A digital twin system for intelligent construction of long-span prefabricated steel bridges

Abstract

This invention discloses a digital twin system for the intelligent construction of long-span prefabricated steel bridges, including a BIM module, an IoT module, a data processing module, and a construction simulation module. A digital twin of the long-span steel bridge construction is established based on the BIM module, data processing module, and construction simulation module. Then, based on the IoT module, data interaction is achieved between the digital twin and the physical entity, establishing a digital twin system for the construction of long-span prefabricated steel bridges. The data interaction achieved through IoT technology can reflect the internal force status and physical characteristics of prefabricated components in real time during transportation and installation, thus enabling intelligent construction of long-span steel bridges, such as component inspection, construction simulation, and prediction.

Description

Technical Field

[0001] This invention belongs to the field of intelligent construction and digital application of large-span prefabricated steel bridges, specifically involving a digital twin system for intelligent construction of large-span prefabricated steel bridges. Background Technology

[0002] Since the beginning of the 21st century, intelligentization, informatization, sustainability, and longevity have been key research and development directions in the global bridge engineering field. Building Information Modeling (BIM) technology is a product of the construction industry's adaptation to the times. The concept of the "Internet of Things" (IoT) was proposed in 1999, connecting all objects to the internet through information sensing devices such as RFID to achieve intelligent identification and management. Originating in the media sector, IoT technology represents the third revolution in information technology. Through information sensing devices and agreed-upon protocols, any object is connected to the network, allowing for information exchange and communication via information transmission media, enabling intelligent identification, positioning, tracking, and monitoring. The concept of digital twins was first explicitly proposed by NASA, referring to the creation of highly accurate digital information models based on real-world objects for real-world description, simulation, and predictive evaluation. Digital twin technology, as a bridge for interaction and integration between the physical and digital worlds, is highly anticipated. However, currently, digital twin technology is mainly used in high-precision industrial applications, and its application in bridge engineering still needs improvement.

[0003] Intelligent construction in engineering is an innovative construction model that, based on the digitization of engineering construction elements and resources, uses Building Information Modeling (BIM) as a carrier and automated equipment and Internet of Things (IoT) information technology as means to achieve digital chain-driven guidance and decision-making for the entire construction process, including status identification, error analysis, error prediction, evaluation and correction, and dynamic adjustment. Ultimately, it aims to deliver engineering structural products with high precision, high quality, and high efficiency. Prefabricated construction, primarily using prefabricated components manufactured in factories and assembled on-site, is characterized by low labor intensity, fast construction speed, and environmental friendliness. The full-process management of intelligent prefabricated construction in bridge engineering, based on lean value chain theory, comprehensively utilizes various information technologies in all stages of prefabricated construction—design, production, transportation, hoisting, operation, and maintenance. Through information technology, it reduces or even eliminates non-value-added activities such as detailed design, long-distance transportation, secondary handling, and construction deviations during construction, achieving safety, quality, schedule, and cost control for the project. This results in full-process management of intelligent prefabricated construction in bridge engineering, increasing enterprise profits. Prefabricated steel bridges have many advantages, such as their lightweight components making transportation convenient, flexible assembly and quick erection, easy disassembly and assembly, and reusable components. They also have high load-bearing capacity, strong structural rigidity, and long fatigue life.

[0004] In summary, the technological development background outlined above demonstrates that digital twin technology is a powerful yet complex technology. This invention, by combining IoT and BIM technologies, can promote the development of digital twin technology in the field of engineering construction. For long-span prefabricated steel bridges, the development of intelligent construction technology is also urgently needed to adapt to the evolving industry landscape. Currently, wireless digital transmission is used for bridge health monitoring (Zhu Jun, Gao Jian, Wang Lei. A wireless digital transmission device for bridge health monitoring [P]. Jiangsu Province: CN208985362U, 2019-06-14.), which greatly improves the efficiency of bridge data monitoring, demonstrating the superiority of IoT technology. Furthermore, a digital simulation pre-assembly construction method for steel structure bridges (Hu Lan, Zeng Yong, Sun Hongjun. A digital simulation pre-assembly construction method for steel structure bridges [P]. Hunan Province: CN109117558A, 2019-01-01.) uses digital simulation to guide the construction of steel structure bridges, but its internal force analysis is insufficient. While existing digital twins of bridge structures (Zhou Jianchun, Li Weimin, Liang Yaocong, Zhou Yang, Li Xiaocong, Jiang Junlai, Huang Haozhi, Huang Hang, Zuo Tong. Digital Twin of Bridge Structure Based on BIM-FEM and its Method [P]. Guangdong Province: CN113806978A, 2021-12-17.) include internal force analysis, they lack simulation of the construction process to guide construction. Therefore, a method is needed to propose a digital twin system based on BIM and IoT technologies to intelligently construct large-span prefabricated steel bridges. Summary of the Invention

