A module unit production method, installation method, and module unit

Abstract

The application discloses a module unit production method, an installation method and a module unit, wherein the module unit production method comprises the following steps: A1, component processing of the module unit; A11, processing of a connecting box of a node connecting device and processing of a fastener friction surface of the connecting box; A12, steel beam processing of the module unit; the step A11 and the step A12 can be performed in sequence or simultaneously; A2, according to the production rhythm obtained from the weight of each component derived from a three-dimensional model and / or the welding work amount of each component calculated according to the model, a production mode is selected to perform assembly, welding, pouring and decoration of the module unit. The production method can guide people to select a suitable production mode to perform assembly, welding, pouring and decoration of the module unit, effectively avoids the safety problem caused by the fact that the weight of the module unit "assembly structure" is too large and the carrying tool capacity is too small, and effectively avoids the phenomenon of work stoppage caused by the fact that the production rhythm is not coordinated.

Description

Technical Field

[0001] This invention belongs to the field of modular building technology, specifically relating to a method for producing and installing modular units, and a modular unit. Background Technology

[0002] Modular Integrated Construction (MiC) refers to a new type of building structure system composed of "modular units" prefabricated in a factory and reliably connected on the construction site to form a whole. Modular units are typically divided by room or a specific three-dimensional building space. The prefabricated parts in the factory include the main structure, enclosure structure, interior decoration, and electromechanical pipelines. Modular buildings can have a prefabrication rate of up to 95%, representing a highly integrated prefabricated building type and an advanced stage of building industrialization.

[0003] MiC modular construction achieves a "five-in-one" integration of standardized design, factory production, prefabricated construction, integrated decoration, and digital management, fundamentally overcoming the shortcomings of traditional construction methods. It breaks down the limitations of fragmented design, production, construction, and decoration, enabling highly specialized collaboration across the entire construction industry chain. This drives the construction industry towards refinement, industrialization, low-carbonization, and digitalization at every stage of construction. Compared to traditional construction methods, modular construction can reduce on-site labor by 70% and shorten the overall construction period by more than one-third. In terms of green and low-carbon aspects, modular construction can reduce on-site construction waste by more than 75% and construction noise pollution by more than 90%, making it a new structural form that the industry has been vigorously promoting and guiding in recent years.

[0004] Inter-module connection nodes are crucial to the safety design of modular steel structures, and their reliability directly affects the overall structural performance. Existing inter-module connection node designs mostly optimize only from a mechanical performance perspective, neglecting construction convenience and lacking engineering applications, resulting in poor practicality. Existing inter-module connection nodes suffer from problems such as large welding workloads, high precision requirements for module unit processing, and installation difficulties. Therefore, a new node connection device has been designed to integrate into the module unit to improve the convenience of module unit connections; however, existing production and installation technologies cannot guide the production and construction of the new module unit. Currently, a new module unit production and installation method is lacking.

[0005] Therefore, a new technology is needed to address the lack of a new modular unit production and installation method in existing technologies. Summary of the Invention

[0006] To address the aforementioned problems in the prior art, this invention provides a modular unit production method that can scientifically guide the production of modular units, ensuring production efficiency and quality.

[0007] A method for producing modular units includes the following steps:

[0008] A1. Component fabrication of modular units;

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

[0010] A12. Steel beam fabrication for modular units;

[0011] Steps A11 and A12 can be performed sequentially or simultaneously.

[0012] A2. Based on the weight of each component derived from the 3D model and / or the production cycle time obtained from the welding workload of each component calculated from the model, select the production mode and carry out the assembly, welding, casting and decoration of the module units.

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

[0014] A21. If the weight of the top or bottom frame of the module unit plus the connecting box is greater than the load-bearing weight of the tooling, and / or if the cycle time of the top frame with the connecting box welded or the bottom frame with the connecting box welded is greater than the production cycle time of the final assembly area, then the side frame production mode shall be adopted; otherwise, the non-side frame production mode shall be adopted.

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

[0016] B1. The long side frame beam of the module unit is welded to the secondary beam;

[0017] B11. The long side top frame beam of the module unit is welded to the top and secondary beams;

[0018] B12, The long side bottom frame beam and the bottom secondary beam of the module unit are welded together;

[0019] Steps B11 and B12 can be performed sequentially or simultaneously.

