A method and platform for intelligent assembly of large-span steel structure roof units

Abstract

This invention provides an intelligent assembly method and platform for large-span steel structure roof units. The method includes performing mechanical analysis on the steel structure roof and decomposing the structural units into various categories. The corresponding 3D models are then imported into the BIM control terminal of the intelligent assembly platform. The assembly sequence of various components within each steel structure roof unit category is designed. An assembly support frame is fabricated, comprising multiple rows of walking tracks spaced at intervals from top to bottom. These tracks are used by a robotic arm to assemble and process the components. Programs are written to complete the technological processes for each steel structure roof unit category. The working sequence of the robotic arm on the assembly support frame is designed. The BIM control terminal controls the robotic arm to complete the assembly and processing of each steel structure roof unit on the assembly support frame. After completion, each steel structure roof unit is transported to the finished product area of ​​the platform. This invention, combined with BIM control, enables intelligent acquisition of steel structure roof units, facilitating the on-site assembly of large-span steel structure roofs.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to an intelligent assembly method and platform for large-span steel structure roof units. Background Technology

[0002] With economic and social development, people's material and spiritual pursuits are constantly improving, giving rise to a large number of large public venues. Unlike traditional buildings, large public venues are characterized by large spans, long cantilevered sections, and irregular shapes, thus placing strict requirements on materials and structures. Thanks to the high strength and light weight of steel structures, they have become the preferred material for the roofs of large public venues. Compared to ordinary concrete roofs, steel structure roofs have higher requirements for design, manufacturing, transportation, assembly, and construction period.

[0003] For large-span steel structure roofs, traditional construction methods mainly involve integral hoisting or high-altitude assembly. In recent years, unit hoisting has begun to be used for installation. Unit hoisting is a common construction method used to install large precast concrete or steel structure units. In the hoisting of steel structure roof units, the units are first prefabricated in a factory or on-site. Then, hoisting equipment (such as cranes and tower cranes) is used to lift the units from the ground or nearby assembly area, suspending them in the air using hoisting ropes or hooks. Next, the hoisting equipment accurately positions the units in their corresponding locations, usually by aligning them with the supporting structure. Once the units are successfully installed, subsequent work such as connection, fixing, and joint treatment can be carried out.

[0004] Although the unit-based hoisting method improves the efficiency and safety of hoisting, the steel structure units still rely on manual labor for repetitive tasks such as assembly, inspection, and painting, failing to significantly reduce worker workload. Current large-span stadiums are characterized by their enormous scale and complex construction processes, making traditional construction methods inadequate to meet their high-quality building requirements. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide an intelligent assembly method and platform for large-span steel structure roof units. This method involves performing mechanical analysis on the steel structure roof and breaking it down into various steel structure roof units. The assembly sequence of various components for each steel structure roof unit is designed, and then a robotic arm is controlled to assemble and process the components on the assembly support to obtain the steel structure roof unit, which facilitates the on-site assembly of large-span steel structure roofs.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0007] A method for intelligent assembly of large-span steel structure roof units includes the following steps:

[0008] The mechanical analysis and structural unit decomposition of the steel structure roof are performed to form various steel structure roof unit categories, and the quantity and material requirements corresponding to each steel structure roof unit category are output.

[0009] Import the 3D model of the split steel structure roof unit category into the BIM control terminal of the intelligent assembly platform. Analyze the 3D model through the BIM control terminal, design the assembly sequence of various components in each steel structure roof unit category, and complete the programming and debugging of the assembly sequence.

[0010] After the initial component preparation is completed in the factory, the components are transported to the site and hoisted onto the platform's material loading area and sorted and arranged.

[0011] An assembly support frame is fabricated, comprising multiple rows of walking tracks spaced at certain intervals from top to bottom. The walking tracks are used for the robotic arm to move and assemble and process components.

[0012] The program is written to complete the process steps for each type of steel structure roof unit, and the operation sequence of the robotic arm on the assembly support is designed. Then, the robotic arm is controlled by the BIM control terminal to complete the assembly and processing of each steel structure roof unit on the assembly support. After completion, each steel structure roof unit is transported to the finished product area of ​​the platform.

