Arc-shaped metal pipeline on-site high-precision manufacturing and installation method

Abstract

The application provides a kind of arc metal pipeline on-site high-precision manufacturing and installation method, belongs to metal pipeline construction technical field, comprising: according to building plan, using BIM software constructs the three-dimensional model of arc pipeline. The model is split, segmented processing is carried out with pipeline breakpoint as center, and each segment parameter such as arc pipe radius, radian angle and the like is marked. Stress is checked by using finite element analysis software, and reinforcing structure such as hoop support and the like is designed. Then, numerical control bending pipe and welding equipment are used to manufacture prefabricated arc pipe segment, and its quality is detected in factory to meet the requirements. Finally, the prefabricated segment is transported to the site, and is accurately installed and welded to the building structure by using laser positioning. The whole process ensures the structural stability and manufacturing quality of the arc pipeline through three-dimensional modeling, parameter marking, stress analysis, prefabrication and accurate installation. The method provided by the application can solve the technical problem that the existing technology cannot meet the requirements of pipeline installation precision of increasingly complex building engineering.

Description

Technical Field

[0001] This invention belongs to the field of metal pipeline construction technology, and specifically relates to a method for high-precision on-site fabrication and installation of arc-shaped metal pipelines. Background Technology

[0002] In modern building engineering, curved metal pipes are widely used in various heating, cooling, and drainage pipeline systems, as their tortuous and flexible geometry allows them to better adapt to complex building environments. However, due to the special structure of curved pipes, there are often many challenges in the actual manufacturing and installation process.

[0003] First, the geometry of curved pipes is complex and variable, making it difficult to accurately predict their stress-strain state through simple numerical calculations or technological experience. During installation, pipes may be subjected to various loads such as internal pressure, gravity, and temperature changes, which can easily lead to problems such as localized stress concentration, excessive deformation, or even buckling failure. Therefore, detailed mechanical analysis and structural optimization design are necessary to ensure their safe and reliable use.

[0004] Secondly, the on-site fabrication and installation of curved pipes are extremely difficult. Due to the complex connection angles between pipe sections, it is difficult to achieve precise manufacturing using traditional steel pipe bending or butt welding processes. While some existing prefabrication and assembly methods can improve the fabrication quality of curved pipes, they still fall short of meeting the increasingly complex requirements for pipe installation precision in construction projects. Summary of the Invention

[0005] In view of this, the present invention provides a high-precision on-site fabrication and installation method for arc-shaped metal pipes, which can solve the technical problem that the existing technology is unable to meet the increasingly complex requirements of pipe installation accuracy in construction projects.

[0006] This invention is implemented as follows:

[0007] This invention provides a method for high-precision on-site fabrication and installation of curved metal pipes, comprising the following steps:

[0008] S10. Create a 3D model: Based on the building's basic floor plan, use BIM software to create a 3D volumetric model of the curved pipe, and draw a detailed model drawing of the curved pipe based on this model.

[0009] S20. Pipeline segmentation: On the arc-shaped pipeline model diagram, with the section where the pipeline break point is located as the center, select arc-shaped pipelines of predetermined length on both sides for straight pipe segment processing. The pipeline break point includes diameter change points, branch points, segmentation points, and pipeline upturn or downturn points.

[0010] S30, Model Decomposition: Decompose the arc-shaped pipe model drawing to form a detailed drawing of multiple arc-shaped pipe segments;

[0011] S40. Parameter marking: Mark the parameters of each arc-shaped pipe section in the detailed drawing, including the arc radius, arc angle, connection angle between the straight pipe section and the arc section, arc length of the arc section and length of the straight pipe section.

[0012] S50. Stress Analysis: Use finite element analysis software to perform stress analysis on each section of the arc-shaped pipe to ensure its structural stability during installation and use, and design the reinforcement structure of each section of the arc-shaped pipe, including reinforcing ribs, corrugated ribs, circumferential reinforcing rings, longitudinal reinforcing ribs, diagonal supports and buckling-resistant rings.

[0013] S60. Manufacturing prefabricated sections: Based on the detailed drawings and stress analysis results of each section of the arc-shaped pipe, multiple prefabricated arc-shaped pipe sections are manufactured using CNC pipe bending machines and precision welding equipment.

[0014] S70, Welded Reinforcement Structure: Welded reinforcement structure for each prefabricated arc-shaped pipe section;

[0015] S80. Quality Inspection: Non-destructive testing of the dimensions, materials, and weld quality of the prefabricated arc-shaped pipe sections after manufacturing is carried out to ensure that they meet the design requirements.

[0016] S90. On-site installation: Multiple prefabricated arc-shaped pipe sections are transported to the construction site, precisely positioned using a laser positioning instrument, and then welded onto the building structure.

[0017] In the design of the reinforcement structure for each segment of the arc-shaped pipe, a set of mechanical equations is established, including the elastic deformation equation, thermal expansion stress equation, fluid pressure stress equation, bending stress equation, shear stress equation, axial stress equation, and fatigue stress equation, to achieve multi-objective optimization of the arc-shaped pipe. The optimization objectives include: structural strength optimization, material usage minimization, seismic performance improvement, thermal stress compensation, fluid impact mitigation, vibration suppression, and service life extension.

[0018] Furthermore, the elastic deformation equation is specifically expressed as follows:

[0019]

[0020] Where u, v, and w represent radial, circumferential, and axial displacements, respectively, and r, θ, and z are coordinates in a cylindrical coordinate system.

[0021] The thermal expansion stress equation is specifically expressed as follows:

[0022]

[0023] Where, σ th Let E be the thermal stress, E be the elastic modulus, α be the coefficient of linear expansion, ΔT be the temperature change, r be the current radius, and R be the outer radius of the pipe.

