Bridge steel structure welding deformation rapid detection method and system

Abstract

The invention discloses a bridge steel structure welding deformation rapid detection method and system. The method comprises the following steps: determining a basic principle of method detection; the process for measuring the out-of-plane welding deformation of the bridge steel structure based on the optical three-coordinate system comprises the following steps: counting the number of longitudinal ribs and transverse partition plates of the steel structure, and arranging longitudinal and transverse measuring point measuring areas; calibrating a light pen, setting an original point, measuring three-dimensional coordinates, and recording in groups; calculating a roof plane normal vector and straightness, and comparing a limit value to judge a correction deviation; the process for measuring the welding deformation in the bridge steel structure surface based on three-dimensional laser scanning comprises the following steps: calibrating and calibrating a three-dimensional laser scanner and stably building the three-dimensional laser scanner, cleaning sundries in a to-be-measured area, scanning after pasting reflective points, processing point cloud data to reconstruct a model, calculating the deformation through coordinate transformation, and generating a cloud picture to present the deformation degree. Compared with traditional manual detection, the method not only breaks through the limitation of detection, but also greatly improves the detection efficiency.

Description

Technical Field

[0001] This invention belongs to the field of bridge construction, and more specifically, relates to a method and system for rapid detection of welding deformation in bridge steel structures. Background Technology

[0002] In the field of modern bridge construction, steel structures, with their outstanding advantages such as high strength, light weight, and short construction period, are widely used in various bridge projects, such as large-scale cross-river and cross-sea bridges, as well as urban viaducts. Welding, as a key process for connecting bridge steel structures, directly affects the overall performance and safety of the bridge due to its quality. However, uneven heating during welding can easily lead to deformation of the steel structure. This deformation includes both out-of-plane and in-plane deformation, which seriously affects the dimensional accuracy and surface flatness of the bridge steel structure, increases the workload of post-weld correction, and even threatens the structural strength and other service performance characteristics.

[0003] Currently, my country's bridge steel structure welding deformation detection technology faces numerous challenges. Traditional manual inspection methods, such as "using a ruler" and "total station measurement," rely on manual operation, which is not only inefficient and unable to meet the inspection needs of large-scale bridge construction, but also subject to significant human factors affecting the accuracy of measurement data, hindering effective data traceability and scientific management. Furthermore, traditional inspection methods are inadequate for complex internal obstructed areas and intricate fillet weld areas within bridge steel structures, leading to a significant increase in the difficulty of welding deformation quality control.

[0004] Bridge construction is rapidly advancing towards high quality, lean manufacturing, and digitalization. The new standard, "Specifications for Manufacturing and Installation of Highway Steel Structure Bridges (JTG / T3651—2022)," sets forth strict and detailed regulations on the permissible deviations of welding deformation in various parts of bridge steel structure production components, placing higher demands on the accuracy, efficiency, and comprehensiveness of welding deformation detection. Against this backdrop, existing testing technologies are no longer sufficient to meet the industry's development needs, urgently requiring an innovative testing method to achieve rapid and accurate detection of welding deformation in bridge steel structure segments, thereby laying a solid foundation for quality control and digital transformation in bridge construction. Summary of the Invention

[0005] The purpose of this invention is to solve the existing problems in the detection of welding deformation in bridge steel structures. By utilizing optical coordinate measuring machines (CMMs) and three-dimensional laser scanning technology, rapid and accurate detection of welding deformation can be achieved, overcoming the shortcomings of traditional manual inspection, such as low efficiency, poor accuracy, and inability to detect special areas. By establishing standardized inspection procedures and pass / fail evaluation methods, the accuracy and standardization of inspections are ensured, providing a reliable basis for construction decisions.

[0006] To address the aforementioned deficiencies or improvement needs of existing technologies, as a first aspect of this invention, the present invention provides a rapid detection method for welding deformation of bridge steel structures, comprising the following steps:

[0007] S1. Determine the basic principles of measuring the out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machine and measuring the in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning.

[0008] S2. Determine the process for measuring out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machines, including:

[0009] The number of longitudinal ribs and transverse diaphragms in the welded steel structure units is counted, and the longitudinal measuring points and measuring areas and the transverse measuring points and measuring areas are arranged respectively.

[0010] Place the dedicated target that comes with the optical coordinate measuring machine pen, calibrate the pen, and set the coordinate origin;

[0011] Use a calibrated light pen to measure the three-dimensional coordinates of longitudinal and transverse measuring points, and record them in groups according to the measuring area;

[0012] Calculate the normal vector of the top plate plane by selecting the coordinates of non-collinear measuring points, calculate the straightness of the plane based on the coordinates of 3 points in the measuring area, compare the straightness with the preset limit, and judge whether the correction deviation is qualified.

[0013] S3. Determine the process for measuring in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning, including:

[0014] The 3D laser scanner should be calibrated and ensured to be set up in a stable environment, avoiding interference from strong light and backlight.

[0015] Clean the surface of the area to be tested, remove debris, and attach reflective standard points in the fillet weld area;

[0016] The bridge steel structure is scanned, and the direction and height of the camera are adjusted according to the actual situation during the scanning process to obtain comprehensive point cloud data;

[0017] The acquired point cloud data is processed to remove noise and outliers, and the data format is converted.

[0018] Reconstruct a three-dimensional model of the bridge steel structure based on the processed data;

[0019] Welding deformation is calculated by transforming point cloud coordinates, generating a welding deformation cloud map that intuitively reflects the degree of welding deformation.