[0013] According to the on-site stacking requirements, all steel structure roof units are stacked from the finished product area to the designated location for retrieval during roof hoisting. This completes the intelligent assembly of one steel structure roof unit. Repeat the above steps until all steel structure roof units are assembled.

[0014] Furthermore, the methods for mechanical analysis and element decomposition of steel structure roofs include:

[0015] Create a Tekla model of the entire steel roof structure based on the design drawings;

[0016] By omitting non-core components and retaining the assembly theme, the core framework of the steel roof structure is initially divided into various steel roof structure unit categories. If a mechanical calculation unit model is provided by the design unit, that unit model is used as a steel roof structure unit category for further division.

[0017] Modeling and mechanical calculations are performed on all steel structure roof unit categories after the splitting to ensure that each steel structure roof unit category meets the design requirements of the steel structure roof.

[0018] Based on the categories of the split steel structure roof units, the parts that have been adjusted or changed are remodeled, and then the entire steel structure roof model is rebuilt. Mechanical calculations are performed on the steel structure roof to ensure that the steel structure roof meets the original design requirements.

[0019] Output Tekla model data for all steel roof unit categories in IFC format or other file formats compatible with BIM;

[0020] Output the category, size, quantity, and order of arrival of the required components for each steel structure roof unit, as the basis for material preparation requirements.

[0021] Furthermore, the method for designing the assembly sequence of various components within each steel structure roof unit category is as follows:

[0022] Import the IFC file of the Tekla model data corresponding to each steel structure roof unit category into the BIM control terminal for modeling, and identify the constraint relationships and positional relationships in each steel structure roof unit category;

[0023] The structural units in each steel structure roof unit category are set up so that the BIM control terminal can identify all structural units assembled into each steel structure roof unit category.

[0024] Each structural unit is assigned a unique first-class code, and each component in each structural unit is assigned a unique second-class code.

[0025] For each coded steel structure roof unit, the category and corresponding quantity are statistically analyzed and the data is stored.

[0026] Based on the constraints and positional relationships in each identified steel structure roof unit category, as well as the coded steel structure roof unit category and its corresponding quantity, the assembly sequence is set. If multiple assembly sequences exist, all assembly sequences are simulated, and the optimal assembly sequence is selected for programming and debugging based on its efficiency. Otherwise, the obtained assembly sequence is directly programmed and debugged.

[0027] Furthermore, the method for setting the assembly sequence is as follows:

[0028] Define the process steps, including material handling, assembly, testing, and painting.

[0029] Each process requires at least one robotic arm to complete the work. Specifically, the robotic arm grips the component, the spatial positioning device uses a spatial locator to position the component, the welding robotic arm performs welding operations on the component, the bolting robotic arm tightens the bolts on the component, the stress detection robotic arm detects the stress of high-strength bolts, and the painting robotic arm paints the component.

[0030] The assembly sequence is simulated in the BIM control terminal to obtain the time corresponding to the assembly sequence, and the assembly sequence with the shortest time is selected as the optimal assembly sequence.

[0031] Furthermore, the method for classifying and arranging all components is as follows:

[0032] Place the component in the recognition area;

[0033] The first industrial depth camera acquires the first identification image of the component. The BIM control terminal performs laser point cloud processing on the component in the identification area to extract the outline and size of the component, identify the type of component and match it with the component in the material preparation area, and assign a second type code to the component and its corresponding image.

[0034] Repeat the above steps until all components have been identified.

[0035] Furthermore, the method of controlling the robotic arm on the assembly support to complete the assembly and processing of each steel structure roof unit through the BIM control terminal is as follows:

[0036] Multiple second industrial depth cameras are set on the assembly bracket, and each industrial depth camera is assigned a unique third type of code;

[0037] For each process, a corresponding second industrial depth camera is set using the third type of coding;

[0038] Image recognition is performed at the BIM control terminal. Images of the corresponding work points for each process are acquired through a second industrial depth camera. The image processor calculates the number of pixels of the component in the image using an algorithm to convert the component's work point position data. Specifically, the algorithm calculates the number of pixels occupied by the component's width in the image and the number of pixels occupied per unit distance, and finally converts this into the difference between the work point position and the center of the image. The component's work point position data is then sent to the BIM control terminal. The BIM control terminal issues corresponding running commands and running distances, and transmits these commands and distances to the robotic arm drive device. The robotic arm drive device moves the robotic arm according to the commands provided by the BIM control terminal and directs the end effector to accurately move to the component's work point position to perform the work.

