A method and system for positioning and measuring the foundation bolt of a blast furnace main belt corridor

Abstract

The application discloses a kind of blast furnace main belt corridor foot bolt positioning measurement method and system, it is related to construction surveying technical field;It is to intuitively convert the coordinate of a large number of discrete bolt points on design drawing into continuous visible reference in construction site under the premise of not relying on physical mold, and the following technical scheme is proposed: step S1: coordinate system is established with measurement reference;Step S2: total station is flexibly built;Step S3: the design of single-point accurate point position;Step S4: the generation of continuous visual installation reference;Step S5: batch collaborative installation based on visual reference.The application only needs to measure a horizontal distance to calculate the coordinate, and the operation is simple and reliable in precision;It improves construction efficiency, and also reduces the communication and cooperation difficulty between measurement and installation team.

Description

Technical Field

[0001] This invention relates to the field of construction surveying technology, specifically to a method and system for measuring the positioning of anchor bolts in the main belt conveyor corridor of a blast furnace. Background Technology

[0002] The main conveyor belt corridor of a blast furnace is a crucial transport structure connecting the raw material yard and the blast furnace roof. Its steel structure is typically connected to a concrete foundation by a group of hundreds or even thousands of anchor bolts. The positioning accuracy of these anchor bolt groups directly determines the accuracy of the corridor structure installation, construction efficiency, and long-term operational safety. In large-scale metallurgical engineering construction, how to efficiently and accurately measure and position the dense anchor bolt groups has always been a core challenge in the field of engineering surveying.

[0003] Currently, there are two main types of solutions in existing technologies: The first type is the point-by-point layout surveying method, mainly using theodolites and total stations. This method involves professional surveyors using instruments to lay out the theoretical position of each bolt on the construction site. However, the construction area for corridor foundations is usually filled with scaffolding and reinforcing steel, resulting in extremely poor visibility between the instrument and the layout points. This forces surveyors to frequently move stations and change points, which is not only inefficient but also prone to error accumulation. Moreover, this method generates discrete coordinate data, which cannot directly guide installation workers in rapid operation, leading to a serious disconnect between surveying and construction.

[0004] The second type is the positioning method using physical molds. For example, the fixing and positioning device disclosed in prior art CN116378090B pre-fixes the entire bolt group using a prefabricated steel structure support, and then uses a physical crosshair as a reference for overall installation. Another example is the precise and rapid positioning and installation device for anchor bolts disclosed in CN115507719A, which uses an operating panel with a scale and adjustable positioning plate to position individual bolts. These solutions all use physical tooling to "replace" the measurement process.

[0005] However, the above-mentioned solutions have fundamental flaws: the physical mold itself is a precision component, and its positioning still relies on traditional tools such as measuring tapes and steel wires to reference the surrounding axes. Its accuracy is limited by the manufacturing precision of the mold and the stability of the axis grid, and it cannot achieve high-precision control of all bolts over a large area under a unified coordinate system. When faced with non-standardized, large-area, multi-reference bolt group arrangements, the versatility and flexibility of such solutions are severely lacking, and the manufacturing cost of physical molds is high and the cycle is long. Summary of the Invention

[0006] This invention provides a method and system for locating and measuring anchor bolts in the main belt conveyor corridor of a blast furnace. The purpose is to intuitively transform the coordinates of a large number of discrete bolt points on the design drawings into a continuously visible reference on the construction site without relying on physical molds.

[0007] The technical solution of the present invention to solve the above-mentioned technical problems is as follows:

[0008] A method for measuring the positioning of anchor bolts in the main conveyor belt corridor of a blast furnace includes the following steps:

[0009] S1. Establishment of Coordinate System and Measurement Benchmark: The design coordinates of the anchor bolts to be installed are uniformly converted into coordinate data under an independent rectangular coordinate system with the longitudinal centerline of the corridor as the first axis and the transverse centerline as the second axis; Based on the longitudinal centerline of the corridor, two end control points are established in the construction area, and at least one intermediate control point is established between the two end control points. The two end control points and all intermediate control points are located on the longitudinal centerline of the corridor. One of the end control points is fixed by a forced centering device, and the three-dimensional coordinates of the end control point are obtained.