[0024] The fluid pressure stress equation is specifically expressed as follows:

[0025]

[0026] Where, σ p Where p is the pressure stress, r is the current radius, t is the pipe wall thickness, and b is the inner radius of the pipe.

[0027] The bending stress equation is specifically expressed as follows:

[0028]

[0029] Where, σ b Let M be the bending stress, M be the bending moment, y be the distance from the neutral axis, I be the moment of inertia of the cross section, and D be the bending stress. o and D i These refer to the outer diameter and inner diameter of the pipe, respectively.

[0030] The shear stress equation is specifically expressed as follows:

[0031]

[0032] Where τ is the shear stress, V is the shear force, A is the cross-sectional area, r is the current radius, and R is the outer radius of the pipe.

[0033] The axial stress equation is specifically expressed as follows:

[0034]

[0035] Where, σ a denoted as axial stress, F as axial force, A as cross-sectional area, p as internal pressure, r as average radius, and t as pipe wall thickness.

[0036] The fatigue stress equation is specifically expressed as follows:

[0037]

[0038] Where, σ a Let σ be the amplitude of the alternating stress. e For fatigue limit, σ m For the mean stress, σ u It represents the ultimate strength.

[0039] Furthermore, the steps for solving the aforementioned system of mechanical equations specifically include:

[0040] Step 1: Discretization

[0041] The curved pipe is divided into a finite number of elements, each connected by nodes. For each element, a local stiffness matrix is ​​established.

[0042] Step 2: Assemble the global stiffness matrix

[0043] Assemble all local stiffness matrices into a global stiffness matrix K;

[0044] Step 3: Apply boundary conditions

[0045] Modify the global stiffness matrix and load vector based on the pipeline's support and constraint conditions;

[0046] Step 4: Solve the system of linear equations

[0047] Solve the equation KU=F, where U is the nodal displacement vector and F is the nodal force vector;

[0048] Step 5: Calculate stress and strain

[0049] Calculate the stress and strain of each element based on the nodal displacements;

[0050] Step 6: Post-processing

[0051] The analysis results identified the hazardous areas and points of maximum stress in the pipeline.

[0052] Step 7: Optimize the design

[0053] Based on the analysis results, adjust the position and size of the reinforcement structure, and repeat steps 1-6 until the design requirements are met.

[0054] Specifically, step S10, establishing a three-dimensional model, includes:

[0055] Step 101: Based on the given building foundation plan, collect information such as the geometric dimensions, location, and relationship with the surrounding building structure of the curved pipe;

[0056] Step 102: Using BIM software, create a 3D model of the curved pipe based on the collected information, and define the pipe's material, wall thickness, process parameters, and other attributes.

[0057] Step 103: Check the initially established 3D model to ensure that the model's geometry, size, position, and other information are consistent with the actual design requirements, and make local optimizations and adjustments if necessary.

[0058] Step 104: Based on the 3D model, use the drawing function of BIM software to output detailed construction drawings such as plan view, elevation view, and section view of the curved pipe.

[0059] Specifically, step S20, pipeline segmentation, includes:

[0060] Step 201: On the 3D pipeline model, identify the locations of breakpoints such as diameter changes, branches, segments, and bends.

[0061] Step 202: For each pipe break point, select a 5-10 meter long pipe segment on each side as the segmentation object;

[0062] Step 203: Convert the selected pipe segment into a straight pipe segment model to simplify subsequent parameter annotation and stress analysis.

[0063] Step 204: Reorganize and arrange the processed straight pipe sections according to the overall structure of the pipeline to form multiple independently processable arc-shaped pipe sections.

[0064] Specifically, step S30, model splitting, includes:

[0065] Step 301: Carefully check the geometry, dimensions, and connection relationships of each arc-shaped pipe segment to ensure that each segment meets the requirements for subsequent manufacturing and installation.

[0066] Step 302: Use the drawing function of BIM software to generate detailed two-dimensional process drawings for each independent arc-shaped pipe segment, including plan view, elevation view, section view, etc.

[0067] Step 303: For the generated pipe section detailed drawings, check the geometric dimensions, positional relationships, connection details and other information again to ensure the accuracy and completeness of the drawing content;

[0068] Step 304: Output the optimized pipe section detailed drawings in standard CAD or BIM format to provide data support for subsequent process parameter annotation, stress analysis and manufacturing processes.

[0069] Specifically, step S40, parameter marking, includes:

[0070] Step 401: Extract the geometric dimension parameters of each arc-shaped pipe segment's detailed drawing, including the arc radius, arc angle, straight pipe segment length, and arc pipe segment length;

[0071] Step 402: Mark the connection angle between the arc pipe section and the straight pipe section on the pipe section detail drawing to reflect the overall spatial shape of the pipeline;

[0072] Step 403: Label the material properties for each pipe segment, including the pipe grade, strength grade, coefficient of thermal expansion, and modulus of elasticity;

[0073] Step 404: Mark the extracted geometric, connection, and material parameters on the pipe section detailing drawing using text annotations.

[0074] Specifically, step S50, stress analysis, includes:

[0075] Step 501: Based on the detailed drawings and parameter information of the pipe section, use finite element analysis software to establish its three-dimensional finite element model, and define the material properties, wall thickness, support conditions, etc. in detail.

[0076] Step 502: For each pipe segment, set various loads that it may be subjected to, such as internal pressure, gravity, temperature change, and pipe vibration, as boundary conditions for finite element analysis.

[0077] Step 503: Using finite element analysis software, calculate the elastic deformation, thermal stress, compressive stress, bending stress, shear stress, axial stress, etc. of the pipeline under the above loads.

[0078] Step 504: Based on the calculation results, evaluate the structural strength and stability of the pipeline during installation and use, and design reinforced structures for high-stress areas;

[0079] Step 505: Adopt measures such as reinforcing ribs, circumferential reinforcing rings, and anti-buckling rings to design a reasonable reinforcing structure, and repeat steps 501-504 until the design requirements are met.