[0005] To address the challenges of rational interaction between finite element analysis and Building Information Modeling (BIM), the establishment of a digital twin system integrating prefabricated steel bridge construction processes with Internet of Things (IoT) technology, and the intelligent construction process of large-span prefabricated steel bridges, this invention proposes a digital twin system for the intelligent construction of large-span prefabricated steel bridges. This system includes a BIM module, an IoT module, a data processing module, and a construction simulation module. A digital twin of the large-span steel bridge construction is established based on these modules. Then, using the IoT module, data interaction between the digital twin and the physical entity is achieved, establishing the digital twin system for large-span prefabricated steel bridge construction. The data interaction achieved through IoT technology can reflect the internal force status and physical characteristics of prefabricated components in real time during transportation and installation, thus enabling the intelligent construction process of large-span steel bridges. For example, managers can compare and analyze the components' compliance based on the digital twin established using BIM and other technologies. Simultaneously, the digital twin system can simulate and map the specific construction process in real time. Furthermore, digital twin systems can simulate the proposed construction process to predict the construction process, thereby conducting analysis and making scientific decisions to guide construction.

[0006] The present invention is achieved through the following technical solution.

[0007] A digital twin system for intelligent construction of long-span prefabricated steel bridges includes a physical entity and a digital twin, wherein the digital twin includes an Internet of Things (IoT) module, a BIM module, a data processing module, and a construction simulation module; the physical entity and the digital twin interact with each other via the IoT module.

[0008] The physical entity part includes the physical prefabricated components during transportation and the prefabricated construction process;

[0009] The digital twin is a real-time digital mapping of the physical entity, that is, simulating the actual construction process and analyzing the internal forces of the steel bridge components or the prefabricated steel bridge as a whole during construction.

[0010] The BIM module performs information-based simulation of physical entity components, which serves as the information foundation for the digital twin.

[0011] The data processing module is used to classify and process the acquired analysis data, and to analyze it in conjunction with finite element software to understand the internal forces of the building.

[0012] The construction simulation module is used to simulate the construction process of long-span prefabricated steel bridges to reflect the construction site.

[0013] Furthermore, the physical entity includes prefabricated components during transportation, components at the construction site, and the external environmental conditions of the construction site.

[0014] Furthermore, the prefabricated components used in the transportation process include components that are prone to damage and changes in internal forces during transportation.

[0015] Furthermore, the components at the construction site include support components, bridge end components, and some erection equipment.

[0016] Furthermore, the external conditions of the construction site include temperature and wind speed.

[0017] Furthermore, the BIM module includes a building information model of a long-span steel bridge, a transportation process for simulating long-span prefabricated components, and all construction components on the construction site.

[0018] Furthermore, the IoT module includes an information sensing layer, a network transmission layer, and an information application layer; the information sensing layer transmits the collected data to the information application layer through the network transmission layer, and the information application layer processes the received information in the data processing module.

[0019] Furthermore, the information sensing layer includes a displacement gauge, a stress-strain sensor, and a temperature sensor.

[0020] Furthermore, after classifying and organizing the data, the data processing module uses finite element software and the BIM built from the collected data to analyze the components, the constructed steel bridge sections, and the whole structure during the transportation and construction processes.

[0021] Furthermore, the construction simulation module refers to using software to perform 3D simulation of the construction process of long-span steel bridges, while also simulating the anticipated construction conditions to guide the construction on-site and reduce the occurrence of construction errors.

