Prefabricated pier and column formwork integrated construction method

Abstract

This invention relates to an integrated construction method for prefabricated pier formwork, belonging to the field of bridge and civil engineering construction technology. This method aims to solve the problems of low efficiency and difficulty in ensuring accuracy in the traditional pier positioning and formwork adjustment process, which relies on manual labor. The key technical points are: calibrated measuring prisms are installed on the top, sides, and formwork system of the prefabricated pier component; a measuring robot synchronously collects the three-dimensional coordinates of all prisms; the central control system calculates the measured coordinates and spatial posture of the center point of the pier top, the actual axis of the pier, and the actual coordinates of the inner surface of the formwork based on the coordinate data, and compares these with the theoretical design model to obtain various deviations; the adjustment calculation module calculates the action quantities driving the pier adjustment mechanism and the formwork adjustment mechanism, forming a closed-loop feedback control until the deviation is less than a set threshold. This method is mainly used to achieve high-precision, automated collaborative positioning and installation of piers and formwork.

Description

Technical Field

[0001] This invention belongs to the field of bridge and civil engineering construction technology, and specifically relates to an integrated construction method for prefabricated pier and column formwork. Background Technology

[0002] In the construction of prefabricated bridge piers, the installation and positioning of the precast pier components and the installation and adjustment of the formwork system are key procedures. Traditional construction methods typically involve manually measuring the center point of the pier top using surveying instruments such as total stations, and roughly judging the verticality of the pier by suspending a plumb bob on the side of the pier or using a theodolite. The formwork system is then hoisted into place, and workers manually adjust it using tools such as jacks and crowbars based on the measurement results to ensure that a casting cavity that meets the design requirements is formed between the inner surface of the formwork and the precast pier component.

[0003] This method has several problems and drawbacks in practical applications. First, the efficiency and accuracy of the measurement process are limited. Since the center point of the pier top is usually calculated indirectly by measuring multiple feature points, and the pier axis needs to be determined by measuring multiple side feature points at different heights, these measurement operations are often performed step-by-step and time-consuming. The measurement data is not synchronized in real time, making it difficult to quickly and completely acquire the actual spatial pose of the pier. Second, the adjustment process relies on manual experience and repeated trials. Workers need to manually operate multiple adjustment points based on discrete, non-real-time measurement readings to gradually bring the pier and formwork closer to the design position. This process is not only labor-intensive and time-consuming, but also suffers from poor coordination between adjustment points, easily leading to situations where one aspect is neglected while another is addressed. It is difficult to achieve overall coordinated optimization of the pier and formwork poses, resulting in unstable final alignment accuracy.

[0004] The main reason for these problems lies in the fact that traditional methods relatively separate measurement, calculation, and adjustment processes, lacking a central control system capable of simultaneously acquiring overall spatial state information of the pier and formwork, and generating unified, quantitative analysis and commands based on this information. Measurement data fails to be directly and quickly converted into precise drive commands for specific adjustment mechanisms. Attempts to increase measurement frequency or use more advanced measuring instruments have been made, but without a closed-loop system that allows for real-time linkage with the actuators, the core problems of cumbersome adjustment processes and difficulty in precision control remain unresolved. Furthermore, the challenge in establishing such a linkage system lies in how to integrate spatial coordinate data from multiple monitoring points on the pier and formwork system in real time, accurately calculate the actual spatial axis and top posture of the pier, and the actual position of the inner surface of the formwork, and then calculate the comprehensive adjustment amount that can simultaneously correct pier misalignment, tilt, and formwork misalignment. In addition, designing a mechanism system capable of simultaneously driving the adjustment of the pier and formwork, and establishing an accurate mathematical model between their motion and posture changes, is also a technical challenge.

[0005] Therefore, under current technological conditions, prefabricated pier construction generally faces problems such as cumbersome pier positioning and formwork installation and adjustment processes, low efficiency, high susceptibility to human factors in accuracy, and difficulty in achieving synchronous and precise control of the pier and formwork positions. This affects the stability of construction quality and project progress, and is a technical aspect that urgently needs improvement for modern bridge engineering with increasingly stringent precision requirements. Summary of the Invention

[0006] The purpose of this invention is to provide a construction method that enables coordinated, automatic, and high-precision positioning and adjustment of precast pier components and formwork systems, thereby overcoming the problems of traditional methods that rely on manual labor, involve cumbersome adjustments, and are difficult to control precision.

[0007] To address the aforementioned problems and achieve the objectives and other advantages of this invention, an integrated construction method for prefabricated pier formwork is provided, comprising: S1. Install a top measuring plate on the top of the precast pier component, and install multiple calibrated top measuring prisms on the top measuring plate; S2. Install multiple side measuring prisms on the outer surface of the precast pier component; S3. Hoist the formwork system to the periphery of the precast pier. The formwork system includes inner formwork panels, outer formwork panels, and a support truss connecting the inner and outer formwork panels. Install multiple calibrated formwork measuring prisms on the support truss. S4. Utilize a measuring robot to simultaneously measure the three-dimensional coordinate data of all top measuring prisms, side measuring prisms, and template measuring prisms; S5. Based on all the three-dimensional coordinate data obtained in step S4, the central control system calculates the measured coordinates and spatial posture of the center point of the top of the precast pier component, the actual spatial axis of the precast pier component, and the actual coordinates of the inner surface of the inner template. S6. The measured coordinates of the center point of the top of the pier precast component, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template obtained in step S5 are compared with the theoretical center point coordinates of the top of the pier precast component, the theoretical spatial axis of the pier precast component, and the theoretical coordinates of the inner surface of the inner template in the pre-stored three-dimensional design model, respectively, to obtain the planar position deviation of the top of the pier precast component, the axial direction deviation of the pier precast component, and the coordinate deviation of the inner surface of the inner template. S7. The adjustment amount calculation module uses a mathematical model that includes the kinematic relationship between the pier adjustment mechanism and the template adjustment mechanism. It takes the measured coordinates and spatial attitude of the center point of the top of the pier precast component obtained in step S5, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template as comprehensive inputs to calculate the first set of adjustment amounts for adjusting the position and attitude of the pier precast component and the second set of adjustment amounts for adjusting the position and attitude of the template system, so as to reduce the various deviations obtained in step S6. S8. Drive the corresponding pier adjustment mechanism and template adjustment mechanism to move according to the first set of adjustment amount and the second set of adjustment amount, and repeat steps S4 to S8 to form a closed loop feedback control until all deviations obtained in step S6 are less than their respective set thresholds. S9. After the adjustment is completed, the formwork system is sealed and tightened and the concrete is poured and cured. S10. After the curing is completed, dismantle the formwork system and adjustment mechanism.

[0008] Preferably, in the prefabricated pier formwork integrated construction method, in step S1, at least three top measuring prisms are evenly installed on the edge of the top measuring plate; in step S2, a side measuring prism is installed at three different height positions on the outer surface of the pier precast component; in step S4, the measuring robot completes its own positioning and orientation by observing at least two pre-laid fixed measuring reference points; in step S8, the set thresholds for various deviations are as follows: the planar position deviation of the top of the pier precast component is less than 2mm, the perpendicularity deviation of the actual spatial axis of the pier precast component relative to the theoretical spatial axis is less than 0.3%, and the coordinate deviation of the inner surface of the inner formwork piece is less than 3mm.

[0009] Preferably, in the prefabricated pier formwork integrated construction method, step S9, before concrete pouring, further includes a sealing verification step, which includes: Water is injected into the cavity between the precast pier and the inner formwork through the grouting hole at the bottom of the formwork system and pressurized to 0.06 MPa, and held at pressure for 8 minutes. During the pressure holding period, the measuring robot remeasures the coordinates of the template measuring prism; The central control system calculates the coordinate differences ΔX, ΔY, and ΔZ in the three-dimensional coordinate system between the remeasured coordinates and the original coordinates of each template measuring prism in the X, Y, and Z directions. The central control system calculates the spatial displacement distance of the measuring prism of each template by taking the square root of the sum of the coordinate differences ΔX, ΔY, and ΔZ. If the spatial displacement distance corresponding to all template measuring prisms is less than 0.8mm, the verification is passed and subsequent concrete pouring is permitted. If the spatial displacement distance corresponding to any template measuring prism is greater than or equal to 0.8mm, the central control system will issue an alarm signal and suspend the construction process. Subsequently, the operators inspected and eliminated any faults in the sealing, fastening, or structure of the template system; After troubleshooting, repeat the sealing verification steps starting from water injection and pressurization until the spatial displacement distance corresponding to all template measuring prisms is less than 0.8mm before proceeding with subsequent concrete pouring.

[0010] Preferably, in the prefabricated pier formwork integrated construction method, after the central control system issues an alarm signal, and before the operator checks and eliminates faults in the sealing, fastening or structure of the formwork system, the central control system also performs auxiliary analysis to generate area prompt information to guide subsequent fault checks. The auxiliary analysis includes the following steps: 4.1 The central control system lists all template measuring prisms with a displacement distance greater than or equal to 0.8 mm based on the alarm signal, and sorts them in descending order of displacement distance value; 4.2 The central control system performs the following operations on each template measuring prism in the list in the order specified in step 4.1: 4.2.1 Obtain the three-dimensional installation coordinates of the template measuring prism currently being processed; 4.2.2 Calculate the distance between the three-dimensional installation coordinates of the current template measuring prism obtained in step 4.2.1 and the three-dimensional coordinates of all template splicing seams and support truss connection nodes in the pre-stored three-dimensional design model; 4.2.3 From the distance calculation results in step 4.2.2, find the template splice seam or the support truss connection node that is closest to the three-dimensional installation coordinates of the current template measuring prism obtained in step 4.2.1, and add the found splice seam or connection node to a set of suspected fault locations; 4.3 The central control system organizes the set of suspected fault locations generated in step 4.2 and generates area prompt information; 4.4 The central control system provides area prompts and alarm signals to the operation interface. The area prompts are used to guide operators to perform targeted inspections and troubleshooting of the template system's sealing, fastening, or structural faults.

[0011] Preferably, in the prefabricated pier formwork integrated construction method, step S5 specifically includes: 5.1 Based on the three-dimensional coordinate data of all the top measuring prisms obtained in step S4, the central control system calculates the measured coordinates and spatial attitude of the center point of the top of the pier precast component, including: 5.1.1 The central control system calls the calibration data of each top measuring prism. The calibration data is the three-dimensional coordinates of the top measuring prism in the top measuring disk coordinate system. The top measuring disk coordinate system is established as follows: the physical installation contact surface between the top measuring disk and the top of the pier precast component is taken as the reference plane, the normal direction of the reference plane is taken as the Z-axis, and the point on the reference plane corresponding to the design center of the top of the pier precast component is taken as the origin of the coordinate system. 5.1.2 The central control system acquires the three-dimensional coordinates of each top measuring prism in the field measurement coordinate system obtained in step S4; 5.1.3 The central control system performs multi-point spatial registration calculation to solve for a rotation matrix and a translation vector. The goal of the multi-point spatial registration calculation is to minimize the overall error between the coordinates of all top measuring prisms after transforming from the top measuring disk coordinate system to the field measuring coordinate system according to the solved rotation matrix and translation vector, and the coordinates of the corresponding top measuring prisms obtained by direct measurement in step S4. 5.1.4 The central control system uses the translation vector obtained in step 5.1.3 as the measured coordinates of the center point of the top of the pier precast component; 5.1.5 The central control system uses the Z-axis direction corresponding to the rotation matrix obtained in step 5.1.3 as the spatial attitude of the top of the pier precast component; 5.2 Based on the three-dimensional coordinate data of all side measuring prisms obtained in step S4, the central control system calculates the actual spatial axis of the pier precast component, including: 5.2.1 The central control system combines the three-dimensional coordinates of all the side measuring prisms obtained in step S4 into a spatial point set; 5.2.2 The central control system performs least-squares spatial line fitting on the set of spatial points to obtain an optimal fitted line; 5.2.3 The central control system defines the optimal fitted straight line obtained in step 5.2.2 as the actual spatial axis of the pier precast component; 5.3 Based on the three-dimensional coordinate data of all template measuring prisms obtained in step S4, the central control system calculates the actual coordinates of the inner surface of the inner template sheet, including: 5.3.1 The central control system calls the calibration data of each template measuring prism. This calibration data is a three-dimensional vector, which represents the direction and distance from the template measuring prism to a specified corresponding point on the inner surface of the inner template sheet. 5.3.2 For each template measuring prism, the central control system adds the three-dimensional coordinates measured in step S4 to the corresponding three-dimensional vector called in step 5.3.1 to obtain a result coordinate; 5.3.3 The central control system records the coordinates obtained in step 5.3.2 as the actual coordinates of the corresponding points on the inner surface of the inner template sheet; 5.3.4 The central control system repeats steps 5.3.2 and 5.3.3 for all template measuring prisms to obtain the actual coordinate set of all specified corresponding points on the inner surface of the inner template sheet, which is the calculated actual coordinate of the inner surface of the inner template sheet.

