Digital manufacturing and construction method for special-shaped stone facing in large venue

Abstract

The invention relates to a digital manufacturing and construction method for a special-shaped stone veneer in a large venue, and aims to solve the problems of low machining precision, high mounting difficulty, low construction efficiency and the like of special-shaped stone in construction of an outer vertical face and an inner veneer of a building. The method comprises the following steps: firstly, measuring a building special-shaped structure by using a three-dimensional scanner or a BIM (Building Information Modeling) technology to generate a three-dimensional geometric model; based on the model, combining the material characteristics of the stone, and optimizing the geometric shape and size of the stone through a typesetting algorithm; then the optimized data are imported into five-axis CNC numerical control equipment for precise cutting; pre-assembly is conducted after cutting, errors are detected through laser scanning equipment, and adjustment is conducted till the precision requirement is met; and finally, a laser positioning system and a mechanical sensor are combined, a manual construction team manually installs the stone, and it is ensured that the installation precision meets the design requirement. According to the method, the machining and mounting precision of the special-shaped stone is effectively improved, the construction efficiency is improved, and the structural safety and the attractive effect of a building are guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of building construction, and in particular to a digital manufacturing and construction method for special-shaped stone facings in large venues. Background Art

[0002] In modern architectural design and construction, with the integration of architectural art and technology, the facade and interior design of buildings pay more and more attention to beauty and innovation. Especially in public buildings such as large venues, exhibition centers, theaters, etc., special-shaped building structures are becoming more and more common. The characteristics of special-shaped buildings are that their surfaces are usually irregular and complex, containing a large number of curved surfaces, arcs and nonlinear structures. Therefore, the selection of facade and interior materials for such buildings becomes extremely important, which not only needs to meet the safety and durability of the structure, but also meet the visual beauty and design requirements.

[0003] As a high-end building decoration material, stone is widely used in the decoration of various high-end buildings due to its unique texture, excellent physical properties and rich aesthetic expression. Especially for the exterior walls and interior surfaces of large venues, the use of stone can not only improve the durability of the building, but also enhance its overall beauty and cultural connotation. However, in special-shaped buildings, the processing and installation technology of traditional stone faces a series of challenges.

[0004] Traditional stone processing and installation techniques are often based on straight lines and plane designs, which are difficult to handle with special-shaped curved structures. This often leads to the following technical difficulties when using stone in special-shaped buildings:

[0005] Difficulty in measurement and design: Due to the complex geometric shapes of special-shaped buildings, it is difficult to accurately obtain the geometric data of the building surface through traditional manual measurement methods. Even with modern measuring instruments, the complexity of the curved surface may still lead to inaccurate measurement data. Each stone on the building surface has large individual differences in shape and size, the design and layout workload is huge, and the manual calculation error is large.

[0006] Difficulty in stone layout: In special-shaped buildings, stone layout must not only consider the curvature of the building surface, but also the stress and aesthetic requirements of the stone. Traditional plane layout algorithms cannot adapt to the needs of complex curved surfaces, and unreasonable layout may lead to large gaps between stones or uneven splicing.

[0007] Low processing precision: Traditional stone processing usually relies on manual or semi-automatic tools, such as manual cutting or ordinary CNC processing equipment. These methods cannot cope with the complex geometric shapes of special-shaped stones, especially in situations where high precision is required. It is difficult to ensure the accuracy of the size and curvature of each stone, resulting in the accumulation of errors in the subsequent assembly and installation process.

[0008] Installation difficulties: The installation of special-shaped stones requires construction workers to have high skills. The shape, weight and complexity of the stone make the installation process very complicated. The traditional manual installation method is inefficient and there are safety hazards when installing stones at high altitudes and over large areas. At the same time, during the stone installation process, if the stone is not positioned accurately, the splicing error will gradually increase, ultimately resulting in substandard decorative effects.

[0009] Lack of effective error detection and correction methods: In the traditional stone installation process, manual visual inspection and simple measuring tools are often relied on for detection and adjustment, which cannot accurately detect the installation position and angle of each stone in real time. This method not only has low accuracy, but also easily causes rework, increasing construction costs and time.