[0022] This invention discloses a digital twin system for the intelligent construction of long-span prefabricated steel bridges. The method for establishing the digital twin includes the following steps:

[0023] Step 1: Establish a Building Information Model (BIM) for a long-span prefabricated steel bridge;

[0024] Step 2: Establish a data processing module, which mainly includes information management and finite element analysis;

[0025] Step 3: Establish a construction simulation module to reflect the construction process in 3D;

[0026] Step 4: The modules established in the previous three steps are combined and interact to form a digital twin.

[0027] Compared with existing technologies, the beneficial effects of the present invention are as follows:

[0028] 1. This invention has certain reference value for the in-depth application of BIM models of large-span prefabricated steel bridges combined with technologies such as the Internet of Things, and provides a reference for promoting the application of BIM in the industry.

[0029] 2. The establishment of a digital twin of a long-span prefabricated steel bridge reflects the construction conditions of the long-span prefabricated steel bridge in real time, which is of great significance for promoting the digitalization of the construction of long-span prefabricated steel bridges.

[0030] 3. This invention utilizes digital twin technology to intelligently construct long-span prefabricated steel bridges, providing significant guidance for optimizing bridge construction technology. It also aligns with future industry development trends, promoting rapid industry growth and possessing substantial practical value and economic benefits. Attached Figure Description

[0031] Figure 1 Here is a flowchart of a digital twin system for the intelligent construction of a long-span prefabricated steel bridge, as an example.

[0032] Figure 2 This is a schematic diagram of a digital twin portion of an embodiment;

[0033] Figure 3 This is an ANSYS import diagram of a beam segment from Example 1;

[0034] Figure 4 The following is a diagram showing the results of finite element analysis of a certain construction stage in an example.

[0035] Figure 5 This is a workpiece drawing for the assembly and construction stage of an embodiment;

[0036] Figure 6 This is an external simulation diagram of the assembly and construction stage of an example. Detailed Implementation

[0037] The present invention will now be described in more detail with reference to specific embodiments and the accompanying drawings. It should be understood that the examples are merely for illustrating the implementation process of the invention more specifically, thereby facilitating understanding by those skilled in the art, but the invention is not limited thereto. Simple modifications or improvements made under the main concept of the invention are all within the scope of protection of the present invention.

[0038] The main idea and method of the embodiments are as follows, but the specific implementation may vary depending on different needs in terms of the steps and tools used. The specific embodiments will be described in detail later.

[0039] like Figure 1 The digital twin system for intelligent construction of a long-span prefabricated steel bridge shown includes a physical entity and a digital twin. The digital twin includes an Internet of Things (IoT) module, a BIM module, a data processing module, and a construction simulation module. The physical entity and the digital twin interact with each other via the IoT module.

[0040] The physical entity part includes components in the actual transportation process and the prefabricated construction process; the physical entity part includes prefabricated main beams, components at the construction site, and external environmental conditions at the construction site (such as temperature, wind speed, and vibration); the components at the construction site include support components, bridge end components, and erection tools, etc.

[0041] The digital twin is a real-time digital mapping of the physical entity, that is, using information technology (simulation software and analysis software) to simulate the actual construction process and analyze the internal force of the steel bridge components or the steel bridge as a whole during construction.

[0042] The IoT module comprises an information sensing layer, a network transmission layer, and an information application layer. The information sensing layer primarily utilizes IoT sensors, including displacement gauges, stress-strain sensors, and temperature sensors. The network transmission layer employs a 5G-based wireless transmission method and consists of a 5G gateway and a CAN gateway. The information application layer mainly uses a PC to receive information for data processing and application. The IoT module enables rapid and accurate digital mapping of the digital twin to the physical entity.

[0043] The BIM module performs information-based simulation of physical entity components, which serves as the information foundation for the digital twin.

[0044] The data processing module mainly classifies and organizes the data, then uses appropriate finite element software and appropriate data (i.e., the usable data obtained from the data collected by IoT sensors) and utilizes the established BIM to analyze the components during the transportation and construction process, or to analyze the existing steel bridge sections and the whole structure, in order to understand the internal force of the building.

[0045] The construction simulation module simulates the construction process of a long-span prefabricated steel bridge to reflect the construction site. Using software such as Navisworks or 3ds Max, the module performs 3D simulation of the construction process, dynamically and intuitively displaying the construction process. It also simulates anticipated construction conditions to guide on-site construction and reduce the occurrence of errors.