[0080] Specifically, step S60, manufacturing the prefabricated segment, includes:

[0081] Step 601: Based on the detailed pipe section drawing and stress analysis results, determine the manufacturing process parameters required such as bend radius, arc angle, pipe specifications, and welding method;

[0082] Step 602: Using a CNC pipe bending machine, the pipe is precisely bent and formed according to the determined process parameters to produce prefabricated parts of each arc-shaped pipe section.

[0083] Step 603: Using precision automatic welding equipment, butt welding is performed on the pipe ends of each arc-shaped pipe section prefabricated component, and the welding process meets the relevant standard requirements.

[0084] Step 604: Conduct a comprehensive inspection of each prefabricated arc-shaped pipe section after manufacturing to ensure that it meets quality standards, including dimensional accuracy, material properties, and weld quality.

[0085] Specifically, step S70, welding the reinforced structure, includes:

[0086] Step 701: Based on the stress analysis results, reinforce the key parts of each arc-shaped pipe section prefabricated component by making reinforcing ribs, corrugated ribs, circumferential reinforcing rings and other reinforcing structures.

[0087] Step 702: Fix the fabricated reinforcing structural components to the corresponding precast pipe sections using precision welding to ensure a reliable connection;

[0088] Step 703: After the reinforcement structure is installed, use finite element analysis again to calculate the stress of the entire prefabricated pipe section to verify the effectiveness of the reinforcement measures.

[0089] Step 704: If the stress analysis results are still not ideal, the dimensions, location and other parameters of the reinforced structure need to be optimized and adjusted, and steps 701-703 are repeated.

[0090] Specifically, step S80, quality inspection, includes:

[0091] Step 801: Use a coordinate measuring machine and other equipment to check whether the geometric dimensions of each arc-shaped pipe section prefabricated component meet the requirements of the design drawings;

[0092] Step 802: Use a spectrometer, tensile testing machine, etc. to test the chemical composition, mechanical properties and other indicators of the pipe material to ensure that it meets the design and usage conditions;

[0093] Step 803: Perform non-destructive testing on the welds of each precast section, such as ultrasonic testing and X-ray imaging, to comprehensively evaluate the internal quality of the welds.

[0094] Step 804: Comprehensively evaluate the test results of dimensions, materials and weld quality. Only qualified prefabricated sections can proceed to the subsequent on-site installation.

[0095] Specifically, step S90, on-site installation, includes:

[0096] Step 901: At the construction site, use equipment such as laser rangefinders to conduct detailed measurements of the installation location of the pipeline and its relative position to the surrounding building structures.

[0097] Step 902: Using a three-dimensional measurement system such as a laser tracker, combined with on-site measurement data, accurately locate each precast pipe section in three-dimensional space.

[0098] Step 903: Using skilled workers' manual welding techniques, firmly weld each prefabricated arc-shaped pipe section onto the building's supporting structure.

[0099] Step 904: Conduct a comprehensive inspection of the overall geometric dimensions, spatial position, welding quality, and other indicators to ensure that the installation quality meets the design standards;

[0100] Step 905: In accordance with the design requirements, debug and test run the entire pipeline system to verify parameters such as pipeline pressure, flow rate, and temperature, as well as the vibration and deformation of the structure.

[0101] Optionally, in the parameter marking of step S40, the value range of the arc radius R is 5-50 meters, the value range of the arc angle θ is 30°-180°, the value range of the straight pipe section length Ls is 5-10 meters, and the value range of the arc pipe section length La is 5-10 meters, so as to meet the design requirements of pipelines of different scales and complexities.

[0102] Optionally, in the stress analysis of step S50, the internal pressure p ranges from 0.5 to 2.0 MPa, the temperature change ΔT ranges from -20 to 50℃, and the pipeline vibration Fv ranges from 50 to 200 N, so as to cover various load conditions that the pipeline may suffer in the actual operating environment.

[0103] Optionally, in step S60, when manufacturing the prefabricated section, the minimum bending radius of the CNC pipe bending machine is not less than 5 times the pipe diameter to ensure that the pipe does not undergo excessive deformation and damage during the bending process.

[0104] Optionally, in the step S70 welding of the reinforcing structure, the thickness of the reinforcing ribs and corrugated ribs is not less than 1.5 times the pipe wall thickness, and the spacing of the circumferential reinforcing rings is not greater than 1 / 4 of the pipe length, so as to improve the overall deformation resistance and buckling resistance of the pipe.

[0105] Optionally, in the quality inspection step S80, the allowable deviation for the dimensional inspection is ±2mm, the mechanical performance index of the material inspection should not be lower than the requirements of the corresponding pipe material in GB / T 3098.1-2010 standard, and the weld quality should meet the acceptance standards of GB / T14173-2008 standard to ensure the manufacturing quality of the prefabricated section.

[0106] Compared with existing technologies, this invention fully integrates advanced technologies such as BIM modeling, finite element analysis, CNC machining and precision assembly, and realizes a high degree of digitalization and intelligence in the entire process from design and manufacturing to on-site installation, which greatly improves the overall accuracy and reliability of arc-shaped pipeline construction.

[0107] Specifically, this method first establishes a 3D model of the curved pipeline using BIM software, and then draws detailed construction drawings based on this model. On this basis, finite element analysis is used to perform stress calculations and structural optimization design for each curved pipe segment, ensuring the safety and stability of the pipeline under various loads.

[0108] In the manufacturing process, this method utilizes CNC pipe bending machines and precision welding equipment to produce high-quality prefabricated arc-shaped pipe sections according to optimized design parameters. With the aid of laser measurement and 3D positioning technology, these prefabricated sections are precisely installed onto the building structure on-site, achieving a high degree of automation and one-time molding of the pipeline installation.

