Expressway bridge whole hole synchronous jacking intelligent control method based on multi-sensor fusion

Abstract

The invention discloses an expressway bridge full-hole synchronous jacking intelligent control method based on multi-sensor fusion, and belongs to the technical field of expressway bridge engineering construction.The expressway bridge full-hole synchronous jacking intelligent control method comprises the steps that S1, a digital twinborn body corresponding to an entity bridge is constructed; s2, body sensors are arranged on the top face of a capping beam and the bottom of a beam body of the bridge; s3, deploying an inspection unmanned aerial vehicle over a jacking area including the bridge pier and the bridge abutment; s5, the target displacement and the target jacking force of each jacking point are calculated, and the central controller controls the hydraulic jack cluster to execute the synchronous jacking action; and S8, the central controller judges the jacking state based on the simulation prediction data and the real-time monitoring data of the digital twin. Sensor data, unmanned aerial vehicle images, digital twinning and an executing mechanism are deeply integrated through the central controller, the system can automatically execute jacking, automatically adjust supporting and automatically judge the state, and the total construction period of jacking operation is remarkably shortened.

Description

Technical Field

[0001] This invention relates to the field of highway bridge construction technology, and in particular to an intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion. Background Technology

[0002] With the continuous improvement of my country's transportation infrastructure, the demand for repairing, reinforcing, or adjusting the elevation of existing bridges is increasing. Bridge span jacking technology, as an economical and efficient renovation method, has been widely applied. However, in current technological practice, this construction process still faces a series of technical challenges that urgently need to be addressed.

[0003] First, the monitoring system primarily relies on sensors positioned between the bridge beams and cap beams, forming an "island-like" data acquisition network with blind spots, making it impossible to comprehensively grasp the overall attitude and lateral displacement of the bridge. Second, the control system typically uses PLC systems for "post-event" adjustments based on preset programs, lacking the ability to proactively predict potential risks such as the redistribution of internal forces and the formation of micro-cracks. Third, the temporary support system uses manual placement of steel pads, which is inefficient and lacks precision, posing safety risks. Finally, the subsystems lack coordination, making it difficult to form an intelligent closed-loop control system. Summary of the Invention

[0004] In order to overcome the shortcomings of the existing technology, the purpose of this invention is to realize a method for synchronous jacking control of the entire span of a highway bridge that can achieve all-round perception, intelligent prediction and decision-making, and precise adaptive execution.

[0005] The objective of this invention is achieved through the following technical solution: A smart control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion includes the following steps: S1: Construct a digital twin corresponding to the physical bridge; S2: Arrange body sensors on the top surface of the bridge cap beam and the bottom of the beam body, and fix the body sensors on the top surface of the cap beam and the bottom of the beam body; S3: Deploy inspection drones over the lifting area that includes bridge piers and abutments; S4: The central controller receives monitoring data from the main body sensors and the inspection drone; S5: The central controller calculates the target displacement and target lifting force of each lifting point based on the monitoring data and the digital twin, and controls the hydraulic jack cluster to perform synchronous lifting actions. S6: After the hydraulic jack has been lifted by one stroke, a shape memory alloy temporary support pad is installed between the hydraulic jack and the bottom of the beam. S7: An external excitation is applied to the shape memory alloy temporary support pad, and the shape memory alloy temporary support pad responds to the external excitation and generates a high deformation; S8: The central controller determines the lifting status based on the simulation prediction data and real-time monitoring data of the digital twin; the central controller decides on subsequent lifting actions based on the determination result.

[0006] In step S1, constructing the digital twin corresponding to the physical bridge involves: establishing a three-dimensional model in a computer system based on the bridge design drawings, and importing the bridge's connection, span, pier numbers, and design lifting height data into the model.

[0007] In step S2, the main body sensor includes a wire displacement sensor and an inclination sensor. The wire displacement sensor is fixed to the top surface of the cap beam and the bottom of the beam body. Specifically, the wire end of the wire displacement sensor is fixed to the bottom of the beam body, the main body of the wire displacement sensor is fixed to the top surface of the cap beam, and the inclination sensor is fixed to the surface of the beam body.

[0008] In step S3, the inspection drone is equipped with a high-definition camera; the inspection drone is deployed to monitor the lateral displacement of the beam during the lifting process.

