Rapid butt-joint positioning method for hyperbolic arc-shaped steel beams

Abstract

The invention discloses a rapid butt-joint positioning method for a hyperbolic arc-shaped steel beam, belongs to the technical field of steel structure building construction, and mainly aims to solve the problems of high butt-joint positioning difficulty, low precision, poor efficiency and high safety risk of the hyperbolic arc-shaped steel beam in high-altitude assembly installation. The temporary connecting plate with the spherical hinge joint and the annular positioning boss and the temporary connecting base with the spherical hinge nest and the annular positioning groove are welded to the end of the steel beam, a measuring instrument is used for obtaining the coordinate of the mark point and fitting deviation, and the steel beam is controlled to descend stably through synchronous hoisting, active swing restraining, adjustable supporting and a real-time monitoring system. And after preset position deviation and weight transfer rate threshold values are reached, the horizontal position is finely adjusted, so that the spherical hinge head sinks into the spherical hinge nest, the annular positioning boss is embedded into the annular positioning groove, and finally fastening is completed by adopting a conical centering pin rod and a bolt. By means of the method, high-precision, high-efficiency, safe and reliable butt joint of the hyperbolic arc-shaped steel beams is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of steel structure construction. More particularly, the present application relates to a rapid butt joint positioning method for hyperbolic arc-shaped steel beams. BACKGROUND

[0002] Steel structure buildings have been widely used in large-span space structures (such as stadiums, airport terminals, high-speed railway stations, and cultural centers) due to their high strength, light weight, and fast construction speed. In order to meet the dual pursuit of aesthetics and functionality in modern architecture, these structures often adopt complex curved shapes, among which hyperbolic arc-shaped steel beams are a representative key load-bearing component. Hyperbolic arc-shaped steel beams refer to steel beams with curvature arcs in two directions (usually vertical and horizontal). Their spatial form is neither a simple arch (single curvature) nor a regular cylindrical or spherical surface, but a more complex and twisted three-dimensional spatial curve form. This unique shape gives the building a smooth, dynamic, and tension-filled visual effect, and is a core structural element for achieving the "odd, special, and new" appearance of many landmark buildings.

[0003] However, the beautiful shape of hyperbolic arc-shaped steel beams poses a high degree of difficulty in their manufacturing and installation. Due to their complex spatial geometric characteristics, they are usually manufactured in sections in the factory and then transported to the site for high-altitude scattered assembly. In this process, the butt joint positioning faces unprecedented technical challenges. Not only the three-dimensional coordinates (X, Y, Z) of the interface need to be controlled, but also the three rotation dimensions (pitch, yaw, and roll) need to be accurately controlled. Any slight deviation will be magnified in the long-span beam body, resulting in a serious mismatch between the overall line shape and the design. The segmented steel beams are in a cantilever state at high altitudes, and are extremely sensitive to wind loads and the swing of the hoisting equipment itself, making it difficult to accurately position. The manufacturing errors of the steel beams themselves, welding deformation, and errors in the previous stage of installation will accumulate section by section, requiring the butt joint method to have high fault tolerance and active compensation ability.

[0004] Traditional docking methods rely heavily on the experience of skilled workers, using tools such as cranes, jacks, chain hoists, and crowbars for trial-and-error adjustments. This method suffers from inherent drawbacks, including low efficiency, poor precision control, high safety risks, and strong dependence on worker skill. While it may be adequate for simple straight beams, it is nearly impossible to achieve the high-precision docking required for hyperbolic curved beams, especially in high-altitude environments. Problems frequently arise, such as misaligned bolt holes, inability to insert high-strength bolts, and uneven structural alignment, severely impacting construction quality, schedule, and structural safety. Therefore, there is an urgent need for an automated, high-precision, quantifiable, controllable, and reliable rapid docking and positioning method suitable for hyperbolic curved steel beams to address these long-standing deficiencies and meet the needs of modern large-span complex steel structure construction. Summary of the Invention

[0005] One object of the present invention is to solve at least the above-mentioned problems and to provide at least the advantages that will be described later.

[0006] To achieve these objectives and other advantages according to the present invention, a rapid docking and positioning method for hyperbolic arc steel beams is provided, comprising: A temporary connecting plate with a ball joint is welded to the end of the steel beam to be connected. The temporary connecting plate has multiple bolt holes distributed in a rectangular pattern. An annular positioning boss is provided on the mating surface of the temporary connecting plate. The outer diameter of the annular positioning boss is smaller than the outer diameter of the temporary connecting plate. A temporary connecting seat with a ball joint socket is welded to the end of the adjacent steel beams to be connected. The radius of curvature of the temporary ball joint socket is greater than the radius of curvature of the ball joint. The mating surface of the temporary connecting seat is provided with an annular positioning groove that matches the annular positioning boss. The depth of the annular positioning groove is greater than the height of the annular positioning boss. The coordinate data of multiple marker points set on the surface of the steel beam are obtained by using an optical angle and distance measuring instrument, and the spatial position deviation value of the theoretical docking point is calculated by a data fitting algorithm. The steel beams are hoisted to a position close to the designed height using a synchronous hoisting system, and the suspension height of the steel beams is set above the designed height by a predetermined distance. An active damping device is then installed at the predetermined position of the steel beams. At least three adjustable support devices are installed below the steel beam. Each adjustable support device includes: a vertical actuator whose bottom is supported on the ground or foundation and whose top is used to support the steel beam; a horizontal fine adjuster installed on the top of the vertical actuator for fine-tuning the horizontal direction of the supporting structure thereon; and a pressure monitoring unit installed on the supporting structure or integrated into the vertical actuator for real-time monitoring of the load borne by the support point. The vertical actuator is controlled to lower the steel beam at a preset speed, and in the process, the spatial position of the docking component at the end of the steel beam is tracked in real time by the pose monitoring system, and the load data of each support point is collected in real time by the pressure monitoring unit; When the center deviation of the ball joint and the ball joint socket is less than a first preset threshold and the weight transfer rate reaches a second preset threshold, the lowering operation of the vertical actuator is stopped. The horizontal position of the steel beam is fine-tuned by the horizontal fine-tuning mechanism, the ball joint enters the guide structure of the ball joint socket, and the ball joint sinks to the bottom of the ball joint socket under the weight of the steel beam, forming a temporary joint connection, and the annular positioning boss is embedded in the annular positioning groove. After the bolt holes between the temporary connection plate and the temporary connection seat are aligned, a conical centering pin is inserted, bolts are sequentially passed through the temporary connection plate, the central through hole of the conical centering pin, and the temporary connection seat, and a pre-tightening force is applied by tightening the nut. The adjustable support device and the hoisting system are removed, and non-destructive testing is performed on the docking weld, and the steel beam is positioned after passing the non-destructive testing.

