Module unit production method, module unit installation method and module unit

Abstract

The invention discloses a module unit production method, a module unit installation method and a module unit. The module unit production method comprises the following steps that A1, components of the module unit are machined; a11, processing a connecting box of the node connecting device, and processing a friction surface of a fastener of the connecting box; a12, steel beams of the module units are machined; the step A11 and the step A12 can be carried out in sequence and can also be carried out at the same time; and A2, selecting a production mode according to the weight of each component derived by the three-dimensional model and / or the production takt time obtained according to the welding workload of each component measured and calculated by the model, and carrying out assembly, welding, pouring and decoration on the module units. According to the production method, people can be guided to select a proper production mode for assembling, welding, pouring and decorating the module units, the safety problem caused by the fact that the weight of an assembling structure of the module units is too large and the tool bearing capacity is too small is effectively avoided, and the phenomenon that a worker is lost due to the fact that the production takt is not coordinated is effectively avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of modular buildings, and in particular relates to a modular unit production method, an installation method and a modular unit. Background Art

[0002] Modular Integrated Construction (MiC) refers to a new type of building structure system that is formed by reliably connecting "module units" prefabricated in factories at the construction site. Module units are usually divided by rooms or a certain three-dimensional building space. The prefabricated parts in the factory include the main structure, enclosure structure, interior decoration, and electromechanical pipelines. The prefabrication ratio of modular buildings can be as high as 95%. It is a highly integrated prefabricated building and an advanced stage of the development of building industrialization.

[0003] MiC modular buildings have achieved the integration of standardized design, factory production, prefabricated construction, integrated decoration, and digital management. They have fundamentally overcome the shortcomings of traditional construction methods, broken the limitations of each link in design, production, construction and decoration, and achieved highly specialized collaboration in the upstream and downstream of the construction industry chain, promoting the transformation and upgrading of the construction industry to refinement, industrialization, low carbonization, and digitalization from all aspects of construction. Compared with traditional construction methods, modular buildings can reduce the on-site labor by 70% and the comprehensive construction period by more than 1 / 3; in terms of green and low carbon, modular buildings can reduce on-site construction waste by more than 75% and construction noise pollution by more than 90%. It is a new structural form that the industry has been vigorously promoting and guiding in recent years.

[0004] The connection nodes between modules are the key to the safe design of modular steel structures, and their reliability directly affects the performance of the overall structure. Most of the existing designs of connection nodes between modules are optimized only from the perspective of mechanical properties, without comprehensive consideration of construction convenience, and lack engineering applications, so their practicality is poor. The existing connection nodes between modules have problems such as large welding workload, high requirements for module unit processing accuracy, and difficult installation. Therefore, a new node connection device is currently designed and integrated into the module unit to improve the convenience of connecting module units. However, the existing production and installation technology cannot guide the production and construction of the new module unit. At present, there is a lack of a new module unit production method and installation method.

[0005] Therefore, a new technology is needed to solve the problem of lack of a new module unit production method and installation method in the prior art. Summary of the invention

[0006] In order to solve the above problems in the prior art, the present invention provides a modular unit production method, which can scientifically guide the production of modular units and ensure production efficiency and production quality.

[0007] A method for producing a modular unit comprises the following steps:

[0008] A1. Component processing of module units;

[0009] A11. Processing of the connection box of the node connection device and the friction surface treatment of the fasteners of the connection box;

[0010] A12, steel beam processing of module units;

[0011] The step A11 and the step A12 can be performed sequentially or simultaneously;

[0012] A2. According to the weight of each component derived from the 3D model and / or the production rhythm obtained from the welding workload of each component calculated according to the model, the production mode is selected to assemble, weld, cast and decorate the module units.

[0013] Furthermore, the step A2 comprises the following steps:

[0014] A21. If the weight of the top frame or bottom frame of the module unit plus the connection box is greater than the load-bearing weight of the tooling, and / or if the workstation tact of the top frame with connection box welding and the bottom frame with connection box welding is greater than the production tact of the general assembly area, the side frame production mode is adopted, otherwise, the non-side frame production mode is adopted.

[0015] Furthermore, in the step A2, when the selected production mode is the side frame production mode, the following steps are included:

[0016] B1. Assembly welding of the long side frame beam and secondary beam of the module unit;

[0017] B11, assembly welding of the long side top frame beam and top secondary beam of the module unit;

[0018] B12, assembly welding of the long side bottom frame beam and bottom secondary beam of the module unit;

[0019] Wherein, step B11 and step B12 can be performed successively or simultaneously;

[0020] B2. The columns and connection boxes of the module units are welded together to form a side frame;

[0021] B3, the side frame is welded with the top frame and bottom frame of the module unit to form an integral steel frame module;

[0022] B4. Top and bottom frame steel plate welding and bolting construction;

[0023] B5. Pipeline pre-embedding and concrete pouring;

[0024] B6. Interior decoration and mechanical and electrical construction of modular units;

[0025] In the step A2, when the selected production mode is the non-side frame production mode, the following steps are included:

[0026] C1. Position welding of the long side frame beam of the module unit and the connection box;

[0027] C2, the robot arm grabs the secondary beams in turn and de-welds them with the long side frame beams;

[0028] C3, welding of connection box and short side frame beam;

[0029] C4, top frame steel plate welding;

[0030] C5, column assembly welding;

[0031] C6, bottom frame steel plate welding and bolting construction;

[0032] C7, pipeline pre-embedding and concrete pouring;

[0033] C8. Modular unit interior decoration and mechanical and electrical construction.