[0020] Furthermore, the basic principle of measuring the out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machines in S1 is as follows:

[0021] When measuring the external welding deformation of the steel structure of a bridge, several test areas are divided on the structural component to be tested. Each test area consists of three characteristic test points, namely the left and right end points A and B and the midpoint M. The endpoints A and B of adjacent test areas can be shared.

[0022] After all measurements of the plane to be measured on a steel structural member are completed, three non-collinear points within this plane are selected, with coordinates (x1, y1, z1), (x2, y2, z2), and (x3, y3, z3). The normal vector of the top plate plane is calculated using the coordinates of these three points, and the specific calculation formula is as follows:

[0023] a=(y2-y1)(z3-z1)-(y3-y1)(z2-z1)

[0024] b = (z2 - z1)(x3 - x1) - (z3 - z1)(x2 - x1)

[0025] c=(x2-x1)(y3-y1)-(x3-x1)(y2-y1)

[0026] The three-dimensional coordinates of endpoint A, endpoint B, and midpoint within each survey area are denoted as (x...). A ,y AB ,z A ), (x B ,y B ,z B ), (x M ,y M ,z M The out-of-plane deformation of a survey area is calculated using the three-dimensional coordinates of three characteristic measuring points within that area. The formula for calculating the out-of-plane deformation Δ of the survey area is:

[0027]

[0028] The calculated out-of-plane deformation Δ is compared and analyzed with the out-of-plane deformation limit ΔL.

[0029] Furthermore, the basic principle of measuring in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning in S1 is as follows:

[0030] Emit a laser beam to the surface of the target object;

[0031] The CCD camera receives information about the laser beam reflection from the surface of the target object;

[0032] Based on the angle between the incident light and the reflected light, the position of the target object in the preset coordinate system is calculated through the geometric relationship of the triangle, thereby obtaining the geometric shape and size information of the target object.

[0033] Furthermore, the arrangement method of the longitudinal measuring points and measuring areas in S2 is as follows:

[0034] The arrangement of longitudinal measuring points and areas includes determining the longitudinal section, determining the longitudinal measuring points, determining the longitudinal measuring area, and matching the longitudinal measuring points and areas. Determining the longitudinal section involves taking the center plane between every two longitudinal ribs as the longitudinal section and numbering the longitudinal sections. Determining the longitudinal measuring points involves identifying the transverse diaphragms and the center point between every two transverse diaphragms as longitudinal measuring points in the intersection line formed by each longitudinal section and the top surface of the top plate. Determining the longitudinal measuring area involves identifying the interval between every two transverse diaphragms as one longitudinal measuring area in the intersection line formed by each longitudinal section and the top surface of the top plate, and numbering the longitudinal measuring areas. Each longitudinal section has two longitudinal measuring areas. Matching the longitudinal measuring points and areas involves grouping three longitudinal measuring points within each longitudinal measuring area into a set to match that longitudinal measuring area. The three longitudinal measuring points in each longitudinal measuring area include endpoint A, endpoint B, and the midpoint.

[0035] Furthermore, the arrangement method of the transverse measuring points and measuring areas in S2 is as follows:

[0036] The arrangement of transverse measuring points and areas includes the determination of cross sections, the determination of transverse measuring points, the determination of transverse measuring areas, and the matching of transverse measuring points and areas. The determination of cross sections involves taking the center plane between every two adjacent transverse diaphragms as the transverse section and numbering the transverse sections. The determination of transverse measuring points involves identifying the intersections of each longitudinal rib and the top plate, as well as the midpoints of the lines connecting the intersections of every two adjacent longitudinal ribs and the top plate, as transverse measuring points in each transverse section. Each transverse section has no fewer than 7 transverse measuring areas. The matching of transverse measuring points and areas involves grouping 3 transverse measuring points within each transverse measuring area into a set to match that transverse measuring area. The 3 transverse measuring points in each transverse measuring area include endpoint A, endpoint B, and midpoint.

[0037] Furthermore, S2 also includes:

[0038] Horizontal and vertical measurement zones are delineated on the diaphragm structural unit, with a spacing of not less than 200cm between each measurement zone, and these zones must avoid the locations of manholes and longitudinal ribs.

[0039] Furthermore, the specific method for calibrating the 3D laser scanner in step S3 is as follows:

[0040] The positional distance between the device and the workpiece is calculated based on the pre-set scanning mode of the 3D scanner;

[0041] When calibrating the scanner, adjust the 3D scanning environment settings of the equipment system according to the workpiece;

[0042] After calibration, the measurement object with known 3D data is scanned with a 3D scanner for comparison. If the scanner's scanning accuracy is found to be insufficient, the scanner needs to be recalibrated.

[0043] Furthermore, in step S3, welding deformation is calculated through point cloud coordinate transformation. The specific method is as follows:

[0044] Coordinate System 1: To achieve unified data analysis, the point cloud data obtained from scanning needs to be converted to the same reference coordinate system; assuming the original point cloud coordinates are (x... ori ,y ori ,z ori The coordinates (x, y) are transformed using a rotation matrix R and a translation vector T to obtain the transformed coordinates. trans ,y trans ,z trans The conversion formula is:

[0045]

[0046] The rotation matrix R is used to adjust the orientation of the point cloud data, and the translation vector T is used to adjust the position of the point cloud data. They are determined according to the selected reference coordinate system.