[0007] Preferably, the measuring instrument based on optical angle measurement and distance measurement is a total station with an angle measurement accuracy of not less than 1", the data fitting algorithm is the least squares method, and the marker point is a reflective target, and the reflective target is arranged on the steel beam surface with an interval of 3-5m.

[0008] Preferably, the synchronous hoisting system is a double-winch synchronous lifting system or a hydraulic synchronous lifting system, the suspension height of the steel beam is 4-6mm higher than the design height, the active damping device is a hydraulic damping pendulum, the mass of the hydraulic damping pendulum is 5%-8% of the mass of the steel beam, the damping coefficient is 0.6-0.8, and the preset position is at the lower end of the steel beam 1 / 4 span.

[0009] Preferably, the number of adjustable support devices is three, arranged in a triangular shape, the vertical actuator is a hydraulic jack with a rated lifting capacity of not less than 50 tons, the horizontal fine-tuner is a horizontal adjustment screw, which performs horizontal fine-tuning by driving a slide or a U-shaped bracket arranged on the top of the vertical actuator, the specification of the horizontal adjustment screw is not less than M36, the pressure monitoring unit is a pressure sensor arranged in a load-bearing platform above the horizontal fine-tuner, and the range of the pressure sensor is 0-50 tons.

[0010] Preferably, the preset speed is 200-300mm / min, the pose monitoring system is a total station, the frequency of monitoring the spatial position by the total station is 1 per second, and the frequency of collecting data by the pressure monitoring unit is 10 times per second.

[0011] Preferably, the first preset threshold value is 15 mm, the second preset threshold value is 85% to 90%, the single feeding amount of the horizontal fine adjustment mechanism during fine adjustment is not more than 0.5 mm, the guide structure is a guide cone surface arranged at the entrance of the spherical hinge socket, the cone angle of the guide cone surface is 30° to 45°, the depth of the ring-shaped positioning boss embedded in the ring-shaped positioning groove is 4 to 7 mm, and the speed of the vertical actuator during the lowering operation is controlled to be between 200 mm / min and 300 mm / min.

[0012] Preferably, the conical centering pin rod is made of alloy structural steel, the small end diameter is 18 to 20 mm, the large end diameter is 24 to 26 mm, the taper is 1:10, and the surface of the conical centering pin rod is coated with a molybdenum disulfide coating.

[0013] Preferably, a central controller is arranged to simultaneously receive the spherical hinge joint position data from the pose monitoring system, the weight transfer rate data from the pressure monitoring unit, and the stroke encoder data of the vertical actuator, and the central controller is built-in with a cooperative control algorithm for performing the following steps: aligning and fusing the position data of the pose monitoring system and the stroke data of the vertical actuator based on the sampling frequency of the pressure monitoring unit as a reference clock signal; when the center deviation value of the spherical hinge joint and the spherical hinge socket is in a deceleration warning interval and the weight transfer rate is in a transfer rate warning interval, the cooperative control algorithm predicts the future stroke of the vertical actuator according to the current lowering speed, and issues a deceleration instruction in advance to gradually reduce the lowering speed of the vertical actuator, wherein the deceleration warning interval is 16 to 20 mm, the transfer rate warning interval is 80% to 84%, and the deceleration instruction gradually reduces the lowering speed of the vertical actuator to 50 to 100 mm / min; when the conditions of the center deviation being less than the first preset threshold value and the weight transfer rate reaching the second preset threshold value are simultaneously met, the central controller sends a stop instruction to the vertical actuator.

[0014] Preferably, a safety redundancy module is arranged to be integrated into the cooperative control algorithm of the central controller, and the safety redundancy module is used to perform the following steps: real-time comparison of the position change amount calculated from the position data of the pose monitoring system and the stroke encoder data of the vertical actuator, and if the deviation between the two exceeds a preset deviation threshold value for three times in a row, it is determined that the pose monitoring system data is abnormal, and the automatic switching is performed to only rely on the data of the stroke encoder and the pressure monitoring unit for predictive control; after the central controller issues a deceleration instruction or a stop instruction, the actual lowering speed of the vertical actuator is continuously monitored; if the actual speed does not start to decrease or does not stop within a preset time after the instruction is issued, it is determined that the main control instruction is invalid, and a backup relay is automatically started to directly cut off the power supply of the vertical actuator; A normally closed electromagnetic overflow valve is connected in parallel in the vertical actuator oil circuit of the adjustable support device, and the set pressure of the electromagnetic overflow valve is 105%-110% of the rated working pressure of the vertical actuator; when the central controller monitors that the instantaneous value of the weight transfer rate exceeds a safety threshold or the descending speed of the vertical actuator exceeds a speed safety threshold, the electromagnetic overflow valve is triggered to open, so that the vertical actuator oil cylinder is depressurized. Wherein, the preset deviation threshold is 5mm, the preset time is 200ms, the safety threshold is 95%, and the speed safety threshold is 350mm / min.

