted composite welding and stiffness adaptive enhancement technology, using laser hybrid welding combined with carbon fiber composite materials to create a variable cross-section grid structure.

[0015] Preferably, it further includes the steps of an overall data-driven maintenance and optimization platform, constructing a comprehensive digital simulation system to integrate monitoring, design, and welding steps, using digital simulation technology to simulate pump pipe behavior, setting the optimal working height of the pump pipe through production data recording and experiments, using the sag height as a key input parameter and applying probability calculation methods to calculate the pump pipe replacement frequency, and including the steps of a digital simulation platform and preventive maintenance optimization framework, constructing a digital simulation model of the pump pipe system to support virtual experimental verification.

[0016] Preferably, the system further includes a multimodal sensor fusion monitoring and prediction system step, which develops a hybrid sensor network based on fiber Bragg gratings and laser ranging, combined with vibration and strain sensors, to achieve multi-dimensional real-time monitoring of sag height. The optimal working height of the pump pipe is set through production data recording and on-site verification, and the sag height is integrated into a statistical model as the primary monitoring parameter to calculate the pump pipe replacement frequency.

[0017] Preferably, the optimization design step of the S2 pump inlet further includes dynamic optimization driven by CFD-DEM simulation, simulating the flow behavior of concrete using computational fluid dynamics and discrete element method, designing an adaptive rotary pump inlet structure including a built-in hydraulic regulator and wear-resistant polymer lining, determining the pump inlet design parameters based on production data records and control experiments, and feeding back the sag height monitoring data to the design model to calculate the pump pipe replacement frequency.

[0018] Preferably, the process further includes a material durability enhancement step, which involves introducing a corrosion-resistant coating and a fatigue-resistant bio-based composite material into the pump inlet and the welded steel reinforcement structure, determining material parameters through production data recording and accelerated aging experiments, setting the optimal working height of the pump pipe, and using the sag height as a monitoring parameter to adjust the material replacement frequency.

[0019] Preferably, the process further includes optimization steps, designing a modular installation frame to support rapid replacement and positioning of pump pipes, determining installation parameters through production data recording and on-site testing, setting the optimal working height of the pump pipes, and using the sag height as a monitoring parameter to optimize the construction cycle and replacement frequency.

[0020] Preferably, the design includes a pump pipe sag height monitoring system, a pump pipe inlet optimization structure, and a pump pipe reinforcement welded structure. The pump pipe sag height monitoring system includes an integrated laser rangefinder and a central monitoring platform. The pump pipe inlet optimization structure includes a retractable buffer sleeve made of highly elastic polymer and an embedded helical spring mechanism. The pump pipe reinforcement welded structure includes a continuous helical structure of carbon fiber reinforced steel bars along the pump pipe axis. The design uses production data recording and experimental settings to determine the optimal working height of the pump pipe, and uses the sag height as a monitoring parameter to calculate the pump pipe replacement frequency.

[0021] Beneficial effects

[0022] This invention provides a welding method and design for compensating sag of cantilever pump pipes used in electric pole pumping. It offers the following advantages:

[0023] 1. This technical solution effectively solves the problem of contact and wear between the pump pipe and the reinforcing steel frame caused by the sag of the cantilever pump pipe due to its own weight, as described in the background technology. The solution installs a high-precision infrared laser sensor at the cantilever end of the pump pipe (a key point at 12-18 meters), combined with ZigBee wireless transmission and statistical analysis (such as moving average and trend analysis) from a central monitoring platform, to measure the sag height in real time and dynamically adjust the optimal working height (such as the experimentally verified 5cm threshold). Compared to the lack of real-time monitoring in existing technologies, this method significantly reduces friction between the pump pipe and the reinforcing steel, prevents the formation of sharp edges due to prolonged wear, extends the service life of both the pump pipe and the reinforcing steel, and reduces the risk of wear during production.

[0024] 2. This solution successfully addresses the steel reinforcement damage and safety hazards caused by pump pipe vibration and impact in the background technology through a telescopic buffer sleeve, a helical spring mechanism, and an adaptive buffer nozzle system. To address the risks of pump pipe vibration under pumping pressure, resulting in the outlet striking the steel reinforcement cage and even breaking the prestressed main reinforcement (φ7.0mm), the solution uses a highly elastic silicone rubber sleeve (10-20cm telescopic range) and a stainless steel helical spring (0°-15° angle) to absorb the impact, supplemented by a hydraulic control module that automatically adjusts the sleeve position based on sag data. Combined with a CFD-DEM simulation-optimized rotary pump pipe inlet structure, the energy transmission from vibration is further reduced. Compared to the shortcomings of existing technologies with no buffer design, this innovation effectively prevents steel reinforcement breakage and personnel injury, ensuring the safety of pole production.

[0025] 3. This solution overcomes the high scrap rate problem caused by the single maintenance strategy in the previous technology by using a multimodal sensor fusion monitoring and data-driven maintenance platform. Addressing the limitations of existing technologies that rely on manual inspection and periodic replacement, this solution deploys a multi-sensor array, including fiber Bragg gratings, vibration accelerometers, and strain gauges, at key nodes of the pump pipe. Combined with acoustic detection devices and a visual inspection system, it monitors sagging, strain, and microcrack data in real time. Trends are analyzed through a cloud platform and SQL database to dynamically adjust the replacement frequency. Supplemented by corrosion-resistant epoxy coatings, fatigue-resistant bio-based composite materials, and a modular installation frame to optimize the construction cycle, this method reduces the scrap rate and ensures the mechanical performance and production efficiency of the poles, compared to the lack of preventative maintenance in existing technologies. Attached Figure Description

[0026] Figure 1 This is an overall structural diagram of the present invention;

[0027] Figure 2 This is a simulation diagram of the droop height monitoring of the present invention;

[0028] Figure 3 This is a simulation diagram of the optimized response of the pump inlet according to the present invention;

[0029] Figure 4 Simulation diagrams were added to enhance the stiffness of this invention;

[0030] Figure 5 Simulation diagram of pump tube replacement frequency;

[0031] Figure 6 This is a plan view of the pump pipe. Detailed Implementation

[0032] 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. Specific Implementation Example 1:

[0034] like Figures 1 to 6 As shown, a welding method and design for compensating sag of cantilever pump pipes used in power pole pumping is presented. Addressing the sag problem caused by the weight of the cantilever pump pipes during concrete pole production, this technical solution aims to solve problems such as steel bar wear, vibration impact, and decreased mechanical properties caused by pump pipe sag through real-time monitoring of sag height, optimized design of the pump pipe inlet, and reinforcement welding to enhance rigidity. The solution employs an integrated sensor system, advanced material design, and digital simulation technology, combined with production data recording and experimental verification, forming a complete closed-loop process from monitoring to maintenance.