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

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

[0022] B4. Welding and stud installation of top and bottom frame steel plates;

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

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

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

[0026] C1. Positioning and welding of the long side frame beam of the module unit to the connecting box;

[0027] C2. The robotic arm sequentially grabs the secondary beams and unwelds them to the long side frame beams.

[0028] C3. The connecting box is welded to the short side frame beam;

[0029] C4. Welding of top frame steel plate;

[0030] C5. Column assembly welding;

[0031] C6. Welding and stud installation of the bottom frame steel plate;

[0032] C7. Pipeline pre-embedding and concrete pouring;

[0033] C8. Interior decoration and electromechanical construction of modular units.

[0034] Furthermore, when the selected production mode is the non-side frame production mode, during the overall assembly of the module unit, the bottom frame is first positioned to obtain a positioning point, and a positioning point is set in the middle of the assembled frame. The verticality of the column is ensured by the coordinates of the two points. When installing the top frame, the position of the top frame is repositioned to ensure installation accuracy.

[0035] Another objective of this invention is to provide a method for installing modular units, which can scientifically guide the installation of modular units and ensure installation efficiency and quality.

[0036] A method for installing a modular unit includes the following steps:

[0037] D1. Produce according to the module unit production method described above, and transport the qualified module units after production to the construction site.

[0038] D2. Module unit hoisting;

[0039] D3. Module unit leveling;

[0040] D4. Connection between module units and on-site working structures;

[0041] D5. Fireproof sealing of gaps between module units. Then, install the connecting plates between module units, hoist the upper module unit and connect it to the lower module unit through fastening components, repeating until all module units are installed.

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

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

[0044] Furthermore, in step D3, when leveling each module unit, leveling is achieved by placing steel plates of different thicknesses at the connection box location, while the steel plates must avoid the through holes on the connection box.

[0045] Furthermore, the overall height error of the module units after leveling is required to be less than ±1mm.

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

[0047] A modular unit, manufactured according to the modular unit production method described above, is characterized in that it includes a base frame, columns, a top frame, and a node connecting device; the node connecting device includes a connecting box, which includes a bottom connecting box and a top connecting box; the base frame includes a bottom frame beam; at the bottom node position, the bottom frame beam is connected to the column through the bottom connecting 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 connecting box.

[0048] 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 mounted 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 mounted on the top frame beam;

[0049] The module unit also includes wall panels; the wall panels are installed on the frame beams of the module unit as needed, for enclosure.

[0050] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0051] This invention discloses a modular unit production method, specifically designed for modular units with novel connecting boxes. This method scientifically guides the production of new modular units, ensuring both production efficiency and quality. It guides the orderly processing of modular unit components on-site and helps in selecting appropriate production modes for the assembly, welding, casting, and finishing of modular units. This effectively avoids safety issues caused by excessive weight of the modular unit's "assembly structure" and insufficient load-bearing capacity of the tooling, and effectively prevents idle time due to uncoordinated production cycles.

[0052] The present invention provides an installation method for a modular unit, which is a field construction and installation method specifically designed for modular units with novel connecting boxes. This installation method can scientifically guide people to correctly install the novel modular units, ensuring installation efficiency and quality.

[0053] The present invention provides a modular unit with a novel connecting box, which is manufactured by a modular unit production method of the present invention. This modular unit facilitates modular assembly and solves the problems of high assembly difficulty, low assembly efficiency, and large amount of welding in previous modular units. Attached Figure Description

[0054] The technology of the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0055] Figure 1 This is a schematic diagram of the structure of the long side frame beam and the secondary beam assembled when the present invention is produced using the side frame production mode;

[0056] Figure 2 This is a schematic diagram of the structure of the present invention when the side frame production mode is adopted, in which the column is first assembled with the connecting box and then with the short side frame beam.

[0057] Figure 3 This is a structural diagram of the steel frame module assembled from the columns and the long side frame beams with secondary beams when the present invention is produced using the side frame production mode.

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

[0059] Figure 5 This is a partial structural diagram of the module unit after stud construction when the present invention is produced using the side frame production mode;

[0060] Figure 6 This is a schematic diagram of the structure of the bottom frame of the module unit after concrete pouring when the present invention is produced using the side frame production mode.