[0015] Preferably, four fan-shaped lightening grooves are evenly arranged on the side wall of the annular positioning boss of the temporary connecting plate in the circumferential direction, the depth of the fan-shaped lightening grooves is 1 / 2-2 / 3 of the height of the annular positioning boss, and the width of the fan-shaped lightening grooves is 1 / 8-1 / 6 of the circumference of the annular positioning boss. Four fan-shaped rubber buffer pads are arranged on the bottom surface of the annular positioning groove of the temporary connecting seat at the corresponding positions, and the thickness of the fan-shaped rubber buffer pads is 1-2mm greater than the depth of the fan-shaped lightening grooves. A conical guide head is arranged at the center of the end surface of the annular positioning boss, the height of the conical guide head is 3-5mm, and the taper angle is 60°. A conical guide recess matched with the conical guide head is arranged at the center of the bottom surface of the annular positioning groove, and the depth of the conical guide recess is 0.5-1mm greater than the height of the conical guide head. During the embedding of the annular positioning boss into the annular positioning groove, the conical guide head first contacts the conical guide recess to preliminarily center, and then the fan-shaped rubber buffer pads are deformed under pressure and fill the fan-shaped lightening grooves.

[0016] The present application at least includes the following beneficial effects: Firstly, the present application provides a high-precision physical interface for high-altitude double-curved steel beam butt joint by arranging the temporary connecting plate with the ball hinge joint and the annular positioning boss, and the temporary connecting seat with the ball hinge recess and the annular positioning groove. The design of the ball hinge pair allows the existence of multi-degree-of-freedom angle deviation during initial butt joint, effectively absorbs the influence of manufacturing errors, hoisting swing and thermal deformation, and avoids rigid collision. The cooperation of the annular boss and the groove eliminates the radial movement degree of freedom, ensures the stability of the butt joint and the axial positioning accuracy. Combined with total station measurement, data fitting, synchronous hoisting, active swing suppression, adjustable support and real-time monitoring of multiple sensors, the digital perception and precise control of the steel beam falling process are realized. Through double threshold (position deviation and weight transfer rate) judgment, the butt joint process is ensured to be safe and stable to transition to the fine adjustment stage, and finally reliable connection is realized by using the conical centering pin and the step-by-step pre-tightening bolt. The method changes the traditional trial-and-error operation depending on manual experience into an automatic, quantifiable and high-precision assembly process, significantly improving the efficiency, accuracy and safety of the butt joint.

[0017] Second, the present application effectively solves the control lag problem caused by the differences in sampling frequency, response time and communication delay in the cooperative work of multiple systems (total station, pressure sensor, hydraulic actuator) through the central controller and the cooperative control algorithm. The algorithm synchronizes and fuses multiple source data based on pressure data, ensuring the high consistency of state perception and control instructions. Its predictive control function can issue a deceleration command in advance before the docking critical state, realizing the smooth transition of actuator speed and creating stable conditions for precise docking. The dual judgment logic that combines spatial position and mechanical state greatly improves the accuracy and reliability of the stop command, effectively avoiding overshoot, impact or deviation at the moment of final docking, protecting the precise ball joint interface and improving the success rate and automation level of the entire docking process.

[0018] Third, the safety redundancy module integrated in the central controller greatly improves the fault tolerance and engineering practicability of the system through a triple protection mechanism. The data cross-validation mechanism can identify sensor abnormalities in real time and implement seamless downgrading of control strategies, ensuring the safe operation or shutdown of the system in the event of a fault. The instruction execution feedback verification link forms a closed-loop control that can quickly cut off the power source when the main control instruction fails, preventing accidents. The final protection of the mechatronic system (such as an electromagnetic overflow valve) provides an absolutely reliable safety barrier that can immediately terminate the action through physical means when dangerous conditions such as overload or overspeed are detected. This redundancy design ensures that even in complex field environments, partial subsystem instantaneous failures can be avoided to the greatest extent, preventing equipment damage and safety accidents, making the entire high-precision docking process safe and reliable.

[0019] Fourth, the present application introduces a flexible buffering mechanism in the precise mechanical positioning structure by opening fan-shaped weight-reducing grooves on the side wall of the annular positioning boss and setting corresponding fan-shaped rubber buffer pads on the groove bottom. This effectively absorbs the slight impact and lateral deviation caused by slight eccentricity or inclination during the fitting process, avoiding rigid collision and jamming between metals. Combined with the pre-centering guidance of the conical guide head and the guide socket, the initial docking guidance accuracy and smoothness are significantly improved. The combination of rigidity and flexibility not only protects the boss and the groove, two precise positioning components, from damage and maintains their long-term precision, but also reduces the requirement for high precision in field operations, thereby improving the success rate, efficiency and reliability of the overall docking.

[0020] Other advantages, objectives and features of the present application will be apparent from the following description, some of which will be understood by those skilled in the art through study and practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0021] Fig. 1 The figure is a schematic diagram of the docking positioning process of one of the technical solutions of the present application. Fig. 2 The upper and lower position schematic view of the temporary connecting plate and the temporary connecting seat of one of the technical solutions of the present application; Fig. 3 The preliminary positioning state schematic view of the ball hinge joint and the ball hinge nest of one of the technical solutions of the present application; Fig. 4 The abutting positioning schematic view of the annular positioning boss and the annular positioning groove after preliminary positioning of one of the technical solutions of the present application.

[0022] Description of the drawings: temporary connecting plate 1, temporary connecting seat 2, ball hinge joint 3, ball hinge nest 4, annular positioning boss 5, annular positioning groove 6. DETAILED DESCRIPTION

[0023] The present application will be further described in detail below with examples, so that those skilled in the art can implement according to the description.

[0024] It should be noted that the experimental methods in the following embodiments are conventional methods unless otherwise specified, and the reagents and materials can be obtained from commercial channels unless otherwise specified.

[0025] At present, the high-altitude butt joint of hyperbolic arc steel beams mainly relies on manual experience. The operator uses a total station to perform rough positioning, and then repeatedly adjusts through tools such as cranes, jacks, hand-operated hoists, and crowbars to make the steel beam segments to be butt jointed in place. The efficiency is extremely low, and the adjustment process is time-consuming and long; the precision completely depends on the technical level and experience of workers, and the controllability is poor; in the high-altitude dynamic environment, the steel beam is easily affected by wind load and hoisting swing, and is difficult to stabilize and control; due to the flexible deformation and manufacturing errors of the steel beam, the bolt hole is often not aligned, resulting in that the high-strength bolt cannot be installed, and finally has to be expanded or flame corrected, which seriously affects the construction quality and structural safety.