[0034] Furthermore, when the selected production mode is the non-side frame production mode, when the module unit is assembled as a whole, the bottom frame is first positioned to obtain a positioning point, and a positioning point is set in the middle of the assembly frame to ensure the verticality of the column through the two-point coordinates; when installing the top frame, the upper frame position is repositioned to ensure installation accuracy.

[0035] Another object of the present invention is to provide a method for installing a module unit, which can scientifically guide the installation of the module unit and ensure the installation efficiency and quality.

[0036] A method for installing a module unit comprises the following steps:

[0037] D1. Produce according to the modular unit production method, and transport the produced qualified modular units to the construction site;

[0038] D2. Module unit hoisting;

[0039] D3, module unit leveling;

[0040] D4, modular units are connected to the on-site operating structure;

[0041] D5. Carry out fireproof sealing of gaps between module units, then place the connecting plates between module units, hoist the upper module units and connect them to the lower module units through fastening components, and repeat until all module units are installed.

[0042] Furthermore, during the installation process of step D5, waterproofing and fireproofing of horizontal and vertical seams between the facade module units are interspersed, and the roofing layer, partial decoration of the facade, and pipeline connection construction are carried out.

[0043] Furthermore, in the step D1, it is required that the production error of the overall height of the qualified module unit is negative and less than 3 mm.

[0044] Furthermore, in the step D3, when each layer of module units is leveled, the leveling is achieved by placing steel plates of different thicknesses at the position of the connection box, and the steel plates need to avoid the through holes on the connection box.

[0045] Furthermore, it is required that the overall height error of the module unit after leveling is less than ±1mm.

[0046] Another object of the present invention is to provide a modular unit to facilitate people to assemble the modular structure.

[0047] A module unit is manufactured according to the module unit production method, characterized in that it comprises a bottom frame, a column, a top frame and a node connection device; the node connection device comprises a connection box, and the connection box comprises a bottom connection box and a top connection box; the bottom frame comprises a bottom frame beam; at the bottom node position, the bottom frame beam is connected to the column through the bottom connection box; the top frame also comprises a top frame beam; at the top node position, the top frame beam is connected to the column through the top connection box;

[0048] The bottom frame further comprises a bottom secondary beam and a cast-in-place reinforced concrete floor slab; the bottom secondary beam and the cast-in-place reinforced concrete floor slab are arranged on the bottom frame beam; the top frame further comprises a top secondary beam and a steel plate; the top secondary beam and the steel plate are arranged on the top frame beam;

[0049] The module unit also includes a wall panel; the wall panel is arranged on the frame beam of the module unit as needed according to actual conditions for enclosure.

[0050] Compared with the prior art, the present invention has the following beneficial effects:

[0051] The modular unit production method of the present invention is a production method specifically designed for modular units with new connection boxes, which can scientifically guide the production of new modular units and ensure production efficiency and production quality. The production method can guide the orderly processing of modular unit components on site, and at the same time, can guide people to choose a suitable production mode for the assembly, welding, casting and decoration of modular units, effectively avoiding the safety problems caused by the excessive weight of the "assembly structure" of the modular unit and the small carrying capacity of the tooling, and effectively avoiding the phenomenon of idle work caused by uncoordinated production rhythm.

[0052] The present invention discloses a method for installing a module unit, which is a field construction installation method specifically designed for a module unit with a novel connection box. The installation method can scientifically guide people to correctly install the novel module unit, thereby ensuring installation efficiency and installation quality.

[0053] A module unit of the present invention has a novel connection box, and its overall manufacturing is obtained through a module unit production method of the present invention; the module unit can facilitate people to assemble the modular structure, solving the problems of high difficulty in assembling the module units, low assembly efficiency and large amount of welding in the past. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The technology of the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments:

[0055] Figure 1 It is a structural schematic diagram of the long side frame beam and the secondary beam when the present invention adopts the side frame production mode for production;

[0056] Figure 2 It is a structural schematic diagram of the present invention in which the column is first assembled with the connection box and then assembled with the short side frame beam when the side frame production mode is adopted;

[0057] Figure 3 It is a structural schematic diagram of a steel frame module in which columns and long side frame beams with secondary beams are assembled when the side frame production mode is adopted in the present invention;

[0058] Figure 4 It is a schematic diagram of the structure after the top and bottom frames are welded with steel plates when the side frame production mode is adopted in the present invention;

[0059] Figure 5 It is a schematic diagram of the local structure after the module unit bolts are constructed when the present invention adopts the side frame production mode;

[0060] Figure 6 It is a schematic diagram of the structure of the bottom frame of the module unit after concrete pouring when the side frame production mode is adopted in the present invention;

[0061] Figure 7 It is a structural schematic diagram of the long side frame beam and the connection box when the present invention is produced in a non-side frame production mode;

[0062] Figure 8 It is a schematic diagram of the structure formed when the present invention adopts the non-side frame production mode, the secondary beam is first assembled with the long side frame beam, and then the connection box is assembled with the short side frame beam;