[0061] Figure 7 This is a schematic diagram of the structure of the long side frame beam and the connecting box assembled when the present invention is produced using the non-side frame production mode;

[0062] Figure 8 This is a schematic diagram of the structure formed when the secondary beam is first assembled with the long side frame beam and then the connecting box is assembled with the short side frame beam during the production of the present invention using a non-side frame production mode.

[0063] Figure 9 This is a simplified structural diagram of the top frame after the steel plate has been welded when the present invention is produced using a non-side frame production mode.

[0064] Figure 10 This is a schematic diagram of the structure of the top frame with steel plate, the bottom frame without steel plate, and the column being welded together when the present invention is produced in a non-side frame production mode.

[0065] Figure 11 This is a schematic diagram of the structure after the bottom frame steel plate is welded when the present invention is produced using a non-side frame production mode;

[0066] Figure 12 This is a partial structural diagram of the module unit after stud construction when the present invention is produced using a non-side frame production mode;

[0067] Figure 13 This is a schematic diagram of the structure of the bottom frame of the module unit after concrete pouring when the present invention is produced using a non-side frame production mode.

[0068] Figure 14 This is a schematic diagram of the structure after several modular units are installed using the "Modular Unit Installation Method" of the present invention;

[0069] Figure 15 This is a structural schematic diagram of the first type of connector box;

[0070] Figure 16 This is a structural schematic diagram of the first type of connecting plate;

[0071] Figure 17 yes Figure 16 Top view;

[0072] Figure 18 This is a partial schematic diagram (node ​​diagram) (exploded view) showing the connection between the upper-level module unit and the lower-level module unit through a first-type connecting box and a third-type connecting plate;

[0073] Figure 19 This is a schematic diagram of the structure connecting the upper-level module unit and the lower-level module unit through a second-type connecting box and a second-type connecting plate;

[0074] Figure 20 yes Figure 19 Layout diagram (node ​​diagram) (exploded view) of the I-beams at the joint of the central column connecting box;

[0075] Figure 21 yes Figure 20 A structural schematic diagram (node ​​diagram) of an I-beam with corrugated plates at the bottom;

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

[0077] Figure label:

[0078] 1-Module unit; 11-Long side frame beam; 12-Secondary beam; 13-Column; 14-Connecting box; 15-Top frame; 16-Bottom frame; 17-Short side frame beam; 18-Steel frame module; 19-Steel plate; 20-Stud; 21-Concrete; 22-Fastener; 23-Connecting plate; 24-Fastening assembly; 25-Nut; 26-I-beam; 27-Operating opening;

[0079] E - Fastener friction surface; 141 - Through hole; E1 - Bottom connecting box; E2 - Top connecting box; 142 - Positioning hole; 143 - Operating opening; J1 - First type connecting box; J11 - First area; J12 - Second area; K1 - Column position; K2 - Beam position; J2 - Second type connecting box; J21 - Column position area; L1 - Circular shaft hole; L2 - Frustum-shaped 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-level module unit; F2 - Lower-level module unit;

[0083] G1 - Horizontal; G2 - Vertical;

[0084] H1 - Protrusion; H2 - Through hole; M1 - Type 1 connecting plate; M2 - Type 2 connecting plate; M3 - Type 3 connecting plate;

[0085] N - Central column; P - Bottom corrugated plate; P1 - Wave crest. Detailed Implementation

[0086] The following will provide a clear and complete description of the concept, specific structure, and technical effects of the present invention in conjunction with embodiments and accompanying drawings, so as to fully understand the purpose, solution, and effects of the present invention. It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The same reference numerals used throughout the accompanying drawings indicate the same or similar parts.

[0087] It should be noted that, unless otherwise specified, when a feature is referred to as "fixed" or "connected" to another feature, it can be directly fixed or connected to the other feature, or indirectly fixed or connected to the other feature. Furthermore, the descriptions of "up," "down," "left," and "right" used in this invention are only relative to the relative positional relationships of the various components of the invention in the accompanying drawings.

[0088] This invention provides a modular unit production method that can scientifically guide the production of modular units, ensuring production efficiency and quality.

