BIM (Building Information Modeling) auxiliary manufacturing method of steel bridge cable bent tower

Abstract

The invention relates to the technical field of bridge engineering manufacturing, in particular to a BIM auxiliary manufacturing method for a steel bridge cable bent tower. According to the method, fine manufacturing of the steel bridge cable bent tower can be achieved by constructing a whole-process BIM auxiliary system including model establishment, in-plant manufacturing, precision control and field installation. According to the method, a three-dimensional BIM model of the cable bent tower is established based on Tekla Strauctures software, and reasonable segmentation and structure disassembly are completed; the problems of anchor box non-orthogonal positioning and limited space welding are solved through model deepening design, and component layout is optimized through collision detection; extracting coordinates of key control points of the model, and fitting and comparing the coordinates with measured values to realize segment precision control; the whole tower pre-assembly is replaced by the segmented simulation pre-assembly; and extracting a three-dimensional drawing from the model to generate a two-dimensional drawing. The manufacturing precision and efficiency can be effectively improved, the cost and the construction risk are reduced, and reliable technical guarantee is provided for construction of the complex modeling steel bridge cable bent tower.

Description

Technical Field

[0001] This invention relates to the field of bridge engineering manufacturing technology, specifically to a BIM-assisted manufacturing method for steel bridge pylons. Background Technology

[0002] Building Information Modeling (BIM) is a method that digitally simulates the real information of a building, promoting collaborative work and information sharing throughout the building's lifecycle. BIM technology has effectively helped improve the digitalization and intelligence of bridge construction management.

[0003] As bridge construction evolves towards longer spans, greater complexity, and more aesthetically pleasing designs, steel bridge towers, as the core load-bearing components of bridges, are experiencing increasingly complex structural designs and higher requirements for manufacturing and installation precision. Currently, the manufacturing process of steel bridge towers faces numerous technical challenges: First, the internal cable anchor boxes of the upper tower columns are mostly non-orthogonal, requiring extremely high precision in cable angles. Positioning the anchor boxes and wall panels is difficult, and the dense welds in the anchoring structure, often full-penetration welds, and narrow welding space result in a large workload and difficulty in guaranteeing welding quality. Second, the tower's cross-sectional dimensions are limited, and the numerous internal components such as steel strands, anchor boxes, and stairs have complex spatial relationships. Traditional two-dimensional design struggles to accurately represent the component positions, easily leading to component collisions and interference, resulting in rework and rectification. Third, the tower... The column segments are large in size, with the longest segment often exceeding 10m, and the number of transverse diaphragms within a single segment is small (mostly one layer). The requirements for the precision of segment manufacturing and port size control are stringent, and the traditional manual layout and actual measurement comparison method is inefficient and has large errors. Fourth, the tower structure is huge, and due to limitations such as factory site and transportation conditions, it is impossible to pre-assemble the entire tower, which can easily lead to problems such as excessive misalignment when connecting segments on site. Fifth, the two-dimensional drawing representation of spatial irregular components has limitations, and traditional drawing methods are prone to dimensional deviations, affecting the component processing accuracy.

[0004] In existing technologies, the manufacturing of steel bridge pylons largely relies on 2D drawings for guidance, supplemented by manual measurement and positioning. This results in shortcomings such as insufficient design detail, difficulty in component coordination, limited precision control methods, and high construction risks. Although some projects have introduced BIM technology, its application is mostly limited to single stages, failing to form a collaborative management and control system covering the entire manufacturing process. This makes it difficult to fully leverage the visualization, parametric, and collaborative advantages of BIM technology. Therefore, there is an urgent need for a comprehensive and refined BIM-assisted manufacturing method to solve a series of technical challenges in the current manufacturing of steel bridge pylons, improve manufacturing quality and efficiency, and reduce project costs. Summary of the Invention

[0005] The technical problem to be solved by this invention is to provide a BIM-assisted manufacturing method for steel bridge towers, which can effectively improve manufacturing accuracy and efficiency, reduce costs and construction risks, and provide reliable technical support for the construction of complex-shaped steel bridge towers.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A BIM-assisted manufacturing method for steel bridge pylons mainly includes the following steps: S1, Model Building Stage: A full 3D BIM model of the cable tower structure is built based on Tekla Structures software. The cable tower structure is segmented according to the cable tower design requirements and construction drawings, and component coding rules are formulated. After the modeling is completed, the BIM model is further designed and collision detection is performed, and 2D drawings are generated based on the 3D model. S2, the in-factory manufacturing stage, sequentially adopts the process of parts cutting and processing, plate unit and anchor box unit manufacturing, single-sided chamber tower column manufacturing, tower column segment manufacturing, and segment pre-assembly to complete construction preparation, unit component manufacturing, segment manufacturing and bridge site operation preparation. S3, the precision control stage of component manufacturing based on BIM collaborative construction, uses Tekla Structures software to refine the model and draw detailed processing drawings. The precision control of large-size segments is carried out by extracting coordinates from the model, comparing actual measurements, and correcting deviations in sequence. Special inspections of individual side chamber column segments and the whole segment are carried out according to the preset process. S4, on-site installation phase: The installation plan is dynamically adjusted based on the BIM model. The segment connection accuracy is verified by segmented simulation pre-assembly, and the hoisting process is monitored in real time to complete subsequent bridge site operations and final acceptance.