[0012] Preferably, in the prefabricated pier formwork integrated construction method, during the process of repeatedly executing steps S4 to S8 to form a closed-loop feedback control, when the deviations obtained in step S6 are all less than their respective set thresholds for the first time, the central control system controls the measurement robot to continue to execute the measurement and calculation process of steps S4 to S6 for at least two more rounds to verify stability. If the deviations calculated in each subsequent step S6 remain less than their respective set thresholds, the central control system will ultimately determine that the adjustment is complete. If any deviation calculated in any subsequent step S6 is greater than or equal to the set threshold, the central control system continues to execute closed-loop feedback control until the condition that each deviation is simultaneously less than its respective set threshold for the first time is met again and the stability verification is completed.

[0013] Preferably, in the prefabricated pier formwork integrated construction method, step S7 specifically includes: 7.1 The adjustment calculation module calls the pre-stored forward kinematics model of the pier adjustment mechanism and the forward kinematics model of the template adjustment mechanism; The forward kinematics model of the pier adjustment mechanism is a set of mathematical equations. Based on the physical configuration of the first adjustment mechanism, which consists of at least three first-group drive cylinders, one end of each cylinder is hinged to the foundation pier, and the other end is hinged to a pre-set hinge seat at the bottom of the pier precast component. The forward kinematics model describes the quantitative relationship between the change in the length of the first-group drive cylinders and the change in the pose of the pier precast component by establishing a set of geometric constraint equations including the length of the first-group drive cylinders, the coordinates of the hinge points, and the pose parameters of the pier precast component. The pose parameters of the pier precast component include displacement in the X and Y directions in the horizontal plane, and rotation around the vertical axis. The forward kinematics model of the template adjustment mechanism is a set of mathematical equations. This model is based on the physical configuration of the second adjustment mechanism, which consists of at least three second-group drive cylinders. One end of each second-group drive cylinder is hinged to the external support structure, and the other end is hinged to a pre-set hinge seat on the support truss of the template system. The forward kinematics model describes the quantitative relationship between the change in the length of the second-group drive cylinders and the change in the pose of the inner surface of the inner template sheet by establishing a set of geometric constraint equations including the length of the second-group drive cylinders, the coordinates of the hinge points, and the pose parameters of the template system. The pose parameters of the template system include displacement in the X and Y directions in the horizontal plane, and rotation around the vertical axis. 7.2 The adjustment calculation module combines the measured coordinates of the center point of the top of the pier precast component obtained in step S5 with the spatial orientation, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template piece, and refers to the current measured state. The adjustment calculation module converts the planar position deviation of the top of the pier precast component, the axial direction deviation of the pier precast component, and the coordinate deviation of the inner surface of the inner template obtained in step S6 into various expected pose changes according to the following rules: The negative number of the planar position deviation value of the top of the precast pier is set as the expected change in planar displacement of the precast pier. The opposite of the axial deviation value of the precast pier column is set as the expected change in the rotation angle around the vertical axis of the precast pier column. Calculate the average value of the coordinate deviation vector of the inner surface of the inner template sheet, and set the negative of the average deviation vector as the expected comprehensive planar displacement change of the template system; 7.3 The adjustment quantity calculation module performs inverse kinematics calculation; The inverse kinematics solution process is as follows: Starting from the current measured state obtained in step 7.2, and taking the expected pose changes obtained in step 7.2 as the motion targets, the forward kinematics solution model of the pier adjustment mechanism and the forward kinematics solution model of the template adjustment mechanism called in step 7.1 are combined to construct a mathematical model with the length changes of all the first group of drive cylinders and the second group of drive cylinders as optimization variables, and the goal of reducing the deviations obtained in step S6 as optimization objective; this mathematical model is solved using a numerical iterative optimization algorithm to obtain a set of optimal length changes of the first group of drive cylinders and the second group of drive cylinders; 7.4 The adjustment amount calculation module assigns the optimal drive cylinder length change amount obtained in step 7.3 to different categories; all the length change amount instructions of the first group of drive cylinders constitute the first group of adjustment amounts used to adjust the position and attitude of the pier precast component; all the length change amount instructions of the second group of drive cylinders constitute the second group of adjustment amounts used to adjust the position and attitude of the template system.

[0014] Preferably, in the prefabricated pier formwork integrated construction method, after the pier adjustment mechanism and the formwork adjustment mechanism are driven to operate according to the command in step S8, an adjustment verification step is added. The adjustment verification step includes: 8.1 After the pier adjustment mechanism and the template adjustment mechanism in step S8 complete their actions, the central control system controls the measuring robot to immediately execute a new round of step S4 to obtain the three-dimensional coordinate data of all measuring prisms after adjustment. 8.2 Based on the coordinate data obtained in step 8.1, the central control system executes a new round of steps S5 and S6 to calculate the planar position deviation of the top of the precast pier after adjustment, the axial direction deviation of the precast pier after adjustment, and the coordinate deviation of the inner surface of the inner template after adjustment. 8.3 The central control system calculates three actual reductions: 8.3.1 The actual reduction in the planar position deviation of the top of the precast pier is equal to the planar position deviation value before adjustment obtained in step S6 minus the planar position deviation value of the top of the precast pier obtained in step 8.2. 8.3.2 The actual reduction in the axial direction deviation of the pier precast component is equal to the axial direction deviation value before adjustment obtained in step S6 minus the axial direction deviation value of the pier precast component after adjustment obtained in step 8.2. 8.3.3 The actual reduction in coordinate deviation of the inner surface of the inner template sheet is equal to the coordinate deviation value before adjustment obtained in step S6 minus the coordinate deviation value of the inner surface of the inner template sheet after adjustment obtained in step 8.2. 8.4 The central control system determines whether the three actual reductions calculated in step 8.3 are all greater than zero; 8.5 If step 8.4 determines that all actual reductions are greater than zero, the central control system determines that the adjustment has a positive effect and continues to execute the subsequent processes in the closed loop; 8.6 If step 8.4 determines that any actual reduction is less than or equal to zero, the central control system determines that the adjustment has not produced the expected effect. The central control system then uses the planar position deviation of the top of the precast pier, the axial direction deviation of the precast pier, and the coordinate deviation of the inner surface of the inner template obtained in step 8.2 as new inputs, jumps to step S7, calculates a first set of supplementary adjustment amounts and a second set of supplementary adjustment amounts for supplementary adjustment, and executes step S8 and the adjustment verification step again.

[0015] The present invention has at least the following beneficial effects: This invention integrates a measurement robot, multiple calibrated measurement prisms, a central control system, and a specialized pier and formwork adjustment mechanism to construct a complete automated closed-loop construction process. It achieves integrated, synchronized, and high-precision measurement and adjustment of the spatial orientation of pier precast components and formwork systems, fundamentally overcoming the core drawbacks of traditional manual methods, such as fragmented measurement, calculation, and adjustment processes, reliance on experience, low efficiency, and difficulty in guaranteeing accuracy.

[0016] This invention ensures the comprehensiveness, representativeness, and consistency of coordinate references of the measurement data by specifying that at least three prisms are evenly distributed on the top measuring plate, side prisms are distributed at three different heights on the precast pier, and fixed reference points are used for positioning the measuring robot. At the same time, it clearly sets precise thresholds of less than 2mm for planar position deviation, less than 0.3% for verticality deviation, and less than 3mm for coordinate deviation of the inner surface of the template, providing clear and quantifiable accuracy targets for automated closed-loop control, thereby ensuring high reliability and predictability of results throughout the measurement and adjustment process.

[0017] This invention innovatively introduces a sealing verification step performed before concrete pouring. This involves injecting clean water into the formwork cavity and pressurizing it to 0.06 MPa for 8 minutes. A measuring robot is then used to monitor the micro-displacement of the formwork's measuring prism. An objective standard for a successful seal is that the spatial displacement distance at all measuring points is less than 0.8 mm. This quantitative inspection method can extremely sensitively detect sealing hazards that are difficult to detect with the naked eye, effectively preventing pouring under conditions of potential leakage and avoiding quality defects and rework caused by grout leakage at the source.

[0018] This invention also provides intelligent fault location assistance when the sealing verification fails. The central control system can automatically analyze and suggest the nearest template splice or support truss connection node as the suspected fault location based on the coordinates of the template measuring prism that exceeds the displacement limit. This narrows down the fault investigation from a wide range to a specific area, greatly improving the efficiency of operators in checking and troubleshooting, reducing construction interruption time, and enhancing the intelligence level of the process.

[0019] This invention employs precise multi-point spatial registration calculations to determine the coordinates and orientation of the center point at the top of the precast pier component. It then uses the least squares method to fit the actual spatial axis of the pier and utilizes calibration vectors to calculate the actual coordinates of the inner surface of the inner template. This series of rigorous calculation methods ensures high accuracy and reliability in the conversion from raw measurement data to key engineering parameters, laying a solid data foundation for subsequent deviation comparisons and adjustment command generation.

[0020] This invention adds a stability verification step to the closed-loop adjustment process. Specifically, after all deviations simultaneously meet the standards for the first time, the system continues to undergo at least two more rounds of retesting under static conditions. Only when multiple consecutive verifications consistently meet the standards is the adjustment deemed complete. This mechanism effectively distinguishes between accidental compliance and stable compliance, ensuring the durability and reliability of the adjustment results and further enhancing the guarantee level of the final construction quality.

[0021] This invention, by calling a pre-stored forward kinematics model of the pier and template adjustment mechanism and performing inverse kinematics calculations, can intelligently transform the spatial geometric deviation to be eliminated into the optimal length change of each drive cylinder. This process achieves automated decision-making from "measuring the deviation" to "generating precise coordinated adjustment commands," avoiding manual trial and error and significantly improving the coordination of adjustment actions and overall adjustment efficiency.

[0022] This invention adds an adjustment verification step immediately after each adjustment mechanism action. By comparing the actual reduction in various deviations before and after the adjustment, the effectiveness of the action is determined. If the expected effect is not achieved, a supplementary adjustment cycle is immediately initiated. This mechanism ensures that every adjustment action is effective, preventing the system from spinning in the wrong direction due to execution errors, and greatly enhancing the convergence robustness and process reliability of the closed-loop control system.

[0023] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0024] Figure 1 This is a flowchart of the integrated construction process for prefabricated pier and column formwork. Detailed Implementation

[0025] The present invention will now be described in further detail so that those skilled in the art can implement it based on the description.

[0026] like Figure 1 As shown, the present invention provides an integrated construction method for prefabricated pier column formwork, comprising: S1. A top measuring plate is installed on top of the precast pier component, and multiple calibrated top measuring prisms are installed on the top measuring plate. The calibration data consists of the precise three-dimensional coordinates of each measuring prism in its own coordinate system within the measuring plate or support. This data is obtained through high-precision offline measurement: in a stable environment (such as a factory workshop or a vibration-free on-site calibration area), a laser tracker or high-precision total station is used to measure the measuring plate or support with the prisms installed. A coordinate system fixed to the measuring plate / support is established using this equipment, and the coordinate value of the reflection center of each prism in this coordinate system is accurately determined. This set of coordinate values ​​is the calibration data, which is pre-entered as known parameters and stored in the central control system.