[0089] A method for producing modular units includes the following steps:

[0090] A1. Component fabrication of module unit 1;

[0091] A11. Machining of the connecting box 14 of the node connecting device, and treatment of the fastener friction surface E of the connecting box 14;

[0092] A12. Steel beam fabrication of module unit 1; the steel beam includes the top frame beam 151 (with long side frame beam 11 and short side frame beam 17), top secondary beam 152, column 13, bottom frame beam 161 (with long side frame beam 11 and short side frame beam 17), and bottom secondary beam 162 of module unit 1.

[0093] Steps A11 and A12 can be performed sequentially or simultaneously; in one embodiment, step A0 is included before step A1, wherein step A0 is the setup of the welding platform.

[0094] A2. Based on the weights of each component derived from the 3D model and / or the production cycle time obtained from the welding workload of each component calculated from the model, select the production mode, referring to... Figures 1 to 6 ,or Figures 7 to 13 The assembly, welding, casting, and finishing of the modular units are carried out.

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

[0096] A21. If the weight of the top frame 15 or bottom frame 16 of module unit 1 plus the connecting box 14 exceeds the load-bearing weight of the tooling, and / or if the cycle time of the top frame 15 (including the connecting box welding) or the bottom frame 16 (including the connecting box welding) is greater than the production cycle time of the final assembly area, then the side frame production mode is adopted; otherwise, the non-side frame production mode is adopted. This side frame production mode reduces the working time in the top and bottom frame production areas, eliminating idle time caused by the lack of cycle time coordination in the overall flow.

[0097] In one embodiment, the production mode adopted is one or both of the side frame production mode and the non-side frame production mode. The determination of the side frame production mode and the non-side frame production mode can be carried out using step A21. When the production area is large enough, both 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 preferentially.

[0098] In one embodiment, the module unit 1 uses a positioning fixture during assembly. The positioning fixture employs a component clamping mechanism, which clamps and positions the component using a hydraulic cylinder.

[0099] In one embodiment, in step A2, reference is made 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 of module unit 1 is welded to the secondary beam 12;

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

[0102] B12, The long side bottom frame beam 161 of module unit 1 is welded to the bottom secondary beam 162;

[0103] Steps B11 and B12 can be performed sequentially or simultaneously.

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

[0105] B3. The side frame is welded to the top frame 15 and bottom frame 16 of the module unit 1 to form an integral steel frame module 18. Specifically, the side frame is first welded to the short side frame beam 17 of the top frame 15 and the short side frame beam 17 of the bottom frame 16 of the module unit 1, and then the assembled structure is welded to the long side frame beam 11 of the top frame 15 and the long side frame beam 11 of 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. Pipeline pre-embedding and (bottom frame) concrete pouring;

[0108] B6. Interior decoration and electromechanical construction of module unit 1;

[0109] In one embodiment, during step B3, when the side frame is welded to the top frame 15 and bottom frame 16 of the module unit 1 to form an integral steel frame module 18, temporary diagonal bracing is added for temporary reinforcement. This temporary diagonal bracing is to ensure the verticality of the column 13 of the module unit 1.

[0110] In one embodiment, after step B3, step B3.5 is also included. Step B3.5 involves the trial assembly of the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2. When the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2 are aligned and tested, 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 inserted, rectification should be carried out.

[0111] In one embodiment, step B5 includes binding the bottom slab reinforcement before pouring concrete 21; in another embodiment, step B5 also includes wall panel installation.

[0112] In step A2, 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 module unit 1 is positioned and welded to the connecting box 14;

[0114] C2. The robotic arm sequentially grabs the secondary beam 12 and unwelds it to the long side frame beam 11.

[0115] C3. The connecting box 14 is welded to the short side frame beam 17;

[0116] C4, top frame made of 15 steel plate and 19 welded;

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

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

[0119] C7. Pipeline pre-embedding and (bottom frame) concrete pouring;

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

[0121] In one embodiment, after implementing step C3, step C3.5 is also included. Step C3.5 is the trial assembly of the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2. When the bottom frame 16 of the upper module unit F1 and the top frame 15 of the lower module unit F2 are aligned and assembled, 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 inserted, rectification should be carried out.