[0010] S2. Flexible Station Establishment with Total Station: Set up the total station at any position along the longitudinal centerline. Using the two end control points as references, observe using the direct and inverted mirror method and the full circle method, and re-measure the intermediate control points. Adjust the position of the total station until the center of the total station is precisely collinear with the two end control points and all intermediate control points. Then, by measuring the horizontal distance from the center of the total station to one of the end control points, and combining the known coordinates of the end control point with the azimuth of the connecting line, calculate the three-dimensional coordinates of the center of the total station. Using the end control point as the zero direction, complete the station establishment using the direction method.

[0011] S3. Design of precise single-point location: Place the positioning target, which integrates a measuring prism and a laser line projector, near the designed bolt position; use a total station to track the measuring prism, obtain the current coordinates of the positioning target center in real time, and calculate its three-dimensional deviation from the design coordinates; adjust the position of the positioning target according to the three-dimensional deviation guide until the three-dimensional deviation meets the preset tolerance, at which point the position of the positioning target center is the precise design point for the anchor bolt to be installed;

[0012] S4. Generation of continuous visual installation benchmarks: The measuring prism and the laser line projector have a known fixed spatial relationship on the positioning target; at the first bolt point where the precise design points have been completed, the laser line projector projects a horizontal laser line that passes through the first bolt point and is consistent with the design elevation, and a longitudinal laser line that passes through the first bolt point and is parallel to the longitudinal center line of the corridor, thereby transforming the discrete point coordinates into continuous visual installation benchmarks.

[0013] S5. Batch collaborative installation based on visual benchmarks: The subsequent bolt installation is aligned with the horizontal laser line as the elevation benchmark and the vertical laser line as the axis benchmark. The design spacing between the bolts is controlled by measuring tools for initial fixing, thus completing the positioning and installation of the subsequent bolts.

[0014] Furthermore, in step S3, the three-dimensional deviation guidance specifically involves: the data processing terminal connected to the total station displays the three-dimensional deviation value in real time, and the positioning target is adjusted in the X, Y, and H directions based on the displayed three-dimensional deviation value.

[0015] Further, step S2 includes: using the upright mirror to aim at one end control point and read the horizontal angle α1, and using the reverse mirror to aim at the other end control point and read the horizontal angle α2, requiring the deviation of |α1-α2±180°| to meet the preset requirements; then using the full circle method to observe the intermediate control point, and finely adjust the position of the total station until the two end control points and all intermediate control points are collinear with the center of the total station.

[0016] Furthermore, step S5 also includes: using a total station to sample and verify the bolts that have been initially fixed according to a predetermined ratio; if the deviation exceeds the limit, step S4 is repeated to calibrate the laser line.

[0017] A positioning and measurement system for anchor bolts in the main belt conveyor corridor of a blast furnace includes: a control network subsystem, a total station, a data processing terminal, and a positioning target;

[0018] The control network subsystem includes two end control points and one intermediate control point arranged along the longitudinal centerline of the corridor, as well as a forced alignment device; the forced alignment device is located at one of the end control points and is used to fix the end control point and ensure alignment accuracy.

[0019] The total station is connected to the data processing terminal; the total station establishes a station based on the control points of the control network subsystem and tracks the measuring prism of the positioning target; the data processing terminal is configured to calculate and display in real time the three-dimensional deviation between the current coordinates of the measuring prism of the positioning target and the preset design coordinates.

[0020] The positioning target includes the target body, as well as a measuring prism and a laser line projector fixed on the target body; the measuring prism is used for total station tracking measurement; the laser line projector and the measuring prism are in a fixed relative position and orientation, and their spatial relative position and attitude are determined in advance; the laser line projector is configured to project a horizontal laser line and a longitudinal laser line parallel to the longitudinal center line of the corridor to establish a visual installation reference.

[0021] Furthermore, the data processing terminal stores the design coordinate data of the anchor bolts to be installed; the design coordinate data is coordinate data in an independent rectangular coordinate system with the longitudinal centerline and transverse centerline of the corridor as coordinate axes.

[0022] Furthermore, the centering error of the forced centering device is no greater than 0.5 mm; the angle measurement accuracy of the total station is at least 1″, and the distance measurement accuracy is at least 1 mm + 1 ppm.