[0109] Compared with existing methods for constructing curved pipes, this invention has the following significant advantages:

[0110] 1. Significantly improved design accuracy. By establishing a three-dimensional model, mechanical equations, and finite element analysis, the stress-strain state of the pipeline under various working conditions can be comprehensively evaluated, and structural optimization design can be carried out for key parts to ensure the safety and reliability of the pipeline.

[0111] 2. Significantly improved manufacturing quality. By employing CNC forming and precision welding processes, prefabricated arc-shaped pipe sections with high dimensional accuracy and excellent welding quality can be manufactured, laying a solid foundation for subsequent on-site installation.

[0112] 3. Significantly improved installation accuracy. Utilizing laser measurement and 3D positioning technology, pipelines can be precisely aligned with building structures during on-site installation, preventing the accumulation of errors in the pipeline system and improving overall installation quality.

[0113] 4. Significantly improved construction efficiency. By manufacturing prefabricated sections in advance and positioning them precisely, the workload of on-site welding and commissioning is greatly reduced, shortening the pipeline installation cycle.

[0114] In summary, the high-precision on-site fabrication and installation method for arc-shaped metal pipes of the present invention fully leverages the potential of digital modeling, finite element analysis, advanced manufacturing, and precision assembly technologies, and solves the technical problem that existing technologies are unable to meet the increasingly complex requirements of pipe installation precision in construction projects. Attached Figure Description

[0115] Figure 1 A flowchart of the method provided by the present invention. Detailed Implementation

[0116] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0117] like Figure 1 The diagram shown is a flowchart of a high-precision on-site fabrication and installation method for an arc-shaped metal pipe provided by this invention. This method includes the following steps: (The steps are not explicitly stated in the original text.)

[0118] S10. Create a 3D model: Based on the building's basic floor plan, use BIM software to create a 3D volumetric model of the curved pipe, and draw a detailed model drawing of the curved pipe based on this model.

[0119] S20. Pipeline segmentation: On the arc-shaped pipeline model diagram, take the section where the pipeline break point is located as the center, and select arc-shaped pipelines of predetermined length on both sides for straight pipe segment processing. Pipeline break points include diameter change points, branch points, segmentation points, and pipe upturning or downturning points.

[0120] S30, Model Decomposition: Decompose the arc-shaped pipe model drawing to form a detailed drawing of multiple arc-shaped pipe segments;

[0121] S40. Parameter marking: Mark the parameters of each arc-shaped pipe section in the detailed drawing, including the arc radius, arc angle, connection angle between the straight pipe section and the arc section, arc length of the arc section and length of the straight pipe section.

[0122] S50. Stress Analysis: Use finite element analysis software to perform stress analysis on each section of the arc-shaped pipe to ensure its structural stability during installation and use, and design the reinforcement structure of each section of the arc-shaped pipe, including reinforcing ribs, corrugated ribs, circumferential reinforcing rings, longitudinal reinforcing ribs, diagonal supports and buckling-resistant rings.

[0123] S60. Manufacturing prefabricated sections: Based on the detailed drawings and stress analysis results of each section of the arc-shaped pipe, multiple prefabricated arc-shaped pipe sections are manufactured using CNC pipe bending machines and precision welding equipment.

[0124] S70, Welded Reinforcement Structure: Welded reinforcement structure for each prefabricated arc-shaped pipe section;

[0125] S80. Quality Inspection: Non-destructive testing of the dimensions, materials, and weld quality of the prefabricated arc-shaped pipe sections after manufacturing is carried out to ensure that they meet the design requirements.

[0126] S90. On-site installation: Multiple prefabricated arc-shaped pipe sections are transported to the construction site, precisely positioned using a laser positioning instrument, and then welded onto the building structure.

[0127] The specific implementation methods of the above steps are described in detail below:

[0128] Step S10: Create a 3D model

[0129] The specific implementation method is as follows:

[0130] 1. Data collection: First, based on the given building foundation plan, collect information such as the geometric dimensions, location, and relationship with the surrounding building structure of the curved pipe.

[0131] 2. 3D Modeling: Using BIM (Building Information Modeling) software, such as Revit or ArchiCAD, a 3D model of the curved pipe is created based on the collected information. During the modeling process, attributes such as the pipe's material, wall thickness, and manufacturing parameters need to be defined.

[0132] 3. Model Optimization: Check the initially established 3D model to ensure that its geometry, dimensions, and positions are consistent with the actual design requirements. Local optimization and adjustments may be made as necessary to ensure the model's accuracy and integrity.

[0133] 4. Drawing Output: Based on the 3D model, detailed construction drawings, including plan views, elevation views, and section views, are output using the drawing functions of BIM software. These drawings will provide a basis for subsequent pipeline segmentation, parameter labeling, and other related work.

[0134] The purpose of this step is to establish an accurate and complete 3D model of the curved pipeline, providing fundamental data support for subsequent pipeline segmentation, parameter annotation, and other processes. BIM technology enables the organic integration of the pipeline model with surrounding building information, helping to improve the accuracy and reliability of pipeline installation.

[0135] Step S20: Pipeline segmentation

[0136] The specific implementation method is as follows:

[0137] 1. Identify pipe breaks: Carefully examine and identify the locations of pipe breaks, such as diameter changes, branches, sections, and bends, on the 3D pipe model. These breaks will serve as the basis for pipe segmentation.

[0138] 2. Determine the segment length: For each pipe break point, select a certain length of pipe segment on both sides as the segment object. This predetermined length can be determined according to the overall geometry of the pipe and the installation process requirements, and is usually 5-10 meters.

[0139] 3. Straight Pipe Section Processing: For each pipe segment, convert it into a straight pipe section model. The purpose of this step is to simplify subsequent parameter annotation and stress analysis, as straight pipe sections are relatively easy to calculate and fabricate.