[0122] In one embodiment, step C7 includes binding the bottom slab reinforcement before pouring concrete 21; in another embodiment, step C7 also includes wall panel installation.

[0123] In one embodiment, when the selected production mode is the non-side frame production mode, in step C5, 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 assembled frame (such as the middle of the column 13). The verticality of the column 13 is ensured by the coordinates of the two points. When the top frame 15 is installed, the position of the top frame is repositioned to ensure the installation accuracy.

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

[0125] Another objective of this invention is to provide a method for installing modular units, which can scientifically guide the on-site installation of modular units and ensure installation efficiency and quality.

[0126] A method for installing a modular unit includes the following steps:

[0127] D1. Produce according to the module unit production method described above, and transport the qualified module unit 1 after production to the construction site.

[0128] D2. Hoisting of module unit 1;

[0129] D3, Leveling of module unit 1;

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

[0131] D5. Fireproof seal the gaps between module units. Then, install the connecting plate 23 between module units 1, hoist the upper module unit F1 and connect it to the lower module unit F2 using the fastening assembly 24, repeating until all module units 1 are installed (refer to...). Figure 14 ).

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

[0133] In one embodiment, during step D1, module unit 1 is transported to the construction site using a specially designed low-bed trailer.

[0134] In one embodiment, the fireproof sealing of the gaps between module units is a horizontal G1 fireproof sealing of the gaps between 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 carried out intermittently, along with roofing, partial facade decoration, and pipeline connection construction.

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

[0137] In one embodiment, in step D1, the overall height production error of the qualified module unit 1 is required to be negative and less than 3mm. This technical limitation ensures that negative errors in the module unit can be leveled by placing steel plates of different thicknesses, avoiding the situation where positive errors in the module unit lead to excessive overall design height that cannot be leveled, thus rendering the entire module unit 1 unusable. This technical limitation ensures that only qualified module units 1 are transported to the site, avoiding inconvenience in on-site rectification and reducing unnecessary transportation costs.

[0138] In one embodiment, during step D3, leveling of each module unit 1 is achieved by placing steel plates of varying thicknesses at the connection box 14, while ensuring that these steel plates avoid the through holes 141 on the connection box 14. These steel plates can be the connection plate 23 itself.

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

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

[0141] Reference Figures 14 to 22 A modular unit 1, manufactured according to the modular unit production method described above, is characterized by comprising a bottom frame 16, a column 13, a top frame 15, and a node connecting device; the node connecting device includes a connecting box 14 (based on its arrangement position), the connecting box 14 includes a bottom connecting box E1 and a top connecting 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 connecting 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 connecting box E2;

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

[0143] The module unit 1 also includes wall panels; the wall panels are installed on the frame beams of the module unit 1 as needed, for enclosure.

[0144] Reference Figures 14 to 17In one embodiment, the connecting 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 protrusion H1 of the connecting plate 23; the plurality of through holes 141 are used for the fastener 22 to pass through; the connecting box 14 is provided with an operation opening 143 on one side adjacent to the fastener friction surface E.

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

[0146] Reference Figure 15 In one embodiment, the first region J11 has one positioning hole 142; the second region J12 has four through holes 141; the four through holes 141 are arranged in a row and column arrangement; specifically, the four through holes 141 are arranged in two rows and two columns.

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

[0148] Reference Figure 20 In one embodiment, the positioning hole 142 in the column position area J21 is provided; the through hole 141 in the column position area J21 is provided; the four through holes 141 are arranged in a row and column 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 Figure 15 In one embodiment, the positioning hole 142 is composed of a circular shaft hole L1 and a frustum-shaped hole L2.

[0150] Reference Figure 18 In one embodiment, the operating opening 143 on the connecting box 14 is used for tightening the fastener 22 (such as for tightening high-strength bolts), and its size is generally large. In this case, the size of the square operating opening 143 is generally greater than 150mm × 200mm. The operating opening 143 on the connecting box 14 is used for installing the nut 25, and its size is generally greater than 150mm × 120mm, so as to facilitate reaching in and using a manual high-strength bolt wrench or a small electric high-strength bolt tightening tool (tools for small spaces) for operation.