[0009] In step S4, the monitoring data includes the data measured by the main sensor and the overall attitude image of the bridge taken by the inspection drone.

[0010] In step S5, the central controller is a PLC hydraulic synchronous control system; the central controller controls the hydraulic jack cluster to perform synchronous lifting action, and its lifting speed is controlled at 1mm / 3min.

[0011] In step S6, the shape memory alloy temporary support pad is a cubic block made of nickel-titanium alloy with a height of 50mm or 100mm.

[0012] In step S7, an external excitation is applied, specifically by electrically heating the shape memory alloy temporary support pad.

[0013] The electric heating is achieved through electrodes connected to both ends of the shape memory alloy temporary support pad, and the on / off state of the electrodes is automatically controlled by the central controller based on real-time monitoring data.

[0014] In step S8, determining the lifting status specifically involves comparing real-time monitoring data with preset thresholds. The preset thresholds include: the synchronization error between each lifting point must not exceed 1 mm, and the pressure error of the jack must not exceed 5%.

[0015] Compared with existing technologies, the intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion has the following advantages: (1) This application proposes an intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion. By constructing a digital twin, the system can simulate the stress and deformation trends of the structure before jacking and predict them during jacking. This enables the system to make forward-looking adjustments, issue warnings and automatically correct potential problems (such as exceeding the synchronization error limit or stress concentration) before they occur, and stabilize the control accuracy within ±0.5mm, fundamentally avoiding major safety risks such as beam cracking or overturning. (2) This application proposes an intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion. It introduces an inspection drone to perform a global scan of the jacking area from the air and fuse it with the data from the ground-based body sensors. This not only cross-verifies the accuracy of the data from the body sensors, but also monitors the overall posture of the beam and the lateral displacement that is difficult to detect from the bottom in real time, forming a three-dimensional monitoring system without blind spots, ensuring the stability and controllability of the overall posture of the highway bridge during the jacking process; (3) The intelligent control method for synchronous jacking of the entire span of highway bridge based on multi-sensor fusion of this application uses shape memory alloy temporary support pads during the installation of aluminum formwork. The shape memory alloy temporary support pads are used to generate controllable and precise height deformation through excitation methods such as electric heating. This process can be completed automatically by the central controller, realizing "one-click" remote fine adjustment of the height of the temporary support. Compared with traditional steel pads, there is no need for repeated manual hammering, which greatly improves the work efficiency, reduces the risk and time cost of high-altitude operations, and ensures the uniformity and stability of the support. (4) This application proposes an intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion. The method deeply integrates sensor data, UAV images, digital twin simulation prediction, and actuators (hydraulic jacks and shape memory alloy excitation devices) through a central controller (PLC system). The system can automatically perform jacking, automatically adjust supports, and automatically judge the status, minimizing the interference of human factors. This not only makes the construction process more standardized and reliable, but also significantly shortens the total construction period of the jacking operation. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and, together with their descriptions, serve to explain the invention and do not constitute an undue limitation of this application. In the drawings: Figure 1 The flowchart shows the intelligent control method for synchronous jacking of the entire span of a highway bridge using multi-sensor fusion according to the present invention. Figure 2 This is a flowchart of the multi-sensor monitoring process of the present invention; Figure 3This is a flowchart of determining the lifting state in step S8 of the present invention. Detailed Implementation

[0017] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0018] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrative purposes and has no specific meaning in itself. Therefore, "module," "part," or "unit" may be used interchangeably.

[0019] Figures 1-3 This invention discloses an intelligent control method for synchronous jacking of a highway bridge span based on multi-sensor fusion. The method comprises the following steps: S1: Constructing a digital twin corresponding to the physical bridge; S2: Arranging body sensors on the top surface of the bridge cap beam and the bottom of the bridge body, fixing the body sensors to these surfaces; S3: Deploying an inspection drone over the jacking area including the piers and abutments; S4: Receiving monitoring data from the body sensors and the inspection drone; S5: Calculating the target displacement and target jacking force at each jacking point based on the monitoring data and the digital twin, and controlling the hydraulic jack cluster to perform synchronous jacking actions; S6: Installing a shape memory alloy temporary support block between the hydraulic jack and the bottom of the bridge body after the hydraulic jack has completed one stroke; S7: Applying an external excitation to the shape memory alloy temporary support block, causing it to deform in response; S8: Determining the jacking status based on the simulation prediction data and real-time monitoring data from the digital twin; and deciding on subsequent jacking actions based on the determination result.