[0026] The present application provides a rapid butt joint positioning method for hyperbolic arc steel beams, as shown in the accompanying drawings, which specifically comprises the following steps: Figs. 1 to 4 S1, prefabricating and welding a temporary connecting part. A temporary connecting plate 1 is welded at the butt joint end of the first steel beam, which is made of Q355B steel material, and a plurality of rectangularly distributed bolt holes are processed thereon, and the diameter of the bolt hole is 23-25mm. An annular positioning boss 5 with a height of 5-8mm is processed on the butt joint surface of the temporary connecting plate, and the outer diameter of the annular positioning boss is 20-30mm smaller than the outer diameter of the temporary connecting plate. A ball hinge joint 3 is welded on the temporary connecting plate and located beside the annular positioning boss, and the two are independently arranged.

[0027] ​At the end of the adjacent second steel beam to be joined, a temporary connecting seat 2 is welded. This temporary connecting seat has a ball joint socket 4, the radius of curvature of which is 2-4 mm larger than that of the ball joint. On the mating surface of the temporary connecting seat, an annular positioning groove 6 is machined to mate with the annular positioning boss. The depth of the annular positioning groove is 0.5-1 mm greater than the height of the annular positioning boss.

[0028] S2. Measurement and Positioning. Using a total station with an angle measurement accuracy of no less than 1″ (as a measuring instrument based on optical angle and distance measurement), the three-dimensional coordinate data of multiple reflective targets (as marker points) pre-attached to the surface of the steel beam are acquired. The reflective targets are set at intervals of 3-5m. The least squares method (as the data fitting algorithm) is used to process these coordinate data to calculate the spatial position deviation value of the theoretical docking point, providing precise guidance for subsequent hoisting.

[0029] S3. Lifting and Sway Control. The first steel beam is lifted to a position close to its designed height using a dual-winch synchronous lifting system (the synchronous lifting system), with the beam suspended 4-6 mm above its designed height (a preset distance). A hydraulically damped pendulum (the active damping device) is installed at the lower 1 / 4 span of the steel beam (a preset position) to suppress swaying during lifting and positioning.

[0030] S4. Install a support and monitoring system. Three adjustable support devices are arranged in a triangular pattern below the steel beam. Each adjustable support device includes: a hydraulic jack with a rated lifting capacity of not less than 50 tons (as the vertical actuator), its bottom supported on the ground; a horizontal adjusting screw (as the horizontal fine-tuner) with a specification of not less than M36, which performs horizontal fine-tuning by driving a U-shaped bracket mounted on top of the hydraulic jack; and a pressure sensor with a range of 0-50 tons (as the pressure monitoring unit), mounted on a load-bearing platform above the horizontal adjusting screw, for real-time monitoring of the load borne by the support point.

[0031] S5. Controlled Lowering and Real-time Monitoring. The hydraulic jacks are controlled to lower the steel beam at a preset speed of 200-300 mm / min. During this process, a total station (as the posture monitoring system) is used to simultaneously track the spatial position of the ball joint (as the docking component) at the end of the steel beam in real time at a frequency of once per second, and a pressure sensor is used to collect load data at each support point in real time at a frequency of 10 times per second, thereby calculating the weight transfer rate.

[0032] S6. Judgment and Stopping of Descent. When the total station detects that the center deviation between the ball joint and the ball socket is less than 15mm (first preset threshold), and the weight transfer rate calculated based on the pressure sensor data reaches 85% to 90% (second preset threshold), the central controller sends a command to the hydraulic jack to stop its descent operation.

[0033] S7. Horizontal Fine-tuning and Initial Positioning. The horizontal position of the steel beam is fine-tuned using a horizontal adjusting screw (as the horizontal fine-tuning mechanism). The single feed amount during fine-tuning should not exceed 0.5 mm, allowing the ball joint to enter the guide cone surface at the entrance of the ball joint socket (as the guide structure, the cone angle is 30°-45°). The weight of the steel beam causes the ball joint to sink into the bottom of the ball joint socket, forming a temporary hinged connection. Simultaneously, the annular positioning boss on the temporary connecting plate is embedded into the annular positioning groove on the temporary connecting seat, with an embedding depth of 4-7 mm.

[0034] S8. Final Connection and Tightening. After aligning the bolt holes between the temporary connecting plate and the temporary connecting seat, insert a tapered centering pin (made of alloy structural steel, with a small end diameter of 18-20mm, a large end diameter of 24-26mm, a taper of 1:10, and a molybdenum disulfide coating). Utilize its tapered structure to fine-tune and ultimately lock the circumferential relative position of the two connecting parts, ensuring precise alignment of all bolt holes. Use 10.9 grade high-strength bolts to sequentially pass through the center through-hole of the temporary connecting plate, the tapered centering pin, and the temporary connecting seat. Apply pre-tightening force by tightening the nuts three times using a hydraulic torque wrench (first time: 200-250 N·m, second time: 400-450 N·m, third time: 500-600 N·m) for tightening.

[0035] S9. Dismantling and Inspection. Dismantle all adjustable support devices and the dual winch synchronous lifting system. Finally, perform ultrasonic testing (non-destructive testing) on ​​the butt welds of the steel beams. Once the welds are confirmed to be qualified, the butt welding and positioning of the steel beams is completed.

[0036] This implementation method addresses four core challenges faced during the high-altitude assembly of hyperbolic steel beams: difficult positioning, cumbersome adjustments, low precision, and high risk. It transforms the traditional trial-and-error operation, which relies on manual experience, into a quantifiable, controllable, predictable, and highly automated precision assembly process.