[0035] Monitoring steps for pump pipe sagging height parameters: This step achieves real-time measurement of sagging height using an integrated laser ranging sensor system. The integrated laser ranging sensor system consists of multiple laser ranging modules, including a high-precision laser transmitter, receiver, and data processing unit. These modules are installed at multiple key points on the pump pipe cantilever end (e.g., 12-18 meters from the support point), calculating the sagging height based on the distance difference between the laser beam and the ground or reference point. The sensor employs infrared laser technology to ensure anti-interference capabilities in the concrete production environment. Measurement data includes sagging distance, rate of change, and the influence of ambient temperature, and is transmitted in real-time to a central monitoring platform via the ZigBee wireless communication protocol. The central monitoring platform is an industrial-grade server-based system installed in the main control room of the production workshop, equipped with data receiving modules, a storage database, and analysis software. The platform receives wireless data via serial port, stores it in an SQL database, processes the data using statistical analysis methods (such as moving average and trend analysis), identifies sag trends, and sets the optimal working height of the pump tube based on thresholds determined through experimental verification (such as adjusting the installation angle through simulation testing). The sag height is used as the core parameter to dynamically calculate the pump tube replacement frequency.

[0036] The optimized design steps for the pump inlet: This step optimizes the pump inlet design by adding a retractable buffer sleeve and embedding a helical spring mechanism to adjust the angle and length. The retractable buffer sleeve is made of highly elastic silicone rubber material with an outer layer thickness of 5 mm and an inner layer filled with foam cushioning. The sleeve length can be extended or retracted between 10-20 cm depending on the sag adjustment range. The front end of the sleeve is designed with an arc shape to avoid the formation of sharp angles. The embedded helical spring mechanism consists of a stainless steel spring with a diameter matching the inner diameter of the pump inlet and a length of approximately 15 cm. It is fixed inside the sleeve and connected to the pump inlet via a nut and guide rail structure. The spring provides a counter-pull force when the pump pipe sags. The angle (0°-15°) and length are changed by adjusting the fixing bolts on the guide rail to absorb the impact of pump pipe bounce. The design parameters are determined by production data records (such as pumping pressure and impact logs) and laboratory impact tests to determine the optimal configuration, setting the optimal working height of the pump pipe (e.g., ensuring a gap of ≥2 cm with the rebar through simulation), and feeding the sag height data back to the hydraulic control module to automatically adjust the sleeve position and prevent direct contact between the pump inlet and the rebar.

[0037] The pump pipe reinforcement welding process involves welding carbon fiber reinforced steel bars along the pump pipe axis to form a continuous spiral structure, thereby enhancing the pump pipe's rigidity. The carbon fiber reinforced steel bars are made of carbon fiber prepreg and a high-strength steel core, with a rectangular cross-section (10 mm wide, 3 mm thick) and a length consistent with the pump pipe axis. The welding process utilizes laser-assisted composite technology, equipped with a 1500-watt continuous wave laser. Welding is performed along the outer wall of the pump pipe in a spiral path (approximately 8 cm spacing), with the weld points secured using high-temperature adhesive to form a continuous spiral mesh structure. The steel bars are welded with high density near the pump pipe end, gradually decreasing in density at the distal end to optimize weight distribution. Optimal welding parameters are determined through production data recording (e.g., post-weld stiffness test values) and control experiments (e.g., bending load tests). Combined with experimental verification, the optimal working height of the pump pipe is set (e.g., adjusting the post-weld sag compensation angle). The sag height data is integrated into an optimization model to calculate the pump pipe replacement frequency.

[0038] Extended monitoring closed-loop framework and detection system: Based on S1, a closed-loop monitoring framework integrating IoT data acquisition is developed. Multi-sensor arrays, including laser rangefinders, strain gauges, and temperature sensors, are installed at key nodes of the pump pipe (such as support points and cantilever ends). Production data (such as pumping pressure and ambient humidity) is collected via a LoRa wireless network. Data is transmitted to a cloud platform consisting of a distributed server cluster deployed in the production base's server room, equipped with high-capacity storage and data processing software, and a historical database is maintained. Statistical analysis methods (such as regression analysis) are used to analyze data patterns, setting the optimal working height of the pump pipe (e.g., experimentally determining the cantilever end height deviation threshold). Acoustic detection devices (based on ultrasonic probes) and a visual inspection system (equipped with a high-definition camera) are introduced to monitor microcracks in the pump pipe and welded structures. Detection thresholds are verified through production data recording and accelerated fatigue experiments. Sag height is used as a core parameter to dynamically adjust the replacement frequency.

[0039] Adaptive optimization and modular design of the pump inlet: Based on S2, an adaptive buffer nozzle system is introduced. A multi-layer composite structure is designed at the pump inlet end. The outer layer uses a high-wear-resistant polyurethane sheath (4 mm thick), and the inner layer has a built-in adjustable hydraulic buffer mechanism, consisting of a hydraulic cylinder and a piston. The cylinder is fixed to the inner wall of the pump pipe, and the piston stroke range is 5-10 cm. The design parameters are determined by production data recording (such as runout frequency logs) and laboratory impact tests to determine the optimal stroke and set the optimal working height of the pump pipe (e.g., ensuring the gap between the outlet and the mold through simulation). The modular installation interface consists of a detachable flange and adjusting bolts, supporting quick replacement and angle adjustment (0°-20°). The interface parameters are verified through simulation experiments (such as finite element analysis). The sag height data is fed back to the hydraulic control module to automatically compensate for runout and prevent damage to the reinforcing steel.

[0040] Enhanced stiffness and optimized parameters of steel reinforcement welding: Based on S3, parametric laser-assisted hybrid welding technology was implemented. High-strength alloy steel bars (tensile strength ≥1000MPa) were used to form a variable-density grid structure along the pump pipe axis, with a near-end spacing of 4 cm and a far-end spacing of 10 cm. The laser was equipped with an automatic scanning head and welded along a spiral path, combined with carbon fiber composite materials to create a variable cross-section grid (near-end thickness 3 mm, far-end thickness 2 mm). The optimal parameters for the welding method were determined through production data recording (such as weld strength testing) and control experiments (such as cyclic load testing). The optimal working height of the pump pipe was set (e.g., adjusting the stiffness after welding through experiments). The sag height data was integrated into a regression analysis model to calculate the replacement frequency. Laser hybrid welding technology was adopted, and the melting point temperature was controlled at 1500°C to reduce the heat-affected zone.