[0020] In step S1, a digital twin corresponding to the physical bridge is constructed. Specifically, a three-dimensional model is created in the computer system based on the bridge design drawings, and the bridge's connection, span, pier numbers, and design lifting height data are imported into the model.

[0021] In one embodiment of this application, the multiple sensors include a body sensor and an aerial inspection sensor.

[0022] In step S2, the main body sensors include a wire displacement sensor and a tilt sensor. The wire displacement sensor is fixed to the top surface of the cap beam and the bottom of the beam body. Specifically, the wire end of the sensor is fixed to the bottom of the beam body, and the sensor body is fixed to the top surface of the cap beam. The wire displacement sensor is the core sensor for controlling synchronization accuracy. It directly measures the real-time vertical displacement of the beam body relative to the cap beam, ensuring that the jacking synchronization accuracy is controlled within ±1mm. The tilt sensor is fixed to the surface of the beam body to monitor whether the overall posture of the beam body is stable during the jacking process, preventing the beam body from twisting or tilting due to asynchronous or eccentric loads.

[0023] The main sensor also includes a pressure sensor located in the hydraulic circuit of the hydraulic jack, which monitors the lifting force of each hydraulic jack in real time, achieving "dual control of displacement and lifting force". When the pressure error exceeds 5%, the machine will automatically alarm and stop to prevent structural overload.

[0024] In one embodiment of this application, the aerial inspection sensor includes a high-definition optical camera and an inspection drone.

[0025] In step S3, an inspection drone equipped with a high-definition camera is deployed to monitor the lateral displacement of the bridge beam during the lifting process. This macroscopic monitoring of the beam's lateral displacement and overall alignment cross-validates the data with that from the onboard sensors, compensating for blind spots in ground-based monitoring. The inspection drone also features a laser scanner for rapidly acquiring 3D point cloud data of the bridge, which is then matched with a digital twin model with high precision to intuitively and accurately calibrate the bridge's actual configuration in 3D space.

[0026] In step S4, the monitoring data includes the displacement measured by the wire displacement sensor, the tilt angle measured by the tilt sensor, the lifting force measured by the pressure sensor, and the overall attitude image of the bridge taken by the inspection drone.

[0027] In step S5, the central controller is a PLC hydraulic synchronous control system; it controls the hydraulic jack cluster to perform synchronous lifting actions, and its lifting speed is controlled at 1mm / 3min.

[0028] In step S6, the shape memory alloy temporary support pad is a cubic block made of nickel-titanium alloy with a height of 50mm or 100mm.

[0029] In step S7, an external excitation is applied, specifically by electrically heating the shape memory alloy temporary support pad.

[0030] In this embodiment, a cubic pad is pre-manufactured using a nickel-titanium alloy, and its "memory" shape is a cube with a precise height of 50mm or 100mm.

[0031] In the factory, this shape is "memorized" in the material through a special heat treatment process ("shaping treatment").

[0032] During installation, after the hydraulic jack has been raised one stroke, the workers place the shape memory alloy pad, which is in a martensitic state, into the support point between the hydraulic jack and the bottom of the beam. In this state, the pad is relatively soft and can tolerate a certain amount of installation error. The installation process is exactly the same as with traditional steel pads and requires no special skills.

[0033] Once all the support blocks are in place, the system needs to be precisely leveled. At this point, the central controller uses real-time elevation data from the guy wire displacement sensor to determine which support blocks need to be "activated" to compensate for height differences.

[0034] External excitation is applied: a safe voltage current (electric heating) is applied to the specific pad that needs to be raised, causing its temperature to rise. When the pad's temperature exceeds its phase transition point, it will actively and precisely return to its preset height of 50mm or 100mm. Because it is installed under compression, this return process generates a supporting force on the superstructure, precisely raising the beam elevation at that point, achieving fine-tuning. This is a closed-loop control. The central controller continuously compares the displacement of each point until the elevation synchronization error of all monitoring points is less than ±1mm, at which point heating is stopped.