[0037] It provides a precise initial physical positioning benchmark and fault-tolerant mechanism. The ball joint (ball joint + ball socket) provides a universal joint function. In the initial stage of docking, it allows for small angular deviations of multiple degrees of freedom between adjacent steel beam segments. It effectively absorbs relative posture deviations caused by hoisting sway, manufacturing errors, thermal deformation, etc., avoiding rigid collisions and jamming, and creating conditions for subsequent fine adjustments. The boss and groove pair provides axial positioning and shear resistance. Once the ball joint is initially positioned, the annular positioning boss embeds into the groove, immediately restricting the radial movement (shear force) between the steel beam interfaces, ensuring the stability of the docking. Its mating clearance (depth greater than 0.5-1mm) ensures smooth embedding and ultimately determines the axial docking depth. The ball joint contacts first, providing angular freedom and absorbing errors; then the boss embeds into the groove, eliminating translational freedom and achieving precise radial and axial positioning. The combination of the two constitutes a high-precision, high-reliability physical interface.

[0038] This system enables digital sensing and real-time feedback during the docking process. Total station monitoring solves the problem of real-time quantitative measurement of spatial pose (X, Y, Z, pitch, yaw, roll). It transforms abstract deviations into concrete numbers, providing a basis for decision-making in automated control. Pressure sensor monitoring solves the problem of real-time quantitative sensing of load transfer. Weight transfer rate is a key safety and control indicator, accurately reflecting the proportion of steel beam weight transferred from the hoisting system to the lower support system, avoiding the risks of insufficient support or overload. By continuously acquiring process status (position, weight) through sensors and comparing this data with preset target values ​​(thresholds), the system determines the next action (such as stopping descent).

[0039] This system enables controllable, synchronous, and stable positioning of the steel beam. Vertical actuators (such as hydraulic jacks) provide controllable and stable descent power. This replaces the inching operations that are difficult to control precisely with a crane, achieving a uniform and smooth descent and greatly reducing swaying and impact. Horizontal fine-tuning devices (such as adjusting screws) provide precise positioning capabilities. Fine-tuning of the horizontal position is performed before final docking to ensure the ball joint is accurately aligned with the inlet of the ball joint socket. The three support points arranged in a triangle form a stable, statically determinate support system, ensuring the steel beam remains stable during descent and preventing overturning. The support device decomposes the macroscopic hoisting and positioning process into two independently controllable and more precise sub-processes: vertical descent and horizontal fine-tuning.

[0040] Define precise docking completion criteria and control logic. A center deviation threshold ensures positioning accuracy. Further fine-tuning and alignment are only permitted when the spatial positions of the two ball centers are sufficiently close; otherwise, an adjustment command is issued. A weight transfer rate threshold ensures operational safety and process reliability. An 85%-90% transfer rate means that the majority of the steel beam's weight is borne by the underlying stable support system, with the lifting system's hook bearing only a very small portion (10%-15%). At this point, the steel beam is very stable with minimal sway. Simultaneously, this also means that the ball joint and ball socket are about to contact, requiring extremely slow speed and precise control to avoid impact. Meeting only the positional accuracy requirement may pose a risk due to unstable support; meeting only the weight transfer requirement may result in excessive positional deviation. Both must be met simultaneously to signify that the docking process has safely and smoothly entered the final precise positioning stage.

[0041] To ensure the precision and reliability of the final connection, the tapered centering pin utilizes the self-centering property of its tapered surface to automatically correct and ultimately lock any minute circumferential (rotational direction) deviations between the temporary connecting plate and the temporary connecting seat. This ensures 100% alignment of all bolt holes, which is crucial for the successful insertion of high-strength bolts. Applying preload in stages ensures even stress distribution across the bolt group, preventing deformation of the connecting plate due to premature preload on a single bolt, which could affect the tightening effect of other bolts and ultimately guarantee the tightening force and sealing of the connection surface.

[0042] This implementation method absorbs initial errors through a precision mechanical interface (ball joint + boss), achieves digital perception of the process through a multi-sensor system (total station + pressure sensor), achieves smooth and controllable positioning through a controllable actuator (support device), precisely controls the docking rhythm through intelligent decision-making logic (dual threshold judgment), and finally ensures the reliability of the final connection through a precision positioning tool (conical pin) and a standardized process (step-by-step pre-tightening).

[0043] In a preferred embodiment of the present invention, the measuring instrument based on optical angle and distance measurement specifically employs a total station with an angle measurement accuracy of not less than 1″. Before conducting the measurement, multiple reflective targets need to be arranged on the surface of the steel beam to be connected as measurement markers. These reflective targets should be evenly distributed along the axis of the steel beam, with the spacing between adjacent reflective targets controlled between 3-5m to ensure that the spatial morphology of the hyperbolic arc steel beam is fully reflected.

[0044] During measurement, the total station is operated to sequentially aim at and measure the center point of each reflecting target to obtain its three-dimensional coordinate data (X, Y, Z) in the station coordinate system.

[0045] After acquiring the coordinate data of all reflective targets, the least squares method is used as the data fitting algorithm for processing. This algorithm compares the actual coordinates of all measured reflective target points with their theoretical design coordinates and performs adjustment calculations. Finally, it calculates the deviation between the current actual pose of the steel beam and the theoretical design pose, and accurately obtains the spatial position deviation value of the theoretical docking point (usually including three translations and three rotations).

[0046] This implementation method, by employing a high-precision total station, standardizing the arrangement of reflective targets, and utilizing the mature least squares method, ensures the accuracy and reliability of the initial measurement data, providing a crucial data foundation for subsequent precise hoisting and docking.

[0047] In another embodiment of the present invention, a dual-winch synchronous lifting system is used as the synchronous hoisting system to hoist the steel beam to a position close to its designed height, with the suspension height of the steel beam 5mm higher than its designed height. A hydraulic damping pendulum is installed at a predetermined position at the lower 1 / 4 span of the steel beam as an active damping device. The mass of the hydraulic damping pendulum is configured as 7% of the mass of the steel beam, and its damping coefficient is set to 0.7.

[0048] The hydraulically damped pendulum, through its internal hydraulic damper, generates a corresponding damping force based on the real-time swing speed of the steel beam. This damping force is in the opposite direction to the swing direction, effectively suppressing low-frequency swaying of the steel beam caused by wind load or inertia during hoisting and high-altitude positioning. Installing the hydraulically damped pendulum at the lower 1 / 4 span of the steel beam provides optimal sway suppression at this location, tailored to the vibration mode characteristics of this type of steel beam, thus enhancing the stability of the steel beam during the connection process.