[0010] Based on the above problems, in recent years, with the development of digital modeling technology, CNC processing technology and intelligent construction technology, some new processes and methods have gradually been applied to the processing and construction of special-shaped stones. Among them, the introduction of BIM (Building Information Modeling) technology makes it possible to accurately obtain and process building geometric data. Through three-dimensional laser scanning technology, it is possible to measure the complex special-shaped building surface with high precision and generate the corresponding three-dimensional geometric model. With the help of the BIM platform, the digital management of the entire process of architectural design, stone layout, processing and installation can be realized, thereby greatly improving the accuracy and efficiency of construction. The development of intelligent installation systems has also brought revolutionary changes to the construction of special-shaped stones. Traditional manual installation methods have problems such as large errors, low efficiency and high safety risks. After the introduction of the intelligent installation system, construction personnel can use laser positioning systems and mechanical sensors to accurately locate the installation position of the stone, and monitor the force of the stone during the installation process in real time to avoid damage to the stone due to excessive force. At the same time, through the linkage between the BIM platform and the on-site intelligent equipment, real-time monitoring and adjustment of the construction progress can be achieved to make the entire construction process accurate and error-free.

[0011] In summary, with the increasing demand for special-shaped structures in the construction field, the processing and installation technology of special-shaped stones is developing rapidly. There are many problems in the existing technology in the design, layout, processing and installation of special-shaped stones that need to be solved urgently. To this end, a new digital manufacturing and construction method is proposed. Through the combination of three-dimensional modeling, CNC machining and intelligent installation technology, it can effectively improve the processing accuracy, material utilization rate and construction efficiency of special-shaped stones, and meet the decoration needs of complex buildings such as large venues. Summary of the invention

[0012] The purpose of the present invention is to address the deficiencies of the prior art and provide a digital manufacturing and construction method for special-shaped stone facings in large venues, comprising the following steps:

[0013] Step 1: Use 3D scanner or BIM technology to measure the special-shaped building surface of the venue and generate a 3D geometric model of the special-shaped structure of the venue;

[0014] Step 2: Based on the 3D geometric model, combined with the material properties and finishing requirements of the stone, the geometric shape and size of each stone are optimized through a specific layout algorithm, and the stone layout plan is generated. The structure is optimized according to the surface modeling and force analysis, so that the special-shaped stone is highly compatible with the building surface; the stone layout adopts the following optimization algorithm:

[0015] The geometric shape and layout of the stone are optimized using the layout optimization function f(x). The formula is:

[0016]

[0017] Among them, A i is the area of ​​the i-th stone, C i is the matching degree between the stone and the curvature of the facing, S is the side length of the stone, S max is the maximum permissible stone size, α is the weight coefficient;

[0018] Step 3: Import the optimized stone geometry data into the five-axis CNC machining equipment, and perform precise cutting of the stone according to the machining parameters. The cutting path and speed are controlled by the optimization algorithm to reduce material waste and improve surface accuracy.

[0019] Step 4: Pre-assemble the CNC processed stones, use laser scanning equipment to detect the surface flatness and geometric accuracy of the pre-assembled stones, calculate the pre-assembly error, and compare it with the design model to ensure that the error value is within the specified tolerance range; the pre-assembly detection in step 4 uses high-precision 3D laser scanning equipment to perform a full-field scan of the pre-assembled surface of the stone, and calculate the geometric error E of each stone through the error calculation formula s :

[0020]

[0021] Among them, d i,meas is the actual measured value of the scanning point, d i,design is the corresponding design value, and N is the number of detection points. s Less than 0.5 mm to ensure geometric accuracy before installation.

[0022] Step 5: By combining the laser positioning system with the assistance of mechanical sensors, the manual construction team manually moves the stone to the designated location, and accurately adjusts the position and angle of the stone according to the laser ranging data, and fixes the stone with manual installation tools to ensure that the accuracy of the installation process meets the design requirements.

[0023] As a preferred technical solution of the present invention, the mechanical properties of the stone are taken into consideration during the optimization process, and the stress distribution of each stone is determined by the following formula:

[0024]

[0025] Among them, F i is the external force on the i-th stone, A i It is the area of ​​the stone, so that each stone can withstand the expected load after installation and meet the requirements of compression and bending resistance.

[0026] As a preferred technical solution of the present invention, the CNC machining equipment in step 3 determines the optimal cutting path L through a machining path optimization algorithm. i and cutting speed v c ,The algorithm is optimized based on the hardness of the stone and the ,cutting tool parameters, and the cutting speed formula is as follows:

[0027]

[0028] Among them, r is the radius of the cutting tool, n is the spindle speed, combined with the stone hardness H and the processing path length L i , to ensure cutting accuracy and surface smoothness.

[0029] As a preferred technical solution of the present invention, when the detected geometric error E s When the predetermined threshold is exceeded, the system will generate a correction plan to reprocess the stones that do not meet the precision requirements by adjusting the CNC machining parameters until the errors of all stones are within the threshold range.

