Large-space air duct prefabrication modular rapid assembly construction method

Abstract

The invention discloses a large-space air duct prefabrication modular rapid assembly construction method, and particularly relates to the technical field of building engineering construction, the method comprises the following steps: S1, digital design and modular planning; s2, factory intelligent prefabrication production is carried out; s3, on-site accurate measurement and positioning; s4, standardized installation of the support hanger; and S5, quickly assembling the air duct module. According to the method, static design is upgraded into dynamic adjustable intelligent planning through a closed loop of BIM, 4D construction simulation and self-adaptive adjustment, collision is avoided in the design stage, field change can be actively adapted in the construction stage, the first-pass yield of construction is greatly improved, rework caused by design change and field errors is reduced, and the construction efficiency is improved. The air duct module is accurately, stably and efficiently hoisted, so that the high-altitude manual assembly workload is reduced, the overturning risk in the hoisting process is completely eradicated, and the safety and the hoisting efficiency are both improved.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, and more specifically, to a method for rapid assembly and construction of prefabricated modular air ducts in large spaces. Background Technology

[0002] With the accelerated advancement of my country's industrialization and urbanization, the construction of industrial plants has shown a clear trend towards tall and spacious buildings. These plants typically have high ceilings (mostly exceeding 8 meters), large spans (commonly over 30 meters), and open spaces, providing ample operating space for production processes. However, these architectural features also present unprecedented challenges to the installation of ventilation and air conditioning systems.

[0003] As industrial plants rapidly develop towards larger spaces and wider spans, their supporting ventilation and air conditioning duct systems are also characterized by their massive scale and complex layout. Traditional duct construction methods, which mainly rely on a discrete operation mode of "on-site measurement, on-site processing, and on-site installation," are no longer suitable for such large-space industrial plants, exposing many technical bottlenecks that urgently need to be addressed. First, traditional two-dimensional drawings are difficult to deal with complex scenarios involving the intersection of multiple professional pipelines. Although some projects have adopted BIM technology for three-dimensional design, they are mostly limited to the static "modeling" and "display" stages. They have failed to be deeply integrated with the construction progress and resource allocation. The design model is disconnected from the dynamic construction on site and cannot be adaptively adjusted according to civil engineering errors. This results in prefabricated components being unable to be installed after arriving on site, causing rework and waste. Secondly, existing prefabrication and assembly technologies are mostly concentrated in the factory production of standard straight pipe sections. For non-standard parts, connection nodes, and supports, they still rely on on-site manual processing. The level of automation and intelligence in the factory production process is not high. Especially in fine operations such as welding and internal processing, quality stability is difficult to guarantee, and true "productization" manufacturing cannot be achieved. Meanwhile, on-site installation still relies mainly on manual experience and simple machinery, resulting in low efficiency and large errors in the positioning and layout of supports and hangers; the hoisting of duct modules, especially large-diameter modules, largely depends on manual observation and manual leveling, which poses risks of swaying and overturning. The installation accuracy and safety are highly dependent on the technical level and sense of responsibility of the workers, resulting in low efficiency. In addition, traditional construction management relies on Gantt charts or network diagrams. This two-dimensional line-based schedule is disconnected from the three-dimensional spatial design model. It is difficult for managers to intuitively predict whether the hoisting path of the duct module will conflict with moving large equipment, temporary scaffolding or other professional processes at a specific time and in a specific construction area. This "spatiotemporal conflict" is an important reason for on-site work stoppages, idle work, and poor process connection.

[0004] Therefore, there is an urgent need in this field for a prefabricated rapid assembly construction method for large-space air ducts that can run through the entire process of design, production, assembly, and testing, and deeply integrate information, automation, and intelligent technologies, in order to systematically solve the above problems. Summary of the Invention