[0039] A smart assembly platform for large-span steel structure roof units, applied to the aforementioned smart assembly method for large-span steel structure roof units, includes:

[0040] An assembly support frame, the assembly support frame comprising multiple rows of walking tracks distributed at certain intervals from top to bottom;

[0041] A robotic arm travels along the track to assemble and process components.

[0042] The first industrial depth camera captures the first recognition image. The BIM control terminal performs laser point cloud processing on the components in the recognition area, extracts the outline and size of the components, identifies the type of components and matches them with the components in the material preparation area, and assigns a second type of code to the components and their corresponding images.

[0043] The second industrial depth camera is fixed on the assembly bracket to acquire images of the working points corresponding to each process and to identify the working point location data of the components through the BIM control terminal.

[0044] The intelligent assembly platform includes a BIM control terminal. The BIM control terminal analyzes the model, designs the assembly sequence of various components in each steel structure roof unit, and completes the programming and debugging of the assembly sequence. The program completes the process steps of each steel structure roof unit, and designs the operation sequence of the robotic arm on the assembly support. Then, the BIM control terminal controls the robotic arm to complete the assembly and processing of each steel structure roof unit on the assembly support.

[0045] Furthermore, the robotic arm is a track-based robotic arm, which includes a gripping robotic arm, a spatial orientation positioning device, a welding robotic arm, a bolting robotic arm, a stress detection robotic arm, and a painting robotic arm.

[0046] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0047] (1) Improve efficiency: The assembly of steel structure roof units using this invention is completed automatically by the intelligent assembly platform. Compared with the disadvantages of harsh environment and low efficiency in the traditional manual assembly process, it shows the advantages of high speed and high efficiency. The assembly can be completed according to the same procedure, which can save a lot of coordination time between people and autonomously adapt to the complex tasks and dynamic environment of large-span steel structure roof construction operations.

[0048] (2) Ensure quality: The intelligent assembly platform completes the assembly automatically, eliminating the fatigue and errors of manual assembly. At the same time, the platform monitors and records data for each step, which improves the assembly accuracy, facilitates real-time correction, and reduces the workload of workers.

[0049] (3) Cost saving: By using machinery to replace manual labor and combining BIM control, the independently driven human-machine environment realizes "human-like motion", saving a lot of labor costs and achieving significant economic benefits;

[0050] (4) Safe construction: Although the unit hoisting method has changed the original high-altitude operation to ground operation, welding and large component handling are still dangerous operations for manual labor. The invention of this platform can better reflect the sensing function and the "autonomy" of behavior, complete fully automatic assembly under certain rules, and at the same time have smooth behavior, it can better protect the personal safety of workers through simple and safe steps. Attached Figure Description

[0051] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and are intended to explain the invention, but do not constitute an undue limitation thereof. In the drawings:

[0052] Figure 1 This is a schematic diagram of the intelligent assembly method for large-span steel structure roof units provided by the present invention;

[0053] Figure 2 A schematic diagram of the gripping robotic arm designed for this invention and mounted on an intelligent assembly platform for steel structure roof units;

[0054] Figure 3 A schematic diagram of a welding robotic arm designed for this invention and mounted on an intelligent assembly platform for a steel structure roof unit;

[0055] Figure 4 A schematic diagram of a bolt stress detection robotic arm designed for this invention and mounted on an intelligent assembly platform for steel structure roof units;

[0056] Figure 5 This is a schematic diagram of the steel structure roof unit assembly support designed for this invention;

[0057] Figure 6 This is a schematic diagram showing the arm length and rotation angle of the robotic arm.

[0058] Figure 7 Axonometric drawing of a steel roof with upper and lower chords, selected as an example;

[0059] Figure 8 This is a schematic diagram of the roof unit after mechanical disassembly in a specific embodiment. Detailed Implementation

[0060] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0061] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0062] Example 1

[0063] This embodiment 1 provides an intelligent assembly method for large-span steel structure roof units, such as... Figure 1 As shown, it includes the following steps:

[0064] Step S1: Perform mechanical analysis and structural unit decomposition on the steel structure roof to form multiple steel structure roof unit categories, and output the quantity and material requirements corresponding to each steel structure roof unit category.