[0041] Overall Data-Driven Maintenance and Optimization Platform: This step constructs a comprehensive digital simulation system, integrating steps S1-S3. Digital simulation technology, using finite element software (such as ANSYS), simulates the behavior of pump pipes under a 12-18 meter cantilever. The server is installed in the control room and equipped with high-performance computing units. Production data records include pumping cycles and sag logs. The optimal operating height of the pump pipe is set through experiments (such as simulated load tests), using the sag height as an input parameter. Probabilistic calculation methods (such as Monte Carlo simulation) are used to analyze the replacement frequency. Further, a digital simulation platform is built, with models supporting virtual experimental verification. Parameters are adjusted through multiple sets of control experiments to optimize the maintenance plan.

[0042] Multimodal sensor fusion monitoring system: This step involves developing a hybrid sensor network based on fiber Bragg gratings and laser ranging, installed along the pump pipe. Combining vibration sensors (accelerometer-based) and strain sensors (resistive strain gauges), data is transmitted via an RS485 wired network to achieve multi-dimensional monitoring of sagging height. Data is recorded in production data and validated on-site (e.g., dynamic load tests) to determine the optimal working height. The sagging height is then integrated into a statistical model (e.g., time series analysis) to calculate the replacement frequency.

[0043] CFD-DEM simulation optimization of the pump inlet: Based on S2, computational fluid dynamics and discrete element method were used to simulate concrete flow through Fluent software. An adaptive rotary pump inlet structure was designed, with a built-in hydraulic regulator consisting of a double-piston hydraulic cylinder. The wear-resistant polymer lining is made of polyethylene material (3 mm thick). Parameters were determined through production data recording and control experiments. The optimal working height was set, and the sagging height was fed back to the design model to optimize the replacement frequency.

[0044] Material durability and construction process optimization: To enhance material durability, a corrosion-resistant epoxy coating (0.1 mm thick) and a fatigue-resistant bio-based composite material (based on polylactic acid) were introduced into the pump inlet and welded structure. Parameters were determined through accelerated aging tests (500-hour cycle test) to set the optimal working height. The construction process was optimized by designing a modular installation frame consisting of a steel support frame and adjustable supports. Installation parameters were determined through on-site testing, optimizing the construction cycle and using sagging height as a monitoring parameter to adjust the replacement frequency.

[0045] The pump pipe sagging height monitoring system consists of an integrated laser rangefinder sensor (including a transmitter and receiver) and a central monitoring platform (industrial server); the optimized pump pipe inlet structure includes a retractable buffer sleeve and a helical spring mechanism; the pump pipe's welded steel reinforcement structure uses carbon fiber reinforced steel bars to form a helical mesh. The design uses production data recording and experimental settings to determine the optimal working height, employing sagging height as a monitoring parameter to calculate the replacement frequency. Specific Implementation Example 2:

[0047] like Figures 1 to 6 As shown, the following is a detailed description of the entire system operation process from installation to operation, based on the above embodiments.

[0048] System installation and initialization:

[0049] Operating steps:

[0050] Equipment Installation: A central monitoring platform will be installed at a fixed location in the concrete pole production workshop. The platform consists of an industrial-grade server equipped with a high-performance CPU, 16TB of storage, and an RS485 / ZigBee receiver module, and will be placed in the main control room. An integrated laser ranging sensor system, including three laser transmitters (940nm infrared wavelength) and a receiver, will be installed along the cantilever end of the pump pipe (12-18 meters from the support point). This system will be fixed to the outer wall of the pump pipe, aligned with the pipe's centerline, and connected to a ZigBee wireless module.

[0051] Sensor network deployment: A multimodal sensor network, including fiber Bragg grating sensors (monitoring strain), vibration accelerometers (monitoring vibration), and resistive strain gauges (monitoring deformation), is installed at key nodes of the pump pipe (such as support points and mid-sections). These sensors are connected to the monitoring platform via an RS485 wired network. Acoustic detection devices (ultrasonic probes, 40kHz frequency) and a visual inspection system (equipped with a 1080p camera) are also deployed and fixed 2 meters above the pump pipe.

[0052] Pump inlet and welding structure preparation: Install a retractable buffer sleeve at the pump inlet end. The sleeve is made of a silicone rubber outer layer and a foam inner layer, with an initial length of 15 cm. It is fixed to the pump inlet with bolts, and a stainless steel helical spring (10 cm in diameter and 15 cm in length) is embedded and connected to the guide rail adjustment mechanism. Prepare carbon fiber reinforced steel bars (10 mm × 3 mm cross-section), pre-cut to the pump inlet length, and install laser welding equipment (1500 W continuous wave laser) next to the production line.

[0053] Initial setup: Start the central monitoring platform, input initial parameters (such as pump pipe length 12-18 meters, ambient temperature range 10-40°C), set the sag height threshold through the interface (experimentally determined to be 5cm), and calibrate the sensor network to ensure normal data transmission.

[0054] Real-time monitoring and operation of pump pipe sag height parameters:

[0055] Operating steps:

[0056] Data Acquisition: A laser rangefinder emits an infrared laser beam to measure the distance difference between the cantilever end of the pump pipe and the ground, acquiring data 10 times per second, while simultaneously recording data from a vibration accelerometer (sampling rate 100Hz) and strain gauges. An acoustic detection device emits ultrasonic waves to detect microcracks in the welded structure, and a camera captures an image of the pump pipe surface every minute.

[0057] Data transmission: The collected data is transmitted wirelessly to the central monitoring platform via a ZigBee module (transmission distance 100 meters), and the multimodal sensor data is transmitted to the platform database via an RS485 network.

[0058] Data Analysis and Processing: The platform server runs statistical analysis software to perform moving average processing on the data, generate a sag height curve, and identify trend changes. Acoustic and visual data are analyzed by the signal processing module to detect the location of microcracks and mark them in the database.

[0059] Parameter adjustment: Based on the analysis results, the platform automatically calculates the optimal working height (adjusted to a droop of <5cm through experimental verification), compares the droop height data with the threshold, and if it exceeds the threshold, triggers an alarm and records the replacement frequency recommendation (based on historical data statistical period).

[0060] Optimized design and dynamic adjustment of pump inlet:

[0061] Operating steps:

[0062] Initial installation: Install the adaptive buffer nozzle system at the pump inlet. The hydraulic buffer mechanism consists of a double-piston hydraulic cylinder. The cylinder body is fixed to the inner wall of the pump pipe. The piston stroke is initially set to 5 cm. Connect the wear-resistant polyurethane sleeve (4 mm thick).

[0063] Dynamic adjustment: The hydraulic control module is activated to receive the droop height data transmitted from the monitoring platform. The hydraulic cylinder adjusts the piston position according to the data (stroke range 5-10 cm), while the helical spring adjusts the angle (0°-15°) through the guide rail mechanism to absorb the impact of pump pipe jumping.