[0005] In order to overcome the above-mentioned defects of the prior art, the present invention provides a method for rapid assembly and construction of prefabricated modular air ducts in large spaces.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for rapid assembly and construction of prefabricated modular air ducts in large spaces, comprising the following steps: S1. Digital Design and Modular Planning: Based on Building Information Modeling (BIM), a comprehensive model including architecture, structure, and electromechanical pipelines is constructed. According to the column grid of the factory structure and the equipment layout, the ventilation duct system is divided into spatial partitions and modular divisions to form standard modules and non-standard modules. Multi-disciplinary collaborative design and clash detection are carried out. S2, Factory-based intelligent prefabrication production: The BIM design data processed by S1 is directly imported into the factory's computer-aided manufacturing (CAM) system to drive CNC cutting equipment, automatic seaming machines and closing machines to complete the precise cutting, forming and assembly of duct panels, and assign a unique identification code to each prefabricated duct module. S3. Precise on-site measurement and positioning: Before construction and installation, use 3D laser scanning technology to obtain actual point cloud data of the construction site, compare and verify it with the BIM design model, and accurately determine the installation position of the support and hanger and the installation benchmark of the air duct module. S4. Standardized installation of supports and hangers: Based on the BIM model of S1 and the on-site verification data of S3, the selection, layout and stress analysis of supports and hangers are carried out, and standard support and hanger components prefabricated in the factory are used for rapid assembly and installation. S5. Rapid assembly of duct modules: According to the division and numbering of modules, use special hoisting equipment to hoist the duct modules to the design position in sequence, and use standardized connectors for rapid docking and sealing to complete the assembly of the entire duct system.

[0007] As a further improvement to the technical solution of the present invention, in S1, the modular division is based on the column grid of the factory structure, and the duct system is divided into several standard section modules of equal length in the length direction, and non-standard section modules are divided at spatial turns, diameter changes or connections with equipment; the length of the standard section module is 6 meters and the weight of a single piece does not exceed 200 kilograms.

[0008] As a further improvement to the technical solution of the present invention, after completing the module division, S1 also includes constructing a 4D construction simulation model based on the construction schedule plan, which is used to simulate and optimize the transportation and hoisting sequence of the duct module and its connection with the construction of civil engineering and other electromechanical disciplines.

[0009] As a further improvement to the technical solution of the present invention, the factory-based intelligent prefabrication production in S2 also includes using a welding robot to perform full welding or intermittent welding at the closed joint of the duct module; and spraying a nano-level photocatalytic antibacterial coating inside the duct module.

[0010] As a further improvement to the technical solution of the present invention, in step S3, after acquiring the on-site point cloud data, when the deviation between the actual on-site structure and the design model exceeds a predetermined threshold, an adaptive adjustment algorithm is initiated in the BIM model to automatically adjust and update the dimensions of the affected adjacent duct modules and generate new processing data to guide the supplementary prefabrication of local components.

[0011] As a further improvement to the technical solution of the present invention, the S4 support is a prefabricated composite vibration damping support, which includes a through-wire hanger connected to the top plate of the structure, a vibration damping spring, a steel crossbeam, and a polymer composite material hoop for wrapping the air duct.

[0012] As a further improvement to the technical solution of the present invention, the standardized connecting component in S5 is a double-sealed flange system, which includes a nominal flange frame integrally formed with the duct module, a rubber airtight strip set on the mating surface of the flange frame, and a flame-retardant sealant injected from the outside into the cavity of the flange frame after the module is mated.

[0013] As a further improvement to the technical solution of the present invention, the special hoisting equipment in S5 is a movable modular hoisting gantry, which spans the working area inside the factory. The gantry is equipped with an electric hoist that can move horizontally and vertically for multi-point balanced hoisting of the duct module.

[0014] As a further improvement to the technical solution of the present invention, during the hoisting process, wireless tilt sensors are installed at the hoisting points of the duct module to monitor the module's posture in real time; the electric hoist makes synchronous adjustments based on the data fed back by the wireless tilt sensors to achieve dynamic leveling of the duct module.

[0015] As a further improvement to the technical solution of the present invention, after the S5 duct system is assembled, an infrared thermal imager mounted on a drone is used to perform a cruise scan of the completed duct system. By detecting abnormal temperature points, airtightness defects or missing insulation layers can be located.