[0047] Calculate deformation: After unifying the coordinate system, compare the actual point cloud coordinates with the theoretical model coordinates to calculate the deformation; let the actual point cloud coordinates be (x... act ,y act ,z act ,), the coordinates of the corresponding point on the theoretical model are (x, y). the ,y the ,z the If the deformation along the X, Y, and Z axes is Δx, Δy, and Δz respectively, then the formulas for calculating these deformations are as follows:

[0048] Δx=x act -x the

[0049] Δy=y act -y the

[0050] Δz=z act -z the

[0051] The total deformation D of a point can be calculated using the vector magnitude formula:

[0052]

[0053] For the entire bridge steel structure, it is necessary to traverse all point cloud data involved in the calculation and calculate the deformation of each point separately; through statistical analysis of the deformation of all points, we can understand the overall situation of welding deformation within the steel structure surface; including the average value, maximum value and minimum value;

[0054] Among them, the average value of the deformation at all points is calculated. The formula is

[0055]

[0056] Where n is the total number of points involved in the calculation, and D i Let be the deformation at point i. These statistical values ​​help to assess welding quality and determine whether the steel structure meets design requirements.

[0057] As a second aspect of the present invention, a rapid detection system for welding deformation of bridge steel structures is provided, comprising:

[0058] The principle determination unit is used to determine the basic principles of measuring the external welding deformation of bridge steel structures based on optical coordinate measuring machine and measuring the internal welding deformation of bridge steel structures based on three-dimensional laser scanning.

[0059] An optical coordinate measuring machine (OCM) unit for measuring the out-of-plane welding deformation of bridge steel structures is used to determine the process for measuring the out-of-plane welding deformation of bridge steel structures, including:

[0060] The number of longitudinal ribs and transverse diaphragms in the welded steel structure units was counted, and the measuring points and measuring areas in the longitudinal and transverse directions were arranged respectively.

[0061] Place the dedicated target that comes with the optical coordinate measuring machine pen, calibrate the pen, and set the coordinate origin;

[0062] Use a calibrated light pen to measure the three-dimensional coordinates of longitudinal and transverse measuring points, and record them in groups according to the measuring area;

[0063] Calculate the normal vector of the top plate plane by selecting the coordinates of non-collinear measuring points, calculate the straightness of the plane based on the coordinates of 3 points in the measuring area, compare the straightness with the preset limit, and judge whether the correction deviation is qualified.

[0064] Based on 3D laser scanning measurement of in-plane welding elements in bridge steel structures, a process for determining the in-plane welding deformation measurement of bridge steel structures using 3D laser scanning is established, including:

[0065] The 3D laser scanner should be calibrated and ensured to be set up in a stable environment, avoiding interference from strong light and backlight.

[0066] Clean the surface of the area to be tested, remove debris, and attach reflective standard points in the fillet weld area;

[0067] The bridge steel structure is scanned, and the direction and height of the camera are adjusted according to the actual situation during the scanning process to obtain comprehensive point cloud data;

[0068] The acquired point cloud data is processed to remove noise and outliers, and the data format is converted.

[0069] Reconstruct a three-dimensional model of the bridge steel structure based on the processed data;

[0070] Calculate the specific values ​​of welding deformation, generate a welding deformation cloud map, and intuitively display the welding deformation situation in the plane.

[0071] As a third aspect of the invention, a computer-readable storage medium is also provided, on which a computer program is stored, which is executed by a processor of any step of the method for rapid detection of welding deformation in bridge steel structures.

[0072] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects:

[0073] 1. This invention provides a rapid detection method for welded deformation in bridge steel structures, achieving innovation in detection methods by employing a step-by-step detection technique combining optical coordinate measuring machine (OCM) and three-dimensional laser scanning. When detecting out-of-plane welded deformation in bridge steel structures, the OCM divides the test area into zones according to specifications and calculates the out-of-plane deformation by measuring the three-dimensional coordinates of characteristic points. When measuring in-plane welded deformation, the three-dimensional laser scanning technology acquires data through non-contact stereoscopic scanning. The combination of these two technologies, compared to traditional manual inspection, not only overcomes the limitations of traditional methods but also significantly improves inspection efficiency, enabling rapid acquisition of welded deformation information and making inspection work more efficient and convenient.

[0074] 2. This invention provides a rapid detection method for welded deformation in bridge steel structures. By establishing a comprehensive and standardized strategy for arranging measuring points and areas, the systematic nature and completeness of the detection are ensured. After the parameters of the plate units are statistically numbered, the longitudinal and transverse measuring points and areas are meticulously arranged, clearly defining and numbering the specific location of each measuring point and area. For example, in the arrangement of longitudinal measuring points and areas, precise matching is performed from determining the longitudinal section, measuring points, to the measuring areas, ensuring that all parts of the entire steel structure are within the detection range. This eliminates detection loopholes, makes the detection results more reliable, and provides a comprehensive and accurate basis for subsequent construction decisions.

[0075] 3. This invention provides a rapid detection method for welding deformation in bridge steel structures. By deeply integrating point cloud data from 3D laser scanning with BIM technology, it enhances the digitalization level and application scalability of the detection. In in-plane welding deformation detection, the 3D laser scanner acquires point cloud data, which is then processed and reconstructed into a 3D model to visually display the welding deformation. Simultaneously, the data exchange and sharing between the point cloud data model and BIM enables this technology to excel in areas such as virtual pre-assembly of prefabricated structures, providing rich data for the design optimization and construction simulation of bridge steel structures, and promoting the digitalization and intelligentization of bridge construction. Attached Figure Description

[0076] Figure 1 This is a flowchart of a rapid detection method for welding deformation of bridge steel structures according to an embodiment of the present invention;

[0077] Figure 2 This is a flowchart of the optical coordinate measuring machine (CMM) detection process according to an embodiment of the present invention.