[0027] S2. Install multiple side measuring prisms on the outer surface of the precast pier component; S3. Hoist the formwork system to the periphery of the precast pier. The formwork system includes inner formwork panels, outer formwork panels, and a support truss connecting the inner and outer formwork panels. Install multiple calibrated formwork measuring prisms on the support truss. S4. Utilize a measuring robot to simultaneously measure the three-dimensional coordinate data of all top measuring prisms, side measuring prisms, and template measuring prisms; S5. Based on all the three-dimensional coordinate data obtained in step S4, the central control system calculates the measured coordinates and spatial posture of the center point of the top of the precast pier component, the actual spatial axis of the precast pier component, and the actual coordinates of the inner surface of the inner template. S6. The measured coordinates of the center point of the top of the pier precast component, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template obtained in step S5 are compared with the theoretical center point coordinates of the top of the pier precast component, the theoretical spatial axis of the pier precast component, and the theoretical coordinates of the inner surface of the inner template in the pre-stored three-dimensional design model, respectively, to obtain the planar position deviation of the top of the pier precast component, the axial direction deviation of the pier precast component, and the coordinate deviation of the inner surface of the inner template. S7. The adjustment amount calculation module uses a mathematical model that includes the kinematic relationship between the pier adjustment mechanism and the template adjustment mechanism. It takes the measured coordinates and spatial attitude of the center point of the top of the pier precast component obtained in step S5, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template as comprehensive inputs to calculate the first set of adjustment amounts for adjusting the position and attitude of the pier precast component and the second set of adjustment amounts for adjusting the position and attitude of the template system, so as to reduce the various deviations obtained in step S6. S8. Drive the corresponding pier adjustment mechanism and template adjustment mechanism to move according to the first set of adjustment amount and the second set of adjustment amount, and repeat steps S4 to S8 to form a closed loop feedback control until all deviations obtained in step S6 are less than their respective set thresholds. S9. After the adjustment is completed, the formwork system is sealed and tightened and the concrete is poured and cured. S10. After the curing is completed, dismantle the formwork system and adjustment mechanism.

[0028] In the field of bridge pier construction, the closest existing technology typically employs a segmented manual measurement and adjustment method. Specifically, construction workers first use a total station to measure the top of the hoisted precast pier component, estimating its center position by measuring multiple points. Then, a plumb bob or another instrument is used to measure several points on the side of the precast pier component to manually determine its verticality, i.e., the axial direction. After the formwork system is hoisted, workers, based on the aforementioned discrete, non-real-time synchronous measurement readings, use jacks and crowbars, relying on experience, to repeatedly adjust the position of the precast pier component and the formwork system, striving to align the precast pier component with the design axis and ensure that the distance between the inner surface of the inner formwork panel and the outer surface of the precast pier component meets design requirements. The core problem with this method is that the measurement, calculation, and adjustment stages are fragmented. The measurement data cannot be synchronously integrated in real time, resulting in the inability to obtain a complete correlation between the overall spatial orientation of the precast pier component and the spatial position of the formwork system in a single measurement. The adjustment process relies entirely on manual decision-making and operation, resulting in poor coordination, low efficiency, and the final accuracy is greatly affected by the worker's skill level, making it difficult to consistently meet high standards.

[0029] Compared with the existing technologies mentioned above, this solution achieves fundamental improvements through a series of integrated steps. First, by pre-installing multiple calibrated measuring prisms on the top, sides, and formwork system of the pier precast component, and using a measuring robot for synchronous measurement, the aim is to acquire a complete set of three-dimensional coordinate data reflecting the overall posture of the pier precast component and the overall position of the formwork system in a single, real-time manner, solving the problems of asynchronous and incomplete data acquisition. Based on this synchronous data, the central control system can calculate the precise center point coordinates and spatial posture of the top of the pier precast component, fit the actual spatial axis of the pier precast component, and derive the actual coordinates of the inner surface of the inner formwork piece. The purpose of this calculation process is to quickly and accurately digitize the physical state of the entity on site, providing a benchmark for subsequent precise comparisons. Next, the system automatically compares these calculation results with the theoretical values ​​in the pre-stored three-dimensional design model, directly obtaining the specific deviations of the top of the pier precast component in planar position, the pier precast component in axial direction, and the inner surface of the inner formwork piece in coordinates. The purpose of this step is to quantitatively identify all gaps between the current installation state and the ideal design state.

[0030] Then, the adjustment calculation module, based on a built-in mathematical model that includes the kinematic relationship between the pier adjustment mechanism and the template adjustment mechanism, calculates the first set of adjustment amounts driving the pier adjustment mechanism and the second set of adjustment amounts driving the template adjustment mechanism, using the current measured state as input. This mathematical model describes the quantitative relationship between changes in the length of the adjustment mechanism, such as the driving cylinder, and the resulting changes in the pose of the pier precast component or template system. The purpose of this step is to intelligently convert the spatial geometric deviations that need to be eliminated into action commands that can be directly understood and executed by the mechanical actuators, achieving automatic decision-making from "measuring the problem" to "commanding the solution." After driving the corresponding mechanism according to the calculated adjustment amounts, the system does not end but repeats the entire process from measurement to adjustment, forming a closed-loop feedback control. This closed-loop feedback control refers to the system continuously monitoring the output result, i.e., the actual pose, and comparing it with the target value, i.e., the design pose. Based on new deviations, it continuously issues adjustment commands until all deviations are less than the set threshold. The purpose of this step is to ensure that the adjustment process converges to a stable and highly accurate final state, avoiding the repetitions and oscillations that may occur during manual adjustment. Finally, only after the system confirms that the adjustment meets the standards can the formwork system be sealed and tightened and the concrete be poured.

[0031] Before implementing this method, the prisms on the top measuring plate and the template system need to be calibrated in a factory or high-precision measurement laboratory to obtain accurate calibration data.

[0032] 1. Calibration of the Top Measuring Prisms: Place the top measuring disk horizontally on the calibration platform. Use a laser tracker or a three-dimensional coordinate measuring device of equivalent precision to measure the coordinates of the reflection centers of each top measuring prism. Simultaneously, accurately determine the theoretical installation contact plane between the measuring disk and the precast pier component, and identify a point on this plane corresponding to the design center of the top of the pier. Using this plane as the reference plane (with the normal as the Z-axis) and the identified center point as the origin, establish the "top measuring disk coordinate system". Record the three-dimensional coordinates of each prism in this coordinate system; this is the calibration data for each top measuring prism.

[0033] 2. Installation Position Calibration of Side Measurement Prisms: During the prefabrication of the pier precast components in the factory, each side measurement prism is installed at the theoretical coordinate positions specified on its outer surface according to the pre-stored 3D design model. After installation, measuring equipment (such as a total station) can be used to verify the actual installation position of the prisms to ensure their installation accuracy. For the side measurement prisms, their calibration data are their corresponding theoretical installation coordinates in the pre-stored 3D design model.

[0034] 3. Calibration of the template measuring prism: Place the template system (or representative segment) with the prisms installed on a stable support. Using a laser tracker, simultaneously measure the coordinates of the reflection centers of each template measuring prism, as well as the coordinates of a pre-defined point on the inner surface of the inner template corresponding to that prism. Calculate the three-dimensional vector (ΔX, ΔY, ΔZ) from the prism center to the specified point on the inner surface. This vector is the calibration data for the template measuring prism.

[0035] The aforementioned calibration data was entered into the database of the central control system before construction.

[0036] Before performing the deviation comparison in step S6, the central control system needs to pre-store a complete three-dimensional design model. The pre-stored three-dimensional design model defines the following theoretical data in the global design coordinate system: The theoretical center point coordinates of the top of the precast pier component; The theoretical spatial axis equation of the precast pier column; The theoretical coordinates of the designated corresponding points associated with each template measuring prism on the inner surface of the inner template sheet; The theoretical installation coordinates of all top measuring prisms, side measuring prisms, and template measuring prisms on their respective mounting components (such as measuring discs, pier surfaces, and support trusses).

[0037] Before construction, by measuring at least two fixed measurement reference points stably set up on site (whose coordinates are known in the global design coordinate system), the central control system can calculate the transformation relationship (i.e., rotation matrix and translation vector) between the global design coordinate system and the on-site measurement coordinate system. Using this transformation relationship, the system can uniformly transform all theoretical coordinates in the 3D design model to the on-site measurement coordinate system. Therefore, the comparison in step S6 is performed directly between the measured coordinates and the transformed theoretical coordinates in the same coordinate system (the on-site measurement coordinate system).

[0038] Before implementing this method, a three-dimensional design model of the pier precast component is pre-stored in the central control system. This model contains two core data parts: first, the theoretical installation coordinates of all measuring prisms (including the top and sides) in their own coordinate system of their respective measuring disks or supports; second, the design morphology of the inner surface of the pier precast component (i.e. the surface in contact with the template), which is described by three-dimensional point cloud data or parametric surface equations defined in the global design coordinate system.

[0039] During field measurements, the total station establishes an independent field measurement coordinate system. To compare the measurement data with the design model, coordinate system transformation is required. The specific method is as follows: The system uses the total station to measure at least three reference prisms whose global design coordinates are known in the 3D design model (usually three non-collinear prisms on the top measuring circle are selected). Based on the two sets of coordinate values ​​for these corresponding points (field measurement coordinates and global design coordinates), a spatial coordinate transformation matrix is ​​calculated using spatial analytical geometry principles (such as the least squares method). This matrix includes translation and rotation parameters. Afterward, the field coordinates of any new measured point can be transformed to the global design coordinate system using this matrix, thus allowing for a comparison with the theoretical values ​​in the model using the same reference.

[0040] The threshold values ​​are pre-defined maximum allowable deviations during construction and serve as standards for measuring whether construction accuracy is up to standard. In this scheme, these threshold values ​​specifically include: the planar position deviation of the top of the precast pier component should be less than 2mm; the perpendicularity deviation of the actual spatial axis of the precast pier component relative to the theoretical spatial axis should be less than 0.3%; and the coordinate deviation of the inner surface of the inner formwork sheet should be less than 3mm.

[0041] A surveying robot is an intelligent total station that can automatically search, aim at, and measure the three-dimensional coordinates of a target point.

[0042] A calibrated measuring prism refers to a prism whose spatial relationship between its geometric center and a specific reference point on its mounting bracket has been precisely measured and recorded. Thus, the coordinates of the required reference point can be calculated by measuring the center of the prism.

[0043] Example 1 This method was used for the installation of precast pier components in a bridge project. During construction, four prisms were installed on the measuring plate on the top of the precast pier component, one prism was installed at three different heights on the outer surface of the precast pier component, and six prisms were installed on the support truss of the formwork system. A measuring robot simultaneously measured all 13 prisms, taking approximately 3 minutes. The central control system completed all calculations and deviation analysis within 30 seconds and calculated the adjustment amount. The pier adjustment mechanism and the formwork adjustment mechanism acted synchronously according to instructions. The entire adjustment process underwent two closed-loop iterations, taking approximately 25 minutes in total. After adjustment, the system stability verification passed. The measured deviation of the top plane position of the precast pier component was 1.2 mm, better than the set threshold of 2 mm; the verticality deviation of the precast pier component was 0.18%, better than the set threshold of 0.3%; the maximum coordinate deviation of key points on the inner surface of the inner formwork was 1.8 mm, better than the set threshold of 3 mm. The subsequent sealing verification also passed on the first attempt. After final casting, the position of the precast pier component fully met the design requirements.

