Construction method of variable-curvature super-depth fusiform skylight in steel structure

Abstract

The invention relates to the technical field of building construction, in particular to a construction method of a variable-curvature super-depth fusiform skylight in a steel structure, and solves the construction problem of a complex space curved surface through digital design, factory prefabrication, intelligent installation and real-time monitoring and compensation. Through a digital twin-driven construction technology system, the worldwide problems of the variable-curvature ultra-deep steel structure in the aspects of form precision, mechanical stability and construction efficiency are solved, a technical normal form capable of being popularized is provided for the ultra-deep and variable-curvature steel structure, and building form innovation is promoted. And meanwhile, the dependence on manpower is reduced through modular and mechanical operation, the construction period is shortened, the safety is improved, and the cost is reduced by combining prefabricated unit components with dynamic monitoring.

Description

Technical Field

[0001] The invention relates to the technical field of building construction, and in particular to a construction method of a variable-curvature ultra-depth shuttle-shaped skylight in a steel structure. Background Art

[0002] Steel structures are widely used in the design and construction of large-span, complex spatial structures in modern architecture. Their light weight, high strength and flexible construction make them an important carrier for achieving the integration of architectural aesthetics and functions. In recent years, with the continuous innovation of architectural shapes, special-shaped skylight structures with variable curvature and ultra-depth have gradually become a design trend for large public buildings (such as airport terminals, convention and exhibition centers, etc.). Such structures not only need to meet the complex three-dimensional curved surface form, but also need to take into account the mechanical performance challenges brought by ultra-depth, which puts higher requirements on construction technology.

[0003] However, traditional steel structure construction methods have significant shortcomings when dealing with variable curvature ultra-deep shuttle skylights. Specifically, (1) conventional modeling techniques mostly rely on two-dimensional drawings or static three-dimensional models, which makes it difficult to accurately generate dynamic spatial surfaces with curvature gradient changes, resulting in the accumulation of subsequent construction and design deviations. (2) Existing prefabrication processes have insufficient control over the forming accuracy of multi-curvature composite components, especially in the cold bending process, which is prone to residual stress and curvature errors, affecting the quality of component splicing. (3) The support system generally uses fixed trusses, which lack real-time curvature adjustment capabilities and cannot adapt to the dynamic construction requirements of complex surfaces; the sequential lifting method is mostly used in the assembly stage, which is prone to stress concentration and cumulative errors, and lacks high-precision real-time monitoring and compensation methods. (4) The traditional prestressed tensioning system is simple in design and cannot effectively balance the lateral stress generated by ultra-deep structures, posing a risk to structural stability.

[0004] In the prior art, although some methods attempt to optimize modeling through BIM technology or finite element analysis, they often ignore the dynamic influence of environmental factors (such as temperature and wind load), and fail to achieve real-time data interaction between the model and the construction process. For example, CN116623964A discloses a reverse construction method for a large-span variable curvature roof, in which stands and skywalks are arranged under the roof grid, and curtain wall columns are also arranged on the outside of the skywalk; the stands are arranged in an elliptical shape corresponding to the venue, and an arched truss is arranged on the short span side of the roof grid; the skywalk is arranged corresponding to the stands. By dividing the roof grid into zones, it is beneficial to ensure the overall installation progress of the roof grid and the convenient construction of variable curvature; setting closing sections at the zones is beneficial to the overall connection and uniformity of force during hoisting; through reverse installation and synchronous lifting, it is beneficial to utilize the existing site and lift and install the roof grid in a smaller space; through reverse construction of the stands, aerial walkways and arched trusses below the post-construction, combined with the designed and installed swing columns and bifurcated columns, the nodes can be better strengthened to evenly share the upper load, and finally a complete structural system is formed.

[0005] In addition to the above problems, in the process of component manufacturing and assembly, the precision control of existing processes mostly stays at the millimeter level, which cannot meet the stringent requirements of ultra-deep curved surface structures for sub-millimeter precision. At the same time, the support adjustment and error compensation devices have a low degree of automation and rely on manual intervention, which limits their efficiency and reliability. These problems seriously restrict the efficient and precise construction of variable curvature ultra-deep steel structures, and a systematic innovative method is urgently needed to break through the technical bottleneck. Summary of the invention

[0006] In view of the problem that the prior art cannot satisfy the sub-millimeter precision of ultra-deep curved surface structures, the present invention provides a construction method for an ultra-deep shuttle-shaped skylight with variable curvature in a steel structure.