[0151] Reference Figure 15 In one embodiment, the connecting box 14 is assembled and welded from several steel plates, and all welds of the connecting box 14 are secondary bevel full penetration welds.

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

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

[0154] Reference Figure 16 and Figure 17 In one embodiment, the protrusion H1 is provided on both sides of the connecting plate 23.

[0155] Reference Figure 14 and Figure 17 In the first embodiment, the connecting plate 23 is a first type connecting plate M1, and the first type connecting plate M1 has protrusions H1 on both sides; the first type connecting plate M1 has a protrusion H1 on one side; the first type connecting plate M1 has four through holes 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 Figure 20In the second embodiment, the connecting plate 23 is a second type connecting plate M2, and the second type connecting plate M2 has protrusions H1 on both sides; the second type connecting plate M2 has a protrusion H1 on one side; the second type connecting plate M2 has four through holes 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 Figure 14 and Figure 18 In the third embodiment, the connecting plate 23 is a third type connecting plate M3. The third type connecting plate M3 has protrusions H1 on both sides; two protrusions H1 are provided on one side of the third type connecting plate M3; eight through holes H2 are provided on the third type connecting plate M3, and the eight through holes H2 are arranged in two areas, one area has four through holes H2 and the other area also has four through holes 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 (i.e., connecting the upper and lower module units and the two module units on the left and right sides of the horizontal plane).

[0158] In the fourth embodiment, the connecting plate 23 is a fourth type of connecting plate, and the fourth type of connecting plate has protrusions H1 on both sides; one side of the fourth type of connecting plate has four protrusions H1 (corresponding to four connecting boxes 14); the fourth type of connecting plate has sixteen through holes H2, which are arranged in four areas, and each area has four through holes. This fourth type of connecting plate is adapted to the first type of connecting box J1 and can be used in the connection of connecting boxes 14 at the module unit nodes between horizontal G1 and vertical G2 (i.e., connecting the upper and lower module units and the four module units arranged in a "+" 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 the 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 exerted on the high-strength bolt by the connecting box 14 and the connecting plate 23.

[0161] In one embodiment, the hoisting is performed using the location of the connecting box 14.

[0162] Reference Figure 14 and Figure 18 In one embodiment, at the node of the column 13 of an adjacent module unit 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 the connection plate 23 and the fastening component 24.

[0163] In one implementation, the module unit 1 between the horizontal G1 and the vertical G2 is connected by a connecting box 14. The number of connecting boxes 14 for a single module unit 1 can be eight or twelve: when the length of the module unit 1 is small, four columns 13 can be set, and connecting boxes 14 can be set at the connection positions of the bottom frame 16 and the top frame 15 respectively, for a total of eight connecting boxes 14; when the length of the module unit 1 is large, six columns 13 can be set (i.e., two central columns N are added in the middle), and connecting boxes 14 can be set at the connection positions of the bottom frame 16 and the top frame 15 respectively, for a total of twelve connecting boxes 14.

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

[0165] Reference Figure 19 and Figure 22 In one embodiment, both the upper and lower module units 1 are provided with a central column N; and in this case, the module unit 1 uses a second type of connecting box J2;

[0166] At the bottom node of the middle column N, the upper module unit F1 has an I-beam 26 on one side of the bottom connecting box E1 with the operation opening. At the same time, one end of the bottom corrugated plate P of the upper module unit F1 is connected to the I-beam 26, and the local peaks P1 of the bottom corrugated plate P are convex upwards to avoid obstructing the operation opening 143. This design increases the operating space of the connecting box 14 at the node of the middle column N.

[0167] The lower module unit F2 is located at the top node of the central column N, and the top connecting box E2 has a square-section top frame beam 151 on the side with the operation opening.

[0168] Reference Figure 14 In one embodiment, the top steel plate 153 of the lower module unit F2 has an operating opening 27 at the node position of the central column N connecting box 14; when the module unit 1 is installed, the worker operates indoors and performs high-strength bolt tightening work through the operating opening 27.