[0140] 4. Pipe Segment Organization: The processed straight pipe segments are reorganized and arranged according to the overall pipeline structure to form multiple independently processable arc-shaped pipe segments. These pipe segments will serve as the basic units for subsequent manufacturing and installation.

[0141] The purpose of this step is to divide the complex, integral curved pipe into multiple independently processable straight pipe sections, laying the foundation for subsequent parameter labeling, stress analysis, and manufacturing processes. By rationally segmenting the pipe, calculation analysis and manufacturing processes can be simplified, improving the overall efficiency and accuracy of construction.

[0142] Step S30: Model Splitting

[0143] The specific implementation method is as follows:

[0144] 1. Pipe segment identification: Based on the aforementioned pipe segmentation process, carefully check the geometry, dimensions, connection relationships, and other information of each arc-shaped pipe segment to ensure that each pipe segment meets the requirements for subsequent manufacturing and installation.

[0145] 2. Drawing Generation: Using the drawing functions of BIM software, detailed 2D process drawings are generated for each individual curved pipe segment, including plan views, elevation views, and sectional views. These detailed drawings, specifically for each pipe segment, will provide a basis for subsequent parameter annotation, stress analysis, and manufacturing processes.

[0146] 3. Drawing Optimization: For the generated detailed pipe section drawings, carefully review their geometric dimensions, positional relationships, connection details, and other information to ensure the accuracy and completeness of the drawing content. Local optimization and adjustments can be made if necessary.

[0147] 4. Data Output: The optimized pipe section detailed drawings are output in standard CAD or BIM format to provide data support for subsequent process parameter annotation, stress analysis and manufacturing processes.

[0148] The purpose of this step is to further break down the overall curved pipe model into multiple independent pipe segment detailed drawings, providing accurate and detailed data support for subsequent parameter annotation, stress analysis, and manufacturing processes. This breakdown process allows for more targeted design and manufacturing based on the characteristics of each pipe segment.

[0149] Step S40: Parameter marking

[0150] The specific implementation method is as follows:

[0151] 1. Geometric Parameter Extraction: For each individual arc-shaped pipe segment detailed drawing, extract its geometric dimensional parameters, including the arc radius R, radian angle θ, and straight pipe segment length L. s Length L of the arc pipe section a These geometric parameters will provide fundamental data for subsequent stress analysis and manufacturing processes.

[0152] 2. Connection Parameter Extraction: On the detailed pipe section drawing, mark the connection angle α between the arc pipe section and the straight pipe section. This parameter reflects the overall spatial morphology of the pipeline and has a significant impact on stress analysis and installation process.

[0153] 3. Material Parameter Labeling: Label the material properties for each pipe section, including the pipe grade, strength class, coefficient of thermal expansion α, and modulus of elasticity E. These parameters will be used for subsequent stress calculations and structural optimization.

[0154] 4. Drawing Annotations: The extracted geometric, connection, and material parameters are annotated on the pipe section detailing drawing using text annotations. This ensures that all parameter information is presented intuitively and clearly on the drawing, facilitating subsequent stress analysis and manufacturing processes.

[0155] The purpose of this step is to comprehensively annotate the parameters of each individual curved pipe segment, including geometric dimensions, connection relationships, and material properties. This detailed parameter information will provide reliable data support for subsequent stress analysis calculations and the formulation of manufacturing processes, ensuring the accuracy and reliability of the entire construction process.

[0156] Step S50: Stress Analysis

[0157] The specific implementation method is as follows:

[0158] 1. Establish a finite element model: Based on the detailed drawings and parameter information of each arc-shaped pipe segment, establish a three-dimensional finite element model using finite element analysis software (such as ANSYS, Abaqus, etc.). In the model, the material properties, wall thickness, support conditions, etc. of the pipe need to be precisely defined.

[0159] 2. Load Setting: For each arc-shaped pipe segment, set various possible loads it may experience, including internal pressure p, gravity G, temperature change ΔT, and pipe vibration F. v These load information will be input into the finite element model as boundary conditions.

[0160] 3. Stress Calculation: Using finite element analysis software, stress calculation and analysis are performed on the established pipeline model. Specifically, it is necessary to calculate the elastic deformation u, v, w of the pipeline under the various loads mentioned above, and derive the thermal stress σ accordingly. th Pressure stress σ p Bending stress σ b Shear stress τ, axial stress σ a Various stress components, etc.

[0161] 4. Stress Assessment: Based on the calculation results, assess the structural strength and stability of the pipeline during installation and use. For high-stress areas exceeding the material strength limit, further optimization of the pipeline's reinforcement structure is required.

[0162] 5. Strengthen structural design: For high-stress areas, adopt measures such as reinforcing ribs, corrugated ribs, circumferential reinforcing rings, longitudinal reinforcing ribs, diagonal supports, and anti-buckling rings to design a reasonable strengthening structure. Repeat steps 1-4 until the stress level of the pipeline meets the design requirements.

[0163] The purpose of this step is to comprehensively assess the stress state of each curved pipe segment under various loads and design reasonable reinforcement structures for high-stress areas to ensure the overall structural stability and operational safety of the pipeline. This analysis process fully utilizes the numerical simulation technology of finite element analysis, which can more accurately predict the mechanical behavior of the pipeline under actual working conditions.

[0164] Step S60: Manufacturing prefabricated sections

[0165] The specific implementation method is as follows:

[0166] 1. Determination of process parameters: Based on the detailed drawings and stress analysis results of each arc-shaped pipe section, determine the various process parameters required for its manufacturing, including the bend radius R, arc angle θ, pipe specifications, welding method, etc. These parameters will directly affect the manufacturing quality of the prefabricated section.