[0065] Step S2: Import the 3D model of the split steel structure roof unit category into the BIM control terminal of the intelligent assembly platform. Analyze the 3D model through the BIM control terminal, design the assembly sequence of various components in each steel structure roof unit category, and complete the programming and debugging of the assembly sequence.

[0066] Step S3: After the initial component preparation is completed in the factory, the components are transported to the site and hoisted into the platform's material loading area and sorted and placed.

[0067] Step S4, as follows Figure 5 As shown, an assembly support is fabricated, which includes multiple rows of walking tracks distributed at certain intervals from top to bottom. The walking tracks are used for the robotic arm to move to assemble and process components.

[0068] Step S5: Write a program to complete the process of each steel structure roof unit category, and design the operation sequence of the robotic arm on the assembly support. Then, control the robotic arm on the assembly support to complete the assembly and processing of each steel structure roof unit through the BIM control terminal. After completion, transport each steel structure roof unit to the finished product area of ​​the platform.

[0069] Step S6: According to the on-site stacking requirements, stack all steel structure roof units from the finished product area to the designated location for easy access during roof hoisting. This completes the intelligent assembly of one steel structure roof unit. Repeat the above steps until all steel structure roof units are assembled.

[0070] This embodiment provides an intelligent assembly method for large-span steel structure roof units, which can improve efficiency: When using this invention to complete the assembly of steel structure roof units, the core steps are all completed automatically by the intelligent assembly platform. Compared with the disadvantages of harsh environment and low efficiency in traditional manual assembly, it shows the advantages of high speed and high efficiency. By completing the assembly according to the same procedure, a lot of coordination time between people can be saved, and it can autonomously adapt to the complex tasks and dynamic environment of large-span steel structure roof construction operations.

[0071] Quality assurance: The intelligent assembly platform completes the assembly automatically, eliminating the fatigue and errors associated with manual assembly. At the same time, the platform monitors and records data at every step, improving assembly accuracy, facilitating real-time correction, and reducing the workload of workers.

[0072] Cost savings: By using machinery to replace manual labor and combining it with BIM control, the independently driven human-machine environment achieves "human-like motion," saving a significant amount of labor costs and resulting in remarkable economic benefits.

[0073] Safe construction: Although the unit hoisting method has changed the original high-altitude operation to ground operation, welding and handling of large components are still dangerous operations for manual labor. The invention of this platform can better reflect the sensing function and the "autonomy" of behavior, complete fully automatic assembly under certain rules, and at the same time have smooth behavior, it can better protect the personal safety of workers through simple and safe steps.

[0074] Example 2

[0075] The present invention provides a detailed description of an intelligent assembly method for a large-span steel structure roof unit.

[0076] In step S1, the mechanical analysis and element decomposition methods for the steel structure roof include:

[0077] Step S101: Create a Tekla model of the entire steel structure roof according to the design drawings;

[0078] Step S102: Omit non-core members, retain the assembly theme, and initially decompose the core skeleton of the steel structure roof into various steel structure roof unit categories. If there is a mechanical calculation unit model provided by the design unit, decompose the unit model as a steel structure roof unit category.

[0079] Step S103: Model and perform mechanical calculations on all the steel structure roof unit categories after splitting to ensure that each steel structure roof unit category meets the design requirements of the steel structure roof.

[0080] Step S104: Based on the categories of the split steel structure roof units, remodel the parts that have been adjusted or changed, and then rebuild the model of the entire steel structure roof. Perform mechanical calculations on the steel structure roof to ensure that the steel structure roof meets the original design requirements.

[0081] Step S105: Output the Tekla model data of all steel structure roof unit categories in IFC format or other file formats that can be accessed by BIM.

[0082] Step S106: Output the type, size, quantity, and order of arrival of the required components for each steel structure roof unit, as the basis for material preparation requirements.