[0078] Figure 3 This is a schematic diagram of the bridge steel structure unit construction according to an embodiment of the present invention;

[0079] Figure 4 This is a schematic diagram of the longitudinal measurement area location according to an embodiment of the present invention;

[0080] Figure 5 This is a schematic diagram of the lateral measurement area location according to an embodiment of the present invention;

[0081] Figure 6 This is a schematic diagram illustrating the measurement scenario and calibration according to an embodiment of the present invention;

[0082] Figure 7 This is a schematic diagram of the on-site measurement of the bridge steel structure unit according to an embodiment of the present invention;

[0083] Figure 8 This is a schematic diagram of the on-site measurement of the diaphragm structure unit according to an embodiment of the present invention;

[0084] Figure 9 This is a flowchart of the three-dimensional laser scanning detection process according to an embodiment of the present invention;

[0085] Figure 10 This is a schematic diagram of the on-site calibration of the scanner according to an embodiment of the present invention;

[0086] Figure 11 This is a schematic diagram of the surface treatment of the area to be tested according to an embodiment of the present invention;

[0087] Figure 12 This is a schematic diagram of on-site scanning according to an embodiment of the present invention;

[0088] Figure 13 This is a 3D model reconstruction and welding deformation cloud map of an embodiment of the present invention;

[0089] Figure 14 This is a system unit diagram of an embodiment of the present invention;

[0090] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 1-longitudinal steel structural unit, 2-longitudinal rib, 3-transverse diaphragm. Detailed Implementation

[0091] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0092] Example 1

[0093] Please refer to Figure 1 This embodiment 1 provides a rapid detection method for welding deformation of bridge steel structures, including:

[0094] (1) Determine the basic principles of measuring the out-of-plane welding deformation of bridge steel structure based on optical coordinate measuring machine and measuring the in-plane welding deformation of bridge steel structure based on three-dimensional laser scanning.

[0095] 1.1 Measurement of Out-of-Plane Welding Deformation of Bridge Steel Structure Based on Optical Coordinate Measuring (CMM)

[0096] When measuring the external welding deformation of a bridge steel structure, several test areas can be divided on the structural component to be tested. Each test area consists of three characteristic test points, namely the left and right end points A and B and the midpoint M. The endpoints A and B of adjacent test areas can be shared.

[0097] After all measurements of the plane to be measured on a steel structure component are completed, three non-collinear points (with the distance between the three points as far as possible) are selected within the plane to be measured. Let their coordinates be (x1, y1, z1), (x2, y2, z2), and (x3, y3, z3). The normal vector of the top plate plane is calculated using the coordinates of these three points, and the specific calculation formula is as follows:

[0098] a=(y2-y1)(z3-z1)-(y3-y1)(z2-z1)

[0099] b = (z2 - z1)(x3 - x1) - (z3 - z1)(x2 - x1)

[0100] c=(x2-x1)(y3-y1)-(x3-x1)(y2-y1)

[0101] The three-dimensional coordinates of endpoint A, endpoint B, and midpoint within each survey area are denoted as (x...). A ,y AB ,z A ), (x B ,y B ,z B ), (x M ,y M ,z M The out-of-plane deformation of a survey area is calculated using the three-dimensional coordinates of three characteristic measuring points within that area. The formula for calculating the out-of-plane deformation Δ of the survey area is:

[0102]

[0103] The calculated out-of-plane deformation Δ is compared and analyzed with the out-of-plane deformation limit ΔL. ΔL can be determined according to the "Railway Steel Bridge Manufacturing Specification" (Q / CR9211-2015).

[0104] 1.2 Measurement of In-Plane Welding Deformation of Bridge Steel Structure Based on 3D Laser Scanning (3D-Scan)

[0105] Compared with coordinate measuring machines (CMMs), 3D laser scanning technology is a simple, efficient, and versatile non-contact stereo scanning measurement method, suitable for full-size 3D digital inspection of the geometry of the object being measured. The basic testing principle of the laser triangulation-based 3D optical scanner used in this method can be summarized as follows:

[0106] Emit a laser beam to the surface of the target object;

[0107] The CCD camera receives information about the laser beam reflection from the surface of the target object;

[0108] Based on the angle between the incident light and the reflected light, the position of the target object in the preset coordinate system is calculated using the geometric relationship of triangles, thereby obtaining the geometric shape and size information of the target object.

[0109] (2) Determine the process for measuring the out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machines.

[0110] Please refer to Figure 2 For out-of-plane deformation of large bridge steel structure segments, a standardized detection strategy can be developed. By using an optical coordinate measuring system to measure and calculate the three-dimensional coordinates of characteristic measuring points within the measurement area, the out-of-plane deformation of the measurement area can be quickly and accurately obtained. The data can then be analyzed and organized to form a welding deformation qualification evaluation system suitable for optical coordinate measuring systems. The specific operational points are as follows:

[0111] Board unit parameter statistics number: Please refer to Figure 3 After the steel structure unit 1 to be tested is welded, the number of longitudinal ribs 2 and transverse diaphragms 3 of the steel structure unit is counted. In this construction method example, the measured steel bridge deck unit contains a total of 4 longitudinal ribs, 3 transverse diaphragms and one top plate, which can be adjusted according to the actual working conditions.