[0007] Preferably, in step S1, the model building stage specifically includes: S11: Preliminary preparation: Based on the tower structure design drawings, material performance parameters, transportation restrictions and on-site construction site planning data, and combined with the load-bearing capacity of transport vehicles, hoisting equipment parameters and on-site installation conditions, the tower is divided into segments. At the same time, coding rules for each component are formulated. The coding rules include component type, segment, and processing team information. S12: 3D modeling. In Tekla Structures software, the initial 3D modeling of the tower column wall panel, diaphragm, anchor box, stairs and steel strand components is completed in sequence. For the non-orthogonal anchor box of the upper tower column, the anchor box installation positioning node model is generated by the software's 3D spatial positioning function. S13: Model refinement and drawing output. Based on the initial model, determine the welding space layout and welding process sequence around the anchor box, and conduct collision detection. Adjust the component layout according to the detection results until the collision detection is qualified, forming a three-dimensional refined model. Automatically generate two-dimensional construction drawings and material statistics list based on the three-dimensional refined model, and check and correct the errors in the original design drawings according to the generated drawings and list.

[0008] Preferably, in step S12, the model size, material, and connection method of the three-dimensional initial model are consistent with the design drawings, and the anchor box installation positioning node model matches the relative positional relationship between the non-orthogonal anchor box and the wall panel of the tower column.

[0009] Preferably, in step S13, two-dimensional construction drawings and material statistics lists are automatically generated by using a preset drawing template, and the size of the construction drawings is adjusted according to the proportional relationship between the model and the drawings. Then, the drawings are compared with the original design drawings to achieve error verification and correction.

[0010] Preferably, in step S2, the construction preparation specifically includes: technical preparation, tooling preparation, equipment preparation, material preparation, and personnel preparation; The technical preparation includes construction drawings, material lists, and construction processes; the tooling preparation includes tooling design and fabrication; the equipment preparation includes equipment configuration and debugging; the material preparation includes material re-inspection and warehousing; and the personnel preparation includes personnel training and examination.

[0011] Preferably, in step S2, the unit component manufacturing includes: using digital precision layout technology to cut parts based on the component processing details output from the BIM model, sequentially completing the processing and manufacturing of diaphragm unit components, wall panel unit components, anchor box unit components, stairs and railings, and using the BIM model to compare the component dimensions in real time to correct processing errors.

[0012] Preferably, in step S3, the deviation correction specifically includes: 1) Extract segmented models from the overall BIM model of Sota and establish a dedicated coordinate system to determine the theoretical coordinate values ​​of key control points; 2) Use a total station to detect the actual coordinate values ​​of the segmented components and convert them to a unified coordinate system; 3) Compare the deviation between the fitted theoretical coordinate values ​​and the actual coordinate values. If the deviation is within the allowable range, the dimensions of the segmented component are deemed acceptable. If the deviation exceeds the allowable range, the segmented component is corrected, and steps 2) and 3) are repeated.

[0013] Preferably, in step S3, the specific testing requirements include: for a single side chamber column segment, the following steps are performed sequentially: sample preparation of the jig, pre-welding and post-welding key control point testing, deviation adjustment and retesting. After passing the retest, process partitions or tooling supports are added to segments without end partitions or with partitions more than 600mm from the end. The testing process for the entire tower segment is the same as that for a single side chamber column segment. After passing the retest, process partitions or tooling supports are added to segments with partitions of both side chamber columns more than 600mm from the end.

[0014] Preferably, in step S4, the on-site installation stage specifically includes: using the BIM model to create an installation process animation to enable visual adjustment of the installation plan; comparing the measured data of the segments with the theoretical coordinates of the model to simulate the error of the whole tower assembly; and monitoring the posture and elevation deviation of the components during the hoisting process in real time.