[0064] CFD-DEM simulation optimization: Using Fluent software, pumping pressure and concrete flow data are input to simulate the flow field at the pump outlet. Based on the simulation results, the designers adjust the rotary pump outlet structure (the radius of curvature of the arc matches the pump pipe diameter) and replace worn parts through modular installation interfaces (removable flanges).

[0065] Parameter verification: Record the jumping frequency and impact log during the pumping process, combine with laboratory impact tests (simulating 1000 impacts) to determine the optimal working height (ensuring a gap ≥ 2 cm), and update the replacement frequency recommendations.

[0066] The welding of steel bars for pump pipes shall be performed as follows:

[0067] Operating steps:

[0068] Material preparation: Cut carbon fiber reinforced steel bars (preimpregnated carbon fiber and steel core composite) to the length of the pump tube, coat the surface with high-temperature adhesive, and place them on the worktable of the laser welding equipment.

[0069] Welding process: The 1500W laser is activated, and the spiral path parameters are set (8 cm spacing). The laser head moves axially along the pump tube, melting the reinforcing steel strips and the outer wall of the pump tube. The adhesive is cured at 1500°C, forming a continuous spiral mesh. During welding, a high density (4 cm spacing) is used near the end, and the spacing gradually decreases at the far end (10 cm spacing).

[0070] Stiffness verification: After welding is completed, the stiffness of the grid structure is tested using a bending load testing machine, the data is recorded and compared with the experimental threshold, and welding parameters (such as laser power or spacing) are adjusted.

[0071] Height and frequency settings: Based on the test results, adjust the pump pipe installation angle and set the optimal working height (compensate for sag to 110% of the original design). Input the sag height data into the regression analysis model to calculate the replacement frequency.

[0072] Overall data-driven maintenance and optimization operation:

[0073] Operating steps:

[0074] Data integration: The central monitoring platform collects real-time data from the sensor network, combines it with production logs (pumping cycles, maintenance records), and inputs it into the digital simulation system (based on ANSYS).

[0075] Simulation Operation: Run finite element analysis to simulate the sag behavior of pump pipes under different loads, generate a virtual experimental report, and technicians adjust the installation parameters based on the report.

[0076] Maintenance optimization: The platform uses probabilistic calculation methods (Monte Carlo simulation) to analyze sagging height data, generate preventative maintenance plans, and display replacement frequency suggestions on the platform interface. Operators can then schedule maintenance according to the plan.

[0077] Continuous operation of multimodal sensor fusion monitoring:

[0078] Operating steps:

[0079] Data fusion: Fiber Bragg grating sensors monitor strain data, laser rangefinders record height, vibration sensors detect vibration, and the data is transmitted to the platform via an RS485 network.

[0080] Real-time analysis: The platform runs time series analysis software, integrates multi-source data, generates a droop trend chart, and sets the optimal working height (verified through on-site dynamic load tests).

[0081] Prediction and Feedback: Based on the trend chart, predict the time point when sagging will intensify, update the replacement frequency recommendations, and allow operators to adjust sensor calibration based on feedback.

[0082] Material durability and construction process optimization:

[0083] Operating steps:

[0084] Durability enhancement: A corrosion-resistant epoxy coating (0.1 mm thick) was sprayed onto the pump inlet and welded structure surface, and an anti-fatigue bio-based composite material (polylactic acid) was embedded. A 500-hour accelerated aging test was conducted, and wear data were recorded.

[0085] Construction optimization: Assemble the modular installation frame (steel support frame and adjustable support column), the operator uses a wrench to adjust the height of the support column, position the pump pipe, record the installation time and sag height, and optimize the construction cycle.

[0086] Parameter update: Based on aging test and field test data, set the optimal working height and adjust the material replacement frequency.

[0087] System assembly: Install the pump pipe sag height monitoring system (laser sensor and platform), pump pipe inlet optimization structure (buffer sleeve and spring), and pump pipe steel reinforcement welded structure (spiral mesh) on the production line according to the design drawings.

[0088] Operational verification: Start the pumping process, monitor the platform to record the sag height and the condition of the reinforcing bars, and the operator checks the stability of the buffer sleeve and welded structure.

[0089] Data application: By recording production data and conducting experiments (simulating 100 pumping cycles), the optimal working height is set, the replacement frequency is calculated, and operating parameters are continuously optimized.

[0090] Operational performance and closed-loop management:

[0091] The entire system operates in a closed-loop mode through real-time data acquisition, dynamic adjustment, and preventative maintenance. Laser sensors and multimodal networks ensure accurate sag monitoring, while buffer sleeves and welded structures effectively compensate for sag and impact. Digital platforms and experimental data support continuous optimization, solving the problems of rebar wear and mechanical performance degradation, and ensuring the safety of pole production.

[0092] The entire solution employs a layered architecture for data and control flow design, ensuring efficient data acquisition, processing, and feedback control. The data flow originates from an integrated laser rangefinder, a multimodal sensor network (fiber Bragg gratings, vibration accelerometers, strain gauges), acoustic detection devices, and a vision inspection system. These devices acquire data per second on sag height, strain, vibration, and microcracks, transmitting this data to the central monitoring platform via ZigBee wireless protocol (100-meter range) and RS485 wired network (9600bps). Data packets contain timestamps and sensor IDs and are stored in an SQL database. The platform server runs statistical analysis software (MATLAB) and finite element simulation tools (ANSYS) to process the data, generate trend curves and stress distribution maps, and output recommendations for optimal operating height and replacement frequency. The control flow is issued by the platform, which triggers the hydraulic control module to adjust the buffer sleeve angle (0°-15°) and piston stroke (5-10cm) based on the droop height threshold (5cm). At the same time, the steel mesh is optimized by adjusting the parameters of the laser welding equipment (power 1500W, spacing 8cm). The stiffness verification and construction cycle optimization data are fed back to the platform to form a closed-loop control, ensuring real-time system response and dynamic updates of maintenance plans. Specific Implementation Example 3:

[0094] like Figures 1 to 6 As shown, the following is a detailed explanation of the calculation method of the algorithm in this technical solution:

[0095] Statistical analysis methods (used for monitoring the sag height parameter of pump pipe S1 and processing related data of S2-S9):

[0096] Input data: Real-time data collected from integrated laser rangefinders, multimodal sensor networks (fiber Bragg gratings, vibration accelerometers, strain gauges), acoustic detection devices, and vision inspection systems, including sag height (mm), vibration acceleration (m / s²), strain value (με), microcrack signal frequency (kHz), and ambient temperature (°C). This data is transmitted per second to the central monitoring platform via ZigBee and RS485 networks and stored in an SQL database.