[0030] As a preferred technical solution of the present invention, during the manual installation process in step five, the construction personnel use manual tools to fine-tune the stone to the designed position based on the precise position points or lines projected by the laser positioning system, so that the installation angle and position accurately match the design model.

[0031] As a preferred technical solution of the present invention, during the installation process, the stress condition of the stone is monitored in real time by a mechanical sensor device, so that the pressure during the installation process is controlled within the tolerable range of the stone, thereby avoiding cracking or damage of the stone due to excessive stress.

[0032] As a preferred technical solution of the present invention, after the installation is completed, a three-dimensional laser scanning system is used to conduct a comprehensive inspection of the installed stone, calculate the deviation between the actual installation position and the design model, and calculate the final construction error E by the following formula final :

[0033]

[0034] Among them, d i,actualis the actual position of the i-th scanning point, d i,design is the designed position, and M is the number of scanning points, so that the deviation between the final construction result and the designed model does not exceed 0.5 mm.

[0035] As a preferred technical solution of the present invention, after the construction is completed, the structural strength of the installed stone is tested using compression and bending test equipment, and the compressive stress σ comp and bending stress σ bend Calculated by the following formulas:

[0036]

[0037] Among them, F comp is the pressure, A comp is the load-bearing area, M is the bending moment, and W is the section modulus, so that the structural stability of the stone after construction meets the design requirements.

[0038] Compared with the prior art, the invention has the following beneficial effects: improving the processing and installation accuracy

[0039] 1. The present invention realizes the accurate acquisition, layout and cutting of geometric data of special-shaped stones by introducing three-dimensional digital modeling technology and BIM system, combined with high-precision three-dimensional scanner and five-axis CNC numerical control processing equipment. Through the intelligent control of layout optimization algorithm and processing path, the accuracy of stone cutting is significantly improved, so that each stone can fit closely with the curved surface structure of the special-shaped building. At the same time, the laser positioning system and mechanical sensor are used to monitor the position and force of the stone in real time during the installation process, so that the error of stone installation is controlled within a very small range, greatly improving the installation accuracy.

[0040] 2. The present invention reduces the human error and time-consuming problems in traditional manual measurement, layout and processing through automated processing and intelligent auxiliary tools. By performing error detection in advance in the pre-assembly stage, possible deviations can be adjusted before formal installation, avoiding rework after installation and further improving construction efficiency. The stone layout optimization algorithm not only reduces material waste, but also makes the installation of stone smoother and faster, thereby greatly improving the overall construction quality.

[0041] 3. The present invention not only focuses on the geometric accuracy and installation efficiency of the stone, but also fully considers the mechanical properties of the stone. Through mechanical analysis, the stone can withstand the design load after processing and installation, avoiding the problem of stone cracking and deformation during use. In addition, by optimizing the layout design, the gap between the stone joints is reduced, making the appearance of the building more beautiful and smooth, meeting the high requirements of large venues, exhibition halls and other buildings in terms of functionality and visual beauty. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is a flowchart of a digital manufacturing and construction method for special-shaped stone facings in large venues proposed by the present invention. DETAILED DESCRIPTION

[0043] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] The specific implementation of the present invention is described in detail below in conjunction with the accompanying drawings and multiple embodiments.

[0045] Example 1: Construction of special-shaped stone facing for the facade of a large gymnasium

[0046] Scenario Description

[0047] On the facade of a large gymnasium, special-shaped stones need to be installed to cover the curved surface. The stones vary in specifications and shapes, and the installation accuracy of each stone is required to be high.

[0048] The 3D digital modeling uses a 3D laser scanner to scan the stadium's facade and obtain the geometric data of the curved structure. Subsequently, this data is imported into the BIM (Building Information Modeling) platform to generate an accurate 3D building model and mark the specific installation location of each stone block.

[0049] Stone layout and optimization On the BIM platform, a specific layout algorithm is used to divide and layout the stone. In order to make each stone fit closely with the curved building, the layout algorithm will be optimized according to the curvature of the building and the characteristics of the stone, so as to reduce gaps and errors when the stone is spliced.

[0050] Use the following layout optimization formula:

[0051]

[0052] Among them, A i is the area of ​​the i-th stone, C i is the matching degree between the stone and the curvature of the facing, S is the side length of the stone, S max is the maximum allowable stone size, and α is the weight coefficient.

[0053] After CNC machining completes layout optimization, the geometric data of the stone is input into the five-axis CNC machining equipment to accurately cut each stone according to the designed dimensions. During the processing, the system adjusts the cutting path and speed according to the hardness and thickness of the stone to make the surface of each stone smooth and meet the design requirements.

