Industrial electromechanical pipeline modular integrated installation construction method

Abstract

The application discloses an industrial electromechanical pipeline modular integrated installation construction method, comprising the following steps: S1, multi-specialty collaborative BIM deepening design and module intelligent division, constructing a three-dimensional BIM model for pipeline comprehensive arrangement; S2, mobile intelligent manufacturing center field prefabrication and factory collaborative production, completing modular prefabrication of pipe assembly units and giving a unique identification two-dimensional code; S3, pipe assembly unit overall transportation and synchronous lifting installation, lifting the module to the design elevation as a whole; S4, self-adaptive deviation correction positioning and interface accurate connection, acquiring pose data in real time through a three-dimensional laser scanner; S5, whole-process digital quality traceability and acceptance evaluation, realizing data closed-loop management from design, processing to installation acceptance through a 'one thing one code' system, the application can reduce the number of climbing operations, improve construction efficiency, the installation precision reaches millimeter level, and realizes digital management and quality traceability of the whole construction process.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to a construction method for modular integrated installation of multi-disciplinary electromechanical pipelines in large spaces of industrial plants (such as electronic cleanrooms, food and pharmaceutical plants, automobile manufacturing plants, data centers, etc.). Background Technology

[0002] In industrial plant construction, the installation of electromechanical pipelines is a critical aspect affecting the construction period, quality, and safety. Industrial plants are typically characterized by high ceilings (10-30m), large spans (20-50m), and a wide variety of electromechanical pipelines, requiring the integration of multiple specialized pipelines such as water supply and drainage, HVAC, power pipelines, electrical cable trays, and fire protection pipelines. Traditional construction methods rely on high-altitude work platforms, hoisting and welding pipelines one by one, which presents the following prominent problems:

[0003] (1) The amount of work at height is large and the safety risks are high. Pipeline installation is mainly completed at height. Construction workers need to perform cutting, welding and assembly operations on high-altitude work platforms for a long time. The safety risks of falling from height and being struck by objects are prominent.

[0004] (2) Low construction efficiency and long construction period. Each professional pipeline needs to be hoisted and connected one by one. The coordination of multiple professional construction is complicated, the process is frequently crossed, and the construction period is long. In the existing technology, the installation process of electromechanical pipelines is generally as follows: drawing refinement and measurement layout → material procurement and on-site entry → (integrated) bracket fabrication and installation → pipeline processing and prefabrication → pipeline hoisting and assembly. The main construction process is completed on-site, and the labor efficiency is low.

[0005] (3) Quality control is difficult. Under the conditions of high-altitude operation on site, the welding quality and installation accuracy are greatly affected by the environment, and it is difficult to guarantee the consistency of quality.

[0006] (4) Difficulty in the integrated layout of multi-disciplinary pipelines. Industrial plants have dense pipelines, and collisions between pipelines of different disciplines and between pipelines and structural components are prominent issues, requiring complex integrated layout and collision detection before construction. In view of the above-mentioned problems in the existing technology, there is an urgent need for a modular integrated installation construction method for industrial electromechanical pipelines that can significantly reduce high-altitude operations, improve construction efficiency and quality, and reduce safety risks. Summary of the Invention

[0007] The technical problem to be solved by this invention is to provide a modular integrated installation method for industrial electromechanical pipelines, addressing the existing technical problems of large-scale high-altitude operations, high labor intensity, low construction efficiency, difficult quality control, and complex multi-disciplinary coordination in the installation of electromechanical pipelines in industrial plants.

[0008] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows:

[0009] To address the high safety risks and long construction periods associated with traditional high-altitude pipe hoisting and on-site welding, this invention restructures the construction process into five interconnected steps. In step S1, through multi-disciplinary collaborative BIM-based detailed design and modularization, based on the functional zoning of the factory and the characteristics of pipeline routes, the originally dispersed pipelines of multiple disciplines such as water supply and drainage, HVAC, and electrical systems are integrated into several pipe assembly units, each with its own integrated support and hanger system. This division makes it possible to transform complex high-altitude, three-dimensional operations into modular ground-based operations. Step S2 utilizes a mobile intelligent manufacturing center for on-site prefabrication, integrating CNC cutting, automatic welding, assembly, and testing equipment at the construction site or adjacent areas. Based on the digital processing data package generated in step S1, pipe segment cutting, beveling, assembly, welding, and anti-corrosion treatment are completed, and each unit is assigned a unique QR code, linking processing and testing data with the BIM model. This step transforms traditional decentralized high-altitude processing on-site into a centralized, automated, and digital prefabrication mode on the ground, ensuring consistent processing accuracy while significantly reducing the amount of high-altitude work. Step S3 utilizes an integrated transport bracket to horizontally transport the prefabricated pipe assembly unit below the installation position. Then, a hydraulic synchronous lifting system (including multiple through-type hydraulic jacks, displacement sensors, pressure sensors, proportional servo valves, and a central controller) positioned above the installation position connects the lifting points with steel strands. The central controller collects data from each sensor in real time and adjusts the lifting speed of each lifting point using a closed-loop control algorithm, achieving a smooth overall lifting of the module. This step transforms the traditional serial operation mode of lifting and assembling pipes one by one into a parallel operation mode of lifting and positioning the entire module in one go, significantly shortening the high-altitude operation time. Step S4, when the module is lifted close to the design elevation, uses a 3D laser scanner to acquire the module's pose data in real time. This data is compared with the target pose in the BIM model to calculate the six-dimensional spatial deviation. A fine-tuning hydraulic cylinder group arranged around the module adaptively corrects the deviation. Once the deviation converges to the preset accuracy, the interface connection is completed. This step solves the technical challenge of accurately aligning large modules during high-altitude docking, ensuring installation accuracy at the millimeter level. Step S5 uses a "one item, one code" system to link the design, processing, testing, installation, and acceptance data of each unit to a unified digital management platform, enabling real-time display of construction progress and quality status, as well as anomaly warnings, and archiving of all process data. Thus, this invention forms a complete closed loop from design division, ground prefabrication, overall lifting, precise correction to digital traceability, reducing the number of high-altitude operations by more than 85%, shortening the construction period by more than 80%, and reducing overall labor costs by more than 70%.