[0097] The computational analysis logic is as follows: This method processes historical and real-time data point by point. First, a 5-point moving average technique is used to smooth the sag height curve, eliminating short-term noise and identifying long-term trends. Then, correlation analysis is performed using vibration and strain data to determine whether the sag is caused by structural fatigue. Acoustic and visual data are analyzed using signal spectrum analysis and image edge detection to identify the distribution and severity of microcracks. The analysis process is executed by MATLAB software on the platform server. Operators periodically (hourly) check the trend chart and manually adjust the analysis weights based on production logs (such as pumping frequency).

[0098] Output results: sag height trend curve, microcrack detection report (including crack location and size), optimal working height recommendation (installation angle with sag <5cm), and preliminary replacement frequency estimate (based on cumulative sag time).

[0099] System Applications: The output results are fed back to the hydraulic control module to adjust the angle of the buffer sleeve, guide the laser welding equipment to optimize parameters, trigger audible and visual alarms to remind operators to perform maintenance, and provide a data basis for subsequent probability calculation methods.

[0100] Regression analysis (used for calculating the replacement frequency of S3 rebar welding steps and optimizing the S9 construction process):

[0101] Input data: sag height (mm), mesh stiffness test value after welding (unit: N / mm), construction interruption time (unit: minutes), production data records (such as daily pumping frequency, installation time). These data are collected through bending load tests and field tests and stored in the platform database.

[0102] Calculation and Analysis Logic: This analysis utilizes statistical tools on the platform server, assuming a linear or non-linear relationship between sagging height, stiffness, and construction time. It compares data points one by one to find the best-fit curve. The operator inputs initial parameters (e.g., a stiffness threshold of 3mm), and the system adjusts the curve slope based on historical data (e.g., 100 pumping cycles). Combining this with construction log analysis to determine the causes of interruptions, it deduces the extension of the construction cycle (e.g., 10 minutes) resulting from a 1cm increase in sagging, thereby predicting the replacement frequency. The analysis process is updated weekly to adapt to production changes.

[0103] Output results: Generate stiffness decay curve, construction cycle optimization suggestions (check every 8 hours), and frequency parameter replacement (triggered when sagging > 5cm).

[0104] System applications: The results are used to adjust the laser welding spacing (4-10 cm), optimize the support height of the modular installation frame, and guide operators in arranging maintenance plans.

[0105] Probability calculation method (for S5 overall data-driven maintenance and optimization platform):

[0106] Input data: sag height trend curve, stress distribution map, pumping cycle log (unit: hour), maintenance records. This data is provided by the ANSYS simulation and production database, covering 1000 virtual experiment iterations.

[0107] Calculation and Analysis Logic: This method employs Monte Carlo simulation technology. The platform server randomly generates sag height and stress scenarios (based on historical data distribution), runs 1000 iterations, and statistically analyzes the probability and time distribution of sag exceeding a threshold (5cm). Operators set an initial failure rate (e.g., 1%). The system calculates the average replacement cycle based on the simulation results and adjusts the probability weights in conjunction with maintenance logs to ensure the results reflect actual production conditions. The calculation process is updated every 24 hours.

[0108] Output: Generates a maintenance plan (including replacement frequency recommendations, such as 450-750 hours) and a risk assessment report.

[0109] System Application: The results are displayed through the platform interface, and operators can perform preventive maintenance according to the plan, adjust digital simulation parameters, and optimize pump pipe installation angles.

[0110] Time series analysis (for S6 multimodal sensor fusion monitoring):

[0111] Input data: fiber optic sensor strain data (unit: με), laser ranging height (unit: mm), vibration acceleration (unit: m / s²), with a set of data every 5 minutes, transmitted to the platform via RS485 network.

[0112] Calculation and Analysis Logic: This analysis is executed by dedicated software on the platform server. First, the data is smoothed over a 5-minute window to remove outliers. Then, autocorrelation analysis is applied to identify the hysteresis relationship between sag and vibration, predicting the sag trend for the next 5 hours. The operator verifies the prediction accuracy using on-site load tests (50 cycles) and adjusts the analysis window (e.g., expanding to 10 minutes) to ensure the trend chart accurately reflects the real-time status. The analysis runs hourly.

[0113] Output: Generates a 5-minute sag trend chart, optimal working height recommendations (sag < 5cm), and predicted replacement time.

[0114] System Application: Trend charts are fed back to the hydraulic control module to adjust piston stroke, and predictive data guides operators to calibrate sensors and schedule maintenance.

[0115] The following are the specific operational steps and logic of the core technical means of this solution:

[0116] Integrated laser rangefinder sensor system:

[0117] Three laser modules are installed on the cantilever end of the pump tube and secured with screws, then connected to a ZigBee module. The sensor is activated, emitting an infrared laser (940nm). The receiver records the reflection time difference and calculates the distance. The data is transmitted to the platform via ZigBee, where software smooths the data to generate a curve and triggers a threshold alarm.

[0118] Adaptive buffer nozzle system:

[0119] Install the hydraulic cylinder and polyurethane sleeve at the pump inlet and secure them by welding. Connect the hydraulic pump, receive platform sag data, and adjust the piston position (5-10cm). Adjust the angle of the helical spring via the guide rail; the operator tightens the nut to absorb impact.

[0120] Laser-assisted composite welding:

[0121] Carbon fiber reinforcing bars were placed on the outer wall of the pump pipe and adhesive was applied. A 1500W laser was activated, a spiral path was set, and the bars were fused and welded to form a mesh. A loading test was conducted to verify the stiffness, and the spacing was adjusted to 4-10 cm.

[0122] CFD-DEM simulation optimization:

[0123] Input pressure and particle data in Fluent, and set a 50,000-cell mesh. Run for 48 hours to generate flow field plots, and adjust the hydraulic regulator stroke. Confirm the flow rate through laboratory testing and update the pump inlet design.

[0124] Digital simulation platform:

[0125] Input sensor data into ANSYS and run finite element analysis. Simulate 1000 iterations, generate stress diagrams, and adjust installation parameters. Output a maintenance plan, which the operator executes and updates the data. Specific Implementation Example 4:

[0127] like Figures 1 to 6 As shown, the following is a description of the hardware components of this solution:

[0128] Central monitoring platform:

[0129] Structural Composition: Composed of a server rack, industrial-grade server, display screen, and input devices. The server rack is made of cold-rolled steel and houses the industrial-grade server, which includes a motherboard, Intel Xeon E5-2699 processor, hard drive, RAM, dual power supply modules, RS485 interface card, and ZigBee wireless receiver module. The display screen is an LCD type, fixed at the front of the rack, and connects to the keyboard and mouse via USB interfaces.

[0130] Connection method: The server connects to the RS485 interface card and ZigBee module via the PCIe slot, the power cord is connected to the power distribution unit at the rear of the rack, the display is connected to the server via an HDMI cable, and the keyboard and mouse are plugged into the front USB port.