[0083] Step S1 involves performing mechanical analysis and unit decomposition on the steel structure roof, breaking it down into various steel structure roof unit categories. This ensures that each steel structure roof unit category meets mechanical requirements and allows for the calculation of the quantity of each type of component. The intelligent assembly method for large-span steel structure roof units provided in this embodiment also includes steps such as model export, intelligent assembly platform data input, and intelligent assembly platform program writing and debugging.

[0084] Step S1 starts with the designed steel structure roof drawings, uses Tekla to model the roof, and analyzes it according to mechanical principles, breaking it down into various steel structure roof unit categories. These categories are then checked and adjusted. For example, if tie rods or purlins exist in a single category, they should be removed and installed later in the hoisting process. The hoisting details are then adjusted based on the adjusted steel structure roof unit categories. Finally, a 3D model of the steel structure roof unit categories is exported from Tekla for use by the intelligent assembly platform.

[0085] In step S2, the method for designing the assembly sequence of various components in each steel structure roof unit category is as follows:

[0086] Step S201: Import the IFC file of the Tekla model data corresponding to each steel structure roof unit category into the BIM control terminal for modeling, and identify the constraint relationships and positional relationships in each steel structure roof unit category.

[0087] Step S202: Configure the structural units in each steel structure roof unit category so that the BIM control terminal can identify all structural units assembled into each steel structure roof unit category.

[0088] Step S203: Assign a unique first-class code to each structural unit, and assign a unique second-class code to each component in each structural unit;

[0089] Step S204: Perform category and corresponding quantity statistics for each coded steel structure roof unit category, and store the data;

[0090] Step S205: Based on the constraints and positional relationships in each identified steel structure roof unit category, as well as the encoded steel structure roof unit category and corresponding quantity, set the assembly sequence. If multiple assembly sequences exist, simulate all assembly sequences and select the optimal assembly sequence for programming and debugging based on its efficiency. Otherwise, directly program and debug the obtained assembly sequence.

[0091] In step S205, the method for setting the assembly sequence is as follows:

[0092] Step S2051: Set the process steps, including material picking, assembly, inspection, and painting.

[0093] Step S2052: At least one robotic arm shall be arranged to complete the work for each process, such as... Figures 2-4 As shown, the process involves: gripping the component with a robotic arm; positioning the component using a spatial locator with a spatial orientation positioning device; welding the component with a welding robotic arm; fastening the component with bolts with a bolting robotic arm; stress testing the high-strength bolts with a stress testing robotic arm; and painting the component with a painting robotic arm.

[0094] Step S2053: Simulate the assembly sequence in the BIM control terminal, obtain the time corresponding to the assembly sequence, and select the assembly sequence with the shortest time as the optimal assembly sequence.

[0095] In step S3, the method for classifying and arranging all components is as follows:

[0096] Step S301: Place the component in the recognition area;

[0097] Step S302: The industrial depth camera performs laser point cloud processing on the components in the recognition area, extracts the outline and size of the components, and matches them with the components in the material preparation area, assigning a second type of code to the components and their corresponding images.

[0098] Step S303: Repeat the above steps until all components have been identified.

[0099] In step S3 of Example 2, materials such as steel, bolts, welding rods, and fasteners are prepared according to the drawings, and the various materials are stacked separately in the material picking area. The size and model of the materials are controlled and inspected. At the same time, a typical steel structure roof can be divided into one or several types of roof units, and each type has several to dozens of units. Materials need to be prepared according to the order of assembly categories.

[0100] In step S5, the method for controlling the robotic arm via the BIM control terminal to assemble and process each steel structure roof unit on the assembly support is as follows:

[0101] Step S501: Set up multiple industrial depth cameras on the assembly bracket and assign a unique third-class code to each industrial depth camera;

[0102] Step S502: For each process, set the corresponding industrial depth camera through the third type of coding;

[0103] Step S503: Image recognition is performed on the BIM control terminal to obtain images of the work points corresponding to each process. The image processor calculates the number of imaging pixels of the component in the image through an algorithm to convert the component work point position data. The specific algorithm process is to calculate the number of pixels occupied by the width of the component in the image and the number of pixels occupied per unit distance, and finally convert it into the difference between the work point position and the center of the image. Then, the component work point position data is sent to the BIM control terminal. The BIM control terminal issues the corresponding running command and running distance, and transmits the running command and running distance to the robotic arm drive device. The robotic arm drive device drives the robotic arm to move according to the command provided by the BIM control terminal, and directs the end effector to accurately run to the component work point position to perform the work.