[0044] Comparative Example 1 Adjacent piers in the same project were constructed using traditional manual methods. Surveyors used a total station to measure the top, sides, and relevant points of the precast pier components and formwork three times, with each measurement, recording, and calculation taking approximately 10 minutes, totaling about 30 minutes. Based on the measurement report, workers manually operated multiple jacks to make adjustments using their experience. The adjustment process required repeated pauses for local re-measurement, taking approximately 120 minutes in total. The re-measurement results after adjustment showed that the top plane position deviation of the precast pier component was 4.5 mm, exceeding the 2 mm threshold; the verticality deviation of the precast pier component was 0.5%, exceeding the 0.3% threshold; and the maximum local position deviation of the inner surface of the inner formwork sheet was 5 mm, exceeding the 3 mm threshold. After multiple fine-tunings, some indicators were barely approached but did not fully meet the high standards. Subsequent checks on the sealing of the formwork system relied on visual and manual inspection.

[0045] As can be seen from the comparison, the method used in Example 1 is significantly superior to Comparative Example 1 in terms of adjustment efficiency, reducing the core adjustment time from approximately 120 minutes to 25 minutes. More importantly, Example 1 achieves automated and closed-loop precise control, with all accuracy indicators consistently reaching and exceeding the preset high-standard thresholds, resulting in good consistency in construction results. In contrast, Comparative Example 1 relies on manual labor, which is cumbersome, time-consuming, and its final accuracy is greatly affected by human factors, failing to consistently guarantee that all indicators simultaneously meet the high-standard threshold requirements. This demonstrates the significant progress of this method in improving construction accuracy, efficiency, and reliability.

[0046] In another embodiment, in the prefabricated pier formwork integrated construction method, in step S1, at least three top measuring prisms are evenly installed on the edge of the top measuring plate; in step S2, a side measuring prism is installed at three different height positions on the outer surface of the pier precast component; in step S4, the measuring robot completes its own positioning and orientation by observing at least two pre-laid fixed measuring reference points; in step S8, the specific threshold values ​​for various deviations are: the planar position deviation of the top of the pier precast component is less than 2mm, the perpendicularity deviation of the actual spatial axis of the pier precast component relative to the theoretical spatial axis is less than 0.3%, and the coordinate deviation of the inner surface of the inner formwork piece is less than 3mm.

[0047] In the construction of prefabricated piers, the integrated construction method enables coordinated adjustment of the prefabricated pier components and the formwork system. However, the effectiveness and final accuracy of this method depend on the optimization of a series of key implementation details. If these details are not handled properly, such as an unreasonable number and location of measurement points, or unclear accuracy control standards, it may still lead to problems such as insufficient representativeness of measurement data, unstable calculation models, and ambiguous adjustment targets, thereby affecting the efficiency of closed-loop control and the final installation quality.

[0048] To address the aforementioned issues, further optimization measures enhance the reliability and accuracy of the overall method by refining the parameters and standards of key steps. First, when installing the top measuring plate on the top of the pier precast component, at least three calibrated top measuring prisms are required to be evenly installed along its edge. The purpose of this step is to more stably determine the spatial position and orientation of the plane containing the top measuring plate using multiple evenly distributed points. This provides a redundant and interference-resistant measurement data foundation for the subsequent accurate calculation of the measured coordinates and spatial orientation of the center point of the pier precast component's top, avoiding calculation errors caused by anomalies in single or a few point measurements. Second, when installing multiple side measuring prisms on the outer surface of the pier precast component, it is explicitly required that one prism be installed at each of three different heights. The purpose of this step is to obtain the positional information of the pier precast component on different vertical sections, making the fitted actual spatial axis of the pier precast component more accurately reflect its overall trend and reducing misjudgments of the axis due to local surface unevenness or installation errors.

[0049] In the measurement phase, the measurement robot is required to complete its localization and orientation by observing at least two pre-established fixed measurement reference points. The purpose of this step is to establish a stable and unified field measurement coordinate system for the entire measurement system. Fixed measurement reference points are points on the ground whose positions are known and unchanging. By connecting the measurement robot to these reference points, the robot can eliminate the positional and directional errors inherent in the reference points themselves, ensuring that all collected three-dimensional coordinate data from the top, side, and template measurement prisms are based on an accurate and reliable reference. This is the prerequisite for all subsequent calculations and comparisons.

[0050] Crucially, this scheme explicitly sets acceptable thresholds for various deviations, providing clear and quantifiable termination targets for closed-loop feedback control. Specific thresholds include: the planar position deviation of the top of the precast pier component should be less than 2mm; the perpendicularity deviation of the actual spatial axis of the precast pier component relative to the theoretical spatial axis should be less than 0.3%; and the coordinate deviation of the inner surface of the inner formwork sheet should be less than 3mm. These thresholds represent the limits of permissible construction deviations and are direct standards for the control system to determine whether adjustments are adequate. For example, a 2mm planar position deviation threshold means that the distance between the center point of the top of the precast pier component and the design center point in the horizontal plane must be controlled within 2mm. The purpose of setting these thresholds is to transform the abstract concept of "adequate adjustment" into concrete and rigorously measurable numerical indicators, enabling the central control system to make precise judgments on whether to continue adjustments, thereby ensuring that the final construction results meet the preset high-precision quality standards.

[0051] Through the implementation of these specific steps and standards, the optimized scheme significantly improves the robustness of the basic methods and the predictability of the results. Multiple evenly distributed top measuring prisms and side measuring prisms at different heights ensure comprehensiveness and robustness of state perception; the use of fixed reference points for the measurement robot's self-localization guarantees the uniformity and accuracy of the measurement data benchmark from the source; and clear and strict threshold settings provide an indisputable accuracy benchmark for automated closed-loop control, enabling the entire adjustment process to be targeted and converge efficiently, ultimately ensuring that the installation position, verticality, and formwork positioning accuracy of the pier precast components consistently meet high-level engineering standards.

[0052] In another embodiment, in the prefabricated pier formwork integrated construction method, step S9, before concrete pouring, further includes a sealing verification step, which includes: Water is injected into the cavity between the precast pier and the inner formwork plate through the grouting holes at the bottom of the formwork system, and pressurized to 0.06 MPa, maintaining the pressure for 8 minutes. After the inner formwork plate is closed and locked, the top opening of the formwork system must be temporarily sealed, for example, by installing a cover plate with a sealing ring. Then, water is slowly injected into the annular cavity between the precast pier and the inner formwork plate through the water injection port pre-installed at the bottom of the formwork until water flows steadily out of the vent / overflow port pre-installed at the top of the formwork. The valve is then closed, and pressure is maintained. The sealing is judged by observing whether the pressure gauge reading connected to the water injection circuit drops within a specified time.

[0053] During the pressure holding period, the measuring robot remeasures the coordinates of the template measuring prism; The central control system calculates the coordinate differences ΔX, ΔY, and ΔZ in the three-dimensional coordinate system between the remeasured coordinates and the original coordinates of each template measuring prism in the X, Y, and Z directions. The central control system calculates the spatial displacement distance of the measuring prism of each template by taking the square root of the sum of the coordinate differences ΔX, ΔY, and ΔZ. If the spatial displacement distance corresponding to all template measuring prisms is less than 0.8mm, the verification is passed and subsequent concrete pouring is permitted. If the spatial displacement distance corresponding to any template measuring prism is greater than or equal to 0.8mm, the central control system will issue an alarm signal and suspend the construction process. Subsequently, the operators inspected and eliminated any faults in the sealing, fastening, or structure of the template system; After troubleshooting, repeat the sealing verification steps starting from water injection and pressurization until the spatial displacement distance corresponding to all template measuring prisms is less than 0.8mm before proceeding with subsequent concrete pouring.

[0054] Traditionally, before pouring concrete for prefabricated pier columns, the sealing performance is assessed by operators visually inspecting the formwork joints and manually shaking or tapping the formwork. This method has significant problems. First, it relies entirely on personal experience, is highly subjective, and cannot quantify the sealing effect. Second, human senses are unable to detect tiny gaps or pre-deformations, and these minor defects may expand under the fluid pressure of poured concrete, leading to grout leakage. Grout leakage can cause quality defects such as loose concrete structure and honeycomb-like surface defects, and in severe cases, even affect the load-bearing capacity of the prefabricated pier column. Furthermore, if grout leakage is discovered during pouring and then sealed, construction is interrupted, difficult to handle, and may have already resulted in material waste and localized quality problems. Therefore, there is an urgent need for an objective, quantitative, and proactive pre-pouring method for sealing performance inspection.

[0055] To address the aforementioned issues, this solution incorporates an automated sealing verification step after adjustments are made and before concrete pouring. This step assumes the top of the formwork system is sealed with a temporary sealing cover, creating a pressure-bearing, enclosed space within the annular cavity between the precast pier and the inner formwork panels. The sealing verification process involves injecting clean water into the cavity between the precast pier and the inner formwork panels through pre-drilled grouting holes at the bottom of the formwork system. A water pump is then used to pressurize the water to 0.06 MPa, which is maintained for 8 minutes. The 0.06 MPa pressure is chosen to simulate a portion of the lateral pressure exerted on the formwork during the initial concrete pouring, effectively verifying for leaks at the seals without placing excessive load on the adjusted formwork structure. Maintaining pressure for 8 minutes allows sufficient time to observe whether the pressure can be stably maintained and to fully expose any potential weaknesses.

[0056] During the pressure holding period, the system-controlled measuring robot performs a high-precision remeasurement of the coordinates of all template measuring prisms. The central control system compares the remeasured coordinates of each template measuring prism with the initial coordinates before pressurization, accurately calculating the coordinate changes of each point in the X, Y, and Z directions in three-dimensional space. Then, it calculates the spatial displacement distance of each point using mathematical methods. This distance reflects the overall deformation of the template at the corresponding location under pressure. The system has a preset judgment standard: the calculated spatial displacement distance of all template measuring prisms must be less than 0.8 mm. This 0.8 mm threshold is a strict empirical standard, meaning that under test pressure, the overall deformation of a well-sealed and tightly connected template system should be controlled within a very small range.

[0057] If the displacement of all measuring points is less than 0.8 mm, the system determines that the sealing verification has passed and automatically permits the concrete pouring process. This proves that the formwork system is reliably sealed under simulated pressure, structurally stable, and capable of withstanding the lateral pressure of the initial concrete. If the displacement of any one or more measuring points reaches or exceeds 0.8 mm, the central control system will immediately issue an audible and visual alarm signal and automatically lock the subsequent pouring process. This indicates that the system has detected abnormal deformation, which may be caused by factors such as failure of the formwork joint sealing strip, loose fastening bolts, or loose local support components. At this time, the operator must perform targeted inspection and troubleshooting of the formwork system based on the alarm information, such as retightening bolts, replacing sealing strips, or reinforcing local supports. After troubleshooting, the complete sealing verification procedure must be repeated starting from water injection and pressurization until the displacement of all measuring points meets the requirement of less than 0.8 mm before construction can continue.

[0058] The effectiveness of this sealing verification step is highly evident. It transforms the hidden and elusive sealing quality into measurable and comparable numerical indicators, achieving objectivity and quantification of the inspection process. By measuring micro-deformation under simulated pressure, it can extremely sensitively detect sealing hazards that are imperceptible to the naked eye. A strict 0.8mm displacement threshold and automatic alarm mechanism constitute a reliable quality and safety gate before pouring, effectively preventing pouring under conditions of potential sealing hazards. This not only fundamentally avoids concrete quality defects and rework losses caused by grout leakage, but also ensures the consistency and reliability of construction quality through standardized procedures, enhancing the completeness and maturity of the entire integrated construction method for precast pier components.