[0167] 2. CNC Machining: Using CNC pipe bending machines, pipes are precisely bent and shaped according to determined process parameters to manufacture prefabricated arc-shaped pipe sections. During the bending process, dimensional tolerances must be strictly controlled to ensure that the geometry of each prefabricated section matches the design requirements.

[0168] 3. Precision Welding: For each prefabricated arc-shaped pipe section, butt welding of the pipe ends is performed using precision automated welding equipment. The welding process should meet the relevant standard requirements to ensure that the weld quality meets the service conditions. If necessary, pre-weld, during-weld, and post-weld heat treatment processes can be used to improve weld performance.

[0169] 4. Quality Inspection: Each prefabricated arc-shaped pipe section, once manufactured, should undergo comprehensive testing for dimensional accuracy, material properties, and weld quality. Only after passing rigorous quality inspection can it proceed to the subsequent installation stage.

[0170] In the design of the reinforcement structure for each segment of the arc-shaped pipe, a set of mechanical equations is established, including the elastic deformation equation, thermal expansion stress equation, fluid pressure stress equation, bending stress equation, shear stress equation, axial stress equation, and fatigue stress equation, to achieve multi-objective optimization of the arc-shaped pipe. The optimization objectives include: structural strength optimization, material usage minimization, seismic performance improvement, thermal stress compensation, fluid impact mitigation, vibration suppression, and service life extension.

[0171] Each equation and its analytical process are described in detail below:

[0172] 1. Elastic deformation equation:

[0173]

[0174] Where u, v, and w represent radial, circumferential, and axial displacements, respectively, and r, θ, and z are coordinates in a cylindrical coordinate system.

[0175] 2. Thermal expansion stress equation:

[0176]

[0177] Where, σ th Let E be the thermal stress, E be the elastic modulus, α be the coefficient of linear expansion, ΔT be the temperature change, r be the current radius, and R be the outer radius of the pipe.

[0178] 3. Fluid pressure stress equation:

[0179]

[0180] Where, σ p Where p is the pressure stress, r is the current radius, t is the pipe wall thickness, and b is the inner radius of the pipe.

[0181] 4. Bending stress equation:

[0182]

[0183] Where, σ b Let M be the bending stress, M be the bending moment, y be the distance from the neutral axis, I be the moment of inertia of the cross section, and D be the bending stress. o and D i These refer to the outer diameter and inner diameter of the pipe, respectively.

[0184] 5. Shear stress equation:

[0185]

[0186] Where τ is the shear stress, V is the shear force, A is the cross-sectional area, r is the current radius, and R is the outer radius of the pipe.

[0187] 6. Axial stress equation:

[0188]

[0189] Where, σ a denoted as axial stress, F as axial force, A as cross-sectional area, p as internal pressure, r as average radius, and t as pipe wall thickness.

[0190] 7. Fatigue stress equation:

[0191]

[0192] Where, σ a Let σ be the amplitude of the alternating stress. e For fatigue limit, σ m For the mean stress, σ u It represents the ultimate strength.

[0193] To solve this complex system of equations, a numerical method, such as the finite element method (FEM), is required. The solution steps are as follows:

[0194] Step 1: Discretization

[0195] The curved pipe is divided into a finite number of elements, each connected by nodes. For each element, a local stiffness matrix is ​​established.

[0196] Step 2: Assemble the global stiffness matrix

[0197] Assemble all local stiffness matrices into a global stiffness matrix K.

[0198] Step 3: Apply boundary conditions

[0199] Modify the global stiffness matrix and load vector based on the pipeline's support and constraint conditions.

[0200] Step 4: Solve the system of linear equations

[0201] Solve the equation KU=F, where U is the nodal displacement vector and F is the nodal force vector.

[0202] Step 5: Calculate stress and strain

[0203] Calculate the stress and strain of each element based on the nodal displacements.

[0204] Step 6: Post-processing

[0205] The analysis results identified the dangerous areas and points of maximum stress in the pipeline.

[0206] Step 7: Optimize the design

[0207] Based on the analysis results, adjust the position and size of the reinforcement structure, and repeat steps 1-6 until the design requirements are met.

[0208] The purpose of this step is to manufacture high-quality precast components using advanced CNC machining and precision welding technologies, based on the detailed design information of each curved pipe segment. Through strict control of process parameters and quality inspection, it can be ensured that the geometric accuracy, material properties, and welding quality of each precast segment meet the design requirements, laying the foundation for subsequent on-site installation.

[0209] Step S70: Welding the reinforced structure

[0210] The specific implementation method is as follows:

[0211] 1. Reinforcement Structure Fabrication: Based on the stress analysis results, corresponding reinforcement structures are fabricated for key parts of each arc-shaped pipe section prefabricated component (such as diameter changes, branch points, etc.), including reinforcing ribs, corrugated ribs, circumferential reinforcing rings, longitudinal reinforcing ribs, diagonal supports, and buckling-resisting rings. These reinforcement components can be manufactured by stamping, CNC cutting, or welding of steel plates.

[0212] 2. Reinforced Structure Installation: The various reinforced structural components are then precisely welded onto the corresponding prefabricated pipe sections. The welding process must ensure a reliable connection between the reinforced structure and the pipe body, and the weld quality must pass rigorous inspection.

[0213] 3. Stress Reanalysis: After the reinforced structure is installed, finite element analysis should be used again to calculate the stress of the entire prefabricated pipe section. The purpose is to verify whether the reinforcement measures can effectively reduce the stress level of critical parts of the pipeline and meet the design requirements.

[0214] 4. Optimization and Iteration: If the stress analysis results are still not ideal, the dimensions, location and other parameters of the reinforced structure need to be optimized and adjusted, and steps 1-3 are repeated until the stress level of the pipeline reaches an acceptable range.

[0215] The purpose of this step is to add various reinforcing structures to key areas based on the stress analysis results, in order to effectively reduce the high stress that the pipeline may experience during installation and use, and improve the overall structural strength and stability. Through repeated stress analysis and optimization iterations, the effectiveness and reliability of the reinforcement measures can be ensured.