[0007] The present invention is achieved through the following technical solutions: A construction method for a variable curvature ultra-deep shuttle-shaped skylight in a steel structure comprises the following steps: S1: Establish a three-dimensional hyperbolic space surface model based on parametric modeling and generate a curvature gradient change value matrix; S2: Build an adjustable arc-shaped support truss system, and use the curvature as a reference to match the truss with the three-dimensional double-curvature space surface model in real time; S3: Use the reverse assembly method to hoist the unit components, and assemble them in the air in the order of alternating from the middle to the two sides; S4: Use 3D laser scanner to monitor assembly errors and achieve millimeter-level precision compensation through multi-directional adjustment devices at nodes; S5: After the main structure is assembled, a prestressed tension cable system is applied to balance the lateral stress generated by the ultra-deep structure.

[0008] Preferably, in S1, a dynamic calculation model including material creep coefficient and temperature deformation compensation is established by combining BIM technology with finite element analysis.

[0009] Preferably, the dynamic calculation model includes a wind load dynamic response coefficient and an earthquake action correction factor, and real-time environmental sensor data is used to dynamically correct the model during modeling.

[0010] Preferably, in S3, the adjustable arc-shaped support truss system is composed of a number of standard segments, each segment is provided with a curvature adjustment mechanism, and its adjustment accuracy reaches 0.1° / m.

[0011] Preferably, in S4, the unit component hoisting adopts a modular hoisting system, including an electromagnetic adsorption hoist and an anti-sway control system, and the hoisting positioning accuracy reaches ±3mm.

[0012] Preferably, in S4, the unit components are variable curvature shuttle-shaped unit components manufactured by a segmented prefabrication process to construct an adjustable arc-shaped support truss system, wherein each unit component includes at least three arc segments with different curvature radii.

[0013] Preferably, in S2, the unit component is manufactured by a double curvature cold bending forming process, and the surface curvature error after forming is controlled within the range of ±1.5 mm / m.

[0014] Preferably, in S5, the multi-directional adjustment device is a three-dimensional adjustable cast steel node with X / Y / Z three-directional adjustment functions, an adjustment stroke of ±50mm, and an adjustment accuracy of 0.5mm.

[0015] Preferably, in S6, the prestressed tensioning cable system adopts a cross-net arrangement, including a dual system of primary cables and secondary cables, and the tensioning force is applied in stages and the cable force changes are monitored in real time.

[0016] Preferably, the prestressed tensioning cable system is provided with an intelligent anchor, and a built-in fiber optic Bragg grating sensor monitors the cable force value in real time. The monitoring data is fed back to the central control platform through a wireless transmission module to realize closed-loop control of the tensioning force.

[0017] Compared with the prior art, the present invention has the following beneficial effects: The construction method of a variable curvature ultra-deep shuttle-shaped skylight in a steel structure of the present invention solves the construction problem of complex spatial curved surfaces through digital design-factory prefabrication-intelligent installation-real-time monitoring and compensation. Through the construction technology system driven by digital twins, the world's difficult problems in the morphological accuracy, mechanical stability and construction efficiency of variable curvature ultra-deep steel structures have been overcome, providing a popularizable technical paradigm for ultra-deep and variable curvature steel structures, and promoting innovation in architectural form. At the same time, modularization and mechanized operations reduce dependence on manual labor, improve both construction period and safety, help improve construction efficiency, and prefabricated unit components combined with dynamic monitoring help reduce costs.

[0018] Furthermore, through the coupling of BIM and finite elements, the dynamic calculation model can incorporate parameters such as material creep and temperature deformation in real time, making the design closer to actual working conditions and reducing the risk of rework in the later stage. At the same time, the dynamic response coefficient of wind load and earthquake correction factor are introduced, and the model is dynamically corrected in combination with environmental sensor data, which can significantly improve the structure's disaster resistance and reduce the probability of failure under extreme weather or earthquakes.