[0010] To ensure the rationality of modular division while considering the operability of transportation, hoisting, and on-site construction, this invention further limits the principles for dividing pipe assembly units: using functional zoning of the factory building as the basic unit to avoid cross-zone operations; controlling the pipeline length within the same unit to a range of 6-12m, facilitating the operation of transport brackets and lifting systems while integrating sufficient pipeline length to reduce the number of interfaces; integrating pipelines from no fewer than three electromechanical disciplines within each unit, truly reflecting the advantages of multi-disciplinary integration; and ensuring the total weight of the unit does not exceed 15 tons to accommodate the rated load of conventional hydraulic lifting equipment and the carrying capacity of transport vehicles. In practical application, this principle is automatically calculated using a BIM model to determine the pipeline length, number of disciplines, and estimated weight of each candidate unit, and after iterative optimization, outputs a division scheme that meets the above constraints. Pipe assembly units divided using this principle do not require disassembly during transportation and do not cause difficulties in equipment selection due to overweight or excessive size during hoisting. Simultaneously, it ensures that all professional pipelines are fixed to the same hanger system within the module according to a comprehensive layout scheme, significantly reducing the workload of on-site interface coordination.

[0011] To address the challenges of traditional fixed prefabrication plants being far from construction sites, having long transportation cycles, and being unable to flexibly respond to on-site changes, this invention deploys a mobile electromechanical intelligent manufacturing center at or near the construction site. Composed of at least two standard container modules, it integrates CNC cutting equipment, automatic welding workstations, assembly platforms, and quality inspection equipment. All equipment is networked with an industrial IoT and digital management platform, uploading production data in real time. This setup allows prefabrication capabilities to migrate with the project, achieving a rapid response mode where the "factory is right next to the construction site." During operation, the digital processing data package generated by BIM is distributed from the cloud to the various CNC devices in the intelligent manufacturing center. A CNC intersecting line plasma cutter automatically completes pipe segment cutting (accuracy ±1mm), an automatic flange short pipe welding robot completes the welding of pipe segments and flanges (first-pass yield ≥98%), and an automatic pipe spraying and drying integrated machine completes anti-corrosion treatment. The production status, output, and quality inspection results of all equipment are transmitted back to the management platform in real time, allowing managers to remotely monitor the processing progress and quality of each pipe assembly unit. This technical solution extends the advantages of factory prefabrication of industrial pipelines to the construction site, retaining the high precision and efficiency of automated equipment while eliminating the costs and cycle losses caused by long-distance transportation.

[0012] To address quality issues such as large cutting length errors, inconsistent bevel angles, and misaligned flange bolt holes during traditional manual material preparation and assembly, this invention specifically defines the content of the digital processing data package: it includes the cutting length, bevel angle, welding process parameters, and flange bolt hole angles for each pipe segment. The CNC cutting machine automatically generates CNC machining code based on this data package. The process is as follows: After extracting the precise length, material, bevel type at both ends, and flange connection method of each pipe from the BIM model, the system automatically calculates the pipe segment cutting length (considering weld shrinkage allowance) and generates NC code containing the cutting trajectory, bevel angle, and plasma cutting parameters. The welding process parameters, including welding material grade, welding current, voltage, and interpass temperature, are directly transmitted to the automated welding robot. The flange bolt hole angles ensure that the flange hole positions on different pipe segments within the same pipe assembly unit correspond one-to-one, avoiding on-site hole enlargement or forced connections. This setup fully automates the process from BIM design to CNC machining, keeping material loss within 0.5% and achieving a pipe end machining accuracy of ±1mm, providing high-quality preconditions for subsequent assembly and welding.

[0013] To address the problem of module tilting, deformation, and even damage caused by uneven load and synchronization errors during multi-point hydraulic synchronous lifting of large pipe assembly units, this invention further refines the control strategy of the hydraulic synchronous lifting system: It adopts a "feedforward + feedback" composite control structure. The feedforward channel uses the simulated lifting trajectory as a reference input, while the feedback channel uses the displacement deviation as the input for PID control. The control cycle is 100-200ms in the coarse adjustment stage and 20-50ms in the fine adjustment stage. The synchronization accuracy of each lifting point is controlled within ±2mm. Its working principle is as follows: Before lifting, the system generates an ideal velocity-time trajectory curve based on the module's center of gravity distribution, lifting point arrangement, and lifting height through dynamic simulation, serving as the feedforward input. This allows the hydraulic jacks at each lifting point to pre-adjust their output according to this trajectory. During lifting, displacement sensors (accuracy 0.01mm) and pressure sensors installed on each jack collect data in real time at millisecond frequencies. The central controller calculates the displacement deviation between each lifting point and adjusts the opening of the corresponding proportional servo valve through a PID algorithm, thereby fine-tuning the flow rate and speed of each jack. The coarse adjustment stage employs a relatively long control cycle (100~200ms) to accommodate initial load fluctuations, while the fine adjustment stage shortens this to 20~50ms for rapid response. This control structure ensures that the height difference between each lifting point remains within ±2mm throughout the entire lifting process, effectively preventing plastic deformation of the module or damage to the supports caused by uneven stress.