[0054] Pre-assembly and testing The processed stones are transported to the pre-assembly area and pre-assembled according to the markings in the BIM model. Each stone is tested by a high-precision laser scanner to ensure that the surface flatness and geometric accuracy meet the requirements. The error calculation uses the following formula:

[0055]

[0056] Among them, d i,meas is the actual measured value of the scanning point, d i,design is the corresponding design value, and N is the number of detection points. s Less than 0.5 mm to ensure geometric accuracy before installation.

[0057] In actual manual installation, construction workers manually use vacuum suction cups to move each stone to the installation location, and use a laser positioning system to determine the installation accuracy of the stone. When installing each stone, the position and angle are fine-tuned with manual tools (such as crowbars and shims) to make the joint gaps with adjacent stones consistent.

[0058] Mechanical sensors monitor the forces applied to the stone during installation in real time to prevent the stone from breaking due to external forces.

[0059] After installation, the installation area is fully inspected using a 3D laser scanning system, and the scan results are compared with the design model to ensure that the installation error is less than 0.5 mm. If the error exceeds the threshold, the construction personnel need to manually adjust the stone position.

[0060] Example 2: Special-shaped stone decoration on the interior wall of a large exhibition hall

[0061] Scenario Description

[0062] In the interior decoration of large exhibition halls, the walls need to be covered with special-shaped stones. These stones need to adapt to the complex internal curved structure of the exhibition hall and require high standards of decorative effects.

[0063] 3D digital modeling

[0064] First, a 3D scanner was used to scan the geometric structure of the interior walls of the exhibition hall. Since there are many curved surfaces on the interior walls of the exhibition hall, multiple reference points were used during the scanning process to ensure the accuracy of the geometric model.

[0065] Stone layout and optimization

[0066] In the BIM platform, the layout optimization algorithm is used to generate the block plan of the wall special-shaped stone. Considering the complexity of the wall shape, the system will give priority to the use of larger area stones to reduce the joint gap, and at the same time make the edge of each stone fit perfectly with the curved surface.

[0067] The system conducts mechanical analysis on the stress of each stone to ensure the structural stability after installation.

[0068] CNC machining and polishing According to the designed geometric data, the stone is imported into the five-axis CNC machining equipment for cutting. Since the interior decoration has high requirements for smoothness, the cut stone needs to be polished to make the stone surface smooth and flawless.

[0069] Pre-assembly and testing During the pre-assembly stage, a 3D laser scanner is used to test the pre-assembly results to ensure that the stone edges and surface finish meet the design requirements. The pre-assembly error is calculated using a formula to be controlled within 0.3 mm.

[0070] Manual installation Due to the narrow internal construction space, the construction team used small vacuum suction cups and manual tools to install the stones one by one to the designated position. Laser rangefinders and level meters were used to ensure that the horizontal and vertical angles of the stones met the design requirements during installation.

[0071] After installation, the laser scanning system will scan the entire wall to check whether the installation position of each stone is consistent with the BIM model. Stones with an error of more than 0.3 mm will be readjusted to ensure the overall decorative effect is consistent.

[0072] Example 3: Installation of special-shaped stones for high-rise building curtain walls

[0073] Scenario Description

[0074] This embodiment is applied to the installation of stone curtain walls on the facades of high-rise buildings. The exterior walls are irregular curved structures, and the area of ​​each stone is large, which makes the installation difficult.

[0075] 3D digital modeling uses a 3D laser scanning device carried by a drone to scan the facade of a high-rise building and generate an accurate 3D model. Because the building is tall, multiple reference points need to be set during scanning to ensure data accuracy.

[0076] Stone layout and processing In the BIM system, the stone layout design of the building facade is carried out to generate the size and geometry of each stone. Due to the large area of ​​curtain wall stone, the system gives priority to the strength and wind load requirements of the material during the layout process.

[0077] After the stone layout is optimized, the data is imported into the five-axis CNC equipment for precise cutting.

[0078] Pre-assembly and testing: The cut stones are pre-assembled on the ground, and the edge and surface accuracy of the stones are tested using a laser scanner. The test results are compared with the design model to ensure that the error is less than 0.5 mm.

[0079] Manual installation on high-rise exterior walls, construction workers use large vacuum suction cups and hoists to lift the stone to the installation location, and use a laser positioning system to accurately align the stone. Manual tools are used to adjust the stone angle and gap width, and mechanical sensors monitor the force of the stone in real time to ensure safe construction.