[0049] This embodiment, through the cooperation of the above-mentioned system and device, achieves stable lifting and swing control of the steel beam during the hoisting process, providing stable initial conditions for subsequent precise docking.

[0050] In another embodiment of the present invention, the hydraulic jack is controlled to lower the steel beam at a preset speed of 250 mm / min. During this process, a total station is used as a position and posture monitoring system to track the spatial position of the ball joint at the end of the steel beam as the docking component in real time at a frequency of 1 time / s, and the pressure sensor is used as a pressure monitoring unit to collect the load data of each support point in real time at a frequency of 10 times / s, based on which the weight transfer rate is calculated.

[0051] This implementation method achieves precise control and real-time status monitoring of the steel beam's descent process by setting an appropriate descent speed and coordinating with high-frequency data acquisition. The high pressure data acquisition frequency ensures the real-time and accurate calculation of the weight transfer rate, providing a reliable data foundation for judging the critical docking state; while the continuous attitude monitoring of the total station ensures the real-time availability of the spatial position of the ball joint. The two work together to provide the central controller with comprehensive and timely process data, ensuring that the docking process proceeds smoothly under control and effectively avoiding docking impacts or deviations caused by information lag or untimely control.

[0052] In another embodiment of the present invention, the following implementation steps are included: Set up a central controller and connect it to the total station, pressure sensor, and travel encoder of the hydraulic jack via data cables.

[0053] The central controller incorporates a collaborative control algorithm and configures relevant parameters: the deceleration warning range is set to 16-20mm, the transfer rate warning range is 80%-84%, the target deceleration speed is 50-100mm / min, the first preset threshold is 15mm, and the second preset threshold is 85% to 90%.

[0054] The docking process is initiated, and the central controller begins to simultaneously receive the ball joint position data from the total station, the weight transfer rate data from the pressure sensor, and the stroke encoder data from the hydraulic jack.

[0055] The collaborative control algorithm uses the pressure sensor's sampling frequency of 10 times / s as the reference clock signal to perform timestamp alignment and data fusion processing on the total station's position data and the hydraulic jack's stroke data.

[0056] The center deviation between the ball joint and the ball socket, as well as the real-time weight transfer rate, are calculated in real time.

[0057] When the center deviation value is detected to enter the deceleration warning range of 16-20mm and the weight transfer rate is detected to enter the transfer rate warning range of 80%-84%, the collaborative control algorithm predicts the future stroke of the hydraulic jack based on its current descent speed and issues a deceleration command to the hydraulic jack in advance, so that its descent speed is gradually and smoothly reduced from the current 200-300mm / min to 50-100mm / min.

[0058] The controller continuously monitors the center deviation value and weight transfer rate. When the center deviation value is less than 15mm and the weight transfer rate reaches 85% to 90% at the same time, the central controller immediately sends a stop command to the hydraulic jack to stop its descent.

[0059] This implementation method solves the problem of control lag caused by slight differences in data acquisition frequency, system response time, and command transmission delay among subsystems during the complex docking process involving high precision and multiple systems (total station, pressure sensor, and hydraulic jack). This problem can easily lead to overshoot or micro-impact at the docking critical point, affecting the smooth docking of the ball joint and the ball joint socket.

[0060] This implementation eliminates timing errors between the total station, pressure sensor, and hydraulic jack by introducing a central controller and a collaborative control algorithm, and by performing multi-source data synchronization fusion based on the sampling frequency of the pressure sensor, ensuring a high degree of synchronization between state perception and control commands. Through a predictive control strategy, the hydraulic jack's descent speed is smoothly decelerated in advance, creating stable conditions for precise positioning. By setting dual judgment conditions that integrate spatial position (center deviation) and mechanical state (weight transfer rate), the accuracy and reliability of the stop command are ensured, effectively avoiding impact and deviation at the final docking moment, protecting the precision ball joint surface, and further improving the success rate and accuracy of the entire docking process.

[0061] In another embodiment of the present invention, the following implementation steps are included: A safety redundancy module is set up and integrated into the collaborative control algorithm of the central controller.

[0062] Configure the parameters of the safety redundancy module: set the preset deviation threshold to 5mm, the preset time to 200ms, the safety threshold to 95%, and the speed safety threshold to 350mm / min.

[0063] A normally closed electromagnetic relief valve is connected in parallel in the oil circuit of the hydraulic jack with adjustable support device, and the set pressure of the electromagnetic relief valve is adjusted to 108% of the rated working pressure of the hydraulic jack.

[0064] To initiate the integration process, the security redundancy module will begin executing the following steps: a) Compare the position data from the total station with the position change calculated based on the stroke encoder data from the hydraulic jack in real time. If the deviation between the two exceeds 5mm for three consecutive times, the total station data is determined to be abnormal, and the control strategy is automatically switched to predictive control based solely on the data from the stroke encoder and pressure sensor.

[0065] b) After the central controller issues a deceleration or stop command, continuously monitor the actual descent speed of the hydraulic jack. If the actual speed does not start to decrease or stop within 200ms after the command is issued, it is determined that the main control command has failed, and the backup relay is automatically activated to directly cut off the power supply to the hydraulic jack.

[0066] c) Monitor the instantaneous value of the weight transfer rate and the descent speed of the hydraulic jack in real time. If the instantaneous value of the weight transfer rate exceeds 95% or the descent speed exceeds 350 mm / min, the central controller immediately triggers the opening of the electromagnetic relief valve to depressurize the hydraulic cylinder of the hydraulic jack.

[0067] This implementation addresses the problem of insufficient system safety redundancy and fault handling capabilities in complex electromechanical-hydraulic integrated control systems caused by transient failures, data jumps, or communication interruptions in critical components (such as central controllers, total stations, pressure sensors, or hydraulic systems). This problem can lead to uncontrolled descent of hydraulic jacks, speed loss, or failure of stop commands, thereby impacting or damaging precision ball joints and ball joint socket interfaces, and even the entire steel beam structure.

