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CN-121980641-A - High-precision prefabrication construction method for steel structure

CN121980641ACN 121980641 ACN121980641 ACN 121980641ACN-121980641-A

Abstract

The invention discloses a high-precision prefabrication construction method for a steel structure, and relates to the technical field of steel structure construction. The method comprises six steps of construction early-stage preparation, three-dimensional collaborative deepening modeling, prefabricated component precision machining, module pre-assembly precision control, dynamic precision monitoring and feedback, finished product acceptance and delivery. The data standardization management is realized by constructing a construction database, the three-dimensional modeling and typesetting optimization are completed by adopting Tekla Structures and kernel tyrant software, the automatic processing is realized by combining a numerical control cutting machine and a welding robot, the precision control is realized by utilizing simulation pre-assembly software and a total station, and the full-flow dynamic feedback is realized by an Internet of things monitoring system. The invention solves the problems of design and processing dislocation, low precision and poor efficiency in the prior art, ensures that the cutting error of the component is less than or equal to +/-0.3 mm, the welding deformation is less than or equal to 0.5mm/m, the one-time pre-assembly qualification rate is more than or equal to 98 percent, the comprehensive cost is reduced by 32 percent, and the invention is suitable for the industrialized prefabrication of various steel structure engineering and has remarkable economic and social benefits.

Inventors

  • LIANG MINGDONG
  • LI MINGHUI
  • MA XIAOYUN
  • Wan Bingjie

Assignees

  • 上海利柏特工程技术有限公司

Dates

Publication Date
20260505
Application Date
20251224

Claims (10)

  1. 1. The high-precision prefabrication construction method for the steel structure is characterized by comprising the following steps of: S1, preparing a construction earlier stage, namely collecting steel structure engineering design drawings, material performance parameters and construction site condition data, and establishing a construction database containing design standards, process specifications and precision requirements; S2, three-dimensional collaborative deepening modeling, namely adopting Tekla structurals software to carry out three-dimensional modeling on a design drawing, and combining kernel-tyred plate cutting typesetting optimization software to complete component typesetting optimization, so as to generate a process detailed diagram containing machining precision parameters and a numerical control machining code; S3, accurately machining the prefabricated part, namely performing high-accuracy cutting through a numerical control machine tool based on the process detailed diagram and the numerical control code, performing standardized welding by adopting a welding robot, and synchronously setting a welding line shrinkage allowance and an end groove; S4, module pre-assembly precision control, namely establishing a unified datum point and an axis network system, acquiring component coordinate data by using a total station, and importing X, Y, Z three-way deviation among simulation pre-assembly software analysis modules to generate an error adjustment scheme; S5, dynamic precision monitoring and feedback, namely tracking component size deviation by adopting a real-time monitoring system in the whole prefabrication and assembly process, comparing monitoring data with a construction database, and dynamically adjusting processing parameters; S6, checking and delivering the finished product, namely finishing the detection of the size of the component and the quality of the welding seam according to a preset precision standard, and generating a checking report containing the whole flow data.
  2. 2. The high-precision prefabrication construction method for the steel structure is characterized in that in the step S2, the three-dimensional modeling specifically comprises the steps of carrying out parameterization definition on a component after a design drawing is imported, setting elastic modulus and yield strength performance parameters when the material is Q355B, establishing an integral model comprising stiffening plates and connecting plates, and controlling the model precision error within +/-0.1 mm.
  3. 3. The high-precision prefabrication construction method for the steel structure according to claim 1, wherein the typesetting optimization in the step S2 adopts a nesting algorithm, when the original sheet specification is 1900 x 1000mm, the utilization rate of the optimized material is not lower than 85%, the minimum reusable size of the residual material is not lower than 100mm x 100mm, and the typesetting diagram export format comprises DXF and numerical control machining G codes.
  4. 4. The high-precision prefabrication construction method of the steel structure is characterized in that a numerical control machine tool in the step S3 adopts a large group laser G3015 type optical fiber laser cutting machine, the cutting speed is set to be 3-8m/min, the cutting seam width is controlled to be 0.15-0.3mm, the error of the verticality of a cut is less than or equal to 0.05mm/m, double-sided electroslag welding is adopted for stiffening plates in a box column, the welding current is 500-600A, the voltage is 30-35V, and the welding speed is 15-20cm/min.
  5. 5. The high-precision prefabrication construction method for the steel structure according to claim 1, wherein in the step S3, a groove form is a full penetration V-shaped groove, the groove angle is 60 degrees+/-5 degrees, the blunt edge thickness is 2-3mm, the gap is 2-4mm, rust removal and oil removal treatment is carried out on the groove before welding, and the surface roughness Ra is less than or equal to 25 mu m.
  6. 6. The high-precision prefabrication construction method for the steel structure is characterized in that the datum point in the step S4 is set by adopting a pre-buried stainless steel stake, the diameter of the stake is more than or equal to 20mm, the burial depth is more than or equal to 500mm, the error in plane coordinates is less than or equal to +/-0.2 mm, the error of Gao Chengzhong is less than or equal to +/-0.1 mm, the axle network is set by adopting a total station, and the marking deviation of a crossed axis is less than or equal to 2mm.
  7. 7. The high-precision prefabrication construction method of the steel structure according to claim 1, wherein Xsteel Precast is adopted for simulating pre-assembly software in the step S4, after component CAD files and coordinate measurement data are imported, a matching error threshold value is set to 80mm, the number of automatic binding carrying points per module is not less than 6, the deviation analysis precision reaches 0.1mm level, and the generated adjustment scheme comprises component displacement and angle correction parameters.
  8. 8. The high-precision prefabrication construction method of the steel structure is characterized in that in the step S5, a real-time monitoring system adopts the BIM+ internet of things technology, an RFID tag and a displacement sensor are attached to key parts of a component, the sampling frequency is 10Hz, the data transmission delay is less than or equal to 1S, and when the monitoring deviation exceeds an early warning threshold value +/-0.5 mm, a machining equipment parameter adjustment instruction is automatically triggered.
  9. 9. The high-precision prefabrication construction method for the steel structure according to claim 1, wherein in the step S6, a three-coordinate measuring instrument is adopted for size detection, the measuring range is 0-10m, the measuring precision is +/-0.02 mm, an ultrasonic flaw detector is adopted for weld quality detection, the flaw detection range covers all butt welds, the flaw detection rate is more than or equal to 99%, and the acceptance report comprises component ID, processing parameters, detection data and three-dimensional model comparison results.
  10. 10. The high-precision prefabrication construction method for the steel structure according to claim 1, wherein the construction database in the step S1 further comprises weather influencing parameters, when the ambient temperature changes by more than +/-5 ℃, an expansion and contraction compensation algorithm is automatically called to adjust the machining size, and the compensation coefficient is in a range of 1.2 multiplied by 10 < - 5 /℃-1.5×10⁻ 5 > per degree.