[0063] Fig. 9 It is a simplified structural schematic diagram of the top frame after the steel plate is welded when the present invention is produced in a non-side frame production mode;

[0064] Fig.10 It is a structural schematic diagram of the top frame with steel plates, the bottom frame without steel plates and the columns when the present invention adopts the non-side frame production mode for production;

[0065] Fig.11 It is a structural schematic diagram of the bottom frame after the steel plate is welded when the present invention is produced in a non-side frame production mode;

[0066] Fig.12 It is a schematic diagram of the local structure of the module unit after the bolts are constructed when the present invention is produced in a non-side frame production mode;

[0067] Fig.13 It is a structural schematic diagram of the bottom frame of the module unit after concrete pouring when the present invention adopts the non-side frame production mode;

[0068] Fig.14 It is a structural schematic diagram of several module units after being installed using the "a method for installing a module unit" of the present invention;

[0069] Fig.15 is a schematic diagram of the structure of a first type of connection box;

[0070] Fig.16 is a schematic diagram of the structure of a first type of connecting plate;

[0071] Fig.17 yes Fig.16 A top view of

[0072] Fig.18 It is a partial schematic diagram (node ​​diagram) (exploded effect diagram) of connecting the upper module unit and the lower module unit through the first type connection box and the third type connection plate;

[0073] Fig.19 is a structural schematic diagram of an upper layer module unit and a lower layer module unit being connected via a second type connection box and a second type connection board;

[0074] Fig. 20 yes Fig.19 Layout diagram (node ​​diagram) (explosion effect diagram) of I-shaped steel at the node position of the middle column connection box;

[0075] Fig.21 yes Fig. 20 Structural diagram of the bottom corrugated plate arranged on the I-beam (node ​​diagram);

[0076] Fig. 22 yes Fig.21 Front view (simplified schematic diagram) (node ​​diagram).

[0077] Reference numerals:

[0078] 1-module unit; 11-long side frame beam; 12-secondary beam; 13-column; 14-connection box; 15-top frame; 16-bottom frame; 17-short side frame beam; 18-steel frame module; 19-steel plate; 20-bolt; 21-concrete; 22-fastener; 23-connection plate; 24-fastening assembly; 25-nut; 26-I-beam; 27-operation opening;

[0079] E-fastener friction surface; 141-through hole; E1-bottom connection box; E2-top connection box; 142-positioning hole; 143-operation opening; J1-first type connection box; J11-first area; J12-second area; K1-column position; K2-beam position; J2-second type connection box; J21-column position area; L1-circular shaft hole; L2-truncated cone hole;

[0080] 151-top frame beam; 152-top secondary beam; 153-steel plate;

[0081] 161- bottom frame beam; 162- bottom secondary beam; 163- cast-in-place reinforced concrete floor slab;

[0082] F1-upper module unit; F2-lower module unit;

[0083] G1-horizontal; G2-vertical;

[0084] H1-protrusion; H2-through hole; M1-first type connection board; M2-second type connection board; M3-third type connection board;

[0085] N-middle column; P-bottom corrugated plate; P1-peak. DETAILED DESCRIPTION

[0086] The following will be combined with the embodiments and drawings to clearly and completely describe the concept, specific structure and technical effects of the present invention, so as to fully understand the purpose, scheme and effect of the present invention. It should be noted that the embodiments in this application and the features in the embodiments can be combined with each other without conflict. The same reference numerals used throughout the drawings indicate the same or similar parts.

[0087] It should be noted that, unless otherwise specified, when a feature is referred to as being "fixed" or "connected" to another feature, it may be directly fixed or connected to the other feature, or it may be indirectly fixed or connected to the other feature. In addition, the descriptions of up, down, left, right, etc. used in the present invention are only relative to the relative positional relationship of the components of the present invention in the drawings.

[0088] The present invention provides a modular unit production method, which can scientifically guide the production of modular units and ensure production efficiency and production quality.

[0089] A method for producing a modular unit comprises the following steps:

[0090] A1, component processing of module unit 1;

[0091] A11, processing of the connection box 14 of the node connection device and processing of the friction surface E of the fastener of the connection box 14;

[0092] A12, processing of steel beams of module unit 1; the steel beams include top frame beam 151 (including long side frame beam 11 and short side frame beam 17), top secondary beam 152, column 13, bottom frame beam 161 (including long side frame beam 11 and short side frame beam 17), and bottom secondary beam 162 of module unit 1;

[0093] The step A11 and the step A12 may be performed sequentially or simultaneously. In one embodiment, before the step A1 is performed, the step A0 is also included, and the step A0 is to set up a welding platform.

[0094] A2. Select the production mode based on the weight of each component derived from the 3D model and / or the production cycle obtained based on the welding workload of each component calculated from the model. Figures 1 to 6 ,or Figures 7 to 13 , assemble, weld, cast and decorate the module units.

[0095] In one embodiment, the A2 step includes the following steps:

[0096] A21. If the weight of the top frame 15 or bottom frame 16 of the module unit 1 plus the connection box 14 is greater than the weight of the tooling, and / or if the workstation tact of the top frame 15 with the connection box welding and the bottom frame 16 with the connection box welding is greater than the production tact of the assembly area, the side frame production mode is adopted, otherwise, the non-side frame production mode is adopted. The side frame production mode reduces the operation time in the top and bottom frame production areas, so that the overall flow line does not have the phenomenon of idle work caused by uncoordinated tact.