[0104] The intelligent assembly platform in this embodiment assembles roof units according to a program. Its interface is designed for natural and efficient operation. During assembly, it will issue a real-time warning if the material unsuitable location in the unloading area is detected, reminding workers to remove the assembled steel roof structure from the unloading area. Furthermore, only a small number of personnel are needed for on-site supervision. The intelligent assembly platform will trigger an alarm for any problems, such as insufficient materials in the preparation area, or a shortage of welding rods and bolts.

[0105] While the intelligent assembly platform is assembling the roof units, or after the assembly is completed, workers can simultaneously hoist the roof, thereby improving the efficiency of the entire roof installation.

[0106] The above steps are the general sequence for installing steel structure roofs using the unit hoisting method with the help of an intelligent assembly platform. The platform location and material loading / unloading area can be arranged according to the current conditions.

[0107] Example 3

[0108] Example 3 provides an intelligent assembly platform for large-span steel structure roof units, applied to the above-mentioned intelligent assembly method for large-span steel structure roof units, including:

[0109] An assembly support frame, the assembly support frame comprising multiple rows of walking tracks distributed at certain intervals from top to bottom;

[0110] A robotic arm travels along the track to assemble and process components.

[0111] The first industrial depth camera captures the first recognition image. The BIM control terminal performs laser point cloud processing on the components in the recognition area, extracts the outline and size of the components, identifies the type of components and matches them with the components in the material preparation area, and assigns a second type of code to the components and their corresponding images.

[0112] The second industrial depth camera is fixed on the assembly bracket to acquire images of the working points corresponding to each process and to identify the working point location data of the components through the BIM control terminal.

[0113] The intelligent assembly platform includes a BIM control terminal. The BIM control terminal analyzes the model, designs the assembly sequence of various components in each steel structure roof unit, and completes the programming and debugging of the assembly sequence. The program completes the process steps of each steel structure roof unit, and designs the operation sequence of the robotic arm on the assembly support. Then, the BIM control terminal controls the robotic arm to complete the assembly and processing of each steel structure roof unit on the assembly support.

[0114] The robotic arm is a track-based robotic arm, such as... Figures 2-4 As shown, the robotic arm includes a gripping robotic arm, a spatial orientation positioning device, a welding robotic arm, a bolting robotic arm, a stress detection robotic arm, and a painting robotic arm.

[0115] See Figure 6 This paper presents a partial design of the robotic arm length in a smart assembly method and platform for a large-span steel structure roof unit. In the figure, L1 is the length of the main arm, and L2 and L3 are the lengths of the auxiliary arms. It should be noted that... Figure 6 The diagram mainly shows one scenario of L1, L2, and L3, without providing detailed information or requirements for the base and mechanical gripper.

[0116] The rotation angle of L1 relative to the base is no less than 270°, the relative selection angle between L1 and L2 is 360°, and the relative rotation angle between L2 and L3 is 360°, which ensures the high flexibility and obstacle avoidance capability of the robotic arm.

[0117] To achieve high flexibility, the arm length of the robotic arm should satisfy the following two formulas:

[0118] L1 = k(L2 + L3)

[0119]

[0120] In the two formulas above: L1, L2, and L3 are the arm lengths of the robotic arm;

[0121] K is an adjustment coefficient, and the proposed value range for this invention is 0.85 to 1.15.

[0122] The width of the L-shaped intelligent assembly platform is the distance between the tracks on both sides of the platform where the robotic arms travel.

[0123] Reference Figures 7-8 An example is given to illustrate the application of an intelligent assembly method and platform for large-span steel structure roof units:

[0124] Figure 7 This is a 3D axonometric drawing of the steel roof structure for a large-span sports stadium. The entire structure is symmetrical about the central skylight. The roof is a top and bottom chord structure. After mechanical analysis and structural decomposition of the roof structure, the following results are obtained: Figure 8 The roof unit shown is a clearly illustrated structure, with purlins omitted.