[0014] To further enhance the module's resistance to torsion and swaying during the lifting process, this invention specifies the arrangement of lifting points and guiding devices in the hydraulic synchronous lifting system: 4-8 lifting points are evenly arranged on both sides of the center of gravity of the pipe assembly unit; a guiding device is installed on the pipe assembly unit to constrain horizontal swaying during the lifting process. The principle of this arrangement is that symmetrically distributing the lifting points on both sides of the center of gravity ensures that the resultant tension of each lifting point passes through the module's center of gravity, avoiding additional torque that could cause the module to rotate. The number of 4-8 lifting points is selected based on the module's length and weight: light modules under 6m can use 4 lifting points, while modules 12m long or weighing close to 15 tons use 6-8 lifting points to ensure that the load on each lifting point does not exceed the rated capacity of the hydraulic jack. The guiding device typically consists of guide wheels fixed to the module and slides vertically arranged on structural columns or independent guide rails. During the lifting process, the guide wheels are always in contact with the slides, constraining the module's displacement in the horizontal direction (X, Y directions) and allowing it to move only in the vertical direction (Z direction). This technical solution ensures that even in the event of sudden gusts of wind or instantaneous fluctuations in the hydraulic system, the module will not experience significant horizontal swaying, thus guaranteeing the safety of the lifting process and the initial positioning accuracy before docking.

[0015] To address the challenge of precise alignment and reliable interface sealing when the module approaches the design elevation, this invention specifies the pre-defined accuracy range in step S4: planar position deviation not exceeding ±3mm, elevation deviation not exceeding ±2mm, and levelness deviation not exceeding 1mm / m. This accuracy range is determined based on the technical specifications for flange connections of electromechanical pipelines in industrial plants (such as GB 50235-2010 "Code for Construction of Industrial Metal Piping Engineering") and the compression characteristics of the sealing gaskets. The process is as follows: when the module is raised to approximately 50mm from the design elevation, a 3D laser scanner measures key feature points on the module (such as the four corners of the integrated support and the center of the main pipeline flange interface), calculating the deviations from the BIM target pose (ΔX, ΔY, ΔZ, and levelness). Subsequently, the fine-tuning hydraulic cylinder group performs six-degree-of-freedom correction based on these deviations. Only when all deviations simultaneously meet the aforementioned thresholds does the system issue an "alignment complete" signal, allowing the operator to tighten or weld the flange bolts. The reasonable setting of this preset accuracy avoids the excessive pursuit of higher accuracy, which would significantly increase the correction time (for example, compressing the elevation deviation to ±1mm may require several times the adjustment time), while ensuring the sealing of the interface connection and the uniformity of structural stress. In actual engineering, it achieves a balance between the feasibility and economy of millimeter-level docking.

[0016] To address the challenge of achieving precise six-dimensional micro-displacement control in a fine-tuning actuator, this invention further defines the structure and performance of the fine-tuning hydraulic cylinder group: it possesses translational degrees of freedom in the X, Y, and Z directions, with a displacement resolution of 0.01 mm. This fine-tuning hydraulic cylinder group typically consists of three or more sets of micro hydraulic cylinders arranged in parallel (e.g., a Stewart platform configuration) or in series. Each set of cylinders incorporates a high-precision displacement sensor and a proportional servo valve. Its working principle is as follows: after the central controller calculates the six-dimensional deviations (ΔX, ΔY, ΔZ, Δα, Δβ, Δγ) to be adjusted, it converts these deviations into independent extension commands for each fine-tuning hydraulic cylinder using an inverse kinematics algorithm. Due to the high displacement resolution of 0.01 mm, each hydraulic cylinder can precisely extend and retract in 0.01 mm increments, thereby achieving micron-level attitude adjustment of the entire module. This setting enables the residual deviation after coarse positioning to be eliminated quickly and accurately, and the final pose of the module before docking is highly consistent with the theoretical pose in the BIM model, providing a fundamental guarantee for flange hole alignment and smooth bolt insertion.

[0017] To address the issues of fragmented data, difficulty in traceability, and inconvenient access to module information for on-site installation personnel throughout the construction process, this invention specifically defines a "one item, one code" system: using QR codes or RFID electronic tags, design data, processing data, testing data, and installation guidance information for the pipe assembly unit can be instantly obtained by scanning with a mobile terminal. The process is as follows: after module prefabrication in the mobile intelligent manufacturing center, the system automatically generates a unique code and uploads all relevant information for that module in the BIM model (design drawings, material certificates, welding records, non-destructive testing reports, anti-corrosion coating thickness, etc.) to a cloud database. The QR code is fixed to a prominent position on the module via laser etching or a waterproof label. On-site installation personnel can scan the QR code using a tablet or smartphone to access the module's 3D model, interface direction diagram, bolt torque requirements, adjacent module numbers, and other installation guidance information. Simultaneously, they can input measured data during installation (such as final elevation and bolt tightening torque values) in real time, and the data is automatically written back to the database. RFID electronic tags are suitable for harsh environments or scenarios requiring long-distance batch identification. This technical solution enables seamless data flow and closed-loop management throughout the entire process from design and processing to installation and acceptance. Quality responsibility can be traced back to each pipe assembly unit and each process, significantly improving the integrity of project archives and the usability of operation and maintenance phases.