[0015] Compared with the prior art, the present invention has the following main advantages: 1. This invention significantly improves the accuracy and efficiency of steel bridge pylon manufacturing through full-process BIM-assisted manufacturing technology: Leveraging the visualization and parametric advantages of refined BIM models, the spatial layout of each pylon component can be precisely optimized, enabling accurate positioning of key components such as anchor boxes. It also allows for the prediction and avoidance of component collisions and interference, fundamentally solving the problems of repeated processing and rework caused by inaccurate layout and positioning, and insufficient component precision, thus greatly improving overall construction efficiency. Simultaneously, the full-process precision closed-loop control system ensures that the precision of large-size segment fabrication, port control, and on-site connection meets standards, effectively improving the overall quality of steel structure construction.

[0016] 2. This invention effectively achieves dual control of resource optimization and cost risk: Through the BIM model, the material requirements can be accurately calculated, the component disassembly and processing flow can be rationally planned, resource utilization efficiency can be improved, raw material waste can be reduced, and procurement and processing costs can be reduced; at the same time, the visualization of construction briefing and the simulation optimization of hoisting scheme based on the model greatly reduces the number of hoisting operations, reduces the risk of hoisting operations, monitors construction process parameters in real time and adjusts the scheme in a timely manner, further avoiding safety accidents and cost overrun risks, and ensuring that project costs are controlled within the expected range.

[0017] 3. This invention promotes the technological upgrade of bridge design and construction modes: Through the full-process application of BIM technology, it breaks through the limitations of traditional two-dimensional design, promotes the transformation of bridge design to three-dimensional forward design, not only solves the problem of inaccurate expression of spatial irregular component drawings, but also provides reliable technical support for the implementation of complex landscape bridge architectural schemes, significantly improves the intelligent level of bridge engineering design and construction, and has broad application value. Attached Figure Description

[0018] Figure 1This is an overall flowchart of the BIM-assisted manufacturing method for steel bridge towers in an embodiment of the present invention; Figure 2 This is an elevation layout diagram of the steel bridge tower in an embodiment of the present invention; Figure 3 This is a schematic diagram of the segmentation of the steel tower column in an embodiment of the present invention; Figure 4 This is a three-dimensional model diagram of the P8 tower segment in an embodiment of the present invention; Figure 5 This is a flowchart illustrating the in-plant manufacturing stage in an embodiment of the present invention; Figure 6 This is a flowchart illustrating the precision control stage in an embodiment of the present invention; Figure 7 This is a schematic diagram of the end tooling support for the side chamber column segment in an embodiment of the present invention; Figure 8 This is a schematic diagram of the end tooling support for the entire cable tower section in an embodiment of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0020] It should be noted that, depending on the implementation needs, the various steps / components described in this application can be broken down into more steps / components, or two or more steps / components or parts of the operation of steps / components can be combined into new steps / components to achieve the purpose of this invention.

[0021] In this invention, unless otherwise expressly specified and limited, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise expressly and specifically limited.

[0022] Example 1: This example provides a BIM-assisted manufacturing method for steel bridge pylons, such as... Figure 1 As shown, the main steps include the following: Step S1, Model Building Stage: A full 3D BIM model of the cable tower is constructed using Tekla Structures software. After reviewing the design and construction data of the cable tower, reasonable segmentation and component coding rules are established. After modeling is completed, detailed design, clash detection, and automatic generation of 2D drawings are performed, specifically including: S11, Preliminary Preparations: Review the cable tower structural design drawings, material performance parameters, transportation restrictions, and on-site construction site planning information to clarify the cable tower segmentation principle—combining the load-bearing capacity of transport vehicles, hoisting equipment parameters, and on-site installation conditions, divide the cable tower into several segments to ensure that the size and weight of each segment meet transportation and hoisting requirements; at the same time, formulate unified part and component coding rules, with codes including component type, segment, processing team, and other information to achieve full life-cycle traceability of components.

[0023] S12, 3D Modeling: Based on the basic design parameters of the tower, 3D modeling of components such as tower column panels, diaphragms, anchor boxes, stairs, and steel strands is completed sequentially in Tekla Structures software to ensure that the model dimensions, materials, and connection methods are consistent with the design drawings; for the non-orthogonal anchor boxes of the upper tower column, the relative positional relationship between the anchor box and the panel is accurately determined through the software's 3D spatial positioning function, and an anchor box installation positioning node model is generated.

[0024] S13, Model Refinement and Drawing: Refine the initial model, optimize the welding space layout around the anchor box, adjust the welding process and welding sequence to ensure that welds can be successfully applied in confined spaces; use the model collision detection function to comprehensively investigate spatial interference issues between various components within the tower, communicate with the design team to optimize the component layout for collision points; based on the refined BIM model, automatically generate two-dimensional construction drawings and material statistics lists through preset drawing templates, utilize the correlation between the model and drawings to ensure that the drawing dimensions are completely consistent with the model, and verify and correct drawing errors in the original design by comparing with the original two-dimensional design drawings.