[0216] Step S80: Quality Inspection

[0217] The specific implementation method is as follows:

[0218] 1. Dimensional Inspection: For each prefabricated arc-shaped pipe section, precision measuring equipment such as a coordinate measuring machine is used to check whether its geometric dimensions meet the requirements of the design drawings. Special attention is paid to key parameters such as the arc radius R, arc angle θ, pipe diameter D, and wall thickness t to ensure that all dimensional tolerances are within the allowable range.

[0219] 2. Material Testing: Spectrometers, tensile testing machines, and other testing equipment are used to test the chemical composition and mechanical properties of the pipe materials to ensure they meet design requirements. Heat treatment process tests may be conducted if necessary to verify the stability of the material properties.

[0220] 3. Weld Inspection: Non-destructive testing, such as ultrasonic testing and X-ray imaging, is performed on the welds of each precast section to comprehensively assess the internal quality of the welds. Special attention is paid to inspecting defects such as porosity, slag inclusions, and cracks in the welds to ensure that the weld performance meets relevant standards.

[0221] 4. Comprehensive Evaluation: The inspection results of dimensions, materials, and weld quality will be comprehensively evaluated. Only prefabricated sections that meet all the standards can proceed to the subsequent on-site installation stage. Unqualified products should be reworked or scrapped.

[0222] The purpose of this step is to conduct comprehensive quality inspections on each prefabricated arc-shaped pipe segment to ensure that its geometric dimensions, material properties, and welding quality all meet design requirements. Only through rigorous quality acceptance can the smooth progress of subsequent on-site installation and reliable operation be guaranteed.

[0223] Step S90: On-site installation

[0224] The specific implementation method is as follows:

[0225] 1. On-site measurement: At the construction site, precision measuring equipment such as laser rangefinders are used to measure in detail the installation location of the pipeline and its relative position with the surrounding building structures, providing accurate basic data for subsequent positioning and installation.

[0226] 2.3D Positioning: Multiple prefabricated curved pipe segments are transported to the site. Using a 3D measurement system such as a laser tracker, combined with the aforementioned on-site measurement data, each pipe segment is precisely positioned in 3D space. This step ensures that the pipe segment can be accurately installed in the designed location.

[0227] 3. Welding and Fixing: After precise positioning, skilled workers use manual welding techniques to firmly weld each prefabricated arc-shaped pipe section to the building's supporting structure. Strict control of welding process parameters is required during welding to ensure the weld quality meets usage requirements.

[0228] 4. On-site inspection: After the pipeline installation is completed, a comprehensive inspection should be conducted on the overall geometric dimensions, spatial position, welding quality, and other indicators to ensure that the installation quality meets the design standards. Any problems found should be reworked or corrected in a timely manner.

[0229] 5. System Commissioning: After pipeline installation is completed, the entire pipeline system should be commissioned and trial-run according to design requirements. This includes verifying parameters such as internal pressure, flow rate, and temperature, as well as monitoring the vibration and deformation of the pipeline structure. Only after passing comprehensive commissioning can the system be put into actual use.

[0230] The purpose of this step is to precisely install the pre-manufactured curved pipe segments onto the building to form a complete piping system. Through precise on-site positioning, reliable welding, and comprehensive inspection, the installation quality and performance of the pipeline are ensured to meet design requirements. The final system commissioning stage is the ultimate verification of the pipeline installation quality and operational status.

[0231] In summary, the specific implementation of this invention comprises 10 steps, covering a comprehensive construction process from 3D modeling, pipe segmentation, parameter annotation, stress analysis, manufacturing, to on-site installation. Each step employs corresponding mathematical modeling, numerical analysis, and advanced manufacturing technologies to ensure the geometric accuracy, structural strength, and reliability of the pipe. The entire method fully utilizes BIM technology, finite element analysis, and precision manufacturing to achieve high-precision on-site fabrication and installation of curved metal pipes, providing an effective solution for complex construction projects.

[0232] Specifically, the principle of this invention is:

[0233] 1. BIM Modeling and Stress Analysis

[0234] First, this method utilizes BIM software to create a 3D model of the curved pipe and then draws detailed construction drawings based on design requirements. This modeling process ensures the accuracy of the pipe's geometry and dimensions, laying the foundation for subsequent manufacturing and installation.

[0235] Based on this, finite element analysis was used to calculate stress and optimize the structure of each arc-shaped pipeline segment. By considering various complex loads such as internal pressure, gravity, and temperature changes, the stress-strain state of the pipeline during installation and use can be accurately predicted. Corresponding reinforcement structures, such as reinforcing ribs and circumferential reinforcing rings, were designed for high-stress areas. This analysis process ensures the overall structural stability and safety of the pipeline.

[0236] 2. Advanced manufacturing processes

[0237] In the manufacturing process, this method utilizes CNC pipe bending machines and precision welding equipment to produce high-quality prefabricated curved pipe sections according to optimized design parameters. Compared to traditional cold bending or welding processes for steel pipes, this CNC machining method can precisely control the geometry of the pipe, significantly improving manufacturing accuracy. Simultaneously, the use of precision automatic welding technology ensures the stability of weld quality, laying the foundation for subsequent on-site installation.

[0238] 3. Precise on-site installation

[0239] During pipeline installation, this method utilizes laser measurement and three-dimensional positioning technology to precisely locate each prefabricated arc-shaped pipe segment on-site. This positioning process ensures that the connection angles and relative positions between pipe segments strictly meet design requirements, avoiding the accumulation of pipeline system errors. Subsequently, manual welding is used to firmly fix the pipe segments to the building structure, making the entire installation process highly automated and precisely controllable.