[0046] This invention establishes a digital twin of long-span steel bridge construction based on BIM modules, data processing modules, and construction simulation modules. It refers to the integration and interaction of BIM, data processing, and construction simulation to establish a digital information mapping that is updated in real time during the construction process of long-span steel bridges.

[0047] The intelligence of this invention system is mainly reflected in the following aspects:

[0048] First, digital twin systems are used to simulate the transportation and construction process of prefabricated components, which allows for real-time monitoring of whether damage has occurred during component transportation, thus achieving the purpose of component inspection.

[0049] Secondly, digital twin systems can map the construction process, sense the internal force status of a building during construction and reflect it with data, analyze whether its construction status is safe and reliable, and provide data support and reference for assembly construction.

[0050] Third, thanks to the simulation function of the digital twin system, it can be used to simulate the desired construction method in advance, thereby analyzing whether the desired construction method can be adopted. At the same time, it can simulate and compare some parameters that need to be preset, so as to achieve scientific prediction and provide a guarantee for construction.

[0051] Fourth, when technical conditions permit, it is possible to use simulated data as a guide, intelligent construction equipment as a tool, and data transmission to intelligently control equipment construction.

[0052] The present invention will illustrate the functions implemented by this system based on the following three simple embodiments.

[0053] Example 1

[0054] This embodiment primarily illustrates the function of the working condition analysis of the present invention. To implement the present invention, it is necessary to first establish a corresponding digital twin of the physical entity. Then, according to... Figure 2 The digital twin module of the present invention shown is created according to the above-described digital twin creation steps:

[0055] Step 1: Establish a Building Information Model (BIM) for a long-span prefabricated steel bridge;

[0056] Specific implementation: Based on the construction drawings, BIM models are created for the components during the bridge's transportation process and those constructed on-site, according to component type and construction information. Construction information mainly refers to component location, Poisson's ratio, modulus of elasticity, etc., and the naming convention is "Unit Project + Location + Segment + Component Category + Detailed Unit Division". For example, prefabricated components during transportation mainly involve creating BIM models for prefabricated beams and other major components, while other components cast on-site mainly include abutments and other components.

[0057] Step 2: Establish a data processing module, which mainly includes information management and analysis using finite element software;

[0058] Specific Implementation: Due to the large amount of monitoring information collected in bridge engineering using IoT technology, information processing mainly involves streamlining the collected information and rationally collecting and using effective data (generally including bridge positioning information such as elevation, temperature and wind speed information affecting bridge construction, and stress information of components during transportation and assembly). Data is primarily filtered manually, with temperature analyzed according to time periods and relatively high wind speeds used for analysis. This requires a certain level of experience from the analysts. Simulating internal forces requires finite element analysis. After the BIM model is established, the model's SAT format file is directly exported from Revit. In this example, a file of a rigid beam segment from a large-span assembled steel bridge is imported, such as... Figure 3As shown. This file can be directly imported into ANSYS, and then analysts can process the lightweighted data to analyze certain operating conditions, such as... Figure 4 As shown. In this way, during transportation, the stress data of the prefabricated beam can be measured with the help of IoT technology. The BIM established in step one can then be analyzed relatively quickly in the finite element software ANSYS (or some manufacturer-made finite element analysis software, such as Revit Robot or Advance-Design, can be used for analysis, or secondary development can be adopted to extract geometric elements and then analyze them with finite element software such as Ansys). This can reflect the internal condition of the component in real time.

[0059] Step 3: Establish a construction simulation module to reflect the construction process in 3D;

[0060] Specific Implementation: In addition to simulating internal forces, construction simulation software (Navisworks or 3ds Max) is needed to achieve a 3D simulation of the construction process, combining internal and external simulations to achieve realistic construction simulation. The construction simulation software can import the established BIM model and display the construction steps step by step. This allows for a clear view of the external conditions during construction and the display of preset construction scenarios, providing a reference for comparing construction plans. This embodiment uses Navisworks to simulate bridge construction, intuitively demonstrating the construction process. Screenshots from the process are shown below. Figure 5 and Figure 6 .