[0025] Step S2, in-factory fabrication stage: This stage involves the sequential processes of parts cutting and processing; panel unit and anchor box unit manufacturing; single-sided tower column manufacturing; tower column segment manufacturing; and segment pre-assembly. This completes the construction preparation, unit component fabrication, segment fabrication, and bridge site preparation, specifically including: S21, Construction Preparation Stage 1) Technical preparation: Based on the detailed BIM model, output construction details, material list and special construction process documents, and conduct technical briefings for construction personnel; 2) Tooling preparation: Design and manufacture a special jig and positioning tooling according to the model dimensions to ensure that the tooling accuracy meets the component processing requirements; 3) Equipment preparation: Configure CNC blanking machine, welding robot, total station and other equipment, and complete equipment debugging and calibration; 4) Material preparation: Purchase raw materials according to the material statistics list, and complete the material re-inspection and warehousing; 5) Personnel preparation: Professional training and assessment shall be conducted for personnel engaged in processing, welding, measurement and other operations. Only those who pass the assessment may be allowed to work.

[0026] S22, Unit Component Manufacturing Stage Based on the component processing details output from the BIM model, digital precision layout technology is used to cut the parts to ensure the accuracy of the cutting dimensions. The processing and manufacturing of diaphragm unit components, wall panel unit components, anchor box unit components, stairs and railings are completed in sequence. During the processing, the component dimensions are compared with the BIM model in real time to correct processing errors in a timely manner.

[0027] S23, Segment Production Stage 1) Following the principle of "first fabricating the side chamber column segments, then assembling the tower segments", the tower column segments are assembled on a special jig. 2) All segments are matched and manufactured on a special jig. If the entire tower cannot be pre-assembled due to site and resource limitations, each round of pre-assembly shall not be less than 4+1 segments. 3) After the segment assembly is completed, install the matching parts and lifting lugs, inspect the segment dimensions and welding quality, mark the segments after they pass the inspection, and then proceed to the anti-corrosion process.

[0028] S24, Bridge Site Operation Preparation Plan the segment transportation routes and hoisting sequence in advance based on the BIM model, and formulate special plans for bridge site welding, painting and other operations.

[0029] Step S3, Precision Control Stage for Parts and Components Based on BIM Collaborative Construction: Utilizing Tekla Structures software to refine the model and draw detailed fabrication drawings, precision control of large-size segments is achieved through "model coordinate extraction - actual measurement comparison - deviation correction." Specialized inspections of individual side chamber column segments and entire segments are completed according to the prescribed procedures, specifically including: S31, Deepening Modeling and Digital Processing During the steel structure fabrication stage, Tekla Structures software is used to convert and refine the model from the construction drawing stage, accurately draw detailed factory processing drawings and material lists, disassemble components according to transportation conditions, and adopt digital precision layout and material cutting technology to avoid rework and material waste caused by component fabrication errors or excessive errors.

[0030] S32, Core Process of Segment Precision Control For large-sized cable tower segments with a maximum length exceeding 10m, accuracy control is achieved through a process of "model coordinate extraction - actual measurement comparison - deviation correction": 1) Extract the segment models from the overall BIM model of the tower, establish a segment-specific coordinate system, determine the key control points of segment dimensions (including port outline points, anchor box positioning points, diaphragm center points, etc.), and record the theoretical coordinate values ​​of each control point in the model; 2) After the segmented processing and fabrication are completed, a total station is used to conduct ground sampling and to measure the actual coordinate values ​​of each control point of the actual segmented component. The measured coordinate values ​​are then converted into a coordinate system consistent with the model coordinate system. 3) Use professional data processing software to compare the deviation between the actual coordinate values ​​of each feature point and the theoretical coordinate values ​​of the model control points. If the deviation is within the design allowable range (e.g., ±2mm), the segmented component dimensions are deemed acceptable. If the deviation exceeds the allowable range, the segmented component is corrected. After correction, steps 2) and 3) are repeated until the deviation is acceptable.

[0031] S33, Specialized Testing Requirements 1) Inspection of a single side chamber column segment: Complete the key control point inspection of the jig ground sample in sequence → key control point inspection before welding → key control point inspection after welding → deviation adjustment → key control point re-inspection; after the re-inspection is qualified, for segments without end partitions or with partitions more than 600mm away from the end, add process partitions or tooling supports at each port position in the chamber to ensure the port shape and segment stability. 2) Inspection of the entire tower section: The inspection process is the same as that for a single side chamber column section. After the re-inspection is qualified, if the distance between the partition plate and the end of the two side chamber columns exceeds 600mm, process partition plates or tooling supports need to be added at the port position of each chamber to avoid excessive misalignment of the sections during on-site installation.