[0112] Longitudinal measuring point and measuring area arrangement: Please refer to Figure 4The process includes steps such as determining the longitudinal section, determining the longitudinal measuring points, determining the longitudinal measuring area, and matching the longitudinal measuring points and measuring areas. The longitudinal section is determined by using the center plane between every two longitudinal ribs as the longitudinal section and numbering them. In this construction example, there are three longitudinal sections, numbered L1, L2, and L3. The longitudinal measuring points are determined by identifying the transverse diaphragms and the center point between every two transverse diaphragms along the intersection line formed by each longitudinal section and the top surface of the top plate, totaling 15 measuring points. The longitudinal measuring area is determined by identifying the interval between every two transverse diaphragms along the intersection line formed by each longitudinal section and the top surface of the top plate, and numbering them. Each longitudinal section has two longitudinal measuring areas, totaling six longitudinal measuring areas, numbered L1-1, L1-2, L2-1, L2-2, L3-1, and L3-2. The longitudinal measuring point and measuring area matching involves grouping three longitudinal measuring points within each longitudinal measuring area into a set to match that longitudinal measuring area. The three longitudinal measuring points in each longitudinal measuring area include endpoint A, endpoint B, and the midpoint.

[0113] Lateral measuring point and area arrangement: Please refer to Figure 5 The process includes steps such as determining the cross section, determining the transverse measuring points, determining the transverse measuring areas, and matching the transverse measuring points and measuring areas. Determining the cross section involves using the center plane between every two adjacent transverse diaphragms as the transverse section and numbering these sections. In this example, there are two cross sections, numbered T1 and T2. Determining the transverse measuring points involves identifying the intersections of each longitudinal rib and the top plate, as well as the midpoints of the lines connecting any two adjacent longitudinal ribs to the top plate, within each transverse section. A total of 30 transverse measuring points are identified. Each transverse section has 7 transverse measuring areas, for a total of 14 transverse measuring areas, numbered T1-1, T1-2, T1-3, T1-4, T1-5, T1-6, T1-7, T2-1, T2-2, T2-3, T2-4, T2-5, T2-6, and T2-7. Lateral measurement point and measurement area matching involves grouping three lateral measurement points within each lateral measurement area into a set to match that lateral measurement area. The three lateral measurement points in each lateral measurement area include endpoint A, endpoint B, and midpoint.

[0114] Measurement preparation: Please refer to Figure 6 Place the dedicated target 5 of the optical coordinate measuring machine (CMM) pen 4 next to the steel structure unit 1 to be measured, ensuring that the CMM pen 4 can scan the dedicated target 5 when measuring all longitudinal and transverse measuring points. Calibrate the CMM pen 4 and take a point on the dedicated target 5 as the origin of the coordinate system. The measurement unit of the CMM pen is mm, and the measurement accuracy is 0.01 mm.

[0115] 3D coordinate measurement: Please refer to Figure 7The CMM light pen 4 was used to measure and record the three-dimensional coordinates of all longitudinal and transverse measuring points. The three-dimensional coordinates were recorded in groups according to the measurement area. The three-dimensional coordinates of endpoint A, endpoint B, and midpoint in each measurement area were recorded as (x... A ,y AB ,z A ), (x B ,y B ,z B ), (x M ,y M ,z M The three-dimensional coordinate measurement data record is shown in Table 1.

[0116] Table 1 Sample Table for Recording Three-Dimensional Coordinate Measurement Data

[0117]

[0118]

[0119] Please refer to Figure 8 Horizontal and vertical measurement zones are delineated on the diaphragm structural unit, with a spacing of 200 mm between each zone, avoiding manholes and longitudinal rib locations. In this construction example, for a diaphragm structural unit with a width of 2.96 m and a height of 1.8 m, four horizontal measurement zones T1 to T4 are selected, and four vertical measurement zones V1 to V8 are selected. Since some measurement zones can share measurement points, a total of 20 points need to be measured for the three-dimensional coordinates of the entire top plate unit.

[0120] Calculation of the plane normal vector of the steel structure unit: Select three non-collinear measuring points from endpoints A and B of all survey areas. The distance between these three measuring points should be as far as possible. The coordinates of the three measuring points are (x1, y1, z1), (x2, y2, z2), and (x3, y3, z3). Calculate the plane normal vector of the top slab using the coordinates of these three points.

[0121] Calculation of straightness of steel structure unit plan: The straightness of the measurement area is calculated using the three-dimensional coordinates of three points within all longitudinal and transverse measurement areas. The calculation is performed according to the formula for the straightness Δ of the measurement area, and the results are summarized and recorded in Sample Table 2.

[0122] Table 2 Sample Table of Straightness Calculation Results for Steel Structure Units

[0123]

[0124] Acceptance assessment: The acceptance of the correction deviation in each test area is determined. If Δ≤ΔL, the correction deviation of the test area is considered acceptable; if Δ>ΔL, the correction deviation of the test area is considered unacceptable. ΔL is the straightness limit. In this construction method example, the straightness limit ΔL is determined according to the "Railway Steel Bridge Manufacturing Specification" (Q / CR9211-2015). For all longitudinal test areas, ΔL=4.00mm; for all transverse test areas, ΔL=1.20mm.

[0125] (3) Determine the process for measuring in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning.