[0023] The present invention has the following beneficial effects:

[0024] In this invention, the total station does not need to be set up at a control point with known coordinates. Instead, it can be flexibly set up at any point along the longitudinal centerline of the corridor, completely solving the problems of no place to set up the instrument and frequent relocation of the instrument due to scaffolding and rebar at the construction site. At the same time, since the instrument is always located on the line connecting the two control points, only a horizontal distance needs to be measured to calculate the coordinates, making the operation simple and the accuracy reliable. No special physical molds are required, and it can be adapted to bolt groups of different specifications and arrangements, making it highly versatile and significantly shortening the construction preparation cycle and tooling costs.

[0025] The traditional method required hundreds of bolts to be laid out one by one using a total station, transforming most of the positioning work from specialized surveying to routine installation. Installation workers no longer need to understand complex coordinate data and surveying principles; they can quickly complete the task by simply placing the bolts along the line and adjusting them. This greatly improves construction efficiency and reduces the difficulty of communication and collaboration between the surveying and installation teams. Attached Figure Description

[0026] Figure 1 This is a flowchart of the method for locating and measuring anchor bolts in the main belt conveyor corridor of a blast furnace according to the present invention.

[0027] Figure 2 A schematic diagram of the network construction for control points.

[0028] Figure 2 The reference numerals in the attached figures are: 1 - group of bolts. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0030] Please refer to Figure 1-2 This embodiment provides a method for locating and measuring anchor bolts in the main belt conveyor corridor of a blast furnace, used for accurately locating and laying out the anchor bolt group 1 on a concrete foundation. Specifically, it includes the following steps S1 to S5.

[0031] Step S1: Establishing the Coordinate System and Measurement Datum. First, based on the original coordinates and dimensions of all anchor bolts provided in the design drawings, use CAD software to uniformly convert the design coordinates of all bolts to be installed into a rectangular coordinate system. Using the longitudinal centerline of the corridor as the first axis (Y-axis) and the transverse centerline of the corridor as the second axis (X-axis), the positional relationship of all bolts directly corresponds to the direction of the main axis of the corridor, eliminating the angle conversion step in subsequent measurement calculations. After the conversion is completed, import the data file in CSV or TXT format containing the bolt number and its X, Y, and H (elevation) coordinates into a data processing terminal connected to the total station, such as the total station handheld device or an external computer, for storage and later use.

[0032] Based on the longitudinal centerline of the corridor, two end control points and at least one intermediate control point are set up on stable structures around the construction area, such as completed concrete columns or steel structure platforms, as measurement reference points. This embodiment uses two end control points and one intermediate control point, denoted as points A, B, and C. Point A serves as the three-dimensional coordinate control point, point B as the direction control point, and point C as the verification control point. Points A and B are located at opposite ends of the longitudinal centerline of the corridor, and point C is located on the longitudinal centerline between points A and B. The distance between the three points is no less than 50 meters to ensure the accuracy of direction transmission. Point A is fixed using a forced centering device, which eliminates errors from manual centering and ensures that the center of the equipment always coincides with point A when prisms or instruments are repeatedly set up. The centering error of the forced centering device is no greater than 0.5 mm. After the control points are laid out, the three-dimensional coordinates (X, Y, H) of the three control points A, B, and C are accurately determined using second-order traverse surveying or a surveying method of equivalent accuracy, with a plane accuracy of ±2mm and an elevation accuracy of ±1mm.

[0033] Step S2: Flexible Total Station Setup. Set up the total station at any suitable location on the longitudinal centerline. The total station (such as a Leica icb70) should have an angle measurement accuracy of at least 1″ and a distance measurement accuracy of at least 1mm + 1ppm. The selection of the total station's location should prioritize avoiding construction obstacles and obtaining a good field of view.

[0034] Specific operation for setting up the total station: First, with point A as the zero direction, aim the telescope (left face) at point A and read the horizontal angle α1; then, reverse the telescope (right face) to point B and read the horizontal angle α2. The deviation of |α1-α2±180°| should not exceed 6″ to verify that the instrument's line-of-sight error is within the allowable range. Use the full-circle method to observe point C, located in the middle. Based on the observation results, finely adjust the horizontal position of the total station, repeating this operation until the three control points A, B, and C are collinear with the center of the total station, with a deviation not exceeding 1mm.