[0032] Step S4, On-site Installation Phase: Based on the BIM model, optimize the installation plan, conduct visual briefings, verify segment connection accuracy through segmented simulation pre-assembly, optimize the hoisting scheme and monitor the hoisting process in real time, and complete subsequent bridge site operations and final acceptance inspection. Specifically, this includes: S41, Installation Plan Optimization and Briefing: Utilize the intuitive 3D view function of the BIM model and combine it with video processing software to create installation process animations, clarify key information such as segment transportation sequence, hoisting points, and docking accuracy requirements, and conduct visual construction briefings to ensure that construction personnel accurately grasp the key points of construction; based on the model, rationally arrange the construction and installation plan, determine the elevation coordinates of splicing nodes, and improve construction efficiency.

[0033] S42, Segmented Pre-assembly Simulation: Due to the large size of the tower structure, it is impossible to pre-assemble the entire tower in the factory. Before construction, the preliminary BIM model is combined with the site topography to simulate the construction and installation process. The measured data of the control points at the upper and lower ends of each segment of the tower are converted into coordinate values ​​corresponding to the physical assembly process. These coordinate values ​​are compared with the theoretical coordinate values ​​of the model. All measured control points are input into Tekla Structures software for overall modeling to simulate the full tower assembly effect and verify whether the error meets the installation requirements. If not, the segment is corrected until the simulated assembly is qualified.

[0034] S43, Lifting Process Control: By using BIM technology to establish a three-dimensional model of the building structure, the lifting plan is optimized and simulated to determine the optimal lifting route, lifting angle, and lifting point position; during construction, the BIM model is used to monitor parameters such as component posture and elevation deviation in real time during the lifting process, and the lifting plan is adjusted in a timely manner to maximize construction efficiency and ensure the safety of the lifting process.

[0035] S44, Subsequent Operation Control: After the segment is positioned, the bridge site welding operation is guided by the BIM model. After the welding is completed, grinding and flaw detection are carried out. Rust removal, painting, installation and welding of decorative panels, secondary grinding and painting are completed in sequence, and finally the completion and acceptance are completed.

[0036] Example 2: This example uses a bridge and connecting road project as an example. The bridge is approximately 573m long, including the main bridge and east and west approach bridges. The main bridge is a high-low double-tower single-cable-stayed bridge, and the restraint system adopts a tower-beam fixed connection, such as... Figure 2 As shown: The main tower is a single-column steel bridge tower. The tower column height is 58.5m, and the tower column height is 36m. The tower column has a box-shaped variable width section. The cable stays adopt a single cable surface fan-shaped arrangement, with a total of 30 cable stays for the entire bridge.

[0037] Both bridge towers are widened upright towers, with a transverse dimension of 3400mm and a longitudinal width that varies. The longitudinal dimension of the higher tower ranges from 3500 to 10000mm, while that of the lower tower ranges from 3000 to 8000mm. The towers and beams are fixed together, and tower construction can only proceed after the main beam connection section is completed.

[0038] The diaphragms of the tower columns are arranged radially. The standard spacing of the diaphragms in the low tower is 2 (2.5) m, and the standard spacing of the diaphragms in the high tower is 2 (2.2, 2.5) m. The thickness of the diaphragms is 16 (20) mm. The anchor box segments adopt a single-box three-chamber variable width section. The width of the inner box in the transverse direction of the bridge is 3.4 m. The width of the inner box in the longitudinal direction of the bridge in the low tower is 3~8 m. The width of the inner box in the longitudinal direction of the bridge in the high tower is 3.5~10 m. The thickness of the tower column wall is 25~40 mm, and the thickness of the stiffening rib is 20~30 mm. The stay cables are anchored on the tower using steel anchor boxes. The vertical spacing is 2 m in the low tower and 2.2 m in the high tower. There are ladders in the middle chamber inside the tower column. Below the stay cable segments are staggered inclined ladders, and above are simple straight ladders welded to the tower wall. There are several manholes on the inner wall panels and diaphragms of the tower column.

[0039] This project consists of two steel towers: Tower P7 is a low tower with 17 segments and a net weight of approximately 370.3t in the detailed design; Tower P8 is a high tower with 26 segments and a net weight of approximately 704.3t in the detailed design.

[0040] I. Model Building Phase This project uses Tekla Structures software for modeling. Before modeling, based on the structural characteristics of the bridge tower, combined with transportation constraints and actual site conditions, the bridge tower was reasonably segmented (e.g., Figure 3 As shown) and structural disassembly, and set the component coding rules, then model according to the basic parameters of the bridge tower design (such as Figure 4 (As shown). Compared with ordinary two-dimensional drawings, three-dimensional modeling solves the problem of intuitively expressing landscape effects and makes up for the inconvenience of two-dimensional plans in judging spatial positions.