[0018] To ensure the flexibility of mobile intelligent manufacturing centers while also meeting the specialized production needs of large equipment modules and irregularly shaped components, this invention proposes a collaborative production model between mobile intelligent manufacturing centers and fixed prefabrication plants. Standard pipe sections and integrated supports are produced in the mobile intelligent manufacturing center, while large equipment modules (such as chillers, large water pumps, and air conditioning units) and irregularly shaped components (such as space bends, reducers, and special valve assemblies) are produced in the fixed prefabrication plant and then transported to the site. The principle behind this collaborative model is that standard pipe sections and integrated supports have uniform specifications, mature processing technology, and high repeatability, making them suitable for large-scale, high-efficiency production using automated production lines in mobile intelligent manufacturing centers. In contrast, large equipment modules and irregularly shaped components often require specialized tooling, heavy-duty lifting equipment, and special testing methods, for which fixed prefabrication plants offer more comprehensive supporting facilities. In practice, the BIM model categorizes components into "standardized" and "customized" types, generating processing instructions for each and issuing them to the mobile intelligent manufacturing center and the fixed plant, respectively. After the two types of components are transported to the site, they are finally assembled in the assembly area below the installation location to form a complete pipe assembly unit (embedding large equipment into the integrated support and hanger system), and then lifted as a whole. This collaborative model leverages the advantages of mobile intelligent manufacturing centers—rapid response and low logistics costs—while utilizing the specialized equipment capabilities of fixed factories, achieving optimal resource allocation, and is particularly suitable for large and complex industrial plant projects.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] 1. Significantly reduces high-altitude operations and improves construction safety. This invention transforms the traditional decentralized high-altitude operation mode into a construction mode of "ground modular prefabrication + overall synchronous lifting." The pipe assembly units are assembled on the ground or in a mobile intelligent manufacturing center, requiring only a single overall lifting to be in place. According to statistics, using modular overall lifting technology can reduce the number of high-altitude operations by more than 85%, effectively reducing safety risks such as falls from heights and being struck by objects.

[0021] 2. Significantly improved construction efficiency. This invention enables rapid on-site prefabrication through a mobile intelligent manufacturing center, allowing parallel operations with civil construction and eliminating limitations imposed by fixed factory capacity and transportation distance. The pipe assembly units are installed in one go using a whole-unit lifting method, reducing construction time by more than 80% compared to the traditional method of hoisting and welding pipes one by one.

[0022] 3. Significantly improved installation quality. This invention utilizes multi-disciplinary collaborative BIM-based detailed design to identify and resolve pipeline collision issues in advance; it achieves millimeter-level precision machining through CNC equipment, resulting in a first-time welding pass rate of over 98%; and it ensures high precision in the installation position and interface connection of pipe assembly units through an adaptive synchronous lifting and correction positioning system.

[0023] 4. Achieve end-to-end digital management and control. This invention establishes a "one item, one code" quality traceability system, enabling traceability of data for each pipe assembly unit from design, processing, testing to installation. The digital management platform reflects construction progress and quality status in real time, providing data support for project management decisions.

[0024] 5. Reduced overall costs. This invention reduces the need for manual labor in high-altitude operations, reduces material waste (material loss can be controlled within 0.5%), and shortens the construction period. Overall labor costs can be reduced by more than 70%, and material waste by more than 40%.

[0025] 6. Highly adaptable and widely applicable. This invention adopts a collaborative production model combining fixed factories and mobile intelligent manufacturing centers. It can achieve large-scale standardized production through fixed factories, while providing rapid response services to remote project sites through mobile intelligent manufacturing centers. It is suitable for the installation of electromechanical pipelines in various industrial plants, large public buildings, and other projects. Attached Figure Description

[0026] Figure 1 This is a flowchart illustrating the overall process of the modular integrated installation method for industrial electromechanical pipelines according to the present invention.

[0027] Figure 2 A schematic diagram showing the division of the pipe assembly unit module.

[0028] Figure 3 A prefabricated schematic diagram of the mobile intelligent manufacturing center. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to these embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0030] Example 1: As Figure 1 , Figure 2 , Figure 3 As shown, the present invention provides a modular integrated installation method for industrial electromechanical pipelines, comprising the following steps:

[0031] Step S1: Multi-disciplinary collaborative BIM detailed design and intelligent module partitioning

[0032] First, collect all design drawings and technical parameters for the electromechanical systems within the industrial plant, including water supply and drainage systems (production water supply, domestic water supply, fire water supply, and drainage pipes), HVAC systems (supply air ducts, return air ducts, smoke exhaust ducts, refrigerant pipes, and hot water pipes), power piping systems (compressed air, steam, nitrogen, etc.), electrical systems (cable trays and busbars), and fire protection systems (sprinkler pipes and fire hydrant pipes). Import the design data for these systems into a BIM platform (such as Autodesk Revit, Navisworks, or equivalent software), and using the plant structure model as a reference, create a 1:1 scale 3D integrated model containing all electromechanical pipelines.

[0033] Pipeline layout and clash detection are performed in a multi-disciplinary collaborative environment. The software's clash detection function automatically identifies intersections and collisions between pipelines and structural components. The average accuracy of pipeline clash detection based on BIM technology exceeds 98%. Following the layout principles of "pressurized pipes yielding to unpressurized pipes, smaller pipes yielding to larger pipes, branches yielding to main trunks, and flexible pipes yielding to rigid pipes," collision points are optimized and adjusted item by item, while also performing headroom analysis and maintenance space analysis.