[0016] The beneficial effects of this invention are: 1. This invention upgrades static design into dynamic and adjustable intelligent planning through a closed loop of "BIM model → 4D construction simulation → adaptive adjustment". This not only avoids collisions in the design stage, but also actively adapts to changes on site in the construction stage, which greatly improves the first-time pass rate of construction and reduces rework caused by design changes and on-site errors. 2. By using welding robots, CNC production lines and functional coatings, the duct modules are upgraded from semi-finished products to high-quality industrial products, ensuring the dimensional accuracy, structural strength and environmental friendliness of the components, laying a solid foundation for the long-term stable, efficient and healthy operation of the system. 3. The adoption of a movable modular hoisting gantry + wireless tilt sensor + dynamic leveling technology enables precise, stable and efficient hoisting of duct modules, reducing the amount of manual assembly work at height, eliminating the risk of tipping over during hoisting, and improving both safety and hoisting efficiency; the application of prefabricated composite vibration damping supports and double sealing flange system enables rapid installation of supports and efficient sealing of duct connections without glue, improving installation speed while also enhancing system airtightness and reducing vibration and noise. 4. By using drones equipped with infrared thermal imagers for systematic scanning and inspection, a comprehensive survey of air tightness and insulation quality that would take several days in traditional methods can be completed in a few hours. This improves inspection efficiency several times over and can accurately locate minute defects that are difficult for humans to detect, thus ensuring the quality of project delivery. 5. With a unified BIM model and data standards as the core, the entire information chain from design, production, logistics to installation and testing has been connected, realizing full-process visualized management, traceable control and data-driven decision-making. The overall construction period has been shortened, the comprehensive construction cost has been reduced, and the efficiency, quality and economic benefits have been optimized simultaneously. Attached Figure Description

[0017] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] As attached Figure 1 The method for rapid assembly and construction of prefabricated modular air ducts in large spaces, as shown, includes the following steps: S1. Digital Design and Modular Planning: Based on Building Information Modeling (BIM), a comprehensive model including architecture, structure, and electromechanical pipelines is constructed. According to the column grid of the factory structure and the equipment layout, the ventilation duct system is divided into spatial partitions and modular divisions to form standard modules and non-standard modules. Multi-disciplinary collaborative design and clash detection are carried out. S2, Factory-based intelligent prefabrication production: The BIM design data processed by S1 is directly imported into the factory's computer-aided manufacturing (CAM) system to drive CNC cutting equipment, automatic seaming machines and closing machines to complete the precise cutting, forming and assembly of duct panels, and assign a unique identification code to each prefabricated duct module. S3. Precise on-site measurement and positioning: Before construction and installation, use 3D laser scanning technology to obtain actual point cloud data of the construction site, compare and verify it with the BIM design model, and accurately determine the installation position of the support and hanger and the installation benchmark of the air duct module. S4. Standardized installation of supports and hangers: Based on the BIM model of S1 and the on-site verification data of S3, the selection, layout and stress analysis of supports and hangers are carried out, and standard support and hanger components prefabricated in the factory are used for rapid assembly and installation. S5. Rapid assembly of duct modules: According to the division and numbering of modules, use special hoisting equipment to hoist the duct modules to the design position in sequence, and use standardized connectors for rapid docking and sealing to complete the assembly of the entire duct system.

[0020] Preferably, in S1, the modular division is based on the column grid of the factory structure, dividing the duct system into several standard sections of equal length in the length direction, and dividing it into non-standard sections at spatial turns, diameter changes, or connections with equipment; the length of the standard section is 6 meters, and the weight of a single piece does not exceed 200 kilograms.

[0021] Preferably, after completing the module division, S1 also includes building a 4D construction simulation model based on the construction schedule to simulate and optimize the transportation and hoisting sequence of the duct module and its connection with the construction of civil engineering and other electromechanical disciplines.

[0022] Traditional construction management relies on Gantt charts or network diagrams. These two-dimensional line-based schedules are disconnected from three-dimensional spatial design models. Managers struggle to intuitively predict whether the hoisting path of duct modules will conflict with moving large equipment, temporary scaffolding, or other specialized processes at specific times and within specific construction areas. This "spatiotemporal conflict" is a major cause of on-site work stoppages, idle time, and poor process coordination. Therefore, this invention, based on BIM three-dimensional design, deeply integrates 4D construction simulation technology for modular duct assembly. This simulation is not a simple visualization demonstration, but a dynamic simulation and optimization process based on assembly logic and resource constraints. Specifically, it integrates the hoisting sequence of duct modules, logistics and transportation plans, the movement path and occupied area of ​​large machinery (such as hoisting gantry cranes), and the interfaces with civil engineering and other electromechanical processes. The entire assembly process is pre-executed in a virtual environment. Its core purpose is to identify and eliminate spatiotemporal conflicts, optimize the division of construction flow segments, and determine the optimal module delivery and hoisting sequence, thereby ensuring the continuity and efficiency of on-site assembly operations.