[0019] Furthermore, the millimeter-level adjustment of the truss curvature can be achieved through the standard segment + curvature adjustment mechanism (accuracy 0.1° / m), solving the deformation matching problem of ultra-deep structures caused by their own weight or temperature.

[0020] Furthermore, real-time collection and feedback of assembly errors are achieved through three-dimensional laser scanning, and the multi-directional adjustment device (X / Y / Z three-directional adjustment, accuracy of 0.5mm) compensates for millimeter-level deviations to ensure that the overall curved surface is smooth and continuous.

[0021] Furthermore, prestress is applied in stages through a cross-mesh cable system (primary / secondary cables), which effectively balances the lateral thrust of the ultra-deep structure and reduces the burden of the support reaction force on the main structure.

[0022] Furthermore, fiber grating sensors + wireless transmission are used to achieve closed-loop control of cable tension, dynamically compensate for load changes, and improve the long-term service performance of the structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 The present invention is a flow chart of a construction method of a variable curvature ultra-depth shuttle-shaped skylight in a steel structure. DETAILED DESCRIPTION

[0024] The present invention is further described in detail below in conjunction with specific embodiments, which are intended to explain the present invention rather than to limit it.

[0025] The invention discloses a construction method of a variable curvature ultra-deep shuttle-shaped skylight in a steel structure, referring to Figure 1 , including the following steps: S1: A three-dimensional hyperbolic space surface model is established based on parametric modeling to generate a curvature gradient change value matrix; specifically, a dynamic calculation model including material creep coefficient and temperature deformation compensation is established by combining BIM technology with finite element analysis. The dynamic calculation model includes the dynamic response coefficient of wind load and the correction factor of earthquake action. Real-time environmental sensor data is used to dynamically correct the model during modeling, and the sensor sampling frequency is not less than 10Hz.

[0026] S2: Build an adjustable arc-shaped support truss system, and use the curvature as a reference to match the truss with the three-dimensional hyperbolic space surface model in real time; specifically, the curvature of the truss is matched with the curvature of the design model in real time through a hydraulic synchronous adjustment device. The adjustable arc-shaped support truss system consists of several standard segments, each of which is equipped with a curvature adjustment mechanism with an adjustment accuracy of 0.1° / m.

[0027] S3: The unit components are hoisted by the reverse assembly method, and the aerial assembly is carried out in the order of alternating extension from the middle to the two sides; specifically, the unit components are hoisted by a modular hoisting system, including an electromagnetic adsorption hoist and an anti-sway control system, and the hoisting positioning accuracy reaches ±3mm. Among them, the unit components are variable curvature shuttle-shaped unit components made by the segmented prefabrication process, and each unit component contains at least three arc segments with different curvature radii. Among them, the unit components are made of 8-12mm thick steel plates through a double curvature cold bending forming process. After forming, the surface curvature error is controlled within the range of ±1.5mm / m. After the double curvature cold bending forming process is completed, laser quenching treatment is performed to form a hardened layer with a thickness of 0.2-0.5mm on the surface of the unit component, and the surface hardness reaches HRC45-50.

[0028] S4: Use a three-dimensional laser scanner to monitor assembly errors, and achieve millimeter-level precision compensation through a multi-directional adjustment device at the node: Specifically, the multi-directional adjustment device is a three-dimensional adjustable cast steel node with X / Y / Z three-directional adjustment function, an adjustment stroke of ±50mm, and an adjustment accuracy of 0.5mm.

[0029] S5: After the main structure is assembled, a prestressed cable system is applied to balance the lateral stress generated by the ultra-deep structure. Specifically, the prestressed cable system adopts a cross-net arrangement, including a dual system of main cables and secondary cables, and the tension is applied in stages and the cable force changes are monitored in real time. Among them, the prestressed cable system is equipped with an intelligent anchor, and the built-in fiber grating sensor monitors the cable force value in real time. The monitoring data is fed back to the central control platform through a wireless transmission module to achieve closed-loop control of the tension force.

[0030] Example 1 The central hall of the T3 terminal of an international airport adopts a shuttle-shaped skylight structure with a span of 82m and a maximum depth of 9.5m. The curvature of the surface varies from R15m to R45m. The construction environment faces the challenges of an average daily temperature difference of 12℃ and an instantaneous wind speed of 8m / s.