[0035] At this point, the center of the total station is precisely located on the line connecting points A and B. Measure the horizontal distance D from the total station center to the prism at point A. Combining this with the known three-dimensional coordinates (X1, Y1, H1) of point A and the azimuth angle of the line connecting points A and B, calculate the three-dimensional coordinates of the total station center using the following formula:

[0036] Station X = X1 + D × cos(azimuth A → instrument) Station Y = Y1 + D × sin(azimuth A → instrument)

[0037] Station height H = H1 + (instrument height - prism height)

[0038] Finally, with point A as the zero direction, the direction method was used to establish the station, and the direction value of point B was remeasured to ensure that the deviation from the theoretical value was no more than 5″.

[0039] Step S3: Design of precise single-point location. The operator places the positioning target near the designed location of the first or critical bolt to be installed. The positioning target is mounted on a tripod, and the operator first adjusts the tripod to center the bubble on the target, completing the initial leveling.

[0040] Operate the total station to aim at and track the measuring prism on the target. The data processing terminal, connected to the total station, receives the measurement data in real time, calculates the current measured coordinates (X_actual, Y_actual, H_actual) of the target center, and compares them with the pre-stored design coordinates (X_design, Y_design, H_design) of the bolt point in the terminal. The deviation values ​​in the three directions are displayed on the screen in real time.

[0041] ΔX = Xactual - Xassumed ΔY = Yactual - Yassumed ΔH = Hactual - Hassumed

[0042] The deviation values ​​are transmitted to the target in real time via the handheld device screen or walkie-talkie. Based on this, the target is moved horizontally (X) and backward (Y), or its position is adjusted using a tripod in the vertical (H) direction. This "measurement-feedback-adjustment" process is repeated until the displayed three-dimensional deviations meet the preset tolerance requirements, typically |ΔX|≤1mm, |ΔY|≤1mm, and |ΔH|≤2mm. At this point, the spatial location of the target center is the precise design point for installing the anchor bolts. A steel nail is driven into the ground at this location or a red paint dot is sprayed on it as a permanent marker.

[0043] Step S4: Generation of continuous visual installation baseline. After completing the precise design of the first bolt point, the discrete point coordinates can be transformed into a continuous visual installation baseline using the laser line projector integrated on the positioning target.

[0044] The measuring prism and the laser line projector have a fixed spatial relationship on the positioning target. When the measuring prism is tracked by the total station and reaches the precise design point, the spatial offset between the optical center of the laser line projector and the design point is pre-calibrated. Therefore, after the target center is designed with coordinates in step S3, the laser line projector is activated, and the laser line it projects represents the design elevation plane and design axis direction passing through the design point, without the need for additional measurement and calibration.

[0045] The laser line projector can simultaneously project a horizontal laser line and a vertical laser line. The horizontal laser line passes through the bolt point and is aligned with its designed top surface elevation, used to control the installation height of all subsequent bolts; the vertical laser line passes through the bolt point and is parallel to the longitudinal centerline of the corridor, used to control the longitudinal arrangement direction of all subsequent bolts.

[0046] Step S5: Batch Collaborative Installation Based on Visual Benchmarks. Following the horizontal and vertical laser lines described above, batch install all subsequent bolts. For each subsequent bolt, after placing it in its approximate designed position, first adjust the bolt's top surface elevation to align with the horizontal laser line; second, adjust the bolt's lateral position to align with the vertical laser line, ensuring its center lies within the vertical plane of the laser line; finally, using measuring tools such as a steel tape measure, measure the designed spacing between the bolt and the previously fixed bolt along the vertical laser line to assist in controlling the bolt's longitudinal (Y-axis) position. After completing the alignment in these three dimensions, the bolt can be initially fixed to the positioning bracket or foundation reinforcement.

[0047] After the initial bolt fixing is completed, to ensure the overall installation quality, the following quality inspection steps are performed: Before concrete pouring, using the same total station and the same control network, approximately 10% of the initially fixed bolts are randomly sampled for verification and measurement. The allowable deviation is: X / Y direction ≤ 2mm, H direction ≤ 3mm. If the deviation exceeds the limit, it indicates that the laser reference may have shifted due to external disturbances. In this case, it is necessary to return to step S4, re-set the target at the reference point and calibrate the laser line, and then adjust the affected bolts.