[0041] One of the advantages of BIM is that it allows for the direct generation of 2D drawings from a 3D BIM model. The correlation between the model and the drawings ensures the accuracy and quality of the output. This project automatically generated drawings and a material list using a set drawing template. By comparing these with the original 2D design drawings, problems in the original 2D drawings can be identified.

[0042] II. In-factory production stage Based on the structural characteristics of this product, the overall manufacturing approach for the tower adopts the following process: "parts cutting and machining → plate unit and anchor box unit manufacturing → single-side chamber tower column manufacturing → tower column segment manufacturing → segment pre-assembly". The overall manufacturing process is as follows: Figure 5 As shown: 1) Construction preparation stage: including technical preparation (construction drawings, material list, construction process); tooling preparation (tooling design and fabrication); equipment preparation (equipment configuration and commissioning); material preparation (material re-inspection and warehousing); personnel preparation (personnel training and examination). 2) Unit component manufacturing stage: including parts cutting and processing → diaphragm unit component manufacturing, wall panel unit component manufacturing, diaphragm unit component manufacturing, anchor box unit component manufacturing, staircase and railing manufacturing; 3) Segment manufacturing stage: including tower segment manufacturing → segment pre-assembly → installation of matching parts and lifting lugs → inspection → segment marking → transfer to anti-corrosion process; 4) Bridge site operation stage: including segment transportation and hoisting → segment placement → bridge site welding → grinding and flaw detection → rust removal and painting → installation and welding of decorative panels → grinding and painting → completion and acceptance. Based on the structural form of the tower segments, each tower segment is divided into three parts: two side chamber segments, a central diaphragm unit, an anchor box unit, and a wall panel unit. The following manufacturing principles are adopted for segment manufacturing: (1) First, make the side chamber column segments, and then assemble the tower segments.

[0043] (2) All segments are matched and manufactured on a special jig. Depending on the manufacturing site and resources, if the whole tower cannot be pre-assembled, each round of pre-assembly shall not be less than 4+1 segments.

[0044] III. Precision control of component manufacturing based on BIM collaborative construction: 1) During the steel structure fabrication stage, Tekla Structures software is used to convert and refine the model from the construction drawing stage, accurately draw detailed factory fabrication drawings and material lists, disassemble components according to transportation conditions, and digitally and accurately lay out and cut materials, avoiding rework and material waste caused by component fabrication errors or large errors, and intuitively guiding workers to accurately cut materials.

[0045] 2) The tower column segments are large in size, with the longest segment exceeding 10m. Each segment basically contains only one layer of transverse diaphragm. As large-scale segments, the requirements for segment manufacturing and port control precision are very high.

[0046] The precision control of pylon segment manufacturing is achieved by extracting the coordinates of the corresponding key control points of the segments from the pylon model and fitting them with the measured coordinate values ​​of the control points in the manufacturing plant of each component, thereby detecting whether the component dimensions are up to standard.

[0047] Furthermore, such as Figure 6 As shown, the precision control of component manufacturing based on BIM collaborative construction mainly includes: Step 1: First, establish the overall model of the tower, extract the segmented models and establish a coordinate system, then determine the key control points for the segment dimensions, and determine the coordinate values ​​of the control points in the model; Step 2: Segmented processing and fabrication, ground sample testing. The actual coordinate values ​​of each control point of the actual segmented component are measured by using a total station, and coordinate transformation is performed. Step 3: Compare the deviation between the actual coordinate values ​​of each fitted feature point and the coordinate values ​​of the model control points. If the deviation is within the allowable range, the segmented component size is deemed acceptable. If the deviation exceeds the allowable range, the segmented component is corrected, and steps 2 and 3 are repeated.

[0048] Furthermore, such as Figure 7 As shown, the testing of a single side chamber column segment mainly includes: key control point testing of the jig ground sample → key control point testing before welding → key control point testing after welding → deviation adjustment → key control point retesting. After the control point retesting is completed, for segments without end septa or with septa more than 600mm from the end, process septa or tooling supports must be added at each port position in the chamber to ensure the port dimensions and segment stability.

[0049] Furthermore, such as Figure 8 As shown, the main inspection steps for the entire cable tower segment are: key control point inspection of the jig ground sample → key control point inspection before welding → key control point inspection after welding → deviation adjustment → key control point re-inspection. After the control point re-inspection is completed, when the distance between the partition and the end of the two side chamber columns exceeds 600mm, process partitions or tooling supports must be added at each port position inside the chamber to ensure the stability of the port dimensions and the segment, so as to avoid excessive misalignment of segments during on-site installation.