[0059] In another embodiment, in the prefabricated pier formwork integrated construction method, after the central control system issues an alarm signal, and before the operator checks and eliminates faults in the sealing, fastening or structure of the formwork system, the central control system also performs auxiliary analysis to generate area prompt information to guide subsequent fault checks. The auxiliary analysis includes the following steps: 4.1 The central control system lists all template measuring prisms with a displacement distance greater than or equal to 0.8 mm based on the alarm signal, and sorts them in descending order of displacement distance value; 4.2 The central control system performs the following operations on each template measuring prism in the list in the order specified in step 4.1: 4.2.1 Obtain the three-dimensional installation coordinates of the template measuring prism currently being processed; 4.2.2 Calculate the distance between the three-dimensional installation coordinates of the current template measuring prism obtained in step 4.2.1 and the three-dimensional coordinates of all template splicing seams and support truss connection nodes in the pre-stored three-dimensional design model; 4.2.3 From the distance calculation results in step 4.2.2, find the template splice seam or the support truss connection node that is closest to the three-dimensional installation coordinates of the current template measuring prism obtained in step 4.2.1, and add the found splice seam or connection node to a set of suspected fault locations; 4.3 The central control system organizes the set of suspected fault locations generated in step 4.2 and generates area prompt information; 4.4 The central control system provides area prompts and alarm signals to the operation interface. The area prompts are used to guide operators to perform targeted inspections and troubleshooting of the template system's sealing, fastening, or structural faults.

[0060] In construction processes that include sealing verification, when the system detects a spatial displacement of the formwork measuring prism exceeding 0.8mm, triggers an alarm, and halts the process, operators face a real challenge: how to quickly locate the fault. The formwork system is composed of multiple inner formwork panels connected by supporting trusses, meaning potential leaks or loosening points are distributed over a wide area. Conducting a comprehensive, non-targeted inspection is time-consuming and labor-intensive, severely impacting construction efficiency, and in complex structures, it's easy to miss the true fault.

[0061] To address the aforementioned difficulty in fault location, this solution executes an auxiliary analysis program after the central control system issues an alarm signal. This program generates area prompts to guide fault inspection. First, based on the alarm signal, it filters out all template measuring prisms with displacement distances greater than or equal to 0.8 mm and sorts them from largest to smallest displacement value. This prioritizes the location with the most significant deformation and closest likelihood of being near the actual fault source, providing priority guidance for inspection.

[0062] Next, following the above sorting, the system analyzes each template measuring prism with excessive displacement as follows: It obtains the prism's three-dimensional installation coordinates on-site. Then, it calculates these coordinates one by one with the three-dimensional coordinates of all template splices and all support truss connection nodes in the pre-stored three-dimensional design model to find the closest template splice or support truss connection node. Here, the template splice refers to the joint gap between two adjacent inner template pieces, a weak point in the seal; the support truss connection node refers to the connection point between the support truss and the inner or outer template piece, a key part for force transmission and ensuring rigidity. The purpose of this step is to associate the abstract coordinate alarm with the specific physical structure based on the engineering logic that "abnormal deformation measuring points are most likely closest to the actual fault location." Each found nearest splice or connection node is added to a set of suspected fault locations.

[0063] After analyzing all the out-of-range measurement points, the central control system organizes this set of suspected fault locations, removes duplicates, and generates clear area prompts. For example, the message might suggest, "Please focus on checking the area near the joint between the inner template panels of No. 3 and No. 4, and the connection node on the upper part of the No. 7 support truss." Finally, the system displays this area prompt along with the alarm signal on the user interface. The direct effect is to transform the ambiguous state of "system alarm, sealing fault present" into a specific action instruction of "please prioritize checking certain specific locations."

[0064] This auxiliary analysis step is remarkably effective. It significantly narrows down the scope of troubleshooting, avoiding blind manual searching. Operators can directly check the integrity of sealing strips and the tightness of pressure plates at designated joints, or inspect bolts for looseness and weld cracks at designated connection nodes, based on system prompts, thus quickly locating and eliminating faults. This not only drastically reduces construction interruption time caused by failed sealing verification and improves overall construction efficiency, but also reduces the risk of secondary impacts on the accuracy of the formwork system due to repeated disassembly and incorrect troubleshooting through precise guidance, making the entire sealing verification and fault handling process more intelligent and efficient.

[0065] In another embodiment, the integrated construction method for prefabricated pier formwork specifically includes step S5 as follows: 5.1 Based on the three-dimensional coordinate data of all the top measuring prisms obtained in step S4, the central control system calculates the measured coordinates and spatial attitude of the center point of the top of the pier precast component, including: 5.1.1 The central control system calls the calibration data of each top measuring prism. The calibration data is the three-dimensional coordinates of the top measuring prism in the top measuring disk coordinate system. The top measuring disk coordinate system is established as follows: the physical installation contact surface between the top measuring disk and the top of the pier precast component is taken as the reference plane, the normal direction of the reference plane is taken as the Z-axis, and the point on the reference plane corresponding to the design center of the top of the pier precast component is taken as the origin of the coordinate system. 5.1.2 The central control system acquires the three-dimensional coordinates of each top measuring prism in the field measurement coordinate system obtained in step S4; 5.1.3 The central control system performs multi-point spatial registration calculation to solve for a rotation matrix and a translation vector. The goal of the multi-point spatial registration calculation is to minimize the overall error between the coordinates of all top measuring prisms after transforming from the top measuring disk coordinate system to the field measuring coordinate system according to the solved rotation matrix and translation vector, and the coordinates of the corresponding top measuring prisms obtained by direct measurement in step S4. 5.1.4 The central control system uses the translation vector obtained in step 5.1.3 as the measured coordinates of the center point of the top of the precast pier component; the translation vector is the coordinate of the origin of the top measuring disk coordinate system defined in step 5.1.1 in the field measuring coordinate system. 5.1.5 The central control system uses the Z-axis direction corresponding to the rotation matrix obtained in step 5.1.3 as the spatial attitude of the top of the pier precast component; 5.2 Based on the three-dimensional coordinate data of all side measuring prisms obtained in step S4, the central control system calculates the actual spatial axis of the pier precast component, including: 5.2.1 The central control system combines the three-dimensional coordinates of all the side measuring prisms obtained in step S4 into a spatial point set; 5.2.2 The central control system performs least-squares spatial line fitting on the set of spatial points to obtain an optimal fitted line; 5.2.3 The central control system defines the optimal fitted straight line obtained in step 5.2.2 as the actual spatial axis of the pier precast component; 5.3 Based on the three-dimensional coordinate data of all template measuring prisms obtained in step S4, the central control system calculates the actual coordinates of the inner surface of the inner template sheet, including: 5.3.1 The central control system calls the calibration data of each template measuring prism. This calibration data is a three-dimensional vector, which represents the direction and distance from the template measuring prism to a specified corresponding point on the inner surface of the inner template sheet. 5.3.2 For each template measuring prism, the central control system adds the three-dimensional coordinates measured in step S4 to the corresponding three-dimensional vector called in step 5.3.1 to obtain a result coordinate; 5.3.3 The central control system records the coordinates obtained in step 5.3.2 as the actual coordinates of the corresponding points on the inner surface of the inner template sheet; 5.3.4 The central control system repeats steps 5.3.2 and 5.3.3 for all template measuring prisms to obtain the actual coordinate set of all specified corresponding points on the inner surface of the inner template sheet, which is the calculated actual coordinate of the inner surface of the inner template sheet.

[0066] A key technical challenge in implementing integrated construction methods lies in accurately and reliably converting the discrete 3D coordinate data of multiple prisms collected by the surveying robot into critical geometric parameters describing the overall spatial state of the precast pier components and formwork system. Inaccurate or inconsistent processing and calculation methods for the coordinate data will directly lead to deviations in the calculated pose, axis, and inner surface position of the precast pier components. This will undermine the basis for subsequent deviation comparisons and adjustments, ultimately affecting the final accuracy of the entire closed-loop control.

[0067] To address the challenge of high-precision conversion of measurement data into engineering parameters, this solution provides detailed and rigorous specifications for the calculation process of the central control system. For the state calculation of the top of the precast pier component, the calibration data of each top measuring prism is first required. This calibration data defines the three-dimensional coordinates of the prism in the top measuring disk coordinate system. The top measuring disk coordinate system is a predefined local coordinate system. It uses the physical installation contact surface between the measuring disk and the top of the precast pier component as the reference plane, the normal direction of this plane as the Z-axis, and the point on the plane corresponding to the design center of the top of the precast pier component as the origin. Simultaneously, the central control system acquires the measured coordinates of these prisms in the field measuring coordinate system. By performing multi-point spatial registration calculations, the system can solve for a rotation matrix and a translation vector. The goal is to minimize the overall error between the coordinates of all prisms after transformation from the top measuring disk coordinate system to the field measuring coordinate system and the measured coordinates. Finally, the solved translation vector is used as the measured coordinate of the center point of the top of the precast pier component, and the Z-axis direction corresponding to the rotation matrix is ​​defined as the spatial attitude of the top of the precast pier component. The purpose of this series of steps is to accurately determine the spatial position and orientation of the top of the precast pier component from multiple top measuring points through a strict coordinate system and spatial transformation.

[0068] For calculating the actual spatial axis of the precast pier, the system treats the three-dimensional coordinates of all side measuring prisms as a set of spatial points. By performing least-squares spatial line fitting on this set of points, an optimal fitted line can be obtained. This line is defined as the actual spatial axis of the precast pier. The purpose of this step is to use multiple measuring points distributed at different heights of the pier to find the line that best represents the overall centerline trend of the pier through mathematical optimization methods, thereby overcoming the random errors that may exist at individual measuring points and obtaining a stable and reliable axis direction.

[0069] To calculate the actual coordinates of the inner surface of the template sheet, the system also needs to access the calibration data of each template measuring prism. This calibration data is a three-dimensional vector that precisely describes the direction and distance from the installation position of the template measuring prism to a specified corresponding point on the inner surface of the template sheet. For each template measuring prism, the central control system adds its measured three-dimensional coordinates in the field measurement coordinate system to this corresponding three-dimensional vector, thereby directly obtaining the actual coordinates of that specified point on the inner surface of the template sheet. By repeating this operation for all template measuring prisms, a set of actual coordinates of a series of representative points on the inner surface of the template sheet can be obtained. The purpose of this step is to indirectly and accurately map the measurement target from the easily observable outer template prism to the key points on the inner surface of the template, which are not easily measured directly, using known and precise geometric relationships.

[0070] Through the standardized calculation process described above, this solution ensures the scientific rigor and repeatability of the transformation from raw measurement data to key engineering parameters. Using calibration data and coordinate transformation eliminates systematic errors caused by sensor installation positions; employing least-squares fitting improves the resistance to interference in estimating overall geometric features such as the pier axis; and vector offset calculation enables accurate inversion of the coordinates of concealed structural surfaces. This results in highly reliable and accurate calculations of the pier precast component's top center point coordinates, spatial orientation, actual spatial axis, and inner formwork surface coordinates. This provides a solid and reliable data foundation for subsequent automatic comparison and intelligent adjustment, and is the core guarantee for achieving high-precision goals in the entire integrated construction method.

[0071] In another embodiment, in the prefabricated pier formwork integrated construction method, during the process of repeatedly executing steps S4 to S8 to form a closed-loop feedback control, when the deviations obtained in step S6 are all less than their respective set thresholds for the first time, the central control system controls the measurement robot to continue to execute the measurement and calculation process of steps S4 to S6 for at least two more rounds (during which the adjustment of steps S7 and S8 is not performed) to verify stability. If the deviations calculated in each subsequent step S6 remain less than their respective set thresholds, the central control system will ultimately determine that the adjustment is complete. If any deviation calculated in any subsequent step S6 is greater than or equal to the set threshold, the central control system continues to execute closed-loop feedback control until the condition that each deviation is simultaneously less than its respective set threshold for the first time is met again and the stability verification is completed.

[0072] In the closed-loop adjustment process of integrated prefabricated pier and formwork construction, a potential risk may arise when, after one or more adjustments and iterations, the planar position deviation of the top of the prefabricated pier component, the axial direction deviation of the prefabricated pier component, and the coordinate deviation of the inner surface of the inner formwork sheet all simultaneously fall below their respective set thresholds for the first time. This "compliant" state may be an accidental, momentary equilibrium, caused by brief fluctuations in measurement noise or instantaneous rebound after the adjustment mechanism's action. If the system immediately determines that the adjustment is complete and proceeds to the subsequent pouring process, the state of the pier or formwork may experience slight drift within a short period, causing the actual deviation to exceed the allowable range again, affecting the final construction quality.