[0034] Based on the optimized BIM integrated model, modular division of pipe assembly units is carried out. The division follows these principles: ① The basic division unit is the functional zoning of the factory (production area, auxiliary area, storage area, power area); ② The length of pipelines within the same pipe assembly unit is controlled within the range of 6~12m; ③ Each pipe assembly unit integrates pipelines of no less than 3 electromechanical disciplines (such as water supply and drainage + HVAC + electrical), achieving a high degree of integration of multi-discipline pipelines; ④ The total weight of the pipe assembly unit is controlled within the processing capacity of the mobile intelligent manufacturing center (generally not exceeding 15 tons) and within the rated load range of the on-site lifting equipment.

[0035] Each pipe assembly unit includes: a comprehensive support system (main crossbeams, vertical hangers, diagonal braces), various professional pipelines (fixed to the comprehensive support system according to the BIM layout), valve assemblies and accessories (valves, filters, compensators, etc.). The comprehensive support system is assembled into a modular structure by welding steel sections (H-beams or channel steel).

[0036] Each pipe assembly unit is assigned a unique number, generating a digital processing data package containing the following information: unit number, region, spatial coordinate range, pipeline list (name, specifications, material, length), cutting length and beveling angle of each pipe segment, flange specifications and bolt hole angles, welding process parameters, and connection interface information. This digital processing data package is synchronized to the CNC equipment in the mobile intelligent manufacturing center via a local area network or cloud platform.

[0037] Step S2: On-site prefabrication at the mobile intelligent manufacturing center and collaborative production with the factory

[0038] Deploy mobile electromechanical intelligent manufacturing centers at or near the construction site. Each mobile intelligent manufacturing center consists of at least two standard container modules and can be flexibly expanded according to production needs. Core equipment includes: ① CNC intersecting line plasma cutting machine (cutting accuracy ±1mm); ② Automatic flange and short pipe welding robot (first-pass welding qualification rate ≥98%); ③ Automatic pipe spraying and drying integrated machine; ④ Mechanical assembly platform and flexible assembly platform (assembly accuracy ±1mm); ⑤ Intelligent warehousing system.

[0039] Each piece of equipment is connected to the digital management platform via the Industrial Internet of Things (IIoT) to upload production data (cutting quantity, welding parameters, inspection results, etc.) in real time. The platform displays the production progress and equipment operating status in real time. In the prefabrication of industrial pipes, data is imported into automated cutting equipment, and automated welding robots are used for pipe welding, increasing the material feeding speed by 50%, achieving an automation rate of 80% for pipe end welding, saving 20% ​​on welding costs, and shortening the construction period by 20%.

[0040] The production process of the mobile intelligent manufacturing center is as follows: raw material (pipes, steel profiles, flanges, etc.) arrival inspection → CNC cutting and blanking → beveling → pipe section and flange assembly → automatic welding → non-destructive testing of welds → anti-corrosion spraying and drying → integrated support and hanger assembly → installation and fixing of various professional pipelines on the support and hangers → valve and accessory installation → overall inspection of pipe assembly units → affixing QR code labels → finished products are put into storage for shipment.

[0041] Each pipe assembly unit is assigned a unique QR code according to the "one item, one code" principle. The QR code is attached to a prominent position on the pipe assembly unit by laser etching or waterproof labeling. By scanning the QR code with a mobile terminal, the design data, processing data, test data and installation guidance information of the unit can be obtained instantly.

[0042] Large equipment modules such as chillers and large water pumps, as well as irregularly shaped components, are produced collaboratively in fixed prefabrication plants. After prefabrication, they are transported to the construction site by special transport vehicles.

[0043] Step S3: Overall transportation and synchronous lifting installation of the pipe assembly unit

[0044] After the pipe assembly units are prefabricated and inspected at the mobile intelligent manufacturing center, they are transported horizontally using an integrated transport bracket. The transport bracket adopts a welded steel frame structure with roller assemblies installed at the bottom to transport the pipe assembly units directly below their corresponding installation positions.

[0045] A hydraulic synchronous lifting system is installed above the installation location (on the steel structure roof or concrete beam-slab structure of the factory building). The hydraulic synchronous lifting system includes: 4-8 through-hole hydraulic jacks (each with a rated lifting force of 100-500kN), displacement sensors (accuracy 0.01mm), pressure sensors, proportional servo valves, and a central controller. The hydraulic jacks are connected to lifting points on the pipe assembly unit via steel strands, with the lifting points evenly distributed on both sides of the center of gravity of the pipe assembly unit.

[0046] A guiding device, including a vertical guide rail and a limit stop, is installed on the pipe assembly unit to restrain horizontal swaying and rotation during the lifting process.

[0047] The hydraulic synchronous lifting system is activated, and the central controller collects data from each displacement and pressure sensor at a frequency of 50-100Hz, calculating the displacement deviation and load distribution at each lifting point in real time. The control system adopts a "feedforward + feedback" composite control structure: the feedforward channel uses the simulated lifting trajectory as a reference input, and the feedback channel uses the real-time displacement deviation as the input for PID control. Related research shows that using an improved PID control method can achieve effective control of the synchronization accuracy of the hydraulic cylinder group.