[0050] IV. On-site Installation Phase 1) During the construction and installation process, the intuitive 3D view function of BIM was used in combination with video processing software to reasonably arrange the construction and installation plan, determine the elevation coordinates of splicing nodes, and ultimately achieve the goal of improving efficiency and reducing costs.

[0051] 2) Due to the large size of the tower structure, it was not feasible to pre-assemble the entire tower in the factory. To achieve the expected installation schedule, the construction and installation procedures were simulated using the pre-construction BIM model combined with the site topography before construction, and installation process videos were created to guide the construction. During construction, this model was used to guide on-site positioning, installation, and verification.

[0052] The overall simulation pre-assembly of each segment component is carried out. The measured data of the control points at the upper and lower ends of each segment of the tower are converted into coordinate values ​​(coordinate values ​​in the model) corresponding to the actual assembly process and compared with them. All measured control points are input into Tekla Structures software for overall modeling to simulate the overall assembly effect. The error is carefully verified to see if it meets the installation requirements. If it does not meet the requirements, it must be corrected to achieve the effect of overall segment assembly.

[0053] 3) The hoisting of large components is an indispensable process in the manufacturing and installation of bridge towers. How to properly arrange the hoisting process of large components will directly affect whether the bridge project can be completed smoothly and meet the requirements of construction progress and quality.

[0054] Prior to construction, a 3D model of the building structure was created using BIM technology, and the hoisting plan was optimized and simulated. During construction, BIM technology was used to monitor parameters and construction status in real time during hoisting, and the hoisting plan was adjusted promptly to maximize construction efficiency and ensure the safety of the hoisting process.

[0055] Example 3: Based on the same inventive concept, this example also provides a steel bridge tower, which is manufactured using the BIM-assisted manufacturing method described above.

[0056] Furthermore, all parts of this application that are not described in detail are the same as or implemented using existing technology.

[0057] In summary: 1. This invention significantly improves the accuracy and efficiency of steel bridge pylon manufacturing through full-process BIM-assisted manufacturing technology: Leveraging the visualization and parametric advantages of refined BIM models, the spatial layout of each pylon component can be precisely optimized, enabling accurate positioning of key components such as anchor boxes. It also allows for the prediction and avoidance of component collisions and interference, fundamentally solving the problems of repeated processing and rework caused by inaccurate layout and positioning, and insufficient component precision, thus greatly improving overall construction efficiency. Simultaneously, the full-process precision closed-loop control system ensures that the precision of large-size segment fabrication, port control, and on-site connection meets standards, effectively improving the overall quality of steel structure construction.

[0058] 2. This invention effectively achieves dual control of resource optimization and cost risk: Through the BIM model, the material requirements can be accurately calculated, the component disassembly and processing flow can be rationally planned, resource utilization efficiency can be improved, raw material waste can be reduced, and procurement and processing costs can be reduced; at the same time, the visualization of construction briefing and the simulation optimization of hoisting scheme based on the model greatly reduces the number of hoisting operations, reduces the risk of hoisting operations, monitors construction process parameters in real time and adjusts the scheme in a timely manner, further avoiding safety accidents and cost overrun risks, and ensuring that project costs are controlled within the expected range.

[0059] 3. This invention promotes the technological upgrade of bridge design and construction modes: Through the full-process application of BIM technology, it breaks through the limitations of traditional two-dimensional design, promotes the transformation of bridge design to three-dimensional forward design, not only solves the problem of inaccurate expression of spatial irregular component drawings, but also provides reliable technical support for the implementation of complex landscape bridge architectural schemes, significantly improves the intelligent level of bridge engineering design and construction, and has broad application value.

[0060] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0061] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0062] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A BIM-assisted manufacturing method for steel bridge pylons, characterized in that, Includes the following steps: S1, Model Building Stage: A full 3D BIM model of the cable tower structure is built based on Tekla Structures software. The cable tower structure is segmented according to the cable tower design requirements and construction drawings, and component coding rules are formulated. After the modeling is completed, the BIM model is further designed and collision detection is performed, and 2D drawings are generated based on the 3D model. S2, the in-factory manufacturing stage, sequentially adopts the process of parts cutting and processing, plate unit and anchor box unit manufacturing, single-sided chamber tower column manufacturing, tower column segment manufacturing, and segment pre-assembly to complete construction preparation, unit component manufacturing, segment manufacturing and bridge site operation preparation. S3, the precision control stage of component manufacturing based on BIM collaborative construction, uses Tekla Structures software to refine the model and draw detailed processing drawings. The precision control of large-size segments is carried out by extracting coordinates from the model, comparing actual measurements, and correcting deviations in sequence. Special inspections of individual side chamber column segments and the whole segment are carried out according to the preset process. S4, on-site installation phase: The installation plan is dynamically adjusted based on the BIM model. The segment connection accuracy is verified by segmented simulation pre-assembly, and the hoisting process is monitored in real time to complete subsequent bridge site operations and final acceptance.