[0031] The implementation process is as follows: S1, using the BIM-ANSYS joint platform to build a parametric model, integrating wind speed and temperature sensors (sampling frequency 12Hz), dynamically correcting the wind load coefficient (1.3→1.45) and temperature compensation (ΔL=0.8mm / 10℃) to generate the curvature gradient matrix, and adding an additional 1.2 times the live load safety redundancy in view of the dense passenger flow characteristics of the terminal.

[0032] S2, build an adjustable support truss system with a standard segment length of 6m, and achieve 0.08° / m curvature fine-tuning through a hydraulic servo system (pressure accuracy ±0.5MPa); modular lifting adopts a dual-machine lifting solution: the main crane is a 500t crawler crane equipped with an electromagnetic adsorption hoist (adsorption force 50kN), and the auxiliary crane is a 200t truck crane for posture adjustment. The actual lifting positioning error is measured to be ±2.7mm.

[0033] S3: The reverse assembly method is used to hoist the unit components, and they are assembled in the air in the order of alternating extension from the middle to the two sides; the unit components are made of 10mm thick Q345B steel plates through double curvature cold bending: the main curvature R20m section is cold-bent using a 2000t three-roller plate bending machine, and the secondary curvature R35m section is pressed using a multi-point mold; laser quenching uses a 4kW fiber laser, the scanning speed is 8m / min, the hardened layer thickness is 0.3mm, and the surface hardness reaches HRC48.

[0034] S4, after assembling every three units, use Leica ScanStation P50 to perform full-station scanning, compare the point cloud data with the BIM model, and use the cast steel node adjustment device (X / Y / Z axis electric push rod stroke ±45mm) to compensate for welding deformation, and the cumulative error is controlled within 1.5mm.

[0035] S5, the main cable is made of Φ80mm steel strand (breaking force 1860MPa), and the secondary cable is Φ50mm, forming a 45° cross-mesh layout; the tensioning is implemented in three levels: 30%→60%→100% design tension, and the intelligent anchor monitors the cable tension fluctuation in real time (±2% allowable deviation), and the final lateral stress balance reaches 92.6%.

[0036] Implementation effect: The overall construction period was shortened to 58 days (the traditional process predicted that it would take 105 days), the unit assembly pass rate was 98.7%, and the structure passed the 72-hour wind tunnel test (simulating a level 15 typhoon with no plastic deformation).

[0037] Example 2 (Construction of variable curvature skylight in exhibition center): The main hall of an international exhibition center adopts a variable curvature shuttle skylight structure with a span of 105m and a maximum depth of 12m. The curvature of the surface varies from R12m to R60m, and the design load includes a dynamic load of 3kN / m² for exhibition equipment. The construction site is located in a high-humidity coastal area with an average daily humidity of 85%, and must meet the 8-degree seismic fortification requirements.

[0038] The implementation process is as follows: S1 adopts BIM-Tekla and ABAQUS coupling modeling, integrates temperature and humidity composite sensors (sampling frequency 15Hz), dynamically corrects humidity expansion coefficient (ΔL=0.12mm / %RH) and seismic wave response spectrum; adds 20% aftershock condition redundancy when generating the curvature gradient matrix, and increases the live load safety factor to 1.5 times.

[0039] S2, the adjustable support truss adopts corrosion-resistant aluminum alloy segments (length 8m), and the curvature adjustment is controlled by an electro-hydraulic proportional valve (accuracy 0.07° / m); the double-beam bridge crane is equipped with a vacuum suction cup hoist (adsorption force 80kN), and the lifting path adopts the RTK-GPS positioning system with a positioning error of ±2.1mm.

[0040] S3: The reverse assembly method is used to hoist the unit components, and they are assembled in the air in the order of alternating extension from the middle to the two sides; among them, the unit components are cold-formed with 12mm thick weathering steel S355J2W: the main curvature R15m section uses a 2500t four-roller plate rolling machine with a dynamic straightening system, and the secondary curvature R50m section uses a hydraulic multi-point forming mold (32 pressure points); laser quenching uses a 6kW disk laser, the scanning speed is 6m / min, the hardened layer thickness is 0.4mm, and the surface hardness reaches HRC50.