[0048] When the displacement deviation between each lifting point exceeds ±2mm, the central controller automatically adjusts the opening of the corresponding proportional servo valve to correct the lifting speed of that lifting point. The control cycle is 100~200ms in the coarse adjustment stage and 20~50ms in the fine adjustment stage (within 0.5m of the target height). The lifting speed is controlled between 0.5~2m / min.

[0049] Step S4: Adaptive correction positioning and precise interface connection

[0050] When the pipe assembly unit is raised to near the design elevation (within approximately 50mm), the adaptive correction and positioning program is activated.

[0051] First, a 3D laser scanner is used to perform real-time spatial pose measurement of key feature points of the pipe assembly unit (the four corner points of the integrated support and hanger, the center point of the flange interface of the main pipeline, etc.). The Radian laser tracker is a solution for large-scale precision measurement, with micron-level measurement accuracy (±15μm +6μm / m) and a measurement range of over 160 meters (radius 80 meters), capable of acquiring spatial 3D data in real time. Real-time six-dimensional pose data (X, Y, Z, α, β, γ) of the pipe assembly unit in the global coordinate system is obtained.

[0052] Secondly, the real-time pose data is compared with the target pose in the BIM detailed design model, and the six-dimensional spatial deviations are calculated: ΔX (longitudinal deviation), ΔY (lateral deviation), ΔZ (elevation deviation), Δα, Δβ, and Δγ (attitude deviation).

[0053] Next, adaptive correction adjustment is achieved through fine-tuning hydraulic cylinder groups (4 to 8 groups, each with translational degrees of freedom in the X, Y, and Z directions and a displacement resolution of 0.01 mm) arranged around the pipe assembly unit. The six-dimensional deviation is input into the kinematic model of the fine-tuning hydraulic cylinder group, and the displacement adjustment of each hydraulic cylinder is calculated through Jacobian matrix mapping, driving the coordinated action of each hydraulic cylinder.

[0054] The correction adjustment is complete when the six-dimensional deviations meet the following preset accuracy requirements: planar position deviations ΔX and ΔY do not exceed ±3mm; elevation deviation ΔZ does not exceed ±2mm; and levelness deviation does not exceed 1mm / m. Domestic large-scale utility tunnel module installation practices have proven that millimeter-level docking accuracy is feasible in engineering applications.

[0055] After the deviation meets the standard, the pipe assembly unit is connected to the adjacent unit or the reserved interface. After the connection is completed, the interface sealing test is carried out (performed at 1.15 to 1.5 times the design pressure). Finally, the two ends of the main crossbeam of the integrated support are fixed to the embedded parts on the plant structure with high-strength bolts.

[0056] Step S5: Full-process digital quality traceability and acceptance assessment

[0057] Throughout the construction process, a "one item, one code" system links the design, processing, testing, installation, and acceptance data of each pipe assembly unit to a unified digital management platform. This digital management platform offers the following functions: real-time construction progress display (based on the BIM model, with different colors distinguishing module status), quality status monitoring (automatic marking and warnings for non-conforming items), data traceability (quick retrieval of complete records via barcode scanning), and anomaly warnings (automatic push notifications for progress delays and quality anomalies). Based on BIM, the integrated digital visualization management method for electromechanical installation construction, through a BIM database-driven digital collaboration mechanism, enables data fusion, assembly optimization, and visualized closed-loop management throughout the entire electromechanical installation process, significantly improving project accuracy, efficiency, and controllability. All construction process data is archived in the project quality database and delivered to the owner in digital archive form, providing complete data support for subsequent operation and maintenance management.

[0058] Example 2

[0059] The modular integrated installation method for industrial electromechanical pipelines proposed in this invention has the following overall working principle.

[0060] First, during the construction preparation phase, designers from various disciplines imported the design drawings and parameters of all electromechanical disciplines, including water supply and drainage, HVAC, power pipelines, electrical cable trays, and fire protection pipelines, into the same BIM platform. A 1:1 three-dimensional integrated model was then established based on the factory structure model. The collision detection function automatically identified intersections and conflicts between pipelines and structural components. Following the principles of "pressurized pipes yielding to unpressurized pipes, smaller pipes yielding to larger pipes, branches yielding to main pipes, and flexible pipes yielding to rigid pipes," adjustments were made item by item. Simultaneously, headroom analysis and maintenance space verification were performed. After optimization, the system used the factory's functional zoning as the basic unit, dividing multiple professional pipelines with similar spatial locations and consistent routes, along with the integrated support and hanger system, into several pipe assembly units. Each unit was controlled to be 6 to 12 meters long, integrating no fewer than three disciplines, and with a total weight not exceeding 15 tons. After the division is completed, the BIM system automatically extracts the pipeline specifications, pipe section cutting length, bevel angle, flange bolt hole angle and welding process parameters of each unit, generates a digital processing data package containing all the above information, and synchronously distributes it to each CNC equipment in the mobile intelligent manufacturing center through the Industrial Internet of Things or wired network.