[0240] In summary, the core technical principle of this invention lies in fully utilizing digital modeling, finite element analysis, advanced manufacturing, and precision assembly to achieve highly precise control over the entire process from the design of the curved pipeline to its on-site installation. By establishing a three-dimensional model using BIM technology and performing stress analysis and optimization, the safety and reliability of the pipeline structure are ensured. High-quality prefabricated pipe sections are manufactured using CNC machining and precision welding processes. Finally, laser measurement and three-dimensional positioning technology are used to achieve precise on-site installation of the pipe sections, thereby significantly improving the overall accuracy and efficiency of curved metal pipeline construction.

[0241] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for high-precision on-site fabrication and installation of an arc-shaped metal pipe, characterized in that, Includes the following steps: S10. Create a 3D model: Based on the building's basic floor plan, use BIM software to create a 3D volumetric model of the curved pipe, and draw a detailed model drawing of the curved pipe based on this model. S20. Pipeline segmentation: On the arc-shaped pipeline model diagram, with the section where the pipeline break point is located as the center, select arc-shaped pipelines of predetermined length on both sides for straight pipe segment processing. The pipeline break point includes diameter change points, branch points, segmentation points, and pipeline upturn or downturn points. S30, Model Decomposition: Decompose the arc-shaped pipe model drawing to form a detailed drawing of multiple arc-shaped pipe segments; S40. Parameter marking: Mark the parameters of each arc-shaped pipe section in the detailed drawing, including the arc radius, arc angle, connection angle between the straight pipe section and the arc section, arc length of the arc section and length of the straight pipe section. S50. Stress Analysis: Use finite element analysis software to perform stress analysis on each section of the arc-shaped pipe to ensure its structural stability during installation and use, and design the reinforcement structure of each section of the arc-shaped pipe, including reinforcing ribs, corrugated ribs, circumferential reinforcing rings, longitudinal reinforcing ribs, diagonal supports and buckling-resistant rings. S60. Manufacturing prefabricated sections: Based on the detailed drawings and stress analysis results of each section of the arc-shaped pipe, multiple prefabricated arc-shaped pipe sections are manufactured using CNC pipe bending machines and precision welding equipment. S70, Welded Reinforcement Structure: Welded reinforcement structure for each prefabricated arc-shaped pipe section; S80. Quality Inspection: Non-destructive testing of the dimensions, materials, and weld quality of the prefabricated arc-shaped pipe sections after manufacturing is carried out to ensure that they meet the design requirements. S90. On-site installation: Multiple prefabricated arc-shaped pipe sections are transported to the construction site, precisely positioned using a laser positioning instrument, and then welded onto the building structure.

2. The method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 1, characterized in that, In the design of the reinforcement structure for each segment of the arc-shaped pipe, a set of mechanical equations is established, including the elastic deformation equation, thermal expansion stress equation, fluid pressure stress equation, bending stress equation, shear stress equation, axial stress equation, and fatigue stress equation, to achieve multi-objective optimization of the arc-shaped pipe. The optimization objectives include: structural strength optimization, material usage minimization, seismic performance improvement, thermal stress compensation, fluid impact mitigation, vibration suppression, and service life extension.

3. The method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 2, characterized in that, The elastic deformation equation is specifically expressed as follows: Where u, v, and w represent radial, circumferential, and axial displacements, respectively, and r, θ, and z are coordinates in a cylindrical coordinate system.

4. The method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 3, characterized in that, The thermal expansion stress equation is specifically expressed as follows: Where, σ th Let E be the thermal stress, E be the elastic modulus, α be the coefficient of linear expansion, ΔT be the temperature change, r be the current radius, and R be the outer radius of the pipe.

5. The method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 4, characterized in that, The fluid pressure-stress equation is specifically expressed as follows: Where, σ p Where p is the pressure stress, r is the current radius, t is the pipe wall thickness, and b is the inner radius of the pipe.

6. The method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 5, characterized in that, The bending stress equation is specifically expressed as follows: Where, σ b Let M be the bending stress, M be the bending moment, y be the distance from the neutral axis, I be the moment of inertia of the cross section, and D be the bending stress. o and D i These refer to the outer diameter and inner diameter of the pipe, respectively.

7. A method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 6, characterized in that, The shear stress equation is specifically expressed as follows: Where τ is the shear stress, V is the shear force, A is the cross-sectional area, r is the current radius, and R is the outer radius of the pipe.

8. The method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 7, characterized in that, The axial stress equation is specifically expressed as follows: Where, σ a denoted as axial stress, F as axial force, A as cross-sectional area, p as internal pressure, r as average radius, and t as pipe wall thickness.

9. A method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 8, characterized in that, The fatigue stress equation is specifically expressed as follows: Where, σ a Let σ be the amplitude of the alternating stress. e For fatigue limit, σ m For the mean stress, σ u It represents the ultimate strength.

10. A method for high-precision on-site fabrication and installation of an arc-shaped metal pipe according to claim 9, characterized in that, The steps for solving the aforementioned set of mechanical equations specifically include: Step 1: Discretization The curved pipe is divided into a finite number of elements, each connected by nodes. For each element, a local stiffness matrix is ​​established. Step 2: Assemble the global stiffness matrix Assemble all local stiffness matrices into a global stiffness matrix K; Step 3: Apply boundary conditions Modify the global stiffness matrix and load vector based on the pipeline's support and constraint conditions; Step 4: Solve the system of linear equations Solve the equation KU=F, where U is the nodal displacement vector and F is the nodal force vector; Step 5: Calculate stress and strain Calculate the stress and strain of each element based on the nodal displacements; Step 6: Post-processing The analysis results identified the hazardous areas and points of maximum stress in the pipeline. Step 7: Optimize the design Based on the analysis results, adjust the position and size of the reinforcement structure, and repeat steps 1-6 until the design requirements are met.

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