[0048] This embodiment also provides a positioning and measurement system for anchor bolts in the main conveyor belt corridor of a blast furnace. This system is used to perform the above-described positioning and measurement method. The system includes: a control network subsystem, a total station, a data processing terminal, and a positioning target. Each component will be described in detail below.

[0049] The control network subsystem serves as the global reference for the entire measurement system. It includes two end control points, at least one intermediate control point, and a forced alignment device.

[0050] Control points are laid out along the longitudinal centerline of the corridor, preferably on the top surfaces of already poured and structurally stable concrete columns or steel platforms around the construction area to avoid construction disturbance. The three control points are located at both ends and the middle of the longitudinal centerline, with a minimum distance of 50 meters between adjacent points to ensure accurate directional transmission.

[0051] A forced alignment device is installed at a control point at the end to fix that control point. The alignment error of the center hole of the forced alignment device is no more than 0.5mm, which can ensure the repeatability of the center position when the prism or instrument is set up at different times and by different personnel, thus fundamentally eliminating the impact of alignment error on the accuracy of the control network.

[0052] The total station is the core measuring instrument in this system. Its angle measurement accuracy is at least 1″ and its distance measurement accuracy is at least 1mm+1ppm to meet the requirements of millimeter-level positioning accuracy.

[0053] The data processing terminal communicates with the total station via wired or wireless means. The data processing terminal can be the handheld controller originally provided with the total station, or a portable computer running the corresponding surveying software. The data processing terminal stores the design coordinate data of the anchor bolts to be installed. This data is obtained through coordinate transformation using CAD software. Its coordinate system is established with the longitudinal and transverse centerlines of the corridor as coordinate axes, i.e., the Y-axis represents the longitudinal direction of the corridor, and the X-axis represents the transverse direction.

[0054] In actual operation, the total station establishes a station based on the control points of the control network subsystem and continuously tracks and positions the target. The data processing terminal is configured to receive the measurement data from the total station in real time, calculate the current three-dimensional coordinates of the tracked target center, compare it with the preset design coordinates, and display the three deviation values ​​ΔX, ΔY, and ΔH on the screen in real time, providing the operator with intuitive and immediate adjustment guidance.

[0055] A positioning target is a device that enables the conversion from precise design points to a visual reference. Its structure includes a target body, a measuring prism fixedly mounted on the target body, and a laser line projector.

[0056] The target body serves as the structural base, with a standard interface at the bottom for mounting on a surveying tripod. The measuring prism is fixed to the target body for automatic tracking and precise distance measurement by the total station. The laser line projector is also fixed to the target body, and has a known and fixed spatial relationship with the measuring prism, which is precisely calibrated before leaving the factory.

[0057] The laser line projector is preferably a 360° rotatable, at least 5-line laser line projector capable of projecting one horizontal laser line and one or more vertical laser lines simultaneously. After the target center is precisely assigned the design coordinates through step S3, the laser line projector is activated. The projected horizontal laser line represents the design top surface elevation of that point, and the vertical laser line represents the installation axis passing through that point and parallel to the longitudinal centerline of the corridor. Together, they construct a visualized installation reference coordinate system, directly guiding the installation workers' operations.