[0073] To address the potential instability of the adjustment results, this solution incorporates a stability verification step into the closed-loop feedback control process. When all the deviations calculated in the steps simultaneously fall below their respective set thresholds for the first time, the system does not immediately terminate the adjustment. Instead, it controls the measurement robot to continue executing at least two more complete rounds of measurement and calculation. In other words, based on the initial achievement of the target, the system re-collects the coordinates of all measuring prisms and recalculates the deviation values. The purpose of this step is to observe whether the pose of the pier precast component and formwork system can remain stable under static conditions without further active adjustments, verifying the repeatability and reliability of the initial target achievement.

[0074] The central control system will continuously monitor the deviation values ​​obtained in each subsequent round of calculation. If all deviations remain below their respective set thresholds in each subsequent round of calculation, the system will ultimately determine that the adjustment is complete and confirm that a stable and reliable high-precision state has been achieved. Conversely, if any deviation exceeds or equals its set threshold in any subsequent round of verification, the system will determine that the stability verification has failed. In this case, the central control system will not issue a completion command, but will automatically continue to execute the original closed-loop feedback control process, that is, recalculate the adjustment amount based on the new deviation data and drive the mechanism to move, until all deviations again reach the state where they are simultaneously below the set threshold for the first time, and then restart a new round of at least two rounds of stability verification.

[0075] The effect of this stability verification step is that it adds a "durability" check to the high-precision adjustment results. It effectively distinguishes between "accidental achievement" and "stable achievement," preventing misjudgments caused by transient interference or system transient processes. By adding at least two rounds of continuous static monitoring, the system's ability to judge the reliability of the final adjustment results is significantly improved. This ensures that the entire construction method not only aims to quickly adjust deviations to within the threshold, but also guarantees that the adjusted results can continuously and stably maintain this high-precision state, providing a more solid and reliable foundation for subsequent concrete pouring and further enhancing the quality assurance level of the entire automated construction process.

[0076] In another embodiment, in the integrated construction method for prefabricated pier formwork, step S7 specifically includes: 7.1 The adjustment calculation module calls the pre-stored forward kinematics model of the pier adjustment mechanism and the forward kinematics model of the template adjustment mechanism; The forward kinematics model of the pier adjustment mechanism is a set of mathematical equations. Based on the physical configuration of the first adjustment mechanism, which consists of at least three first-group drive cylinders, one end of each cylinder is hinged to the foundation pier, and the other end is hinged to a pre-set hinge seat at the bottom of the pier precast component. The forward kinematics model describes the quantitative relationship between the change in the length of the first-group drive cylinders and the change in the pose of the pier precast component by establishing a set of geometric constraint equations including the length of the first-group drive cylinders, the coordinates of the hinge points, and the pose parameters of the pier precast component. The pose parameters of the pier precast component include displacement in the X and Y directions in the horizontal plane, and rotation around the vertical axis. The forward kinematics model of the template adjustment mechanism is a set of mathematical equations. This model is based on the physical configuration of the second adjustment mechanism, which consists of at least three second-group drive cylinders. One end of each second-group drive cylinder is hinged to the external support structure, and the other end is hinged to a pre-set hinge seat on the support truss of the template system. The forward kinematics model describes the quantitative relationship between the change in the length of the second-group drive cylinders and the change in the pose of the inner surface of the inner template sheet by establishing a set of geometric constraint equations including the length of the second-group drive cylinders, the coordinates of the hinge points, and the pose parameters of the template system. The pose parameters of the template system include displacement in the X and Y directions in the horizontal plane, and rotation around the vertical axis. 7.2 The adjustment calculation module combines the measured coordinates of the center point of the top of the pier precast component obtained in step S5 with the spatial orientation, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template piece, and refers to the current measured state. The adjustment calculation module converts the planar position deviation of the top of the pier precast component, the axial direction deviation of the pier precast component, and the coordinate deviation of the inner surface of the inner template obtained in step S6 into various expected pose changes according to the following rules: The negative number of the planar position deviation value of the top of the precast pier is set as the expected change in planar displacement of the precast pier. The opposite of the axial deviation value of the precast pier column is set as the expected change in the rotation angle around the vertical axis of the precast pier column. Calculate the average value of the coordinate deviation vector of the inner surface of the inner template sheet, and set the negative of the average deviation vector as the expected comprehensive planar displacement change of the template system; 7.3 The adjustment quantity calculation module performs inverse kinematics calculation; The inverse kinematics solution process is as follows: Starting from the current measured state obtained in step 7.2, and taking the expected pose changes obtained in step 7.2 as the motion targets, the forward kinematics solution model of the pier adjustment mechanism and the forward kinematics solution model of the template adjustment mechanism called in step 7.1 are combined to construct a mathematical model with the length changes of all the first group of drive cylinders and the second group of drive cylinders as optimization variables, and the goal of reducing the deviations obtained in step S6 as optimization objective; this mathematical model is solved using a numerical iterative optimization algorithm to obtain a set of optimal length changes of the first group of drive cylinders and the second group of drive cylinders; 7.4 The adjustment amount calculation module assigns the optimal drive cylinder length change amount obtained in step 7.3 to different categories; all the length change amount instructions of the first group of drive cylinders constitute the first group of adjustment amounts used to adjust the position and attitude of the pier precast component; all the length change amount instructions of the second group of drive cylinders constitute the second group of adjustment amounts used to adjust the position and attitude of the template system.

[0077] In integrated construction, after obtaining various deviations through measurement and comparison, a key challenge lies in how to efficiently and accurately translate these geometric deviations into specific action commands for the mechanical adjustment mechanisms. Without a systematic conversion method, the adjustment process may rely on trial and error based on operator experience, or employ a simple but inefficient step-by-step independent adjustment strategy. This leads to a lengthy adjustment process, uncoordinated actions among mechanisms, difficulty in achieving synchronous optimization of the position and orientation of the precast pier components and the formwork system, and may even introduce new deviations, affecting the final accuracy and efficiency.

[0078] To address the difficulty in generating the aforementioned adjustment instructions, this solution provides an automated calculation process based on kinematic models. First, the adjustment calculation module calls pre-stored forward kinematics models of the pier adjustment mechanism and the template adjustment mechanism. The forward kinematics model of the pier adjustment mechanism is a set of mathematical equations based on its physical configuration, describing the quantitative relationship between the movement of its driving components and the pose changes of the pier precast component. This mechanism typically consists of at least three first-group driving cylinders, each hinged at one end to the foundation pier cap and at the other end to a pre-set hinge seat at the bottom of the pier precast component. The model characterizes how changes in the length of the first-group driving cylinders cause horizontal X-direction displacement, Y-direction displacement, and rotation around the vertical axis in the pier precast component by establishing a set of geometric constraint equations containing the lengths of each first-group driving cylinder, the spatial coordinates of each hinge point, and the pose parameters of the pier precast component. Similarly, the forward kinematics model of the template adjustment mechanism describes the quantitative relationship between the length changes of the second set of drive cylinders and the pose changes of the inner surface of the template sheet in a template adjustment mechanism consisting of at least three second sets of drive cylinders. The purpose of pre-establishing and storing these models is to provide the system with a digital twin describing the intrinsic laws of the mechanism's motion and pose changes, which is the cornerstone for precise and predictable control.

[0079] Next, the adjustment calculation module combines the calculated measured coordinates of the center point of the top of the precast pier with its spatial attitude, the actual spatial axis of the precast pier, and the actual coordinates of the inner surface of the inner formwork plate, collectively referred to as the current measured state. Simultaneously, it converts various deviations into the desired pose change of the system according to predetermined rules. For example, the negative of the planar position deviation value of the top of the precast pier is set as the desired planar displacement change of the precast pier; if the deviation is 2mm eastward, the desired change is a 2mm westward movement. The negative of the axial direction deviation value of the precast pier is set as the desired rotation angle change of the precast pier around the vertical axis. The average value of the coordinate deviation vector of the inner surface of the inner formwork plate is calculated, and the negative of this average deviation vector is set as the desired comprehensive planar displacement change of the formwork system. The purpose of this conversion step is to explicitly translate the target of eliminating deviations into the motion command of the desired pose change.

[0080] Subsequently, the module performs the core inverse kinematics calculation. This process starts with the current measured state, uses the expected pose changes obtained from the above transformation as the motion targets, and combines the forward kinematics models of the pier adjustment mechanism and the template adjustment mechanism to construct a mathematical model with the length changes of all the first and second sets of drive cylinders as optimization variables. The optimization objective of this model is to reduce various deviations. The system uses a numerical iterative optimization algorithm to solve this model, thereby obtaining a set of optimal length changes of the first and second sets of drive cylinders that enable the pier precast component and template system to move collaboratively and accurately to the target pose. The purpose of this step is to automatically find the optimal combination of mechanical actions to achieve complex collaborative adjustment through mathematical optimization, avoiding the blindness and inefficiency of manual trial and error.

[0081] Finally, the adjustment calculation module assigns the calculated optimal length changes of the first and second groups of drive cylinders to different categories. All length change commands from the first group of drive cylinders constitute the first set of adjustment commands used to adjust the position and orientation of the precast pier components; all length change commands from the second group of drive cylinders constitute the second set of adjustment commands used to adjust the position and orientation of the formwork system. The purpose of this assignment step is to generate clearly categorized, specific action commands that can directly drive the corresponding actuators.

[0082] Through this complete calculation process, this solution achieves automated and optimized conversion from spatial geometric deviations to mechanical drive commands. It makes complex multi-mechanism coordinated adjustments systematic, precise, and efficient. Based on accurate forward kinematics models and optimization algorithms, the system can calculate a coordinated action plan in one go, significantly reducing the number of iterations required for adjustments, shortening the overall adjustment time, and ensuring that the precast pier components and formwork system can reach the theoretical design position synchronously and accurately. This greatly improves the intelligence level of integrated construction and the accuracy and reliability of the final results.

[0083] Construction principle of kinematic model of pier adjustment mechanism The forward kinematics model of the pier adjustment mechanism is the core algorithm for achieving intelligent pose adjustment. Essentially, it uses the measurable physical length of the drive cylinders to inversely solve for the pier's spatial pose, which cannot be directly measured. This model is constructed based on the principles of spatial geometry and rigid body kinematics. Taking a typical three-drive cylinder mechanism as an example, the model's establishment process and specific mathematical relationships are explained below.

[0084] 1. Define the coordinate system and parameters First, clearly define the global design coordinate system on which the calculation is based. O - XYZ .

[0085] Pier pose parameters: The pose of the pier in space is fully described by six parameters, namely three translations and three rotation angles, denoted as the pose vector. .

[0086] X , Y , Z : Indicates a pre-defined reference point (such as the geometric center of the bottom surface) on the pier. O - XYZ Coordinate values ​​in a coordinate system.

[0087] α , β , γ : indicates that the piers are arranged in sequence around O - XYZ coordinate system X axis, Y axis, Z The angle of rotation of the axis (using) Z - Y - X (Euler angles in sequence).

[0088] Hinge point coordinates: No. i indivual( i = 1,2,3) The lower hinge point of the drive cylinder (fixed to the base platform) is in O - XYZ The coordinates in the vector are fixed and known three-dimensional column vectors, denoted as . B i .

[0089] No. i The coordinates of the upper hinge point (fixed to the precast pier component) of each drive cylinder in the "body coordinate system attached to the pier" are fixed, known three-dimensional column vectors, denoted as... a i .

[0090] Drive length: th i The real-time physical length of each drive cylinder is a measurable value, denoted as […]. L i .

[0091] 2. Establish coordinate transformation relationships When the pier moves from the design zero position to the current position q At that time, the upper hinge point also moves accordingly. The upper hinge point in the global coordinate system... O - XYZ Real-time coordinates A i It can be calculated using the rigid body transformation formula: in: R ( α , β , γ ) is a 3×3 rotation matrix, consisting of Euler angles ( α , β , γ )according to Z - Y - X The results were obtained through sequential calculation.