[0131] Integrated laser rangefinder sensor system:

[0132] Structural Composition: The system consists of a laser transmitter, a receiver, a data processing unit, and a mounting bracket. The laser transmitter is an infrared laser diode, mounted within an aluminum alloy casing. The receiver is a photodiode, mounted side-by-side with the transmitter. The data processing unit integrates an ARM Cortex-M4 microcontroller, flash memory, and a ZigBee module, all within the same casing. The mounting bracket is made of stainless steel and includes screw holes.

[0133] Connection method: The transmitter and receiver are connected to the data processing unit via a miniature cable. The ZigBee module antenna is exposed. The bracket is fixed to the outer wall of the pump tube with screws. The power cord is connected to the interface on the side of the unit.

[0134] Multimodal sensor networks:

[0135] Structural Composition: The system consists of a fiber Bragg grating sensor, a vibration accelerometer, a resistive strain gauge, and connecting components. The fiber optic sensor probe is made of optical fiber and connects to a spectrometer; it has a built-in RS485 converter. The vibration accelerometer is a MEMS sensor containing a triaxial acceleration detection chip. The resistive strain gauge is a metal foil sheet with an integrated signal amplifier. The connecting components include an RS485 cable and a stainless steel mounting clip.

[0136] Connection method: One end of the fiber optic probe is pasted on the surface of the pump tube, and the other end is inserted into the spectrometer. The vibration sensor and strain gauge are fixed with double-sided tape. The signal line is connected to the amplifier, and the amplifier is connected to the platform via an RS485 cable.

[0137] Acoustic detection device:

[0138] Structural Composition: Composed of an ultrasonic probe, signal generator, receiver, and support structure. The ultrasonic probe uses a piezoelectric ceramic crystal and is built into an aluminum alloy housing. The signal generator and receiver are integrated into a control box, including amplification circuitry and data output ports. The support structure is a stainless steel bracket with screw holes.

[0139] Connection method: The probe is connected to the control box via a coaxial cable. The bracket is fixed to the top of the workshop with screws. The power cord is connected to the side of the control box, and the data cable is connected to the platform.

[0140] Visual inspection system:

[0141] Structural Composition: Composed of an industrial camera, an LED fill light, and a mounting assembly. The camera uses a Sony IMX290 sensor, equipped with a lens and a USB interface. The LED fill light consists of white LED beads integrated into a circular light panel. The mounting assembly comprises an aluminum alloy bracket and a lens mounting ring.

[0142] Connection method: The camera is connected to the platform via a USB cable, the light panel is connected to the power supply in parallel with a wire, the bracket is fixed next to the probe with screws, and the lens ring is tightened to fix the camera.

[0143] Adapted to buffer nozzle systems:

[0144] Structural Composition: It consists of a hydraulic buffer mechanism, a retractable buffer sleeve, and an adjustment mechanism. The hydraulic buffer mechanism includes a double-piston hydraulic cylinder, a hydraulic pump, and a control valve; the cylinder body is made of steel. The retractable buffer sleeve is made of a silicone rubber outer layer and a foam inner layer. The adjustment mechanism includes stainless steel guide rails, a helical spring, and bolts.

[0145] Connection method: The hydraulic cylinder is fixed to the inner wall of the pump pipe by welding, the sleeve is sleeved on the outside of the cylinder, one end of the spring is connected to the sleeve, and the other end is fixed on the guide rail. The bolt is tightened to the pump pipe port, and the hydraulic pipe connects the pump and the valve.

[0146] Laser welding equipment:

[0147] Structural components: Composed of a laser, an automatic scanning head, a cooling system, and a worktable. The laser is an IPG Photonics YLR-1500 model with an output power of 1500W. The automatic scanning head includes a servo motor and optical lenses. The cooling system is a water-cooled circulator connected to the laser. The worktable is a stainless steel platform with clamps.

[0148] Connection method: The laser is connected to the scanning head via optical fiber, the cooling water pipe is connected to the circulator, the scanning head is mounted on the robotic arm, the worktable is fixed to the ground with screws, and the clamp is manually adjusted to position the steel bars.

[0149] Modular installation framework:

[0150] Structural components: It consists of a steel support frame, adjustable supports, and connectors. The support frame is made of Q235 steel, the adjustable supports include threaded steel rods and adjusting nuts, and the connectors are made of steel plates.

[0151] Connection method: The support frame is connected to the column by welding. The column height is adjusted by nuts. The connector is fixed between the pump pipe and the ground by bolts.

[0152] Corrosion-resistant coatings and fatigue-resistant bio-based composite materials:

[0153] Structural composition: It consists of an epoxy coating spray gun, a polylactic acid composite material plate, and an aging chamber. The spray gun includes a nozzle and a compressed air interface, the composite material plate has a multi-layer structure, and the aging chamber includes a heating element, a temperature sensor, and a timer.

[0154] Connection method: The spray gun is connected to the compressed air source through a hose, the composite material board is glued to the surface of the pump pipe, and the aging chamber is connected to a 220V power supply through a power cord.

[0155] Digital simulation platform:

[0156] Structure: Consists of a workstation, monitor, and input devices. The workstation is equipped with an Intel Core i9 processor, RAM, an NVIDIA RTX 3080 graphics card, and an SSD, and runs ANSYS software. The monitor is an LCD type, and it connects to a keyboard and mouse.

[0157] Connection method: The workstation is connected to the monitor via an HDMI cable, the keyboard and mouse are plugged into the USB port, and the software is installed via a CD and connects to the platform database. Specific Implementation Example 5:

[0159] like Figures 1 to 6 As shown, the following are specific use cases of this solution:

[0160] Use Case 1: Compensation for Pump Pipe Sag in Conventional Concrete Pole Production

[0161] Scenario Description: In a concrete pole production environment, operators use cantilevered pump pipes to pump concrete. The pump pipes, ranging in length from 12 to 18 meters, sag due to their own weight, potentially contacting the reinforcing steel reinforcement and causing wear. The operator activates a central monitoring platform; an integrated laser rangefinder sensor system begins real-time monitoring of the sag height, transmitting the data to the platform for analysis. An adaptive buffer nozzle system dynamically adjusts its angle based on the sag data, absorbing the impact of sag, while laser welding equipment enhances the pump pipe's rigidity with carbon fiber reinforced steel bars. A digital simulation platform performs simulation analysis to optimize the maintenance plan; the operator adjusts the pump pipe installation height based on the recommendations, reducing steel reinforcement damage and ensuring smooth production.

[0162] Expected results: Sag height is effectively controlled, the risk of steel bar wear is reduced, the mechanical properties of the pole remain stable, and the production process is more efficient.