[0061] Step 4: The modules established in the previous three steps are combined and interact to form a digital twin.

[0062] When step two achieves real-time simulation of internal forces and step three achieves external construction simulation, they can be used together to simulate the current construction conditions, form a digital mapping of the physical entity, and establish a digital twin.

[0063] After the digital twin is created, such as Figure 1 As shown, the Internet of Things (IoT) technology is needed to connect the physical components with the digital twin components. The IoT refers to connecting objects to a network through information sensing devices, enabling the objects to become information-based, and allowing this information to influence the objects, thus achieving intelligence. IoT technology includes... Figure 1 It is divided into an information perception layer, a network transmission layer, and an information application layer.

[0064] In practical implementation, the information sensing layer mainly uses IoT sensors, including temperature sensors and anemometers at the main span and towers of the bridge, and displacement sensors and acceleration sensors at the bridge end supports. The network transmission layer adopts a wireless transmission method based on 5G networks, consisting of 5G gateways and CAN gateways. The information application layer mainly uses PCs to receive information for data processing and application.

[0065] The specific implementation mainly considers the real-time interaction between internal force analysis and the physical entity. With the help of Internet of Things (IoT) technology, mainly its wireless data transmission, the time for manual measurement is reduced, and the required monitoring data can be quickly obtained. The digital twin can quickly simulate the actual construction process of the bridge and quickly change synchronously with the changes in the physical construction entity of the bridge, realize the perception of the current state of the bridge, quickly reflect the internal force status and external construction conditions during bridge assembly, and map the construction to help construction personnel correctly direct the assembly.

[0066] Example 2

[0067] This embodiment primarily clarifies the component inspection function of the present invention. It employs the technical solution used in Embodiment 1 to establish a digital twin (such as a steel beam segment) of the component during transportation. The model only requires the previously established beam component. Relying on Internet of Things (IoT) technology (mainly for sensing pressure data and rapid wireless transmission), it continuously acquires the pressure exerted by the beam's own weight on the vehicle's support points during transportation. Combined with the aforementioned digital twin, it analyzes the internal forces of the beam during transportation, quickly determining whether damage may occur at the beam support points, thus achieving the component inspection function during transportation. Since the 3D simulation of the transportation process is not particularly valuable, its external simulation can be ignored to reduce workload.

[0068] In this embodiment, the BIM module uses modeling software to first create a building information model of the long-span steel bridge according to the prescribed naming convention. It mainly performs detailed simulations of prefabricated components such as the main beam truss of the long-span prefabricated steel bridge during transportation, as well as all construction components on the construction site. It accurately establishes the building information model of the steel bridge under construction to accurately reflect the information on the construction site, so as to facilitate the application of building information models by other software.

[0069] A method for establishing a digital twin system for the intelligent construction of long-span prefabricated steel bridges includes the following steps: First, a building information model (BIM) of the long-span prefabricated steel bridge is established; then, an Internet of Things (IoT) module is established; next, the data is classified in the data processing module and the internal forces of the structure are analyzed using finite element analysis; the established BIM module, construction simulation module, and data processing module are combined to form a digital twin; then, a digital twin system based on the digital twin and physical entity parts is established using the IoT; finally, the construction process of the intelligent long-span steel bridge is realized using digital twin technology.

[0070] Example 3

[0071] This embodiment clarifies the construction prediction function of the present invention, which can be understood as an extension of Embodiment 1. After the establishment of the digital twin system in Embodiment 1, due to the use of IoT technology, the present invention obtains a large amount of data on the prefabricated construction process of steel bridges, such as temperature, wind speed, and wind direction at the main span and towers, and displacement at the end supports of the bridge. Therefore, before construction, using the possible temperature and wind speed as environmental conditions, the digital twin system is used to simulate both the internal force situation (ANSYS) and the external construction (Navisworks) of the hoisted beams. This scientifically determines the changes in internal forces during bridge hoisting. Since the bridge segments will experience certain deflection and temperature changes during assembly, the internal force simulation accurately determines the deformation distance, scientifically guiding the subtle deviations required for the elevation during hoisting, thus improving the accuracy of construction. The external simulation provides construction personnel with a clear understanding of the construction process. After clearly understanding the general construction process based on the external simulation, construction personnel can carry out construction more accurately, avoiding many construction errors and improving construction safety. However, due to the limitations of smart hardware, it is not possible to achieve intelligent control of large devices such as robotic arms for steel beam assembly using the system.