[0092] P It is a translation vector. .

[0093] 3. Construct the core geometric constraint equations For each driving cylinder, its physical structure determines that, at any given moment, the length of the cylinder is... L i It must be equal to its two hinge points. A i and B i The straight-line distance between them.

[0094] According to the formula for the distance between two points in space, this constraint can be expressed as: The right side of the equation represents a vector ( A i - B i The dot product of a vector with itself is equal to the sum of the squares of the vector's components.

[0095] In step 2 A i Substituting the expression into the above formula, we get: 4. Form a system of forward kinematic equations For three drive cylinders ( i (equations = 1, 2, 3) are listed separately to obtain an equation containing six unknowns. X , Y , Z , α , β , γ The system of equations: for i = 1: for i = 2: for i = 3: This system of equations is the complete mathematical expression of the "forward kinematics model". It establishes the known driving length measurement ( L 1, L 2, L 3) The pier pose parameters to be determined q The quantitative relationship between them.

[0096] 5. Solving and Application of the Model In actual control, the central control system reads the length sensor data of the three hydraulic cylinders in real time. L 1, L 2, L 3) By solving the above nonlinear equations, the current actual pose of the pier can be determined. q .

[0097] The solution is typically obtained using numerical iterative algorithms, such as the Newton-Raphson method. The core steps of this method are: Given an initial pose estimate q 0.

[0098] Calculate the function value of the system of equations under the current estimate. F ( q ) and its Jacobian matrix J ( q (i.e., the matrix formed by the partial derivatives of the function values ​​with respect to each pose parameter).

[0099] By solving the system of linear equations The correction amount Δq for the pose estimate is calculated.

[0100] Update pose estimate: .

[0101] Repeat steps 2 to 4 until the correction amount △ is reached. q The modulus length is less than the preset tolerance, at this time q new This is the desired pose solution.

[0102] It should be noted that the above derivation uses the most common three-cylinder spatial parallel mechanism as an example, providing a complete technical path from establishing geometric constraints to solving the equations in the forward kinematics model. Those skilled in the art will understand that, for cases with different numbers or layouts of drive mechanisms, the same principle of "establishing a coordinate system—defining parameters—listing constraint equations based on geometric relationships—numerical solution" can be followed to construct the corresponding kinematic model.

[0103] The process of establishing the kinematic model of the template adjustment mechanism is exactly the same: replace the fixed foundation coordinate system with the external support structure coordinate system of the template; replace the pier column coordinate system with the coordinate system fixed to the template; and replace the coordinates of the upper and lower hinge points of the hydraulic cylinder in the model with the kinematic model.a i and B i Replace the coordinates of the hinge points in the template adjustment mechanism with the coordinates determined by the design. Then, based on the same principle of "spatial rod length constraint", establish a set of geometric equations and solve them using the same numerical method to achieve the inverse solution from the length of the template adjustment cylinder to the overall pose of the template.

[0104] In another embodiment, in the prefabricated pier column formwork integrated construction method, after the pier column adjustment mechanism and the formwork adjustment mechanism are driven to operate according to the command in step S8, an adjustment verification step is added. The adjustment verification step includes: 8.1 After the pier adjustment mechanism and the template adjustment mechanism in step S8 complete their actions, the central control system controls the measuring robot to immediately execute a new round of step S4 to obtain the three-dimensional coordinate data of all measuring prisms after adjustment. 8.2 Based on the coordinate data obtained in step 8.1, the central control system executes a new round of steps S5 and S6 to calculate the planar position deviation of the top of the precast pier after adjustment, the axial direction deviation of the precast pier after adjustment, and the coordinate deviation of the inner surface of the inner template after adjustment. 8.3 The central control system calculates three actual reductions: 8.3.1 The actual reduction in the planar position deviation of the top of the precast pier is equal to the planar position deviation value before adjustment obtained in step S6 minus the planar position deviation value of the top of the precast pier obtained in step 8.2. 8.3.2 The actual reduction in the axial direction deviation of the pier precast component is equal to the axial direction deviation value before adjustment obtained in step S6 minus the axial direction deviation value of the pier precast component after adjustment obtained in step 8.2. 8.3.3 The actual reduction in coordinate deviation of the inner surface of the inner template sheet is equal to the coordinate deviation value before adjustment obtained in step S6 minus the coordinate deviation value of the inner surface of the inner template sheet after adjustment obtained in step 8.2. 8.4 The central control system determines whether the three actual reductions calculated in step 8.3 are all greater than zero; 8.5 If step 8.4 determines that all actual reductions are greater than zero, the central control system determines that the adjustment has a positive effect and continues to execute the subsequent processes in the closed loop; 8.6 If step 8.4 determines that any actual reduction is less than or equal to zero, the central control system determines that the adjustment has not produced the expected effect. The central control system then uses the planar position deviation of the top of the precast pier, the axial direction deviation of the precast pier, and the coordinate deviation of the inner surface of the inner template obtained in step 8.2 as new inputs, jumps to step S7, calculates a first set of supplementary adjustment amounts and a second set of supplementary adjustment amounts for supplementary adjustment, and executes step S8 and the adjustment verification step again.

[0105] In the closed-loop adjustment process based on measurement and model calculation, there is a potential risk of failure after the central control system drives the pier adjustment mechanism and the formwork adjustment mechanism to act according to the calculated first and second sets of adjustment amounts. The actual movement of the adjustment mechanism may not perfectly execute the commands due to mechanical backlash, hydraulic hysteresis, slight load changes, or control errors, resulting in a small but critical difference between the actual position and the expected target. If the system fails to identify this difference in time and continues to enter the next measurement and adjustment cycle according to the original logic, it may perform new calculations based on a situation that has not been effectively improved, thus generating erroneous subsequent commands. This causes the adjustment process to linger in ineffective or inefficient cycles, or even diverge, affecting construction efficiency and final accuracy.

[0106] To address the issue of uncertain effects from a single adjustment action, this solution immediately inserts an adjustment verification step after each drive mechanism movement. This step first controls the measuring robot to immediately acquire new coordinate data from all top, side, and template measuring prisms after the adjustment action is completed. The purpose is to obtain the true, immediate spatial state of the pier precast component and the template system after the adjustment action, serving as an objective basis for evaluating the adjustment effect.

[0107] Next, based on this new coordinate data, the central control system recalculates the planar position deviation of the top of the precast pier component, the axial direction deviation of the precast pier component, and the coordinate deviation of the inner surface of the inner formwork, obtaining a set of adjusted deviation values. Subsequently, the system performs crucial effect quantification: calculating the difference between the three deviations before and after adjustment, i.e., the actual reduction. For example, if the planar position deviation of the top of the precast pier component was 5mm before adjustment, and the measured deviation after adjustment is 3mm, then the actual reduction is 2mm. The same method is used to calculate the actual reduction of the axial direction deviation of the precast pier component and the coordinate deviation of the inner surface of the inner formwork. The purpose of this step is to transform the abstract question of "whether the adjustment is in place" into a quantifiable and comparable indicator of whether the three specific deviation values ​​have been effectively reduced.

[0108] The central control system then performs logical checks on these three actual reductions. If all three calculated reductions are greater than zero, it indicates that all key accuracy indicators have been positively improved after the adjustment mechanism was activated, and the adjustment has a clear positive effect. The system then determines that the verification is successful and continues to execute subsequent processes in the closed loop, such as proceeding to the next iteration or entering stability verification.

[0109] Conversely, if any actual reduction is less than or equal to zero, it indicates that the adjustment for that indicator has not produced the expected effect, and may even have worsened the situation. In this case, the central control system will not blindly enter the next routine cycle, but will immediately determine that the adjustment has not produced the expected effect. The system then uses the currently measured, adjusted deviation values ​​as new inputs, jumps to the adjustment calculation step, recalculates a first set of supplementary adjustment values ​​and a second set of supplementary adjustment values, and drives the mechanism to perform this supplementary adjustment again. Subsequently, it executes the adjustment verification step again. The purpose of this mechanism is that when a single adjustment fails, the system can promptly identify and initiate a targeted and rapid remedial cycle, rather than continuing ineffective work on an erroneous basis.

[0110] The effectiveness of this adjustment verification step lies in providing real-time quality checks and feedback on the immediate effects of each adjustment action. It ensures that every cycle in the closed-loop control is an effective cycle, greatly avoiding system idling or oscillation in the wrong direction due to actuator errors or minor model mismatches. Through real-time verification and rapid remediation mechanisms, the convergence speed and reliability of the entire adjustment process are significantly improved. This ensures that even if individual adjustment actions do not meet expectations, the system can autonomously and quickly correct its strategy, ensuring that the construction process progresses steadily and efficiently towards the high-precision goal.

[0111] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details.

Claims

1. A prefabricated pier and column formwork integrated construction method, characterized in that, include: S1. Install a top measuring plate on the top of the precast pier component, and install multiple calibrated top measuring prisms on the top measuring plate; S2. Install multiple side measuring prisms on the outer surface of the precast pier component; S3. Hoist the formwork system to the periphery of the precast pier. The formwork system includes inner formwork panels, outer formwork panels, and a support truss connecting the inner and outer formwork panels. Install multiple calibrated formwork measuring prisms on the support truss. S4. Utilize a measuring robot to simultaneously measure the three-dimensional coordinate data of all top measuring prisms, side measuring prisms, and template measuring prisms; S5. Based on all the three-dimensional coordinate data obtained in step S4, the central control system calculates the measured coordinates and spatial posture of the center point of the top of the precast pier component, the actual spatial axis of the precast pier component, and the actual coordinates of the inner surface of the inner template. S6. The measured coordinates of the center point of the top of the pier precast component, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template obtained in step S5 are compared with the theoretical center point coordinates of the top of the pier precast component, the theoretical spatial axis of the pier precast component, and the theoretical coordinates of the inner surface of the inner template in the pre-stored three-dimensional design model, respectively, to obtain the planar position deviation of the top of the pier precast component, the axial direction deviation of the pier precast component, and the coordinate deviation of the inner surface of the inner template. S7. The adjustment amount calculation module uses a mathematical model that includes the kinematic relationship between the pier adjustment mechanism and the template adjustment mechanism. It takes the measured coordinates and spatial attitude of the center point of the top of the pier precast component obtained in step S5, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template as comprehensive inputs to calculate the first set of adjustment amounts for adjusting the position and attitude of the pier precast component and the second set of adjustment amounts for adjusting the position and attitude of the template system, so as to reduce the various deviations obtained in step S6. S8. Drive the corresponding pier adjustment mechanism and template adjustment mechanism to move according to the first set of adjustment amount and the second set of adjustment amount, and repeat steps S4 to S8 to form a closed loop feedback control until all deviations obtained in step S6 are less than their respective set thresholds. S9. After the adjustment is completed, the formwork system is sealed and tightened and the concrete is poured and cured. S10. After the curing is completed, dismantle the formwork system and adjustment mechanism.

2. The prefabricated pier formwork integrated construction method as described in claim 1, characterized in that: In step S1, at least three top measuring prisms are evenly installed on the edge of the top measuring disk; In step S2, a side measuring prism is installed at three different height positions on the outer surface of the pier precast component; In step S4, the measuring robot completes its localization and orientation by observing at least two pre-deployed fixed measuring reference points; In step S8, the specific threshold values ​​for each deviation are as follows: the planar position deviation of the top of the precast pier is less than 2mm, the perpendicularity deviation of the actual spatial axis of the precast pier relative to the theoretical spatial axis is less than 0.3%, and the coordinate deviation of the inner surface of the inner template is less than 3mm.