[0125] The entire steel structure roof can be disassembled into eight roof units, thus requiring the use of an intelligent assembly platform to assemble these eight units. Each roof unit has a unique upper and lower chord structure with limited space between them. Manual assembly would restrict construction space, inevitably increasing assembly difficulty and compromising quality.

[0126] Furthermore, in this case, there are specific requirements for the stress of the high-strength bolts. Using the intelligent assembly platform of this invention to complete the assembly can detect and adjust the gravitational force of each high-strength bolt in a timely manner, thereby improving the accuracy and quality of the assembly.

[0127] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the invention without departing from the scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

[0128] This invention provides an intelligent assembly platform for steel structure roof units, replacing manual assembly of roof units during hoisting. By performing mechanical analysis and structural disassembly of the roof, the disassembled roof units are obtained. The roof unit models are then input into the intelligent assembly platform, which automatically programs the assembly process. Compared to manual assembly, this intelligent assembly platform can not only inspect roof objects at construction sites of large-span steel structure stadiums, but also, based on tasks such as welding, gripping, fastening, and control, demonstrate intelligent robotic arm strategies in real time. This enables a driven, biomimetic process for the assembly of large-span steel structure roofs, making it flexible, mobile, and efficient—a highly mobile, autonomous, and practical intelligent platform.

[0129] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A method for intelligent assembly of large-span steel structure roof units, characterized in that, Includes the following steps: The mechanical analysis and structural unit decomposition of the steel structure roof are performed to form various steel structure roof unit categories, and the quantity and material requirements corresponding to each steel structure roof unit category are output. Import the 3D model of the split steel structure roof unit category into the BIM control terminal of the intelligent assembly platform. Analyze the 3D model through the BIM control terminal, design the assembly sequence of various components in each steel structure roof unit category, and complete the programming and debugging of the assembly sequence. After the initial component preparation is completed in the factory, the components are transported to the site and hoisted onto the platform's material loading area and sorted and arranged. An assembly support frame is fabricated, comprising multiple rows of walking tracks spaced at certain intervals from top to bottom. The walking tracks are used for the robotic arm to move and assemble and process components. The program is written to complete the process steps for each type of steel structure roof unit, and the operation sequence of the robotic arm on the assembly support is designed. Then, the robotic arm is controlled by the BIM control terminal to complete the assembly and processing of each steel structure roof unit on the assembly support. After completion, each steel structure roof unit is transported to the finished product area of ​​the platform. According to the on-site stacking requirements, all steel structure roof units are stacked from the finished product area to the designated location for retrieval during roof hoisting. This completes the intelligent assembly of one steel structure roof unit. Repeat the above steps until all steel structure roof units are assembled.

2. The intelligent assembly method for large-span steel structure roof units according to claim 1, characterized in that, Methods for mechanical analysis and element decomposition of steel structure roofs include: Create a Tekla model of the entire steel roof structure based on the design drawings; By omitting non-core components and retaining the assembly theme, the core framework of the steel roof structure is initially divided into various steel roof structure unit categories. If a mechanical calculation unit model is provided by the design unit, that unit model is used as a steel roof structure unit category for further division. Modeling and mechanical calculations are performed on all steel structure roof unit categories after the splitting to ensure that each steel structure roof unit category meets the design requirements of the steel structure roof. Based on the categories of the split steel structure roof units, the parts that have been adjusted or changed are remodeled, and then the entire steel structure roof model is rebuilt. Mechanical calculations are performed on the steel structure roof to ensure that the steel structure roof meets the original design requirements. Output Tekla model data for all steel roof unit categories in IFC format or other file formats compatible with BIM; Output the category, size, quantity, and order of arrival of the required components for each steel structure roof unit, as the basis for material preparation requirements.