[0097] In one embodiment, the production mode used is one or both of the side frame production mode and the non-side frame production mode, and the determination of the side frame production mode and the non-side frame production mode can be performed using step A21. When the production area is large enough, the side frame production mode and the non-side frame production mode can coexist; when the production area is limited, one of the side frame production mode and the non-side frame production mode is selected.

[0098] In one embodiment, the module unit 1 uses a positioning tool during the assembly process. The positioning tool adopts a component clamping mechanism and completes the clamping and positioning of the component through a hydraulic cylinder.

[0099] In one embodiment, in the A2 step, referring to Figures 1 to 6 , when the selected production mode is the side frame production mode, the following steps are included:

[0100] B1, the long side frame beam 11 and the secondary beam 12 of the module unit 1 are welded together;

[0101] B11, the long side top frame beam 151 and the top secondary beam 152 of the module unit 1 are welded together;

[0102] B12, the long side bottom frame beam 161 and the bottom secondary beam 162 of the module unit 1 are welded together;

[0103] Wherein, step B11 and step B12 can be performed successively or simultaneously;

[0104] B2. The column 13 and the connection box 14 of the module unit 1 are welded together to form a side frame;

[0105] B3, the side frame is welded with the top frame 15 and the bottom frame 16 of the module unit 1 to form an integral steel frame module 18; specifically, the side frame is first welded with the short side frame beams 17 and the short side frame beams 17 of the top frame 15 and the bottom frame 16 of the module unit 1, and then the assembled structure is welded with the long side frame beams 11 and the long side frame beams 11 of the top frame 15 and the bottom frame 16 to form an integral steel frame module 18;

[0106] B4, welding of top and bottom frame steel plates 19, and construction of (bottom frame) studs 20;

[0107] B5, pre-embedding of pipelines and pouring of (bottom frame) concrete 21;

[0108] B6, interior decoration and mechanical and electrical construction of module unit 1;

[0109] In one embodiment, in the B3 step, when the side frame and the top frame 15 and the bottom frame 16 of the module unit 1 are welded together into an integral steel frame module 18, a temporary diagonal brace is added for temporary reinforcement. The temporary diagonal brace is to ensure the verticality of the column 13 of the module unit 1.

[0110] Among them, in one embodiment, after implementing step B3, step B3.5 is also included, and step B3.5 is to align and test assemble the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2; when aligning and testing the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2, the alignment of the through hole 141 of the connecting box 14 should be measured with fasteners 22 of the same diameter. If the fasteners 22 cannot be penetrated, rectification should be carried out.

[0111] In one embodiment, the step B5 further includes binding of bottom plate reinforcement before pouring of concrete 21; and in one embodiment, the step B5 further includes installation of wall panels.

[0112] In the A2 step, refer to Figures 7 to 13 , when the selected production mode is the non-side frame production mode, the following steps are included:

[0113] C1, the long side frame beam 11 of the module unit 1 is positioned and welded with the connection box 14;

[0114] C2, the robot arm sequentially grabs the secondary beam 12 and de-welds it with the long side frame beam 11;

[0115] C3, the connection box 14 and the short side frame beam 17 are welded together;

[0116] C4, top frame 15 steel plate 19 welding;

[0117] C5, welding the columns 13; specifically, the top frame 15 with the steel plate 19, the bottom frame 16 without the steel plate 19 and the columns 13 are welded;

[0118] C6, welding of steel plate 19 of bottom frame 16, construction of (bottom frame) studs 20;

[0119] C7, pre-embedding of pipelines and pouring of (bottom frame) concrete 21;

[0120] C8. Interior decoration and mechanical and electrical construction of module unit 1.

[0121] Among them, in one embodiment, after implementing step C3, step C3.5 is also included, and step C3.5 is to align and test assemble the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2; when aligning and testing the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2, the alignment of the through hole 141 of the connecting box 14 should be measured with fasteners 22 of the same diameter. If the fasteners 22 cannot be penetrated, rectification should be carried out.

[0122] In one embodiment, the step C7 further includes binding of bottom plate reinforcement before pouring of concrete 21; and in one embodiment, the step C7 further includes installation of wall panels.

[0123] In one embodiment, when the selected production mode is a non-side frame production mode, in the C5 step, when the module unit 1 is assembled as a whole, the bottom frame 16 is first positioned to obtain a positioning point, and a positioning point is set in the middle position of the assembly frame (such as the middle of the column 13), and the verticality of the column 13 is ensured by the two-point coordinates; when installing the top frame 15, the upper frame position is repositioned to ensure installation accuracy.

[0124] In one embodiment, after step A2, step A3 is also included. Step A3 is: after the production of module unit 1 is completed, three-dimensional scanning technology is used to achieve virtual pre-assembly of the module unit to further ensure the production and installation accuracy of the module unit.

[0125] Another object of the present invention is to provide a method for installing a module unit, which can scientifically guide the on-site installation of the module unit and ensure the installation efficiency and quality.