3. The prefabricated pier formwork integrated construction method as described in claim 1, characterized in that, In step S9, before concrete pouring, a sealing verification step is also included, which includes: Water is injected into the cavity between the precast pier and the inner formwork through the grouting hole at the bottom of the formwork system and pressurized to 0.06 MPa, and held at pressure for 8 minutes. During the pressure holding period, the measuring robot remeasures the coordinates of the template measuring prism; The central control system calculates the coordinate differences ΔX, ΔY, and ΔZ in the three-dimensional coordinate system between the remeasured coordinates and the original coordinates of each template measuring prism in the X, Y, and Z directions. The central control system calculates the spatial displacement distance of the measuring prism of each template by taking the square root of the sum of the coordinate differences ΔX, ΔY, and ΔZ. If the spatial displacement distance corresponding to all template measuring prisms is less than 0.8mm, the verification is passed and subsequent concrete pouring is permitted. If the spatial displacement distance corresponding to any template measuring prism is greater than or equal to 0.8mm, the central control system will issue an alarm signal and suspend the construction process. Subsequently, the operators inspected and eliminated any faults in the sealing, fastening, or structure of the template system; After troubleshooting, repeat the sealing verification steps starting from water injection and pressurization until the spatial displacement distance corresponding to all template measuring prisms is less than 0.8mm before proceeding with subsequent concrete pouring.

4. The prefabricated pier formwork integrated construction method as described in claim 3, characterized in that, After the central control system issues an alarm signal, and before the operator checks and eliminates faults in the sealing, fastening or structure of the template system, the central control system also performs auxiliary analysis to generate area prompt information to guide subsequent fault checks. The auxiliary analysis includes the following steps: S4.1 The central control system lists all template measuring prisms with displacement distances greater than or equal to 0.8 mm based on the alarm signal, and sorts them in descending order of displacement distance value. S4.2 The central control system performs the following operations on each template measuring prism in the list in the order of steps S4.1: S4.2.1 Obtain the three-dimensional installation coordinates of the template measuring prism currently being processed; S4.2.2 Calculate the distance between the three-dimensional installation coordinates of the current template measuring prism obtained in step S4.2.1 and the three-dimensional coordinates of all template splicing seams and support truss connection nodes in the pre-stored three-dimensional design model. S4.2.3 From the distance calculation results of step S4.2.2, find the template splice seam or the support truss connection node that is closest to the three-dimensional installation coordinates of the current template measuring prism obtained in step S4.2.1, and add the found splice seam or connection node to a set of suspected fault locations. S4.3 The central control system organizes the set of suspected fault locations generated in step S4.2 and generates area prompt information; S4.4 The central control system provides area prompts and alarm signals to the operation interface. The area prompts are used to guide operators to perform targeted inspections and troubleshooting of the template system's sealing, fastening, or structural faults.

5. The prefabricated pier formwork integrated construction method as described in claim 1, characterized in that, Step S5 specifically includes: S5.1 The central control system, based on the three-dimensional coordinate data of all the top measuring prisms obtained in step S4, calculates the measured coordinates and spatial attitude of the center point of the top of the pier precast component, including: S5.1.1 The central control system calls the calibration data of each top measuring prism. The calibration data is the three-dimensional coordinates of the top measuring prism in the top measuring disk coordinate system. The top measuring disk coordinate system is established as follows: the physical installation contact surface between the top measuring disk and the top of the pier precast component is taken as the reference plane, the normal direction of the reference plane is taken as the Z-axis, and the point on the reference plane corresponding to the design center of the top of the pier precast component is taken as the origin of the coordinate system. S5.1.2 The central control system obtains the three-dimensional coordinates of each top measuring prism in the field measurement coordinate system obtained in step S4; S5.1.3 The central control system performs multi-point spatial registration calculation to solve for a rotation matrix and a translation vector. The goal of the multi-point spatial registration calculation is to minimize the overall error between the coordinates of all top measuring prisms after transforming from the top measuring disk coordinate system to the field measuring coordinate system according to the solved rotation matrix and translation vector, and the coordinates of the corresponding top measuring prisms obtained by direct measurement in step S4. S5.1.4 The central control system uses the translation vector obtained in step S5.1.3 as the measured coordinates of the center point of the top of the pier precast component. S5.1.5 The central control system uses the Z-axis direction corresponding to the rotation matrix solved in step S5.1.3 as the spatial attitude of the top of the pier precast component. S5.

2. Based on the three-dimensional coordinate data of all side measuring prisms obtained in step S4, the central control system calculates the actual spatial axis of the pier precast component, including: S5.2.1 The central control system will combine the three-dimensional coordinates of all the side measuring prisms obtained in step S4 into a spatial point set; S5.2.2 The central control system performs least squares spatial line fitting on the spatial point set to obtain an optimal fitted line; S5.2.3 The central control system defines the optimal fitted straight line obtained in step S5.2.2 as the actual spatial axis of the pier precast component; S5.

3. Based on the three-dimensional coordinate data of all template measuring prisms obtained in step S4, the central control system calculates the actual coordinates of the inner surface of the inner template sheet, including: S5.3.1 The central control system calls the calibration data of each template measuring prism. The calibration data is a three-dimensional vector, which represents the direction and distance from the template measuring prism to a specified corresponding point on the inner surface of the inner template sheet. S5.3.2 For each template measuring prism, the central control system adds the three-dimensional coordinates measured in step S4 to the corresponding three-dimensional vector called in step S5.3.1 to obtain a result coordinate. S5.3.3 The central control system records the coordinates obtained in step S5.3.2 as the actual coordinates of the corresponding points on the inner surface of the inner template sheet; S5.3.4 The central control system repeats steps S5.3.2 and S5.3.3 for all template measuring prisms to obtain the actual coordinate set of all specified corresponding points on the inner surface of the inner template sheet, which is the calculated actual coordinate of the inner surface of the inner template sheet.

6. The prefabricated pier formwork integrated construction method as described in claim 1, characterized in that: During the process of repeatedly executing steps S4 to S8 to form closed-loop feedback control, when the deviations obtained in step S6 are all less than their respective set thresholds for the first time, the central control system controls the measurement robot to continue to execute the measurement and calculation process of steps S4 to S6 for at least two more rounds to verify stability. If the deviations calculated in each subsequent step S6 remain less than their respective set thresholds, the central control system will ultimately determine that the adjustment is complete. If any deviation calculated in any subsequent step S6 is greater than or equal to the set threshold, the central control system continues to execute closed-loop feedback control until the condition that each deviation is simultaneously less than its respective set threshold for the first time is met again and the stability verification is completed.

7. The prefabricated pier formwork integrated construction method as described in claim 1, characterized in that, Step S7 specifically includes: S7.1 The adjustment amount calculation module calls the pre-stored forward kinematics model of the pier adjustment mechanism and the forward kinematics model of the template adjustment mechanism; The forward kinematics model of the pier adjustment mechanism is a set of mathematical equations. Based on the physical configuration of the first adjustment mechanism, which consists of at least three first-group drive cylinders, one end of each cylinder is hinged to the foundation pier, and the other end is hinged to a pre-set hinge seat at the bottom of the pier precast component. The forward kinematics model describes the quantitative relationship between the change in the length of the first-group drive cylinders and the change in the pose of the pier precast component by establishing a set of geometric constraint equations including the length of the first-group drive cylinders, the coordinates of the hinge points, and the pose parameters of the pier precast component. The pose parameters of the pier precast component include displacement in the X and Y directions in the horizontal plane, and rotation around the vertical axis. The forward kinematics model of the template adjustment mechanism is a set of mathematical equations. This model is based on the physical configuration of the second adjustment mechanism, which consists of at least three second-group drive cylinders. One end of each second-group drive cylinder is hinged to the external support structure, and the other end is hinged to a pre-set hinge seat on the support truss of the template system. The forward kinematics model describes the quantitative relationship between the change in the length of the second-group drive cylinders and the change in the pose of the inner surface of the inner template sheet by establishing a set of geometric constraint equations including the length of the second-group drive cylinders, the coordinates of the hinge points, and the pose parameters of the template system. The pose parameters of the template system include displacement in the X and Y directions in the horizontal plane, and rotation around the vertical axis. S7.2 The adjustment calculation module combines the measured coordinates of the center point of the top of the pier precast component obtained in step S5 with the spatial posture, the actual spatial axis of the pier precast component, and the actual coordinates of the inner surface of the inner template piece, and refers to the current measured state. The adjustment calculation module converts the planar position deviation of the top of the pier precast component, the axial direction deviation of the pier precast component, and the coordinate deviation of the inner surface of the inner template obtained in step S6 into various expected pose changes according to the following rules: The negative number of the planar position deviation value of the top of the precast pier is set as the expected change in planar displacement of the precast pier. The opposite of the axial deviation value of the precast pier column is set as the expected change in the rotation angle around the vertical axis of the precast pier column. Calculate the average value of the coordinate deviation vector of the inner surface of the inner template sheet, and set the negative of the average deviation vector as the expected comprehensive planar displacement change of the template system; S7.3, The adjustment calculation module performs inverse kinematics calculation; The inverse kinematics solution process is as follows: Starting from the current measured state obtained in step S7.2, and taking the expected pose changes obtained in step S7.2 as the motion targets, the forward kinematics solution model of the pier adjustment mechanism and the forward kinematics solution model of the template adjustment mechanism called in step S7.1 are combined to construct a mathematical model with the length changes of all the first group of drive cylinders and the second group of drive cylinders as optimization variables, and the goal of reducing the deviations obtained in step S6 is to optimize the model. This mathematical model is solved using a numerical iterative optimization algorithm to obtain a set of optimal length changes of the first group of drive cylinders and the second group of drive cylinders. S7.4 The adjustment amount calculation module assigns the optimal drive cylinder length change amount obtained in step S7.3 to different categories; all the length change amount instructions of the first group of drive cylinders constitute the first group of adjustment amounts used to adjust the position and attitude of the pier precast component; all the length change amount instructions of the second group of drive cylinders constitute the second group of adjustment amounts used to adjust the position and attitude of the template system.

8. The prefabricated pier formwork integrated construction method as described in claim 1, characterized in that, After the pier adjustment mechanism and the formwork adjustment mechanism are activated according to the command in step S8, an adjustment verification step is added. The adjustment verification step includes: S8.1 After the pier adjustment mechanism and template adjustment mechanism in step S8 complete their actions, the central control system controls the measuring robot to immediately execute a new round of step S4 to obtain the three-dimensional coordinate data of all measuring prisms after adjustment. S8.

2. Based on the coordinate data obtained in step S8.1, the central control system executes a new round of steps S5 and S6 to calculate the planar position deviation of the top of the precast pier after adjustment, the axial direction deviation of the precast pier after adjustment, and the coordinate deviation of the inner surface of the inner template after adjustment. S8.3, The central control system calculates the three actual reductions: S8.3.1 The actual reduction in the planar position deviation of the top of the precast pier is equal to the planar position deviation value before adjustment obtained in step S6 minus the planar position deviation value of the top of the precast pier obtained in step S8.

2. S8.3.2 The actual reduction in the axial direction deviation of the pier precast component is equal to the axial direction deviation value before adjustment obtained in step S6 minus the axial direction deviation value of the pier precast component after adjustment obtained in step S8.

2. S8.3.3 The actual reduction in the coordinate deviation of the inner surface of the inner template sheet is equal to the coordinate deviation value before adjustment obtained in step S6 minus the coordinate deviation value of the inner surface of the inner template sheet after adjustment obtained in step S8.

2. S8.4 The central control system determines whether the three actual reductions calculated in step S8.3 are all greater than zero; S8.5 If step S8.4 determines that all actual reductions are greater than zero, the central control system determines that the adjustment has a positive effect and continues to execute the subsequent processes in the closed loop. S8.6 If step S8.4 determines that any actual reduction is less than or equal to zero, the central control system determines that the adjustment has not produced the expected effect. The central control system then uses the planar position deviation of the top of the precast pier, the axial direction deviation of the precast pier, and the coordinate deviation of the inner surface of the inner template obtained in step S8.2 as new inputs, jumps to step S7, calculates a first set of supplementary adjustment amounts and a second set of supplementary adjustment amounts for supplementary adjustment, and executes step S8 and the adjustment verification step again.

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