[0126] Please refer to Figure 9 For various complex fillet weld areas within the steel structure segment, reflective markers are affixed according to the proposed standardized inspection strategy. Point cloud data for each measurement area is acquired using a handheld 3D laser scanning device. PolyWorks engineering software is then used to extract planar features from the point cloud data. Linear fitting is performed based on spatial feature points to reconstruct the 3D model of each measurement area. The full-field 3D deformation information of the component is then calculated and analyzed. Specific operational points are as follows:

[0127] Measurement preparation: For 3D scanning, ensure that the 3D scanner is set up in a stable environment, avoid strong light and backlight, and ensure that the 3D scanning results are not affected by external environmental factors.

[0128] Scanner calibration: Please refer to Figure 10 Before scanning with a 3D laser scanner, a crucial step is calibration. Accurate 3D data is paramount, and calibration involves calculating the distance between the scanner and the workpiece based on the scanner's pre-set scanning mode. The 3D scanning environment settings are adjusted according to the workpiece during scanner calibration. Correct camera settings are critical to the accuracy of the scanned data; therefore, calibration must be performed strictly according to the manufacturer's instructions. After calibration, the data can be checked and compared by scanning a known 3D object with the scanner. If the scanner's accuracy is insufficient, recalibration is necessary.

[0129] Surface preparation of the area to be tested: Please refer to... Figure 11 First, the surface dust, welding slag and other debris in the area to be measured are cleaned to reduce the workload of post-processing the point cloud data model. Then, reflective standard points are pasted on the areas to be measured for various complex fillet welds. They should be pasted as randomly as possible and avoid being too sparse in order to improve the scanning accuracy.

[0130] To begin scanning: Please refer to... Figure 12After preparation, the weld area to be tested can be scanned. The 3D scanner is used to capture three-dimensional point cloud data of the object being scanned from different angles. The direction and height of the 3D scanner camera are continuously adjusted to comprehensively scan the object and render the model on the computer screen in real time for easy observation of the scanning process.

[0131] Point cloud data post-processing and 3D model reconstruction: Please refer to Figure 13 Currently, most 3D scanners on the market use automatic point cloud stitching, eliminating the need for manual stitching later. This means that after scanning the structural surface, the system automatically generates a 3D point cloud image of the structure. However, operators are required to remove noise (i.e., redundant point clouds) and smooth the scanned point cloud data to improve data quality. After processing, the point cloud needs to be converted. Currently, the system software automatically converts the point cloud data directly into an STL file. The generated STL data can be imported into Polyworks software for 3D model reconstruction, and welding deformation can be calculated through point cloud coordinate transformation to generate a welding deformation cloud map, visually reflecting the degree of welding deformation.

[0132] In a preferred embodiment, welding deformation is calculated through point cloud coordinate transformation. The specific method is as follows:

[0133] Coordinate System 1: To achieve unified data analysis, the point cloud data obtained from scanning needs to be converted to the same reference coordinate system; assuming the original point cloud coordinates are (x... ori ,y ori ,z ori The coordinates (x, y) are transformed using a rotation matrix R and a translation vector T to obtain the transformed coordinates. trans ,y trans ,z trans The conversion formula is:

[0134]

[0135] The rotation matrix R is used to adjust the orientation of the point cloud data, and the translation vector T is used to adjust the position of the point cloud data. They are determined according to the selected reference coordinate system.

[0136] Calculate deformation: After unifying the coordinate system, compare the actual point cloud coordinates with the theoretical model coordinates to calculate the deformation; let the actual point cloud coordinates be (x... act ,y act ,z act ,), the coordinates of the corresponding point on the theoretical model are (x, y). the ,y the ,z the If the deformation along the X, Y, and Z axes is Δx, Δy, and Δz respectively, then the formulas for calculating these deformations are as follows:

[0137] Δx=x act -xthe

[0138] Δy=y act -y the

[0139] Δz=z act -z the

[0140] The total deformation D of a point can be calculated using the vector magnitude formula:

[0141]

[0142] For the entire bridge steel structure, it is necessary to traverse all point cloud data involved in the calculation and calculate the deformation of each point separately; through statistical analysis of the deformation of all points, we can understand the overall situation of welding deformation within the steel structure surface; including the average value, maximum value and minimum value;

[0143] Among them, the average value of the deformation at all points is calculated. The formula is

[0144]

[0145] Where n is the total number of points involved in the calculation, and D i Let be the deformation at point i. These statistical values ​​help to assess welding quality and determine whether the steel structure meets design requirements.

[0146] Example 2

[0147] Please refer to Figure 14 This embodiment 2 provides a rapid detection system for welding deformation of bridge steel structures, including:

[0148] The principle determination unit is used to determine the basic principles of measuring the external welding deformation of bridge steel structures based on optical coordinate measuring machine and measuring the internal welding deformation of bridge steel structures based on three-dimensional laser scanning.

[0149] An optical coordinate measuring machine (OCM) unit for measuring the out-of-plane welding deformation of bridge steel structures is used to determine the process for measuring the out-of-plane welding deformation of bridge steel structures, including:

[0150] The number of longitudinal ribs and transverse diaphragms in the welded steel structure units was counted, and the measuring points and measuring areas in the longitudinal and transverse directions were arranged respectively.

[0151] Place the dedicated target that comes with the optical coordinate measuring machine pen, calibrate the pen, and set the coordinate origin;

[0152] Use a calibrated light pen to measure the three-dimensional coordinates of longitudinal and transverse measuring points, and record them in groups according to the measuring area;

[0153] Calculate the normal vector of the top plate plane by selecting the coordinates of non-collinear measuring points, calculate the straightness of the plane based on the coordinates of 3 points in the measuring area, compare the straightness with the preset limit, and judge whether the correction deviation is qualified.