[0080] After installation, the entire curtain wall is inspected by a 3D laser scanner to ensure that the actual installation position of each stone is consistent with the designed position. If the error exceeds the specified value, the construction personnel will use manual tools to make minor adjustments.

[0081] The contents not described in detail in this specification belong to the prior art known to professional and technical personnel in the field. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments, or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A digital manufacturing and construction method for special-shaped stone facings in large venues, characterized in that: The following steps are involved: Step 1: Use 3D scanner or BIM technology to measure the special-shaped building surface of the venue and generate a 3D geometric model of the special-shaped structure of the venue; Step 2: Based on the 3D geometric model, combined with the material properties and finishing requirements of the stone, the geometric shape and size of each stone are optimized through a specific layout algorithm, and the stone layout plan is generated. The structure is optimized according to the surface modeling and force analysis, so that the special-shaped stone is highly compatible with the building surface; the stone layout adopts the following optimization algorithm: The geometric shape and layout of the stone are optimized using the layout optimization function f(x). The formula is: Among them, A i is the area of ​​the i-th stone, C i is the matching degree between the stone and the curvature of the facing, S is the side length of the stone, S max is the maximum permissible stone size, α is the weight coefficient; Step 3: Import the optimized stone geometry data into the five-axis CNC machining equipment, and perform precise cutting of the stone according to the machining parameters. The cutting path and speed are controlled by the optimization algorithm to reduce material waste and improve surface accuracy. Step 4: Pre-assemble the CNC processed stones, use laser scanning equipment to detect the surface flatness and geometric accuracy of the pre-assembled stones, calculate the pre-assembly error, and compare it with the design model to ensure that the error value is within the specified tolerance range; the pre-assembly detection uses high-precision 3D laser scanning equipment to perform a full-field scan of the pre-assembled surface of the stone, and calculate the geometric error E of each stone through the error calculation formula s : Among them, d i,meas is the actual measured value of the scanning point, d i,design is the corresponding design value, and N is the number of detection points. s Less than 0.5 mm; Step 5: By combining the laser positioning system with the assistance of mechanical sensors, the manual construction team manually moves the stone to the designated location, and accurately adjusts the position and angle of the stone according to the laser ranging data, and fixes the stone with manual installation tools to ensure that the accuracy of the installation process meets the design requirements.

2. The digital manufacturing and construction method for special-shaped stone facings in large venues according to claim 1 is characterized in that: The mechanical properties of the stone were taken into consideration during the optimization process, and the stress distribution of each stone was determined by the following formula: Among them, F i is the external force on the i-th stone, A i is the area of ​​the stone.

3. The digital manufacturing and construction method for special-shaped stone facings in large venues according to claim 1 is characterized in that: The CNC machining equipment in step 3 determines the optimal cutting path L through the machining path optimization algorithm i and cutting speed v c ,The algorithm is optimized based on the hardness of the stone and the parameters of the cutting tool. The ,cutting speed formula is as follows: Among them, r is the radius of the cutting tool, n is the spindle speed, combined with the stone hardness H and the processing path length L i .

4. The digital manufacturing and construction method for special-shaped stone facings in large venues according to claim 1 is characterized in that: When the detected geometric error E s When the predetermined threshold is exceeded, the system will generate a correction plan to reprocess the stones that do not meet the precision requirements by adjusting the CNC machining parameters until the errors of all stones are within the threshold range.

5. The digital manufacturing and construction method for special-shaped stone facings in large venues according to claim 1 is characterized in that: During the manual installation process in step five, construction workers use tools to fine-tune the stone to the designed position based on the precise position points or lines projected by the laser positioning system.

6. The digital manufacturing and construction method for special-shaped stone facings in large venues according to claim 5 is characterized in that: During the installation process, mechanical sensor equipment is used to monitor the stress conditions of the stone in real time, so that the pressure during the installation process is controlled within the tolerable range of the stone.

7. The digital manufacturing and construction method for special-shaped stone facings in large venues according to claim 6 is characterized in that: After the installation is completed, a 3D laser scanning system is used to conduct a comprehensive inspection of the installed stone, calculate the deviation between the actual installation position and the design model, and calculate the final construction error E using the following formula final : Among them, d i,actual is the actual position of the i-th scanning point, d i,design is the design position, and M is the number of scanning points.

8. According to claim 1, a digital manufacturing and construction method for special-shaped stone facings in large venues is characterized in that: After the construction is completed, the structural strength of the installed stone is tested using compression and bending test equipment, and the compressive stress σ comp and bending stress σ bend Calculated by the following formulas: Among them, F comp is the pressure, A comp is the load-bearing area, M is the bending moment, and W is the section modulus.

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