[0035] Support and Cycle: After fine-tuning, the pads remain in an austenitic state, possessing extremely high strength and stiffness, capable of safely bearing a 100t load, serving as reliable temporary supports. Subsequent jacking cycles follow a similar pattern, with new pads installed during new strokes.

[0036] Electric heating is achieved through electrodes connected to both ends of the shape memory alloy temporary support pad. The on / off state of the electrodes is automatically controlled by the central controller based on real-time monitoring data.

[0037] In step S8, the lifting status is determined by comparing real-time monitoring data with preset thresholds. The preset thresholds include: the synchronization error between each lifting point must not exceed 1mm, and the pressure error of the jacks must not exceed 5%. The process includes the following steps: The central controller receives real-time monitoring data from the wire displacement sensor (displacement), pressure sensor (lift force), tilt sensor (attitude angle), and the overall image of the inspection drone.

[0038] The system performs two independent decision-making threads simultaneously: Thread 1 (Geometric State Judgment): Calculate the difference between the highest and lowest displacement points among all jacking points and compare it with the 1mm threshold.

[0039] Thread 2 (Mechanical State Judgment): Calculate the percentage deviation between the actual pressure and the theoretical pressure (or average pressure) of each hydraulic jack, and compare it with the 5% threshold.

[0040] This data is synchronously input into the digital twin, driving the virtual model to remain synchronized with the physical bridge.

[0041] Situation A (Normal State): such as Figure 3 As shown, when both conditions are met simultaneously, the system determines that the status is "normal". The central controller then decides to continue lifting and enter the next lifting cycle.

[0042] Scenario B (Abnormal State): such as Figure 3 As shown, if any condition is not met, the system immediately determines it to be in an "abnormal state." At this point, automatic protection is activated, the central controller immediately locks the hydraulic system, stops all jacking operations, and achieves "fail-safe" operation. Audible and visual alarms: Trigger on-site alarms to notify command personnel. Precise positioning: In the 3D visualization interface of the digital twin, the system highlights which point(s) have exceeded displacement or pressure limits, greatly reducing troubleshooting time. The system can combine historical data and AI models to suggest possible causes of the fault (e.g., "Pressure of jack #2 on pier #3 exceeds limit, suspected to be due to a hard obstacle below"), providing support for personnel decision-making.

[0043] The implementation process of this application is as follows: First, based on the bridge design drawings, a digital twin corresponding to the physical bridge is constructed in a computer system, importing key parameters such as the bridge's connection, span, pier numbers, and design lifting height. Next, guy wire displacement sensors and tilt sensors are precisely deployed on the top surface of the bridge's cap beam and around the beam body. The guy wires of the guy wire displacement sensors are fixed to the bottom of the beam body, and the tilt sensors are fixed to the beam body surface. Simultaneously, inspection drones equipped with high-definition cameras and laser scanners are deployed above the lifting area, including the piers and abutments, thereby establishing a precise virtual-real mapping model and a comprehensive sensing network. The digital twin enables digital pre-simulation of the construction process, providing a precise virtual environment for subsequent intelligent decision-making. The deployment of multiple sensors forms a "sky-ground-body" three-dimensional monitoring system, completely eliminating monitoring blind spots.

[0044] The central controller (PLC hydraulic synchronization control system) begins receiving and fusing multi-source monitoring data from the bridge's sensors and the inspection drone, including displacement, pressure, tilt angle data, and overall bridge attitude images and 3D point clouds. Based on this real-time data and simulation analysis using a digital twin, the central controller precisely calculates the target displacement and target lifting force at each lifting point, and then controls the hydraulic jack cluster to perform synchronous lifting actions at a rate of 1mm / 3min. This represents a leap from passive control to intelligent prediction. Through multi-source data fusion and digital twin simulation prediction, the system can proactively identify potential risks and provide early warnings and corrections before problems occur. Simultaneously, precise speed control ensures the smoothness of the lifting process, maintaining synchronization accuracy at an extremely high level.