[0023] The specific steps for 4D construction simulation (3D model + time dimension) for the assembly process are as follows: Step 1: Link the BIM 3D model of the duct system with the overall project construction schedule, and assign the planned installation date and time attribute to each duct module; Step 2: Define key construction resources in the simulation environment, including but not limited to: the working radius and movement path of the mobile modular hoisting gantry, the work area of ​​construction personnel, and the capacity of the temporary storage area.

[0024] Step 3: Run the simulation to dynamically check whether the following conflicts exist throughout the entire construction period: Spatial conflict: Will the duct modules being hoisted collide with existing structures or equipment, as well as other professional pipelines being constructed simultaneously? Resource conflicts: Do the demands for hoisting equipment overlap in time, or are their transfer paths between workstations obstructed? Work process conflicts: Is the connection between duct installation and civil engineering finishing, fire protection pipeline installation and other preceding or subsequent work processes reasonable? Are there any idle or competing work areas? Step 4: Based on the bottlenecks and conflicts identified in the simulation results, reverse-engineer and optimize the factory delivery sequence, transportation batches, and on-site hoisting sequence of the duct modules to form the final "Duct Module Assembly Guide" to guide factory production and on-site assembly.

[0025] Preferably, the factory-based intelligent prefabrication production in S2 also includes using welding robots to perform full welding or intermittent welding at the closed joints of the duct module; and spraying a nano-level photocatalytic antibacterial coating inside the duct module.

[0026] Preferably, in S3, after acquiring the on-site point cloud data, when the deviation between the actual on-site structure and the design model exceeds a predetermined threshold, an adaptive adjustment algorithm is activated in the BIM model to automatically adjust and update the dimensions of the affected adjacent duct modules and generate new processing data to guide the supplementary prefabrication of local components.

[0027] Preferably, the S4 support is a prefabricated composite vibration damping support, which includes a through-wire hanger connected to the top plate of the structure, a vibration damping spring, a steel crossbeam, and a polymer composite material hoop for wrapping the air duct.

[0028] Preferably, the standardized connector in S5 is a double-sealed flange system, which includes a nominal flange frame integrally formed with the duct module, a rubber airtight strip set on the mating surface of the flange frame, and a flame-retardant sealant injected from the outside into the cavity of the flange frame after the module is mated.

[0029] Preferably, the special hoisting equipment in S5 is a movable modular hoisting gantry, which spans the working area inside the factory. The gantry is equipped with electric hoists that can move horizontally and vertically for multi-point balanced hoisting of the duct modules.

[0030] Preferably, during the hoisting process, wireless tilt sensors are installed at the hoisting points of the duct module to monitor the module's attitude in real time; the electric hoist makes synchronous adjustments based on the data fed back by the wireless tilt sensors to achieve dynamic leveling of the duct module.

[0031] Preferably, after the S5 duct system is assembled, a drone equipped with an infrared thermal imager is used to perform a cruise scan of the completed duct system to locate airtightness defects or missing insulation layers by detecting abnormal temperature points.

[0032] In summary, this invention upgrades static design to dynamic and adjustable intelligent planning through a closed loop of "BIM model → 4D construction simulation → adaptive adjustment." This not only avoids collisions during the design phase but also proactively adapts to site changes during construction, significantly improving the first-pass yield rate and reducing rework caused by design changes and on-site errors. The application of welding robots, CNC production lines, and functional coatings upgrades duct modules from semi-finished products to high-quality industrial products, ensuring component dimensional accuracy, structural strength, and environmental friendliness, laying a solid foundation for the long-term stable, efficient, and healthy operation of the system. Furthermore, the use of movable modular hoisting gantry frames, wireless tilt sensors, and dynamic leveling technology further enhances the system's capabilities. This system enables precise, stable, and efficient hoisting of duct modules, reducing the amount of manual assembly work at height and eliminating the risk of tipping during hoisting, thus improving both safety and efficiency. The application of prefabricated composite vibration damping supports and double-sealed flange systems allows for rapid installation of supports and efficient sealing of duct connections without the need for glue. This increases installation speed while also improving system airtightness and reducing vibration and noise. Furthermore, the use of drones equipped with infrared thermal imagers for systematic scanning and inspection can complete airtightness and insulation quality checks that would traditionally take days within hours, increasing inspection efficiency several times over. It can also accurately locate minute defects that are difficult for humans to detect, ensuring the quality of project delivery.