[0126] A method for installing a module unit comprises the following steps:

[0127] D1. Produce according to the modular unit production method, and transport the produced qualified modular units 1 to the construction site;

[0128] D2, module unit 1 hoisting;

[0129] D3, module unit 1 leveling;

[0130] D4, the module unit 1 is connected to the on-site operation structure (the on-site operation part can be a concrete structure or a steel structure);

[0131] D5. Fireproof the gaps between the module units, then place the connecting plates 23 between the module units 1, hoist the upper module unit F1 and connect it to the lower module unit F2 through the fastening assembly 24, and repeat until all the module units 1 are installed (refer to Fig.14 ).

[0132] In one embodiment, the D1 step also includes a D0 step, and the D0 step is basic leveling.

[0133] In one embodiment, in step D1, the module unit 1 is transported to the construction site by a special low-bed truck.

[0134] In one embodiment, the fireproof sealing of the gaps between the module units is a horizontal G1 fireproof sealing of the gaps between the module units.

[0135] In one embodiment, during the installation process of step D5, waterproofing and fireproofing of horizontal and vertical seams between facade module units are interspersed, and roofing layer, partial facade decoration, and pipeline connection construction are carried out.

[0136] In one embodiment, the wall panels may also be installed in step D5.

[0137] In one embodiment, in the step D1, the production error of the overall height of the qualified module unit 1 is required to be negative and less than 3 mm. This technical limitation can ensure that the module unit with (negative) error can be leveled by placing steel plates of different thicknesses, avoiding the overall design height being too high due to the positive error of the module unit and being unable to be leveled, resulting in the entire module unit 1 being scrapped. This technical limitation can ensure that qualified module units 1 are transported to the site, avoiding the inconvenience of on-site rectification and reducing unnecessary transportation costs.

[0138] In one embodiment, in the step D3, when each layer of module units 1 is leveled, the leveling is achieved by placing steel plates of different thicknesses at the position of the connection box 14, and the steel plates need to avoid the through holes 141 on the connection box 14. The steel plates may be the connection plates 23 themselves.

[0139] In one embodiment, the overall height error of the module unit 1 after leveling is required to be less than ±1 mm. The thickness of the pre-padded steel plate is 2 mm to 3 mm. In practice, the thickness of the padded steel plate can be prepared in 2 mm and 3 mm specifications.

[0140] Another object of the present invention is to provide a module unit 1 to facilitate people to assemble the modular structure.

[0141] Reference Figures 14 to 22 A module unit 1 is manufactured according to the module unit production method, characterized in that it includes a bottom frame 16, a column 13, a top frame 15 and a node connection device; the node connection device includes a connection box 14, and (according to the arrangement position) the connection box 14 includes a bottom connection box E1 and a top connection box E2; the bottom frame 16 includes a bottom frame beam 161; at the bottom node position, the bottom frame beam 161 is connected to the column 13 through the bottom connection box E1; the top frame 15 also includes a top frame beam 151; at the top node position, the top frame beam 151 is connected to the column 13 through the top connection box E2;

[0142] The bottom frame 16 also includes a bottom secondary beam 162 and a cast-in-place reinforced concrete floor slab 163 (refer to Figure 3 and Figure 6 ); the bottom secondary beam 162 and the cast-in-place reinforced concrete floor slab 163 are arranged on the bottom frame beam 161; the top frame 15 also includes a top secondary beam 152 and a steel plate 153 (refer to Figure 3 and Fig.14 )(the steel plate 153 is the same component as the top frame steel plate 19 mentioned above); the top secondary beam 152 and the steel plate 153 are arranged on the top frame beam 151; wherein the cast-in-place reinforced concrete floor slab 163 can improve the living or use experience in the modular residential building. Preferably, the reinforced concrete 21 of the cast-in-place reinforced concrete floor slab 163 is made of lightweight concrete to reduce the hoisting weight of the module unit 1;

[0143] The module unit 1 further comprises a wall panel; the wall panel is arranged on the frame beam of the module unit 1 as needed according to actual conditions for enclosure.

[0144] Reference Figures 14 to 17In one embodiment, the connection box 14 has a fastener friction surface E; the fastener friction surface E is provided with a plurality of positioning holes 142 and a plurality of through holes 141; the plurality of positioning holes 142 are used for positioning and connecting the protrusions H1 of the connecting plate 23; the plurality of through holes 141 are used for the fasteners 22 to pass through; the connection box 14 is provided with an operating opening 143 on one side surface adjacent to the fastener friction surface E.

[0145] Reference Fig.15 and Fig.18 In the first embodiment, the connection box 14 is a first type connection box J1; a plurality of the positioning holes 142 and a plurality of the through holes 141 are arranged in different areas; a plurality of the positioning holes 142 are arranged in a first area J11 of the fastener friction surface E; a plurality of the through holes 141 are arranged in a second area J12 of the fastener friction surface E; the operation opening 143 corresponds to the second area J12 and is arranged on one side of the connection box 14; when the connection box 14 is arranged on the module unit 1, the first area J11 is at the column position K1 of the module unit 1, and the second area J12 is at the beam position K2 of the module unit 1; after the connection box 14 is arranged, the positioning holes 142 are arranged at the column position K1 and the through holes 142 are arranged at the beam position K2. This arrangement can increase the operation space, facilitate operation, and is more conducive to the assembly between module units.