[0072] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A digital twin system for intelligent construction of long-span prefabricated steel bridges, characterized by: It includes a physical entity component and a digital twin component, wherein the digital twin component includes an Internet of Things (IoT) module, a BIM module, a data processing module, and a construction simulation module; the physical entity component and the digital twin component interact with each other via the IoT module; The physical entity includes prefabricated components during transportation, the prefabricated construction process, prefabricated components during transportation, components at the construction site, and the external environmental conditions of the construction site; the prefabricated components during transportation include components that are prone to damage and internal force changes during transportation; the components at the construction site include support components, bridge end components, and related erection equipment. The digital twin is a real-time digital mapping of the physical entity, that is, simulating the actual construction process and analyzing the internal forces of the steel bridge components or the prefabricated steel bridge as a whole during construction. The Internet of Things (IoT) module includes an information sensing layer, a network transmission layer, and an information application layer. The information sensing layer transmits the collected data to the information application layer through the network transmission layer, and the information application layer processes the received information in the data processing module. The BIM module performs information-based simulation of physical entity components, which serves as the information foundation for the digital twin. The data processing module classifies and organizes the data, and then uses finite element software and the collected data and established BIM to analyze the components during the transportation and construction process, or to analyze the constructed steel bridge parts and the whole. The construction simulation module simulates the construction process of a large-span prefabricated steel bridge to reflect the construction site. The construction simulation module uses Navisworks or 3ds Max software to perform 3D simulation of the construction process of the large-span steel bridge, dynamically and intuitively displaying the construction process. At the same time, it also simulates the expected construction conditions to guide the construction site and reduce the occurrence of construction errors. The method for establishing the digital twin system includes the following steps: First, a corresponding digital twin is created for the physical entity. The method for creating the digital twin includes the following steps: Step 1: Establish a Building Information Model (BIM) for the large-span prefabricated steel bridge; Based on the construction drawings, BIM was created for the components during the transportation process of this bridge and the components under on-site construction, according to the component type and construction information. The construction information refers to the component location, Poisson's ratio, and elastic modulus. The naming method adopts the unit project + location + segment + component category + detailed unit division. Step 2: Establish a data processing module, including information processing and analysis using finite element software; Information processing involves streamlining the collected information, rationally collecting and using effective data, and manually filtering the data. Effective data includes temperature and wind speed information that affect bridge construction, as well as stress information of components during transportation and assembly. During transportation, the stress data of the prefabricated beams are measured with the help of Internet of Things technology. The BIM established in step one is used to realize the analysis in the finite element software ANSYS, which reflects the internal force status of the components in real time. Step 3: Establish a construction simulation module to reflect the construction process in 3D; In addition to simulating the internal force conditions, construction simulation software is used to realize the 3D simulation display of the construction process. The combination of internal and external aspects is used to achieve a realistic simulation of construction. The construction simulation software imports the established BIM model and displays the construction steps step by step to intuitively show the external conditions of the construction and display the preset construction scenarios. Step 4: The modules established in the previous three steps are combined and interact to form a digital twin; When step two achieves real-time simulation of internal forces and step three achieves external construction simulation, they can be used together to simulate the current construction conditions, form a digital mapping of the physical entity, and establish a digital twin. After the digital twin is established, Internet of Things (IoT) technology is needed to connect the physical part with the digital twin part. A digital twin is created during the component transportation process using a digital twin creation method. Relying on Internet of Things technology, the pressure of the beam's self-weight on the support points of the beam during transportation is continuously acquired. Combined with the digital twin, the internal forces of the beam during transportation are analyzed to determine whether damage may occur at the beam support points during transportation, thus achieving the function of component inspection during transportation. Before construction begins, the digital twin system is used to simulate the internal forces and external construction conditions of the steel beams to be hoisted, taking the possible temperature and wind speed as environmental conditions. This simulates the changes in internal forces during the hoisting of the steel beams and guides the subtle adjustments required for the elevation during hoisting, thereby improving the accuracy and safety of the construction.

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