[0041] S4, after every two units are assembled, FARO Focus S350 is used for panoramic scanning (accuracy ±1mm), and the nodes are adjusted by a six-degree-of-freedom robot (repeat positioning accuracy 0.02mm), and the cumulative deformation compensation is controlled within 0.8mm.

[0042] S5, the main cable is made of Φ100mm galvanized steel cable (breaking force 2200MPa), and the secondary cable is Φ60mm, forming a 60° double-helix mesh layout; a hydraulic synchronous tensioning machine (8-point synchronization accuracy ±1.5%) is used, and the intelligent anchor has a built-in piezoelectric ceramic sensor, and the cable force balance reaches 95.3%.

[0043] Implementation effect: The total construction period was shortened to 67 days (the traditional process predicted 128 days), the welding qualification rate was 99.2%, and it passed the simulated 8.5-magnitude earthquake shaking table test (maximum inter-story displacement angle 1 / 350), meeting the LEED Platinum building certification requirements.

[0044] The above description is only a preferred embodiment of the present invention and is not intended to impose any limitation on the technical solution of the present invention. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can also be subjected to several simple modifications and substitutions, and these modifications and substitutions are also within the scope of protection covered by the claims.

Claims

1. A construction method for a variable curvature ultra-deep shuttle-shaped skylight in a steel structure, characterized in that: The following steps are involved: S1: Establish a three-dimensional hyperbolic space surface model based on parametric modeling and generate a curvature gradient change value matrix; S2: Build an adjustable arc-shaped support truss system, and use the curvature as a reference to match the truss with the three-dimensional double-curvature space surface model in real time; S3: Use the reverse assembly method to hoist the unit components, and assemble them in the air in the order of alternating from the middle to the two sides; S4: Use 3D laser scanner to monitor assembly errors and achieve millimeter-level precision compensation through multi-directional adjustment devices at nodes; S5: After the main structure is assembled, a prestressed tension cable system is applied to balance the lateral stress generated by the ultra-deep structure.

2. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 1, characterized in that: In S1, a dynamic calculation model including material creep coefficient and temperature deformation compensation is established by combining BIM technology with finite element analysis.

3. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in the steel structure according to claim 2, characterized in that: The dynamic calculation model includes the dynamic response coefficient of wind load and the correction factor of earthquake action. Real-time environmental sensor data is used to dynamically correct the model during modeling.

4. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 1, characterized in that: In S3, the adjustable arc-shaped support truss system consists of several standard segments, each of which is equipped with a curvature adjustment mechanism with an adjustment accuracy of 0.1° / m.

5. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 1, characterized in that: In S4, the unit component hoisting adopts a modular hoisting system, which includes an electromagnetic adsorption hoist and an anti-vibration control system, and the hoisting positioning accuracy reaches ±3mm.

6. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 1, characterized in that: In S4, the unit components are variable curvature shuttle-shaped unit components manufactured by a segmented prefabrication process to construct an adjustable arc-shaped support truss system, wherein each unit component includes at least three arc segments with different curvature radii.

7. The construction method of the variable curvature ultra-depth shuttle-shaped skylight in the steel structure according to claim 6, characterized in that: In S2, the unit components are manufactured using a double curvature cold-bending forming process, and the surface curvature error after forming is controlled within the range of ±1.5 mm / m.

8. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 1, characterized in that: In S5, the multi-directional adjustment device is a three-dimensional adjustable cast steel node with X / Y / Z three-directional adjustment functions, an adjustment stroke of ±50mm, and an adjustment accuracy of 0.5mm.

9. The construction method of variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 1, characterized in that: In S6, the prestressed cable system adopts a cross-grid arrangement, including a dual system of main cables and secondary cables. The tensioning force is applied in stages and the cable force changes are monitored in real time.

10. The construction method of the variable curvature ultra-deep shuttle-shaped skylight in a steel structure according to claim 9, characterized in that: The prestressed cable system is equipped with intelligent anchors, and the built-in fiber grating sensor monitors the cable force value in real time. The monitoring data is fed back to the central control platform through the wireless transmission module to realize closed-loop control of the tension force.

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