[0045] After the hydraulic jack completes one stroke of lifting, construction workers install temporary support blocks made of nickel-titanium alloy shape memory alloy between the hydraulic jack and the bottom of the beam. The blocks are 50mm or 100mm cubes. Subsequently, the central controller, based on real-time monitoring data, applies electrical heating excitation to the blocks requiring adjustment via electrodes connected to both ends of the blocks. The blocks respond to the excitation with precise height deformation. Then, based on simulation prediction data from a digital twin and real-time monitoring data, the central controller compares the synchronization error between each lifting point with a 1mm threshold and the hydraulic jack pressure error with a 5% threshold to determine the lifting status and decide on subsequent lifting actions based on the judgment results. This application introduces an intelligent temporary support system with active deformation capabilities. Through the excitation response characteristics of the shape memory alloy blocks, it achieves remote and precise fine-tuning of the support height, solving the problems of low efficiency and poor accuracy of traditional supports. Simultaneously, the intelligent status judgment mechanism based on dual thresholds ensures that the system can promptly identify anomalies and automatically protect itself, significantly improving construction safety.

[0046] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of the present invention. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of these fall within the protection scope of the present invention.

Claims

1. A smart control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion, characterized in that: Includes the following steps: S1: Construct a digital twin corresponding to the physical bridge; S2: Arrange body sensors on the top surface of the bridge cap beam and the bottom of the beam body, and fix the body sensors on the top surface of the cap beam and the bottom of the beam body; S3: Deploy inspection drones over the lifting area that includes bridge piers and abutments; S4: The central controller receives monitoring data from the main body sensors and the inspection drone; S5: The central controller calculates the target displacement and target lifting force of each lifting point based on the monitoring data and the digital twin, and controls the hydraulic jack cluster to perform synchronous lifting actions. S6: After the hydraulic jack has been lifted by one stroke, a shape memory alloy temporary support pad is installed between the hydraulic jack and the bottom of the beam. S7: An external excitation is applied to the shape memory alloy temporary support pad, and the shape memory alloy temporary support pad responds to the external excitation and generates a high deformation; S8: The central controller determines the lifting status based on the simulation prediction data and real-time monitoring data of the digital twin; the central controller decides on subsequent lifting actions based on the determination result.

2. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 1, characterized in that: In step S1, constructing the digital twin corresponding to the physical bridge involves: establishing a three-dimensional model in a computer system based on the bridge design drawings, and importing the bridge's connection, span, pier numbers, and design lifting height data into the model.

3. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 2, characterized in that: In step S2, the main body sensor includes a wire displacement sensor and an inclination sensor. The wire displacement sensor is fixed to the top surface of the cap beam and the bottom of the beam body. Specifically, the wire end of the wire displacement sensor is fixed to the bottom of the beam body, the main body of the wire displacement sensor is fixed to the top surface of the cap beam, and the inclination sensor is fixed to the surface of the beam body.

4. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 1, characterized in that: In step S3, the inspection drone is equipped with a high-definition camera; The inspection drone is deployed to monitor the lateral displacement of the beam during the lifting process.

5. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 1, characterized in that: In step S4, the monitoring data includes the data measured by the main sensor and the overall attitude image of the bridge taken by the inspection drone.

6. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 1, characterized in that: In step S5, the central controller is a PLC hydraulic synchronous control system; the central controller controls the hydraulic jack cluster to perform synchronous lifting action, and its lifting speed is controlled at 1mm / 3min.

7. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 1, characterized in that: In step S6, the shape memory alloy temporary support pad is a cubic block made of nickel-titanium alloy with a height of 50mm or 100mm.

8. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion as described in claim 1, characterized in that: In step S7, an external excitation is applied, specifically by electrically heating the shape memory alloy temporary support pad.

9. The aluminum alloy template pull tab system according to claim 8, characterized in that: The electric heating is achieved through electrodes connected to both ends of the shape memory alloy temporary support pad, and the on / off state of the electrodes is automatically controlled by the central controller based on real-time monitoring data.

10. The intelligent control method for synchronous jacking of the entire span of a highway bridge based on multi-sensor fusion according to claim 1, characterized in that: In step S8, determining the lifting status specifically involves comparing real-time monitoring data with a preset threshold. The preset thresholds include: the synchronization error between each lifting point shall not exceed 1 mm, and the pressure error of the jack shall not exceed 5%.

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