[0146] Reference Fig.15 In one embodiment, there is one positioning hole 142 in the first area J11; there are four through holes 141 in the second area J12; the four through holes 141 are arranged in a matrix; specifically, the four through holes 141 are arranged in two rows and two columns.

[0147] Reference Fig. 20 In the second embodiment, the connection box 14 is a second type connection box J2; a plurality of the positioning holes 142 and a plurality of the through holes 141 are arranged in the same area; a plurality of the positioning holes 142 and a plurality of the through holes 141 are arranged on the column area J21 of the fastener friction surface E without interfering with each other; when the connection box 14 is arranged on the module unit 1, the column area J21 is at the column position K1 of the module unit 1.

[0148] Reference Fig. 20 In one embodiment, there is one positioning hole 142 in the column area J21; there are four through holes 141 in the column area J21; the four through holes 141 are arranged in a matrix around the positioning hole 142; specifically, the four through holes 141 are arranged in two rows and two columns around the positioning hole 142, and the positioning hole 142 is located in the middle of the four through holes 141.

[0149] Reference Fig.15 In one embodiment, the positioning hole 142 is composed of a circular shaft hole L1 and a truncated cone hole L2.

[0150] Reference Fig.18 In one embodiment, the operating opening 143 on the connection box 14 is used to tighten the fastener 22 (such as used to tighten high-strength bolts), and its size is generally larger. In this case, the size of the square operating opening 143 is generally larger than 150mm×200mm; the operating opening 143 on the connection box 14 is used to install the nut 25, and its size is generally larger than 150mm×120mm, so as to facilitate reaching in to use a manual high-strength bolt wrench or a small electric high-strength bolt tightening tool (a tool specially designed for small spaces) for operation.

[0151] Reference Fig.15 In one embodiment, the connection box 14 is assembled and welded by a plurality of steel plates, and all welds of the connection box 14 are secondary groove full penetration welds.

[0152] Reference Fig.15 and Fig.17 In one embodiment, the node connection device also includes a connection plate 23; the connection plate 23 is provided with a plurality of protrusions H1 and a plurality of through holes H2; a plurality of the protrusions H1 can be positioned and connected with the positioning holes 142; a plurality of the through holes H2 can be connected with a plurality of the through holes 141 in a one-to-one correspondence.

[0153] Reference Fig.16 and Fig.17 In one embodiment, the protrusion H1 is a positioning cone.

[0154] Reference Fig.16 and Fig.17 In one embodiment, the protrusions H1 are provided on both sides of the connecting plate 23 .

[0155] Reference Fig.14 and Fig.17 In the first embodiment, the connecting plate 23 is a first type connecting plate M1, and the protrusions H1 are provided on both sides of the first type connecting plate M1; one side of the first type connecting plate M1 is provided with a protrusion H1; the first type connecting plate M1 is provided with four vias H2, and the first type connecting plate M1 is adapted to the first type connecting box J1, and can be used in the connection between the bottom connecting box E1 of the upper module unit F1 and the top connecting box E2 of the lower module unit F2.

[0156] Reference Fig. 20In the second embodiment, the connecting plate 23 is a second type connecting plate M2, and the protrusions H1 are provided on both sides of the second type connecting plate M2; one side of the second type connecting plate M2 is provided with a protrusion H1; the second type connecting plate M2 is provided with four vias H2, and the second type connecting plate M2 is adapted to the second type connecting box J2, and can be used in the connection between the bottom connecting box E1 of the upper module unit F1 and the top connecting box E2 of the lower module unit F2.

[0157] Reference Fig.14 and Fig.18 In the third embodiment, the connecting plate 23 is a third type connecting plate M3, and the protrusions H1 are provided on both sides of the third type connecting plate M3; two protrusions H1 are provided on one side of the third type connecting plate M3; eight vias H2 are provided on the third type connecting plate M3, and the eight vias H2 are arranged in two areas, one area is provided with four vias H2, and the other area is also provided with four vias H2. The third type connecting plate M3 is adapted to the first type connecting box J1, and can be used in the connection of the connecting box 14 at the module unit node between the horizontal G1 and the vertical G2 (that is, connecting the upper and lower module units and the left and right module units on the horizontal plane).

[0158] In the fourth embodiment, the connecting plate 23 is a fourth type connecting plate, and the protrusions H1 are provided on both sides of the fourth type connecting plate; four protrusions H1 are provided on one side of the fourth type connecting plate (corresponding to four connecting boxes 1); sixteen vias H2 are provided on the fourth type connecting plate, and the sixteen vias H2 are arranged in four areas, each area is provided with four vias, and the fourth type connecting plate is adapted to the first type connecting box J1, and can be used in the connection of the connecting box 14 at the module unit node between the horizontal G1 and the vertical G2 (that is, connecting the upper and lower module units and the four module units arranged in a "cross" shape on the horizontal plane).

[0159] In one embodiment, the node connection device further includes a fastening assembly 24 ; the fastening assembly 24 includes a fastener 22 and a nut 25 ; the fastener 22 can pass through the through hole 141 and the through hole H2 ; the nut 25 is used to lock the end of the fastener 22 .