[0061] During the prefabrication phase, the mobile intelligent manufacturing center is deployed at or near the construction site, consisting of two or more standard container modules. Internally, it integrates a CNC intersecting plasma cutting machine, an automatic flange short pipe welding robot, an automatic pipe spraying and drying machine, a mechanical assembly platform, and quality inspection equipment. After receiving the digital processing data package, the cutting equipment automatically generates CNC code and cuts the pipe sections according to the preset pipe length and bevel angle. The cut pipe sections and corresponding flanges are pre-assembled on the assembly platform, and then the automatic welding robot performs circumferential welding on the flanges and pipe sections according to the welding process parameters (welding current, voltage, interpass temperature, etc.) in the data package. After welding, non-destructive testing is performed, and the qualified pipe sections enter the automatic spraying and drying machine for anti-corrosion treatment. After undergoing the aforementioned processes, individual pipe sections, along with pre-fabricated integrated support and hanger steel profiles, valve accessories, etc., are assembled on the assembly platform according to their spatial relative positions in the BIM model. First, the main horizontal beams, vertical hangers, and diagonal braces of the integrated support and hanger are welded into a frame. Then, the various specialized pipe sections are fixed onto the support and hanger according to the design layout sequence, and valves, filters, compensators, and other accessories are installed. After the assembled pipe assembly unit passes overall inspection, a unique QR code is affixed or laser-etched in a prominent location. The unit's design drawings, processing data (cutting records, welding parameters, inspection reports), and BIM model are automatically uploaded to the digital management platform via a mobile terminal.

[0062] The prefabricated pipe assembly units are horizontally transported to their installation positions directly below them using an integrated transport bracket (a welded steel frame with rollers at the bottom). Above the installation positions, on the steel roof or concrete beam-slab structure of the factory building, a hydraulic synchronous lifting system is pre-fixed. This system consists of four to eight through-hole hydraulic jacks evenly distributed along both sides of the pipe assembly unit's center of gravity, displacement and pressure sensors mounted on each jack, proportional servo valves, and a central controller. The operator passes one end of a steel strand through the center hole of the hydraulic jack and anchors it, while the other end is connected to the lifting point of the pipe assembly unit via a special lifting lug. After the system is started, the central controller collects real-time data from all displacement and pressure sensors at a frequency of 50 to 100 Hz and compares the actual displacement of each lifting point with the preset ideal lifting trajectory. The control system employs a "feedforward + feedback" composite control algorithm: the feedforward channel pre-adjusts the initial output of each jack based on the simulated lifting trajectory, while the feedback channel adjusts the opening of the proportional servo valve in real time through PID calculations based on the displacement deviation, thereby changing the oil flow rate and lifting speed of each jack. For coarse adjustments, a control cycle of 100 to 200 milliseconds is used when the target elevation is far away. When the module enters the fine adjustment zone within 0.5 meters of the design elevation, the control cycle is shortened to 20 to 50 milliseconds, ensuring that the synchronization accuracy between each lifting point is always controlled within ±2 millimeters. The lifting speed is generally controlled between 0.5 and 2 meters per minute. Throughout the process, the guide device (guide wheels cooperating with the vertical rail) installed on the pipe assembly unit continuously constrains the horizontal swing of the module, allowing it to move only in the vertical direction.

[0063] When the pipe assembly unit is raised to approximately 50 mm above the design elevation, the adaptive correction and positioning stage begins. At this point, one or more 3D laser scanners positioned around the installation area are activated to perform real-time spatial measurements on key feature points of the pipe assembly unit (the four corner points of the integrated support and the center point of the flange interface of the main pipeline), obtaining six-dimensional pose data (X, Y, Z coordinates and rotation angles α, β, γ in three directions) of the module in the global coordinate system. This data is transmitted to the central controller, which compares it item by item with the target pose in the BIM detailed design model in step S1, calculating the six-dimensional spatial deviations (ΔX, ΔY, ΔZ, Δα, Δβ, Δγ). The central controller inputs the six-dimensional deviations into the inverse kinematics model of the fine-tuning hydraulic cylinder group, calculating the required independent elongation of each fine-tuning hydraulic cylinder group positioned around the module using Jacobian matrix mapping. The fine-tuning hydraulic cylinder group has translational degrees of freedom in the X, Y, and Z directions, with a displacement resolution of up to 0.01 mm, and can be precisely controlled by a proportional servo valve. The controller drives each set of hydraulic cylinders to work together according to the calculated elongation, causing the module to translate in the X, Y, and Z directions and rotate around each axis until all six-dimensional deviations converge to the preset accuracy range: planar position deviation not exceeding ±3 mm, elevation deviation not exceeding ±2 mm, and levelness deviation not exceeding 1 mm per meter. After the system confirms that the standards are met, it issues an alignment completion signal.

[0064] After the deviation is met, the operators proceed with the interface connections. First, the two ends of the main crossbeam of the integrated support are locked to the pre-embedded fasteners on the plant structure using high-strength bolts, ensuring stable vertical and horizontal support for the pipe assembly unit. Then, the pipeline flanges or welded joints of this unit are connected to the pre-reserved joints of adjacent units or the plant: for flange connections, the flanges are aligned with the bolt hole angles in the BIM model, bolts are inserted, and tightened symmetrically to the specified torque; for welded connections, the joint welding is performed in a stable posture after the deviation correction is completed. After all interface connections are completed, a sealing test is conducted at 1.15 to 1.5 times the design pressure to confirm no leakage.

[0065] Throughout the construction process, a fully digital quality traceability system operates synchronously. Each pipe assembly unit uses a unique QR code (or RFID tag) as a data index, linked to the unit number in the BIM model from the design phase. During prefabrication in the mobile intelligent manufacturing center, processing parameters and test results for each process are automatically written into the unit's digital archive via the Industrial Internet of Things (IIoT). During transportation and lifting, operators scan QR codes using mobile terminals to record transportation time, hoisting personnel, and key data during the lifting process (displacement records of each lifting point, correction adjustments, etc.). Similarly, during interface connection and testing, bolt torque values, welding records, test pressure, and holding time are entered by scanning QR codes. All data is aggregated in real-time to a unified digital management platform. This platform uses the BIM model as a visual interface, employing different colors to distinguish the processing status (not started, in progress, completed), quality status (qualified, unqualified, pending inspection), and installation progress (awaiting transportation, in progress, in place, connected) of each unit. When delays or quality anomalies occur, the platform automatically sends warning messages to management personnel. Once all construction is completed, the digital management platform will archive the complete data of each pipe assembly unit from design, processing, testing, installation to acceptance into an engineering quality database, and deliver it to the owner in the form of digital archives for subsequent operation and maintenance management.