Description

High-precision prefabrication construction method for steel structure Technical Field The invention relates to the technical field of steel structure construction, in particular to a high-precision prefabrication construction method for a steel structure, and in particular relates to a high-precision prefabrication construction method for the steel structure, which integrates three-dimensional modeling, numerical control machining and dynamic monitoring, and is suitable for industrial prefabrication production of various steel structure components such as industrial plants, high-rise buildings, bridge engineering and the like. Background Along with the acceleration of industrialization and digital transformation in the building industry in China, the steel structure has wider application in engineering fields such as industrial factory buildings, super high-rise buildings, large-span bridges and the like by virtue of the outstanding advantages of high material strength, short construction period, good green environmental protection and the like. According to the report of the development of the China Steel Structure industry in 2024, the total yield of the China Steel Structure in 2023 reaches 1.28 hundred million tons, which is increased by 9.1% in the same ratio, wherein the ratio of the factory-like prefabricated steel structure is increased to 68%, which is increased by 25% in 2020. The prefabrication of the steel structure has become a core path for promoting the high-quality development of the building industry, and the core technical requirements are focused on improving the machining precision of the components, shortening the production period and reducing the comprehensive cost by a digital means. In the prior art, the prefabrication construction of the steel structure mainly depends on a traditional processing mode, such as an installation method of the steel structure disclosed in China patent application with the publication number of CN 107246072A. The method comprises the steps of manufacturing templates according to the number of steel structure columns and the size of steel structure column bottom plates, paying off reserved holes according to positions to be installed of the steel structure, placing all foundation bolts in all preset holes, installing the templates on all foundation bolts in all the reserved holes, adjusting all the foundation bolts with the templates to preset positions, grouting all the foundation bolts adjusted to the preset positions, removing the templates after grouting materials meet preset conditions, hoisting the steel structure on all the foundation bolts, fastening all the foundation bolts, and secondarily grouting the bottom plates of the steel structure columns to finish the installation of the steel structure. The method adopts a mode of combining manual paying-off with common machine tool processing, and improves the production efficiency to a certain extent, but has the following remarkable defects: 1. In the traditional method, a design drawing is manually disassembled into a processing sketch by a technician, then on-site paying off is carried out by tools such as a tape measure, an ink duct and the like, and in the process, the errors of manual drawing recognition and paying off operation are overlapped, so that the size deviation rate of the complex node components is as high as 4% -6%. Construction data of a certain heavy plant project shows that the member reworking rate caused by the errors reaches 15%, the single project direct economic loss exceeds 300 ten thousand yuan, and the field installation progress is seriously affected. 2. The machining precision is obviously affected by human factors, the method relies on the skill of operators to control the machining quality, the cutting dimension error of a common plate shearing machine is usually +/-1.8 mm, the welding line deformation of manual arc welding can reach 2.5mm/m, and the requirement of a modern super high-rise and large-span steel structure on the component precision (the standard requirement of the butt welding line misalignment amount is less than or equal to 0.5 mm) can not be met. Taking bridge steel structure prefabrication as an example, the perpendicularity deviation of the box girder web plate processed by the method often exceeds 0.8mm/m, mechanical polishing correction is required to be additionally input, the correction cost of a single girder is increased by more than 2000 yuan, and the construction period is prolonged by 2-3 days. 3. The entity pre-assembly mode has low efficiency, in order to verify the suitability of the components, the traditional method needs to transport the processed components to a special site for entity pre-assembly, the process not only occupies a large amount of site resources (more than 600m <2 > -pre-assembly sites are occupied by every thousand tons of components), but also the assembly once qualification rate is only 75%. For a multi-module ste