[0068] This implementation method accurately identifies abnormal data sources (as in step a) through data cross-validation and seamlessly switches control strategies in the event of a fault, ensuring the system continues to operate safely or shuts down in degraded mode. A closed-loop control is formed through feedback verification of the control command execution effect (as in step b). When a command is not executed, the final protective measure of cutting off the power source can be quickly taken to prevent accidents. Deep integration of electronic control with mechanical hydraulic protection (electromagnetic relief valve) (as in step c) provides a final and absolutely reliable safety barrier. When dangerous conditions such as overload or overspeed are detected, dangerous actions can be immediately terminated through physical means (pressure relief). Through a triple safety redundancy mechanism (data verification, command verification, and mechanical protection), the fault tolerance and engineering practicality of the entire docking control system in complex construction environments are greatly improved, ensuring that even in extreme cases where some subsystems fail, the entire docking process can still minimize equipment damage and safety accidents.

[0069] In another embodiment of the present invention, the following implementation steps are included: Four fan-shaped weight-reducing grooves are evenly formed circumferentially on the side wall of the annular positioning boss of the temporary connecting plate. The depth of the fan-shaped weight-reducing grooves is 3 / 5 of the height of the annular positioning boss, and the width is 1 / 7 of the circumference of the annular positioning boss.

[0070] On the bottom surface of the annular positioning groove of the temporary connector, four sector-shaped rubber buffer pads are installed at the positions corresponding to the sector-shaped weight reduction grooves. The thickness of the sector-shaped rubber buffer pads is made 1.5mm greater than the depth of the sector-shaped weight reduction grooves.

[0071] At the center of the end face of the annular positioning boss, a conical guide head with a height of 4mm and a cone angle of 60° is machined.

[0072] A conical guide recess is machined at the center of the bottom surface of the annular positioning groove. The depth of the conical guide recess is machined to be 0.8 mm greater than the height of the conical guide head.

[0073] During the process of embedding the annular positioning boss into the annular positioning groove, ensure that the conical guide head contacts the conical guide socket first to achieve initial centering guidance. As the embedding process continues, the sector-shaped rubber buffer pad undergoes elastic deformation under pressure and fills the corresponding sector-shaped weight-reducing groove.

[0074] This embodiment solves the problem of rigid collision and jamming between metals caused by slight tilting or misalignment during the fitting process of the annular positioning boss and the annular positioning groove. This problem affects the smoothness of the guide and may even cause bumps and damage to the edges of the annular positioning boss or the annular positioning groove, affecting the positioning accuracy and docking success rate.

[0075] This embodiment, through the combination of a fan-shaped weight-reducing groove and a fan-shaped rubber buffer pad, provides a localized flexible buffer area before rigid contact, effectively absorbing minor impacts and lateral deviations during the fitting process, avoiding rigid collisions and jamming between metals. The conical guide head and conical guide recess perform preliminary alignment before the main positioning structures (boss and groove) contact, significantly improving the initial guiding accuracy of the docking and reducing the need for subsequent adjustments. The deformation of the fan-shaped rubber buffer pad absorbs energy, protecting the integrity and accuracy of the two precision mechanical positioning structures—the annular positioning boss and the annular positioning groove—preventing damage from accidental collisions. This embodiment combines the precision of mechanical guidance with the fault tolerance of elastic buffering, making the entire fitting process smoother and more reliable, reducing the requirements for ultra-high precision operation, thereby improving the overall docking success rate and efficiency.

[0076] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. Other modifications can be easily made by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and examples shown and described herein.

Claims

1. A rapid docking and positioning method for hyperbolic arc-shaped steel beams, characterized in that, include: A temporary connecting plate with a ball joint is welded to the end of the steel beam to be connected. The temporary connecting plate has multiple bolt holes distributed in a rectangular pattern. An annular positioning boss is provided on the mating surface of the temporary connecting plate. The outer diameter of the annular positioning boss is smaller than the outer diameter of the temporary connecting plate. A temporary connecting seat with a ball joint socket is welded to the end of the adjacent steel beams to be connected. The radius of curvature of the temporary ball joint socket is greater than the radius of curvature of the ball joint. The mating surface of the temporary connecting seat is provided with an annular positioning groove that matches the annular positioning boss. The depth of the annular positioning groove is greater than the height of the annular positioning boss. The coordinate data of multiple marker points set on the surface of the steel beam are obtained by using an optical angle and distance measuring instrument, and the spatial position deviation value of the theoretical docking point is calculated by a data fitting algorithm. The steel beams are hoisted to a position close to the designed height using a synchronous hoisting system, and the suspension height of the steel beams is set above the designed height by a predetermined distance. An active damping device is then installed at the predetermined position of the steel beams. At least three adjustable support devices are installed below the steel beam. Each adjustable support device includes: a vertical actuator whose bottom is supported on the ground or foundation and whose top is used to support the steel beam; a horizontal fine adjuster installed on the top of the vertical actuator for fine-tuning the horizontal direction of the supporting structure thereon; and a pressure monitoring unit installed on the supporting structure or integrated into the vertical actuator for real-time monitoring of the load borne by the support point. The vertical actuator is controlled to lower the steel beam at a preset speed. During this process, the spatial position of the docking component at the end of the steel beam is tracked in real time through the posture monitoring system, and the load data of each support point is collected in real time through the pressure monitoring unit. When the center deviation between the ball joint and the ball socket is less than the first preset threshold and the weight transfer rate reaches the second preset threshold, the descent operation of the vertical actuator is stopped. The horizontal position of the steel beam is finely adjusted by the horizontal fine-tuning mechanism, so that the ball joint enters the guide structure of the ball joint socket. The ball joint sinks into the bottom of the ball joint socket by the weight of the steel beam, forming a temporary hinge connection. At the same time, the annular positioning boss is embedded in the annular positioning groove. After aligning the bolt holes between the temporary connecting plate and the temporary connecting seat, insert a tapered centering pin. Then, pass the bolts through the center through hole of the temporary connecting plate, the tapered centering pin, and the temporary connecting seat in sequence, and tighten them by applying a preload force. The adjustable support device and hoisting system were removed, and the butt welds were subjected to non-destructive testing. After confirming that they were qualified, the steel beams were positioned and connected.

2. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 1, characterized in that, The measuring instrument based on optical angle measurement and distance measurement is a total station with an angle measurement accuracy of not less than 1″. The data fitting algorithm is the least squares method. The marker points are reflective targets, and the reflective targets are set at intervals of 3-5m on the surface of the steel beam.

3. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 1, characterized in that, The synchronous hoisting system is either a double winch synchronous hoisting system or a hydraulic synchronous hoisting system. The suspension height of the steel beam is 4-6mm higher than its design height. The active damping device is a hydraulic damping pendulum. The mass of the hydraulic damping pendulum is 5%-8% of the mass of the steel beam, the damping coefficient is 0.6-0.8, and the preset position is at 1 / 4 span of the lower end of the steel beam.

4. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 3, characterized in that, The adjustable support device consists of three units arranged in a triangle. The vertical actuator is a hydraulic jack with a rated lifting capacity of not less than 50 tons. The horizontal fine-tuning device is a horizontal adjusting screw, which performs horizontal fine-tuning by driving a slide or U-shaped bracket set on top of the vertical actuator. The specification of the horizontal adjusting screw is not less than M36. The pressure monitoring unit is a pressure sensor, which is set in a load-bearing platform located above the horizontal fine-tuning device. The pressure sensor has a range of 0-50 tons.

5. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 4, characterized in that, The preset speed is 200-300 mm / min. The position monitoring system is a total station. The total station monitors the spatial position once per second. The pressure monitoring unit collects data 10 times per second.

6. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 5, characterized in that, The first preset threshold is 15mm, the second preset threshold is 85% to 90%, the single feed amount of the horizontal fine-tuning mechanism during fine-tuning does not exceed 0.5mm, the guide structure is a guide cone surface located at the entrance of the ball joint socket, the cone angle of the guide cone surface is 30°-45°, the depth of the annular positioning boss embedded in the annular positioning groove is 4-7mm, and the speed of the vertical actuator descent operation is controlled between 200-300mm / min.

7. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 1, characterized in that, The tapered centering pin is made of alloy structural steel, with a small end diameter of 18-20mm and a large end diameter of 24-26mm. The taper is 1:10, and the surface of the tapered centering pin is coated with molybdenum disulfide.

8. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 6, characterized in that, A central controller is configured to simultaneously receive ball joint position data from the posture monitoring system, weight transfer rate data from the pressure monitoring unit, and stroke encoder data from the vertical actuator. The central controller has a built-in cooperative control algorithm, which is used to execute the following steps: Using the sampling frequency of the pressure monitoring unit as the reference clock signal, the position data of the posture monitoring system and the stroke data of the vertical actuator are aligned and fused. When the center deviation between the ball joint and the ball joint socket is in a deceleration warning range and the weight transfer rate is in a transfer rate warning range, the cooperative control algorithm predicts the future stroke of the vertical actuator based on the current descent speed and issues a deceleration command in advance, so that the descent speed of the vertical actuator is gradually reduced. The deceleration warning range is 16-20mm, the transfer rate warning range is 80%-84%, and the deceleration command makes the descent speed of the vertical actuator gradually reduce to 50-100mm / min. When the conditions of center deviation being less than the first preset threshold and weight transfer rate reaching the second preset threshold are met simultaneously, the central controller sends a stop command to the vertical actuator.

9. The rapid docking and positioning method for hyperbolic arc steel beams according to claim 8, characterized in that, A safety redundancy module is set up, which is integrated into the collaborative control algorithm of the central controller, and is used to perform the following steps: The position change is calculated by comparing the position data of the posture monitoring system with the stroke encoder data of the vertical actuator in real time. If the deviation between the two exceeds a preset deviation threshold for three consecutive times, the posture monitoring system data is determined to be abnormal, and the system automatically switches to predictive control based solely on the data from the stroke encoder and pressure monitoring unit. After the central controller issues a deceleration or stop command, it continuously monitors the actual descent speed of the vertical actuator. If the actual speed does not start to decrease or stop within a preset time after the command is issued, it is determined that the main control command has failed, and the backup relay is automatically activated to directly cut off the power supply to the vertical actuator. A normally closed electromagnetic relief valve is connected in parallel in the hydraulic circuit of the vertical actuator of the adjustable support device. The set pressure of the electromagnetic relief valve is 105%-110% of the rated working pressure of the vertical actuator. When the central controller detects that the instantaneous value of the weight transfer rate exceeds a safety threshold or the descent speed of the vertical actuator exceeds a speed safety threshold, it triggers the electromagnetic relief valve to open, thereby depressurizing the hydraulic cylinder of the vertical actuator. The preset deviation threshold is 5mm, the preset time is 200ms, the safety threshold is 95%, and the speed safety threshold is 350mm / min.

10. The rapid docking and positioning method for hyperbolic arc-shaped steel beams according to claim 1, characterized in that, On the side wall of the annular positioning boss of the temporary connecting plate, four fan-shaped weight reduction grooves are evenly opened in the circumferential direction. The depth of the fan-shaped weight reduction grooves is 1 / 2 to 2 / 3 of the height of the annular positioning boss, and the width is 1 / 8 to 1 / 6 of the circumference of the annular positioning boss. Four fan-shaped rubber buffer pads are provided at corresponding positions on the bottom surface of the annular positioning groove of the temporary connector. The thickness of the fan-shaped rubber buffer pads is 1-2 mm greater than the depth of the fan-shaped weight reduction groove. A conical guide head with a height of 3-5mm and a cone angle of 60° is provided at the center of the end face of the annular positioning boss. A conical guide recess is provided at the center of the bottom surface of the annular positioning groove, and its depth is 0.5-1mm greater than the height of the conical guide head; During the process of the annular positioning boss being embedded into the annular positioning groove, the conical guide head first contacts the conical guide socket for initial alignment, and then the fan-shaped rubber buffer pad is deformed by pressure and fills the fan-shaped weight reduction groove.

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