Claims

1. A method for measuring the positioning of anchor bolts in the main belt conveyor corridor of a blast furnace, characterized in that, Includes the following steps: S1. Establishment of Coordinate System and Measurement Benchmark: The design coordinates of the anchor bolts to be installed are uniformly converted into coordinate data under an independent rectangular coordinate system with the longitudinal centerline of the corridor as the first axis and the transverse centerline as the second axis; Based on the longitudinal centerline of the corridor, two end control points are established in the construction area, and at least one intermediate control point is established between the two end control points. The two end control points and all intermediate control points are located on the longitudinal centerline of the corridor. One of the end control points is fixed by a forced centering device, and the three-dimensional coordinates of the end control point are obtained. S2. Flexible Station Establishment with Total Station: Set up the total station at any position along the longitudinal centerline. Using the two end control points as references, observe using the direct and inverted mirror method and the full circle method, and re-measure the intermediate control points. Adjust the position of the total station until the center of the total station is precisely collinear with the two end control points and all intermediate control points. Then, by measuring the horizontal distance from the center of the total station to one of the end control points, and combining the known coordinates of the end control point with the azimuth of the connecting line, calculate the three-dimensional coordinates of the center of the total station. Using the end control point as the zero direction, complete the station establishment using the direction method. S3. Design of precise single-point location: Place the positioning target, which integrates a measuring prism and a laser line projector, near the designed bolt position; use a total station to track the measuring prism, obtain the current coordinates of the positioning target center in real time, and calculate its three-dimensional deviation from the design coordinates; adjust the position of the positioning target according to the three-dimensional deviation guide until the three-dimensional deviation meets the preset tolerance, at which point the position of the positioning target center is the precise design point for the anchor bolt to be installed; S4. Generation of continuous visual installation benchmarks: The measuring prism and the laser line projector have a known fixed spatial relationship on the positioning target; at the first bolt point where the precise design points have been completed, the laser line projector projects a horizontal laser line that passes through the first bolt point and is consistent with the design elevation, and a longitudinal laser line that passes through the first bolt point and is parallel to the longitudinal center line of the corridor, thereby transforming the discrete point coordinates into continuous visual installation benchmarks. S5. Batch collaborative installation based on visual benchmarks: The subsequent bolt installation is aligned with the horizontal laser line as the elevation benchmark and the vertical laser line as the axis benchmark. The design spacing between the bolts is controlled by measuring tools for initial fixing, thus completing the positioning and installation of the subsequent bolts.

2. The method for measuring the positioning of anchor bolts in the main belt conveyor corridor of a blast furnace according to claim 1, characterized in that, In step S3, the three-dimensional deviation guidance specifically involves: the data processing terminal connected to the total station displays the three-dimensional deviation value in real time, and the positioning target is adjusted in the X, Y, and H directions based on the displayed three-dimensional deviation value.

3. The method for measuring the positioning of anchor bolts in the main belt conveyor corridor of a blast furnace according to claim 1, characterized in that, Step S2 includes: using the upright mirror to aim at one end control point and read the horizontal angle α1, and using the reverse mirror to aim at the other end control point and read the horizontal angle α2, requiring the deviation of |α1-α2±180°| to meet the preset requirements; then using the full circle method to observe the intermediate control point and finely adjust the position of the total station until the two end control points and all intermediate control points are collinear with the center of the total station.

4. The method for measuring and positioning anchor bolts in the main belt conveyor corridor of a blast furnace according to claim 1, characterized in that, Step S5 also includes: using a total station to sample and verify the bolts that have been initially fixed according to a predetermined ratio; if the deviation exceeds the limit, step S4 is repeated to calibrate the laser line.

5. A positioning and measurement system for anchor bolts in the main conveyor belt corridor of a blast furnace, characterized in that, include: Control network subsystem, total station, data processing terminal, and positioning target; The control network subsystem includes two end control points and at least one intermediate control point arranged along the longitudinal centerline of the corridor, as well as a forced alignment device; the forced alignment device is located at one of the end control points to fix the end control point and ensure alignment accuracy. The total station is connected to the data processing terminal; the total station establishes a station based on the control points of the control network subsystem and tracks the measuring prism of the positioning target; the data processing terminal is configured to calculate and display in real time the three-dimensional deviation between the current coordinates of the measuring prism of the positioning target and the preset design coordinates. The positioning target includes a target body, a measuring prism and a laser line projector fixed on the target body; the measuring prism is used for tracking and measurement by a total station; the laser line projector and the measuring prism are in a fixed relative position and orientation, and their spatial relative positions and attitudes are determined by pre-calibration; the laser line projector is configured to project a horizontal laser line and a longitudinal laser line parallel to the longitudinal center line of the corridor to establish a visual installation reference.

6. The positioning and measurement system for anchor bolts in the main belt conveyor corridor of a blast furnace according to claim 5, characterized in that, The data processing terminal stores the design coordinate data of the anchor bolts to be installed; the design coordinate data is coordinate data in an independent rectangular coordinate system with the longitudinal centerline and transverse centerline of the corridor as coordinate axes.

7. The positioning and measurement system for anchor bolts in the main belt conveyor corridor of a blast furnace according to claim 5, characterized in that, The centering error of the forced centering device shall not exceed 0.5 mm; the angle measurement accuracy of the total station shall be at least 1″, and the distance measurement accuracy shall be at least 1 mm + 1 ppm.

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