[0154] Based on 3D laser scanning measurement of in-plane welding elements in bridge steel structures, a process for determining the in-plane welding deformation measurement of bridge steel structures using 3D laser scanning is established, including:

[0155] The 3D laser scanner should be calibrated and ensured to be set up in a stable environment, avoiding interference from strong light and backlight.

[0156] Clean the surface of the area to be tested, remove debris, and attach reflective standard points in the fillet weld area;

[0157] The bridge steel structure is scanned, and the direction and height of the camera are adjusted according to the actual situation during the scanning process to obtain comprehensive point cloud data;

[0158] The acquired point cloud data is processed to remove noise and outliers, and the data format is converted.

[0159] Reconstruct a three-dimensional model of the bridge steel structure based on the processed data;

[0160] Calculate the specific values ​​of welding deformation, generate a welding deformation cloud map, and intuitively display the welding deformation situation in the plane.

[0161] Example 3

[0162] This embodiment 3 also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, can implement any step of a rapid detection method for welding deformation of bridge steel structures.

[0163] The computer-readable storage medium may include various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0164] For a description of the computer-readable storage medium provided in this application, please refer to the above method embodiments; further details will not be repeated here.

[0165] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A rapid detection method for welding deformation of bridge steel structures, characterized in that, include: S1. Determine the basic principles of measuring the out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machine and measuring the in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning. S2. Determine the process for measuring out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machines, including: The number of longitudinal ribs and transverse diaphragms in the welded steel structure units is counted, and the longitudinal measuring points and measuring areas and the transverse measuring points and measuring areas are arranged respectively. Place the dedicated target that comes with the optical coordinate measuring machine pen, calibrate the pen, and set the coordinate origin; Use a calibrated light pen to measure the three-dimensional coordinates of longitudinal and transverse measuring points, and record them in groups according to the measuring area; Calculate the normal vector of the top plate plane by selecting the coordinates of non-collinear measuring points, calculate the straightness of the plane based on the coordinates of 3 points in the measuring area, compare the straightness with the preset limit, and judge whether the correction deviation is qualified. S3. Determine the process for measuring in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning, including: The 3D laser scanner should be calibrated and ensured to be set up in a stable environment, avoiding interference from strong light and backlight. Clean the surface of the area to be tested, remove debris, and attach reflective standard points in the fillet weld area; The bridge steel structure is scanned, and the direction and height of the camera are adjusted according to the actual situation during the scanning process to obtain comprehensive point cloud data; The acquired point cloud data is processed to remove noise and outliers, and the data format is converted. Reconstruct a three-dimensional model of the bridge steel structure based on the processed data; Welding deformation is calculated by transforming point cloud coordinates, generating a welding deformation cloud map that intuitively reflects the degree of welding deformation.

2. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, The basic principle of measuring the out-of-plane welding deformation of bridge steel structures based on optical coordinate measuring machines in S1 is as follows: When measuring the external welding deformation of the steel structure of a bridge, several test areas are divided on the structural component to be tested. Each test area consists of three characteristic test points, namely the left and right end points A and B and the midpoint M. The endpoints A and B of adjacent test areas can be shared. After all measurements of the plane to be measured on a steel structural member are completed, three non-collinear points within this plane are selected, with coordinates (x1, y1, z1), (x2, y2, z2), and (x3, y3, z3). The normal vector of the top plate plane is calculated using the coordinates of these three points, and the specific calculation formula is as follows: a=(y2-y1)(z3-z1)-(y3-y1)(z2-z1) b = (z2 - z1)(x3 - x1) - (z3 - z1)(x2 - x1) c=(x2-x1)(y3-y1)-(x3-x1)(y2-y1) The three-dimensional coordinates of endpoint A, endpoint B, and midpoint within each survey area are denoted as (x...). A ,y AB ,z A ), (x B ,y B ,z B ), (x M ,y M ,z M The out-of-plane deformation of a survey area is calculated using the three-dimensional coordinates of three characteristic measuring points within that area. The formula for calculating the out-of-plane deformation Δ is: The calculated out-of-plane deformation Δ is compared and analyzed with the out-of-plane deformation limit ΔL.

3. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, The basic principle of measuring in-plane welding deformation of bridge steel structures based on three-dimensional laser scanning in S1 is as follows: Emit a laser beam to the surface of the target object; The CCD camera receives information about the laser beam reflection from the surface of the target object; Based on the angle between the incident light and the reflected light, the position of the target object in the preset coordinate system is calculated through the geometric relationship of the triangle, thereby obtaining the geometric shape and size information of the target object.

4. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, The arrangement method for longitudinal measuring points and measuring areas in S2 is as follows: The arrangement of longitudinal measuring points and areas includes determining the longitudinal section, determining the longitudinal measuring points, determining the longitudinal measuring area, and matching the longitudinal measuring points and areas. Determining the longitudinal section involves taking the center plane between every two longitudinal ribs as the longitudinal section and numbering the longitudinal sections. Determining the longitudinal measuring points involves identifying the transverse diaphragms and the center point between every two transverse diaphragms as longitudinal measuring points in the intersection line formed by each longitudinal section and the top surface of the top plate. Determining the longitudinal measuring area involves identifying the interval between every two transverse diaphragms as one longitudinal measuring area in the intersection line formed by each longitudinal section and the top surface of the top plate, and numbering the longitudinal measuring areas. Each longitudinal section has two longitudinal measuring areas. Matching the longitudinal measuring points and areas involves grouping three longitudinal measuring points within each longitudinal measuring area into a set to match that longitudinal measuring area. The three longitudinal measuring points in each longitudinal measuring area include endpoint A, endpoint B, and the midpoint.

5. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, The arrangement method for the transverse measuring points and measuring areas in S2 is as follows: The arrangement of transverse measuring points and areas includes the determination of cross sections, the determination of transverse measuring points, the determination of transverse measuring areas, and the matching of transverse measuring points and areas. The determination of cross sections involves taking the center plane between every two adjacent transverse diaphragms as the transverse section and numbering the transverse sections. The determination of transverse measuring points involves identifying the intersections of each longitudinal rib and the top plate, as well as the midpoints of the lines connecting the intersections of every two adjacent longitudinal ribs and the top plate, as transverse measuring points in each transverse section. Each transverse section has no fewer than 7 transverse measuring areas. The matching of transverse measuring points and areas involves grouping 3 transverse measuring points within each transverse measuring area into a set to match that transverse measuring area. The 3 transverse measuring points in each transverse measuring area include endpoint A, endpoint B, and midpoint.

6. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, S2 further includes: Horizontal and vertical measurement zones are delineated on the diaphragm structural unit, with a spacing of not less than 200cm between each measurement zone, and these zones must avoid the locations of manholes and longitudinal ribs.

7. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, The specific method for calibrating the 3D laser scanner in S3 is as follows: The positional distance between the device and the workpiece is calculated based on the pre-set scanning mode of the 3D scanner; When calibrating the scanner, adjust the 3D scanning environment settings of the equipment system according to the workpiece; After calibration, the measurement object with known 3D data is scanned with a 3D scanner for comparison. If the scanner's scanning accuracy is found to be insufficient, the scanner needs to be recalibrated.

8. The rapid detection method for welding deformation of bridge steel structures according to claim 1, characterized in that, In S3, welding deformation is calculated through point cloud coordinate transformation. The specific method is as follows: Coordinate System 1: To achieve unified data analysis, the point cloud data obtained from scanning needs to be converted to the same reference coordinate system; assuming the original point cloud coordinates are (x... ori ,y ori ,z ori The coordinates (x, y) are transformed using a rotation matrix R and a translation vector T to obtain the transformed coordinates. trans ,y trans ,z trans The conversion formula is: The rotation matrix R is used to adjust the orientation of the point cloud data, and the translation vector T is used to adjust the position of the point cloud data. They are determined according to the selected reference coordinate system. Calculate deformation: After unifying the coordinate system, compare the actual point cloud coordinates with the theoretical model coordinates to calculate the deformation; let the actual point cloud coordinates be (x... act ,y act ,z act ,), the coordinates of the corresponding point on the theoretical model are (x, y). the ,y the ,z the If the deformation along the X, Y, and Z axes is Δx, Δy, and Δz respectively, then the formulas for calculating these deformations are as follows: Δx=x act -x the Δy=y act -y the Δz=z act -with the The total deformation D of a point can be calculated using the vector magnitude formula: For the entire bridge steel structure, it is necessary to traverse all point cloud data involved in the calculation and calculate the deformation of each point separately; through statistical analysis of the deformation of all points, we can understand the overall situation of welding deformation within the steel structure surface; including the average value, maximum value and minimum value; Among them, the average value of the deformation at all points is calculated. The formula is Where n is the total number of points involved in the calculation, and D i Let be the deformation at point i. These statistical values ​​help to assess welding quality and determine whether the steel structure meets design requirements.

9. A rapid detection system for welding deformation of bridge steel structures, characterized in that, include: The principle determination unit is used to determine the basic principles of measuring the external welding deformation of bridge steel structures based on optical coordinate measuring machine and measuring the internal welding deformation of bridge steel structures based on three-dimensional laser scanning. An optical coordinate measuring machine (OCM) unit for measuring the out-of-plane welding deformation of bridge steel structures is used to determine the process for measuring the out-of-plane welding deformation of bridge steel structures, including: The number of longitudinal ribs and transverse diaphragms in the welded steel structure units was counted, and the measuring points and measuring areas in the longitudinal and transverse directions were arranged respectively. Place the dedicated target that comes with the optical coordinate measuring machine pen, calibrate the pen, and set the coordinate origin; Use a calibrated light pen to measure the three-dimensional coordinates of longitudinal and transverse measuring points, and record them in groups according to the measuring area; Calculate the normal vector of the top plate plane by selecting the coordinates of non-collinear measuring points, calculate the straightness of the plane based on the coordinates of 3 points in the measuring area, compare the straightness with the preset limit, and judge whether the correction deviation is qualified. Based on 3D laser scanning measurement of in-plane welding elements in bridge steel structures, a process for determining the in-plane welding deformation measurement of bridge steel structures using 3D laser scanning is established, including: The 3D laser scanner should be calibrated and ensured to be set up in a stable environment, avoiding interference from strong light and backlight. Clean the surface of the area to be tested, remove debris, and attach reflective standard points in the fillet weld area; The bridge steel structure is scanned, and the direction and height of the camera are adjusted according to the actual situation during the scanning process to obtain comprehensive point cloud data; The acquired point cloud data is processed to remove noise and outliers, and the data format is converted. Reconstruct a three-dimensional model of the bridge steel structure based on the processed data; Calculate the specific values ​​of welding deformation, generate a welding deformation cloud map, and intuitively display the welding deformation situation in the plane.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, The computer program is executed by a processor according to any one of claims 1-8, which describes a rapid detection method for welding deformation of bridge steel structures.

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