3. The intelligent assembly method for large-span steel structure roof units according to claim 1, characterized in that, The method for designing the assembly sequence of various components in each steel structure roof unit category is as follows: Import the IFC file of the Tekla model data corresponding to each steel structure roof unit category into the BIM control terminal for modeling, and identify the constraint relationships and positional relationships in each steel structure roof unit category; The structural units in each steel structure roof unit category are set up so that the BIM control terminal can identify all structural units assembled into each steel structure roof unit category. Each structural unit is assigned a unique first-class code, and each component in each structural unit is assigned a unique second-class code. For each coded steel structure roof unit, the category and corresponding quantity are statistically analyzed and the data is stored. Based on the constraints and positional relationships in each identified steel structure roof unit category, as well as the coded steel structure roof unit category and its corresponding quantity, the assembly sequence is set. If multiple assembly sequences exist, all assembly sequences are simulated, and the optimal assembly sequence is selected for programming and debugging based on its efficiency. Otherwise, the obtained assembly sequence is directly programmed and debugged.

4. The intelligent assembly method for large-span steel structure roof units according to claim 3, characterized in that, The method for setting the assembly order is as follows: Define the process steps, including material handling, assembly, testing, and painting. Each process requires at least one robotic arm to complete the work. Specifically, the robotic arm grips the component, the spatial positioning device uses a spatial locator to position the component, the welding robotic arm performs welding operations on the component, the bolting robotic arm tightens the bolts on the component, the stress detection robotic arm detects the stress of high-strength bolts, and the painting robotic arm paints the component. The assembly sequence is simulated in the BIM control terminal to obtain the time corresponding to the assembly sequence, and the assembly sequence with the shortest time is selected as the optimal assembly sequence.

5. The intelligent assembly method for large-span steel structure roof units according to claim 1, characterized in that, The method for classifying and arranging all components is as follows: Place the component in the recognition area; The first industrial depth camera acquires the first identification image of the component. The BIM control terminal performs laser point cloud processing on the component in the identification area to extract the outline and size of the component, identify the type of component and match it with the component in the material preparation area, and assign a second type code to the component and its corresponding image. Repeat the above steps until all components have been identified.

6. The intelligent assembly method for large-span steel structure roof units according to claim 1, characterized in that, The method of using a BIM control terminal to control a robotic arm to assemble and process each steel structure roof unit on an assembly support is as follows: Multiple second industrial depth cameras are set on the assembly bracket, and each industrial depth camera is assigned a unique third type of code; For each process, a corresponding second industrial depth camera is set using the third type of coding; Image recognition is performed at the BIM control terminal. Images of the corresponding work points for each process are acquired through a second industrial depth camera. The image processor calculates the number of pixels of the component in the image using an algorithm to convert the component's work point position data. Specifically, the algorithm calculates the number of pixels occupied by the component's width in the image and the number of pixels occupied per unit distance, and finally converts this into the difference between the work point position and the center of the image. The component's work point position data is then sent to the BIM control terminal. The BIM control terminal issues corresponding running commands and running distances, and transmits these commands and distances to the robotic arm drive device. The robotic arm drive device moves the robotic arm according to the commands provided by the BIM control terminal and directs the end effector to accurately move to the component's work point position to perform the work.

7. A smart assembly platform for large-span steel structure roof units, applied to the smart assembly method for large-span steel structure roof units as described in any one of claims 1-6, characterized in that, include: An assembly support frame, the assembly support frame comprising multiple rows of walking tracks distributed at certain intervals from top to bottom; A robotic arm travels along the track to assemble and process components. The first industrial depth camera captures the first recognition image. The BIM control terminal performs laser point cloud processing on the components in the recognition area, extracts the outline and size of the components, identifies the type of components and matches them with the components in the material preparation area, and assigns a second type of code to the components and their corresponding images. The second industrial depth camera is fixed on the assembly bracket to acquire images of the working points corresponding to each process and to identify the working point location data of the components through the BIM control terminal. The intelligent assembly platform includes a BIM control terminal. The BIM control terminal analyzes the model, designs the assembly sequence of various components in each steel structure roof unit, and completes the programming and debugging of the assembly sequence. The program completes the process steps of each steel structure roof unit, and designs the operation sequence of the robotic arm on the assembly support. Then, the BIM control terminal controls the robotic arm to complete the assembly and processing of each steel structure roof unit on the assembly support.

8. The intelligent assembly platform for large-span steel structure roof units according to claim 7, characterized in that: The robotic arm is a track-mounted robotic arm, which includes a gripping robotic arm, a spatial orientation positioning device, a welding robotic arm, a bolting robotic arm, a stress detection robotic arm, and a painting robotic arm.

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