[0160] In one embodiment, the fastener 22 is a high-strength bolt, the nut 25 is a nut used in conjunction with the high-strength bolt, the fastener friction surface E is a high-strength bolt friction surface, and the through hole 141 is a high-strength bolt hole. The high-strength bolt friction surface can reduce the shear force of the connection box 14 and the connection plate 23 on the high-strength bolt.

[0161] In one embodiment, during hoisting, the connection box 14 is used for hoisting.

[0162] Reference Fig.14 and Fig.18 In one embodiment, at the node of the columns 13 of the adjacent module units 1, the connection box 14 of one module unit 1 is connected and fixed to the connection box 14 of another module unit 1 through a connection plate 23 and a fastening assembly 24.

[0163] In one implementation, the module units 1 between the horizontal G1 and the vertical G2 are connected by connection boxes 14. The number of connection boxes 14 of a single module unit 1 can be eight or twelve: when the module unit 1 is short, four columns 13 can be provided, and the bottom frame 16 and the top frame 15 are provided with connection boxes 14 at the connection positions of the columns 13, respectively, and there are eight connection boxes 14 in total; when the module unit 1 is long, six columns 13 can be provided (that is, two middle columns N are added in the middle), and the bottom frame 16 and the top frame 15 are provided with connection boxes 14 at the connection positions of the columns 13, respectively, and there are twelve connection boxes 14 in total.

[0164] Reference Fig.19 and Fig. 20 In one embodiment, the upper and lower adjacent module units, the upper module unit 1, has a plurality of bottom connection boxes E1 at its bottom; the lower module unit 1 has a plurality of top connection boxes E2 at its top; the bottom connection boxes E1 of the upper module unit 1 are connected and fixed to the top connection boxes E2 of the lower module unit 1 through the connection plate 23 and the fastening assembly 24. Preferably, the size of the operation opening 143 of the bottom connection box E1 of the upper module unit 1 should generally be greater than 150mm×200mm (square operation opening); the size of the operation opening 143 of the top connection box E2 of the lower module unit 1 should generally be greater than 150mm×120mm (square operation opening).

[0165] Reference Fig.19 and Fig. 22 In one embodiment, the module units 1 at the upper and lower levels are both provided with a middle column N; and at this time, the module unit 1 uses a second type of connection box J2;

[0166] The upper module unit F1 is at the bottom node position of the middle column N, and the bottom connection box E1 is provided with an I-shaped steel 26 on the side with the operation opening. At the same time, one side end of the bottom corrugated plate P of the upper module unit F1 is connected to the I-shaped steel 26, and the local wave crest P1 of the bottom corrugated plate P is just "convex" upwards, avoiding blocking the operation opening 143. Through this design, the operation space of the connection box 14 at the node of the middle column N can be increased;

[0167] The module unit F2 of the lower layer is at the top node position of the middle column N, and the top connection box E2 is provided with a top frame beam 151 with a square cross-section on the side where the operation opening is opened.

[0168] Reference Fig.14 In one embodiment, the top steel plate 153 of the lower module unit F2 is provided with an operation hole 27 at the node position of the middle column N connection box 14; when the module unit 1 is installed, the worker operates indoors and tightens the high-strength bolts through the operation hole 27.

[0169] In one embodiment, the bottom corrugated plate P (ie, the bottom frame steel plate 19 mentioned above) is a corrugated steel plate.

[0170] In one embodiment, a number of the module units 1 are assembled into a large module structure, and then grouting is performed at the node positions with the connection boxes 14 to further increase the node stiffness; preferably, high-strength mortar is used for grouting.

[0171] In one embodiment, the wall panel is arranged on the frame beam of the module unit 1 (such as between the bottom frame beam 161 and the top frame beam 151) to play a protective role; people arrange the module unit 1 according to its actual protective needs to obtain inner partition walls and outer protective walls. After the protective wall, the wall panel is one or two of the inner partition walls and outer protective walls (some module units have only inner partition walls; some module units have only outer protective walls; some module units have inner partition walls and outer protective walls; and some module units have no wall panels); when the wall panel is an inner partition wall, the inner partition wall is an integrated inner wall panel; when the wall panel is an outer protective wall, the outer protective wall adopts a structure of "interior decoration integrated panel-light steel keel plus filling sound insulation material-assembled metal exterior wall panel" from the inside to the outside.

[0172] In one embodiment, the module unit 1 of the present invention is a steel-concrete structure module unit.

[0173] In one embodiment, the building structure is a seven-story modular structure (composed of the steel-concrete structural modular units of the present invention), with a total construction area of ​​5781.32 m 2 , of which the modular building area is 4205.46m 2 Each modular structure contains 17 standard modular units 1, totaling 119 modular units. The size (width × length × height) of each modular unit 1 is 3.8m × 9.3m × 3.925m, with an area of ​​35.34m 2, weighing about 30t. The first type of connection box J1 is used to connect the module units 1; the size of the operation opening 143 of the bottom connection box E1 of the upper module unit 1 is 200mm×200mm, and the size of the operation opening 143 of the top connection box E2 of the lower module unit 1 is 200mm×122mm, which meets the requirement that the operation opening 143 of the connection box 14 has sufficient operation space.

[0174] In one embodiment, the floor of the module unit 1 is provided with tiles by thin-layer tile pasting, and the top surface is provided with a suspended ceiling by an integrated method.