[0163] Use Case 2: Pump Tube Durability Test in High Humidity Environment

[0164] Scenario Description: In a production environment with potentially high humidity, cantilevered pump pipes are used in the manufacture of concrete utility poles. Environmental factors can exacerbate corrosion of the pump pipes and welded steel structures. Operators have implemented material durability enhancement measures, covering the pump pipe inlets and welded areas with corrosion-resistant coatings and fatigue-resistant bio-based composite materials. Acoustic and visual inspection devices continuously monitor for microcracks, and data is transmitted to a central monitoring platform via a multimodal sensor network. CFD-DEM simulation optimizes the pump pipe inlet design to accommodate the effects of moisture. A modular installation frame allows for rapid replacement of damaged pump pipes, and optimized construction procedures adjust installation parameters to maintain optimal working height.

[0165] Expected results: The pump pipe has higher corrosion resistance, microcracks are detected and repaired in time, construction efficiency is improved, and the scrap rate is reduced.

[0166] Use Case 3: Preventive Maintenance Optimization in Large-Scale Production

[0167] Scenario Description: In an environment potentially involving large-scale pole production, multiple cantilevered pump pipes operate simultaneously, facing frequent sagging and vibration issues. Operators utilize a comprehensive data-driven maintenance and optimization platform, integrating sensor data for time-series analysis to predict sagging trends. Laser-assisted composite welding technology periodically enhances pump pipe stiffness, a hydraulic buffer mechanism dynamically compensates for vibration, and a digital simulation platform runs virtual experiments to validate maintenance strategies. Construction process optimization achieves rapid positioning and replacement through a modular framework, with operators adjusting construction cycles and replacement frequencies based on platform recommendations.

[0168] Expected results: Early warning of sagging will be provided, maintenance plans will be more targeted, production interruptions will be reduced, and overall efficiency will be improved. Specific Implementation Example Six:

[0170] like Figures 1 to 6 As shown in the attached figures, the following is a detailed description of this solution:

[0171] Figure 3 This is a plan view of the scheme, where the left triangular area of ​​the pump pipe is the support point and the right side is the free end. The specific design description is as follows:

[0172] A laser is installed in the blank area to the left of the triangular support point on the left side of the pump pipe. The laser can be fixed by welding or can be detached. It is used for laser-assisted composite welding along the pump pipe axis to initiate the formation of the spiral mesh of carbon fiber reinforced steel bars and provide initial stiffness support.

[0173] Carbon fiber reinforced steel bars are welded to the upper surface of the pump tube from the support point to the free end, forming a continuous spiral structure using laser fusion welding. A 4 cm spacing near the near end provides high-strength support, while a 10 cm spacing at the far end reduces weight and enhances the overall rigidity of the pump tube. The spacing is selected based on the specific circumstances.

[0174] Three circular laser rangefinders are installed directly above the top of the free end of the pump pipe. A data processing unit is configured for each sensor and connected to a ZigBee module. The laser sensors measure the droop height using infrared lasers, the data processing unit analyzes the data, and the ZigBee module wirelessly transmits the data to the central monitoring platform for real-time monitoring.

[0175] A semi-circular steel frame is installed directly below the free end of the pump pipe. A buffer sleeve is installed above the steel frame, and a helical spring mechanism is embedded inside the buffer sleeve. A hydraulic buffer mechanism is installed adjacent to the right side of the buffer sleeve. Figure 3 The rectangular block at the bottom is positioned so that the buffer sleeve absorbs the impact of the bounce through silicone rubber and a coil spring. The hydraulic buffer mechanism dynamically adjusts the angle and position through a double piston cylinder to maintain a gap of ≥2 cm with the steel bar and prevent direct wear.

[0176] The steel reinforcement frame serves as the bottom support for the steel reinforcement skeleton inside the mold, allowing the pump pipe to make contact when it droops, thus simulating actual production conditions.

[0177] A rectangular central monitoring platform is installed directly above the top of the pump pipe, covering the sensor area at the free end. The central monitoring platform receives sensor data, analyzes and simulates it, outputs recommendations for optimal working height and replacement frequency, and coordinates hydraulic adjustment and maintenance plans.

[0178] Figure 2 middle:

[0179] The horizontal axis (time, hours) represents the simulated time within 24 hours, ranging from 0 to 25 hours, reflecting the real-time monitoring of the sag height by the laser rangefinder sensor system.

[0180] Vertical axis (droop height, m): Represents the droop height of the pump pipe, in meters, ranging from 0 to 0.35 meters, reflecting the drooping problem caused by its own weight.

[0181] Solid blue line: Real-time sag height, representing the instantaneous sag values ​​measured by the integrated laser rangefinder system at multiple key points (12-18 meters), including noise and random variations.

[0182] Red dashed line: Moving average droop height, based on statistical analysis of a 1-hour window, reflecting the droop trend and used to identify long-term changes.

[0183] Black dashed line: Replacement threshold (0.024 meters, equal to 1.2 times the optimal working height of 0.02 meters), determined by experimental verification. Replacement is triggered when the drooping height exceeds this value.

[0184] Combined with the following content: This diagram simulates the real-time measurement of the droop height using a laser rangefinder in step S1, and combines it with statistical analysis (such as moving average) from the central monitoring platform to dynamically calculate the pump pipe replacement frequency, demonstrating the complete process of the closed-loop monitoring framework.

[0185] Figure 3 Optimized response at pump inlet

[0186] Horizontal axis (time, hours): ... Figure 2 The same indicates the simulation time within 24 hours, reflecting the dynamic adjustment process of the pump inlet optimization design.

[0187] Vertical axis (displacement, m / angle, degrees): Dual vertical axis design, the left vertical axis (0 to 0.4 meters) represents the displacement of the telescopic buffer sleeve, and the right vertical axis (-6 to 4 degrees) represents the angle adjustment range.

[0188] Solid green line: Sleeve displacement, simulating the dynamic response of a highly elastic silicone rubber buffer sleeve under pumping impact, combined with the reverse tension of a helical spring mechanism (stiffness 5000 N / m).

[0189] Magenta dashed line: Adjustment angle, reflecting the 0°-15° angle change adjusted by the guide rail and bolts, absorbing the impact of vibration and preventing direct contact with the reinforcing steel.

[0190] Related content: This diagram corresponds to step S2, which optimizes the pump inlet design through a retractable buffer sleeve and helical spring mechanism. Parameters are determined based on production data (such as pumping pressure logs) and laboratory impact tests to ensure the optimal working height (reinforcing bar gap ≥ 2cm).

[0191] Figure 4 Stiffness enhancement

[0192] Horizontal axis (sensor position, m): indicates the sensor installation position (12, 14, 16, 18 meters), corresponding to the droop measurement point at the cantilever end of the pump pipe.