2. The BIM-assisted manufacturing method for steel bridge towers according to claim 1, characterized in that... Step S1, the model building stage, specifically includes: S11: Preliminary preparation: Based on the tower structure design drawings, material performance parameters, transportation restrictions and on-site construction site planning data, and combined with the load-bearing capacity of transport vehicles, hoisting equipment parameters and on-site installation conditions, the tower is divided into segments. At the same time, coding rules for each component are formulated. The coding rules include component type, segment, and processing team information. S12: 3D modeling. In Tekla Structures software, the initial 3D modeling of the tower column wall panel, diaphragm, anchor box, stairs and steel strand components is completed in sequence. For the non-orthogonal anchor box of the upper tower column, the anchor box installation positioning node model is generated by the software's 3D spatial positioning function. S13: Model refinement and drawing output. Based on the initial model, determine the welding space layout and welding process sequence around the anchor box, and conduct collision detection. Adjust the component layout according to the detection results until the collision detection is qualified, forming a three-dimensional refined model. Automatically generate two-dimensional construction drawings and material statistics list based on the three-dimensional refined model, and check and correct the errors in the original design drawings according to the generated drawings and list.

3. The BIM-assisted manufacturing method for steel bridge pylons according to claim 2, characterized in that... In step S12, the model size, material, and connection method of the initial 3D model are consistent with the design drawings, and the anchor box installation positioning node model matches the relative positional relationship between the non-orthogonal anchor box and the wall panel of the tower column.

4. The BIM-assisted manufacturing method for steel bridge towers according to claim 2, characterized in that... In step S13, two-dimensional construction drawings and material statistics lists are automatically generated using a preset drawing template. The size of the construction drawings is adjusted according to the ratio between the model and the drawings, and then compared with the original design drawings to achieve error verification and correction.

5. The BIM-assisted manufacturing method for steel bridge towers according to claim 1, characterized in that... In step S2, the construction preparation specifically includes: technical preparation, tooling preparation, equipment preparation, material preparation, and personnel preparation. The technical preparation includes construction drawings, material lists, and construction processes; the tooling preparation includes tooling design and fabrication; the equipment preparation includes equipment configuration and debugging; the material preparation includes material re-inspection and warehousing; and the personnel preparation includes personnel training and examination.

6. A BIM-assisted manufacturing method for steel bridge pylons according to claim 5, characterized in that... In step S2, the unit component manufacturing includes: using digital precision layout technology to cut parts based on the component processing details output from the BIM model, sequentially completing the processing and manufacturing of diaphragm unit components, wall panel unit components, anchor box unit components, stairs and railings, and using the BIM model to compare the component dimensions in real time to correct processing errors.

7. The BIM-assisted manufacturing method for steel bridge towers according to claim 1, characterized in that... In step S3, the deviation correction specifically includes: 1) Extract segmented models from the overall BIM model of Sota and establish a dedicated coordinate system to determine the theoretical coordinate values ​​of key control points; 2) Use a total station to detect the actual coordinate values ​​of the segmented components and convert them to a unified coordinate system; 3) Compare the deviation between the fitted theoretical coordinate values ​​and the actual coordinate values. If the deviation is within the allowable range, the dimensions of the segmented component are deemed acceptable. If the deviation exceeds the allowable range, the segmented component is corrected, and steps 2) and 3) are repeated.

8. A BIM-assisted manufacturing method for steel bridge pylons according to claim 7, characterized in that... In step S3, the specific testing requirements include: for a single side chamber column segment, the following steps are performed sequentially: sample preparation of the jig, pre-welding and post-welding key control point testing, deviation adjustment and retesting. After passing the retest, process partitions or tooling supports are added to segments without end partitions or with partitions more than 600mm from the end. The testing process for the entire tower segment is the same as that for a single side chamber column segment. After passing the retest, process partitions or tooling supports are added to segments with partitions of both side chamber columns more than 600mm from the end.

9. A BIM-assisted manufacturing method for steel bridge towers according to claim 1, characterized in that... In step S4, the on-site installation stage specifically includes: using the BIM model to create an installation process animation to enable visual adjustment of the installation plan; comparing the measured data of the segments with the theoretical coordinates of the model to simulate the error of the whole tower assembly; and monitoring the component posture and elevation deviation in real time during the hoisting process.

10. A steel bridge tower, characterized in that, The manufacturing process is carried out using the BIM-assisted manufacturing method as described in any one of claims 1 to 9.

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