[0175] The module unit of the present invention has the following technical advantages:

[0176] (1) The present invention adopts a new connection box 14 and a new connection plate 23, which improves the convenience of connecting the module unit 1 and is conducive to the modular assembly of the module unit 1.

[0177] (2) The connection between the module units of the present invention is preferably made of high-strength bolts, which reduces the amount of welding during installation on the construction site and ensures the quality of the connection;

[0178] (3) The present invention ensures the feasibility of assembly between module units through a series design, especially the layout design of the center column connection box 14, which reduces the difficulty of assembly and improves the assembly efficiency;

[0179] (4) The floor of the module unit 1 of the present invention adopts cast-in-place reinforced concrete floor slab 163, which can optimize the living experience.

[0180] The production method, installation method and other contents of the module unit described in the present invention can be found in the prior art and will not be described in detail here.

[0181] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Therefore, any modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A method for producing a module unit, characterized in that: The following steps are involved: A1. Component processing of module units; A11. Processing of the connection box of the node connection device and the friction surface treatment of the fasteners of the connection box; A12, steel beam processing of module units; The step A11 and the step A12 can be performed sequentially or simultaneously; A2. According to the weight of each component derived from the 3D model and / or the production rhythm obtained from the welding workload of each component calculated according to the model, the production mode is selected to assemble, weld, cast and decorate the module units.

2. The method for producing a modular unit according to claim 1, characterized in that: The A2 step includes the following steps: A21. If the weight of the top frame or bottom frame of the module unit plus the connection box is greater than the load-bearing weight of the tooling, and / or if the workstation tact of the top frame with connection box welding and the bottom frame with connection box welding is greater than the production tact of the general assembly area, the side frame production mode is adopted, otherwise, the non-side frame production mode is adopted.

3. The method for producing a modular unit according to claim 1 or 2, characterized in that: In the step A2, when the selected production mode is the side frame production mode, the following steps are included: B1. Assembly welding of the long side frame beam and secondary beam of the module unit; B2. The columns and connection boxes of the module units are welded together to form a side frame; B3, the side frame is welded with the top frame and bottom frame of the module unit to form an integral steel frame module; B4. Top and bottom frame steel plate welding and bolting construction; B5. Pipeline pre-embedding and concrete pouring; B6. Interior decoration and mechanical and electrical construction of modular units; In the step A2, when the selected production mode is the non-side frame production mode, the following steps are included: C1. Position welding of the long side frame beam of the module unit and the connection box; C2, the robot arm grabs the secondary beams in turn and de-welds them with the long side frame beams; C3, welding of connection box and short side frame beam; C4, top frame steel plate welding; C5, column assembly welding; C6, bottom frame steel plate welding and bolting construction; C7, pipeline pre-embedding and concrete pouring; C8. Interior decoration and mechanical and electrical construction of modular units.

4. The method for producing a modular unit according to claim 3, characterized in that: When the selected production mode is the non-side frame production mode, when the module unit is assembled as a whole, first locate the bottom frame to obtain a positioning point, and then set a positioning point in the middle of the assembly frame to ensure the verticality of the column through the two-point coordinates; when installing the top frame, reposition the upper frame position to ensure installation accuracy.

5. A method for installing a module unit, characterized in that: The following steps are involved: D1. Producing according to the modular unit production method according to any one of claims 1 to 4, and transporting the produced qualified modular units to the construction site; D2. Module unit hoisting; D3, module unit leveling; D4, modular units are connected to the on-site operating structure; D5. Carry out fireproof sealing of gaps between module units, then place the connecting plates between module units, hoist the upper module units and connect them to the lower module units through fastening components, and repeat until all module units are installed.

6. The method for installing a module unit according to claim 5, characterized in that: During the installation process of step D5, waterproofing and fireproofing of horizontal and vertical seams between the facade module units are interspersed, and the roof layer, partial decoration of the facade, and pipeline connection construction are carried out.

7. The method for installing a module unit according to claim 5, characterized in that: In the step D1, it is required that the production error of the overall height of the qualified module unit is negative and less than 3 mm.

8. The method for installing a module unit according to claim 5, characterized in that: In the step D3, when each layer of module units is leveled, the leveling is achieved by placing steel plates of different thicknesses at the position of the connection box, and the steel plates need to avoid the through holes on the connection box.

9. The method for installing a module unit according to claim 8, characterized in that: The overall height error of the module unit after leveling is required to be less than ±1mm.

10. A module unit manufactured according to the module unit production method according to any one of claims 1 to 4, characterized in that: It includes a bottom frame, a column, a top frame and a node connection device; the node connection device includes a connection box, and the connection box includes a bottom connection box and a top connection box; the bottom frame includes a bottom frame beam; at the bottom node position, the bottom frame beam is connected to the column through the bottom connection box; the top frame also includes a top frame beam; at the top node position, the top frame beam is connected to the column through the top connection box; The bottom frame also includes a bottom secondary beam and a cast-in-place reinforced concrete floor slab; the bottom secondary beam and the cast-in-place reinforced concrete floor slab are arranged on the bottom frame beam; the top frame also includes a top secondary beam and a steel plate; the top secondary beam and the steel plate are arranged on the top frame beam.

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