[0193] Longitudinal axis (droop height, m): indicates the droop height of the pump pipe at different locations, ranging from 0.15 to 0.35 meters.

[0194] Blue dots and solid lines: Original sag height, calculated based on the cantilever beam's self-weight, reflecting the sag problem before reinforcement.

[0195] Red square dotted line: Sag height after welding. Combined with the spiral welded structure of carbon fiber reinforced steel bars, it shows the percentage reduction in sag after stiffness enhancement (e.g., 10%-20%, depending on the welding density).

[0196] The diagram corresponds to step S3, which uses laser-assisted composite welding technology to form a continuous spiral structure along the axial direction, enhancing the stiffness of the pump pipe and reducing steel bar wear and mechanical property degradation caused by sagging. The parameters are based on post-weld stiffness testing and bending load experiments.

[0197] Figure 5 Replacement frequency

[0198] The horizontal axis (daily replacement frequency, times) represents the distribution of daily pump tube replacement frequency calculated by Monte Carlo simulation, ranging from 0 to a maximum value (e.g., 2-3 times).

[0199] Vertical axis (number of simulations): Represents the number of times a specific replacement frequency is reached in 1000 Monte Carlo simulations, reflecting the statistical distribution of the replacement frequency.

[0200] Color bar chart:

[0201] Cyan bar chart: Replaces the frequency distribution, calculated based on the number of times the droop height exceeds the threshold (0.024 meters), combined with probabilistic methods (such as Monte Carlo simulation) for analysis.

[0202] Text annotation: Displays the mean (e.g., 1.50 times / day) and standard deviation (e.g., 0.20), providing statistical characteristics of the replacement frequency.

[0203] Content related to this diagram: The diagram corresponds to a data-driven maintenance and optimization platform. Through integrated digital simulation system and multimodal sensor fusion monitoring, the sagging height is used as a key input parameter, and probability calculation methods are used to optimize the replacement frequency.

[0204] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising a reference structure" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0205] 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 of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A welding method for compensating sag of cantilever pump pipes used in electric pole pumping, characterized in that: Includes the following steps: S1. Monitoring steps for pump pipe sag height parameters: The sag height is measured in real time through an integrated laser rangefinder sensor system, and the data is transmitted wirelessly to the central monitoring platform for analysis. S2, the optimized design steps for the pump inlet, involve adding a retractable buffer sleeve made of highly elastic polymer and embedding a helical spring mechanism to adjust the angle and length. The S2 optimized design steps for the pump inlet include introducing an adaptive buffer nozzle system, designing a multi-layer composite structure at the pump inlet end including an outer high-wear-resistant polymer sheath and a built-in adjustable hydraulic buffer mechanism, determining the pump inlet design parameters based on production data records and laboratory experiments, setting the optimal working height of the pump pipe, feeding back the droop height monitoring data to the nozzle control module to achieve automatic compensation, and including a modular installation interface to support quick replacement and angle adjustment. The interface parameters are determined through production data records and simulation experiments. S3, the pump pipe reinforcement welding step, involves welding carbon fiber reinforced steel bars along the pump pipe axis to form a continuous spiral structure. The S3 pump pipe reinforcement welding step includes implementing parametric laser-assisted composite welding technology, using high-strength alloy steel bars to form a variable-density grid structure along the pump pipe axis, with a near-end spacing of 4 cm and a far-end spacing of 10 cm. The welding method is determined through production data recording and control experiments, setting the optimal working height of the pump pipe, and integrating the sag height as a monitoring parameter into the welding optimization model to calculate the pump pipe replacement frequency. This also includes laser-assisted composite welding and stiffness adaptive enhancement technology, using laser hybrid welding combined with carbon fiber composite materials to create a variable cross-section grid structure. The material durability enhancement step involves introducing corrosion-resistant coatings and fatigue-resistant bio-based composite materials into the pump pipe inlet and the reinforcement welding structure. Material parameters are determined through production data recording and accelerated aging experiments, setting the optimal working height of the pump pipe, and adjusting the material replacement frequency using the sag height as a monitoring parameter.

2. The welding method for compensating sag of cantilever pump pipe for electric pole pumping according to claim 1, characterized in that: The monitoring steps for the S1 pump pipe sag height parameter further include developing a closed-loop monitoring framework integrating IoT data acquisition, installing multi-sensor arrays at key nodes of the pump pipe to collect production data, recording historical databases through a cloud platform and analyzing data patterns using statistical analysis methods, setting the optimal working height of the pump pipe, dynamically calculating the pump pipe replacement frequency using the sag height as the core monitoring parameter, and including acoustic detection devices and visual inspection systems to monitor microcracks in the pump pipe and welded structures, and setting detection thresholds through production data recording and experimental verification.

3. The welding method for compensating sag of cantilever pump pipe for electric pole pumping according to claim 1, characterized in that: Further steps include a comprehensive data-driven maintenance and optimization platform, the construction of a comprehensive digital simulation system to integrate monitoring, design, and welding processes, the use of digital simulation technology to simulate pump pipe behavior, the setting of the optimal working height of the pump pipe through production data recording and experimental settings, the calculation of pump pipe replacement frequency using probability calculation methods with the sag height as a key input parameter, and steps including a digital simulation platform and preventive maintenance optimization framework, the construction of a digital simulation model of the pump pipe system to support virtual experimental verification.

4. The welding method for compensating sag of cantilever pump pipe for electric pole pumping according to claim 1, characterized in that: Further steps include a multimodal sensor fusion monitoring and prediction system, developing a hybrid sensor network based on fiber Bragg gratings and laser ranging, combined with vibration and strain sensors, to achieve multi-dimensional real-time monitoring of sag height. The optimal working height of the pump pipe is set through production data recording and on-site verification, and the sag height is integrated into a statistical model as the primary monitoring parameter to calculate the pump pipe replacement frequency.

5. The welding method for compensating sag of cantilever pump pipe for electric pole pumping according to claim 1, characterized in that: The optimization design steps of the S2 pump inlet further include dynamic optimization driven by CFD-DEM simulation, using computational fluid dynamics and discrete element method to simulate concrete flow behavior, designing an adaptive rotary pump inlet structure including a built-in hydraulic regulator and wear-resistant polymer lining, determining pump inlet design parameters based on production data records and control experiments, and feeding back sag height monitoring data to the design model to calculate pump pipe replacement frequency.

6. The welding method for compensating sag of cantilever pump pipe for electric pole pumping according to claim 1, characterized in that: Further steps include optimizing the construction process, designing a modular installation frame to support rapid replacement and positioning of pump pipes, determining installation parameters through production data recording and on-site testing, setting the optimal working height of the pump pipes, and using the sag height as a monitoring parameter to optimize the construction cycle and replacement frequency.

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