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

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

[0171] In one embodiment, the wall panel is installed on the frame beam of module unit 1 (e.g., between the bottom frame beam 161 and the top frame beam 151) to serve as an enclosure. The wall panels are arranged according to the actual enclosure needs of module unit 1, resulting in inner partition walls and outer enclosure walls. After enclosure, the wall panel is one or both of the inner partition walls and outer enclosure walls (some module units only have inner partition walls; some only have outer enclosure walls; some have both inner partition walls and outer enclosure walls; and some have no wall panels). When the wall panel is an inner partition wall, it is an integrated inner wall panel. When the wall panel is an outer enclosure wall, it adopts a structure from the inside out: "integrated interior panel - light steel keel with sound insulation and heat insulation material filling - prefabricated metal outer wall panel".

[0172] In one embodiment, 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 module units of the present invention), with a total building area of ​​5781.32 m². 2 The modular building area covers 4205.46m². 2 Each layer of the modular structure contains seventeen standard module units 1, totaling 119 module units. Each module unit 1 measures 3.8m × 9.3m × 3.925m (width × length × height) and has an area of ​​35.34m². 2The weight is approximately 30t. The module units 1 are connected by a first type of connecting box J1; the operating opening 143 of the bottom connecting box E1 of the upper module unit 1 has a size of 200mm×200mm, and the operating opening 143 of the top connecting box E2 of the lower module unit 1 has a size of 200mm×122mm, which meets the requirement that the operating opening 143 of the connecting box 14 has sufficient operating space.

[0174] In one embodiment, the floor of the module unit 1 is tiled using a thin-lay method, while the ceiling is installed using an integrated method.

[0175] The modular unit of this invention has the following technical advantages:

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

[0177] (2) In the connection between the module units of the present invention, the fastener 22 is preferably made of high-strength bolts, which reduces the amount of welding during on-site installation and can ensure the connection quality.

[0178] (3) Through a series of designs, the present invention ensures the feasibility of assembling between module units, especially the layout design of the central column connecting box 14, which reduces the assembly difficulty and improves the assembly efficiency.

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

[0180] The module unit production method, installation method, and other contents of the module unit described in this invention are referred to in the prior art and will not be repeated here.

[0181] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for producing modular units, characterized in that, Includes the following steps: A1. Component fabrication of modular units; A11. Processing of the connecting box for the node connecting device, and treatment of the friction surface of the fasteners of the connecting box; A12. Steel beam fabrication for modular units; Steps A11 and A12 may be performed sequentially or simultaneously. A2. Based on the weight of each component derived from the 3D model and / or the production cycle time obtained from the welding workload of each component calculated from the model, select the production mode and carry out the assembly, welding, casting and decoration of the module units. Step A2 includes the following steps: A21. If the weight of the top or bottom frame of the module unit plus the connecting box is greater than the load-bearing weight of the tooling, and / or if the cycle time of the top frame with the connecting box welded or the bottom frame with the connecting box welded is greater than the production cycle time of the final assembly area, then the side frame production mode shall be adopted; otherwise, the non-side frame production mode shall be adopted. In step A2, if the selected production mode is the side frame production mode, then the following steps are included: B1. The long side frame beam of the module unit is welded to the secondary beam; B2. The columns and connecting boxes of the module unit are welded together to form the side frame; B3. The side frame is welded to the top frame and bottom frame of the module unit to form an integral steel frame module; B4. Welding and stud installation of top and bottom frame steel plates; B5. Pipeline pre-embedding and concrete pouring; B6. Interior decoration and electromechanical construction of modular units; In step A2, if the selected production mode is the non-side frame production mode, then the following steps are included: C1. Positioning and welding of the long side frame beam of the module unit to the connecting box; C2. The robotic arm sequentially grabs the secondary beams and unwelds them to the long side frame beams. C3. The connecting box is welded to the short side frame beam; C4. Welding of top frame steel plate; C5. Column assembly welding; C6. Welding and stud installation of the bottom frame steel plate; C7. Pipeline pre-embedding and concrete pouring; C8. Interior decoration and electromechanical construction of modular units.

2. The modular unit production method according to claim 1, characterized in that, When the selected production mode is the non-side frame production mode, during the overall assembly of the module unit, the bottom frame is first positioned to obtain a positioning point, and a positioning point is set in the middle of the assembled frame. The verticality of the column is ensured by the coordinates of the two points. When installing the top frame, the position of the top frame is repositioned to ensure installation accuracy.

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