[0033] 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, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for rapid assembly and construction of prefabricated modular air ducts in large spaces, characterized in that, Includes the following steps: S1. Digital Design and Modular Planning: Based on Building Information Modeling (BIM), a comprehensive model including architecture, structure, and electromechanical pipelines is constructed. According to the column grid of the factory structure and the equipment layout, the ventilation duct system is divided into spatial partitions and modular divisions to form standard modules and non-standard modules. Multi-disciplinary collaborative design and clash detection are carried out. S2, Factory-based intelligent prefabrication production: The BIM design data processed by S1 is directly imported into the factory's computer-aided manufacturing (CAM) system to drive CNC cutting equipment, automatic seaming machines and closing machines to complete the precise cutting, forming and assembly of duct panels, and assign a unique identification code to each prefabricated duct module. S3. Precise on-site measurement and positioning: Before construction and installation, use 3D laser scanning technology to obtain actual point cloud data of the construction site, compare and verify it with the BIM design model, and accurately determine the installation position of the support and hanger and the installation benchmark of the air duct module. S4. Standardized installation of supports and hangers: Based on the BIM model of S1 and the on-site verification data of S3, the selection, layout and stress analysis of supports and hangers are carried out, and standard support and hanger components prefabricated in the factory are used for rapid assembly and installation. S5. Rapid assembly of duct modules: According to the division and numbering of modules, use special hoisting equipment to hoist the duct modules to the design position in sequence, and use standardized connectors for rapid docking and sealing to complete the assembly of the entire duct system.

2. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 1, characterized in that: In S1, the modular division is based on the column grid of the factory structure. The duct system is divided into several standard sections of equal length in the length direction, and non-standard sections are divided at spatial turns, diameter changes or equipment connections. The standard section is 6 meters long and weighs no more than 200 kilograms.

3. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 2, characterized in that: After completing the module division, S1 also includes building a 4D construction simulation model based on the construction schedule plan, which is used to simulate and optimize the transportation and hoisting sequence of the duct module and its connection with the construction of civil engineering and other electromechanical disciplines.

4. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 1, characterized in that: The factory-based intelligent prefabrication production in S2 also includes using welding robots to perform full welding or intermittent welding at the closed joints of the duct module; and spraying a nano-level photocatalytic antibacterial coating inside the duct module.

5. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 1, characterized in that: In step S3, after acquiring the on-site point cloud data, when the deviation between the actual on-site structure and the design model exceeds a predetermined threshold, an adaptive adjustment algorithm is initiated in the BIM model to automatically adjust and update the dimensions of the affected adjacent duct modules and generate new processing data to guide the supplementary prefabrication of local components.

6. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 1, characterized in that: The S4 support bracket is a prefabricated composite vibration damping support bracket, which includes a through-wire hanger connected to the top plate of the structure, a vibration damping spring, a steel crossbeam, and a polymer composite material band for wrapping the air duct.

7. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 1, characterized in that: The standardized connector in S5 is a double-sealed flange system, which includes a nominal flange frame integrally formed with the duct module, a rubber airtight strip set on the mating surface of the flange frame, and a flame-retardant sealant injected from the outside into the cavity of the flange frame after the module is mated.

8. The prefabricated modular rapid assembly construction method for large-space air ducts according to claim 1, characterized in that: The special hoisting equipment in S5 is a movable modular hoisting gantry, which spans the working area inside the factory. The gantry is equipped with electric hoists that can move horizontally and vertically for multi-point balanced hoisting of the duct modules.

9. The method for rapid assembly and construction of prefabricated modular air ducts in large spaces according to claim 8, characterized in that: During the hoisting process, wireless tilt sensors are installed at the hoisting points of the duct module to monitor the module's posture in real time; the electric hoist makes synchronous adjustments based on the data fed back by the wireless tilt sensors to achieve dynamic leveling of the duct module.

10. The method for rapid assembly and construction of prefabricated modular air ducts in large spaces according to claim 1, characterized in that: After the S5 duct system is assembled, a drone equipped with an infrared thermal imager is used to perform a cruise scan of the completed duct system. By detecting abnormal temperature points, airtightness defects or missing insulation layers can be located.

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