[0066] In summary, this invention transforms the traditional high-altitude, dispersed, serial, and low-precision electromechanical pipeline installation mode into a ground-integrated, parallel, and high-precision modular installation mode through BIM-driven modular division, automated on-site prefabrication in a mobile intelligent manufacturing center, multi-point hydraulic synchronous lifting and closed-loop control, 3D laser-guided micro-adjustment hydraulic cylinder group adaptive correction, and one-item-one-code full-process traceability. Data exchange and coordinated actions between each step form a complete closed loop from design to acceptance, thereby significantly reducing high-altitude operations, improving construction efficiency, ensuring millimeter-level installation accuracy, and providing full-process quality traceability.

[0067] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A modular integrated installation method for industrial electromechanical pipelines, characterized in that, Includes the following steps: Step S1: Multi-disciplinary collaborative BIM detailed design and module division: Based on the functional zoning of the factory and the characteristics of pipeline routing, the electromechanical pipelines are divided into several pipe assembly units. Each pipe assembly unit contains electromechanical pipelines and integrated support and hanger systems from at least two disciplines. Step S2: On-site prefabrication and factory collaborative production in mobile intelligent manufacturing center: Deploy a mobile electromechanical intelligent manufacturing center at the construction site or adjacent area, integrating CNC cutting equipment, automatic welding workstations, assembly platforms, and quality inspection equipment; based on the digital processing data package generated in Step S1, complete pipe segment cutting, beveling, pipe segment assembly, welding, and anti-corrosion treatment of the pipe assembly unit within the mobile intelligent manufacturing center; assign a unique QR code to each pipe assembly unit, and link the processing data and inspection data with the BIM model; Step S3: Overall Transportation and Synchronous Lifting Installation of Pipe Assembly Units: The prefabricated pipe assembly units are horizontally transported to below the installation position using an overall transport bracket; a hydraulic synchronous lifting system is installed above the installation position, which includes multiple through-hole hydraulic jacks, displacement sensors, pressure sensors, proportional servo valves, and a central controller; the hydraulic synchronous lifting system is connected to the pipe assembly units via steel strands; the hydraulic synchronous lifting system is started, and the central controller collects data from each displacement sensor and pressure sensor in real time, adjusting the lifting speed of each lifting point through a closed-loop control algorithm to lift the entire pipe assembly unit to the designed installation elevation; Step S4: Adaptive Correction Positioning and Precise Interface Connection: When the pipe assembly unit is raised to near the design elevation, the pose data of the pipe assembly unit is acquired in real time using a 3D laser scanner; the real-time pose data is compared with the target pose in the BIM detailed design model in Step S1 to calculate the six-dimensional spatial deviation; adaptive correction adjustment is performed using fine-tuning hydraulic cylinders arranged around the pipe assembly unit to bring the deviation to a preset accuracy range; after the deviation meets the standard, the pipe assembly unit is connected to adjacent units or reserved interfaces; Step S5: Full-process digital quality traceability and acceptance assessment: Throughout the construction process, the design data, processing data, testing data, installation data and acceptance data of each pipe assembly unit are linked to a unified digital management platform through the "one item, one code" system; The construction progress, quality status, and abnormal warning information are displayed in real time using a digital management platform; system debugging and overall acceptance are carried out after construction is completed; and all construction process data are archived into the project quality database.

2. The method according to claim 1, characterized in that, The division of the pipe assembly unit in step S1 follows the following principles: the division is based on the functional zoning of the factory building; the length of the pipeline in the same pipe assembly unit is controlled within the range of 6 to 12 meters; each pipe assembly unit integrates no less than 3 electromechanical pipelines; and the total weight of the pipe assembly unit does not exceed 15 tons.

3. The method according to claim 1, characterized in that, The ground prefabrication described in step S2 is completed in a mobile electromechanical intelligent manufacturing center. The mobile electromechanical intelligent manufacturing center is deployed at the construction site or in the adjacent area and consists of at least two standard container modules, integrating CNC cutting equipment, automatic welding workstations, assembly platforms and quality inspection equipment. Each device is connected to the digital management platform through the Industrial Internet of Things and uploads production data in real time.

4. The method according to claim 1, characterized in that, The digital processing data package mentioned in step S2 includes the cutting length, bevel angle, welding process parameters and flange bolt hole angle of each pipe section. The CNC cutting machine automatically generates CNC machining code based on the digital processing data package.

5. The method according to claim 1, characterized in that, The hydraulic synchronous lifting system described in step S3 adopts a "feedforward + feedback" composite control structure. The feedforward channel uses the simulated lifting trajectory as a reference input, and the feedback channel uses the displacement deviation as the input of PID control. The control cycle is 100~200ms in the coarse adjustment stage and 20~50ms in the fine adjustment stage. The synchronization accuracy of each lifting point is controlled within ±2mm.

6. The method according to claim 1, characterized in that, The hydraulic synchronous lifting system described in step S3 has 4 to 8 lifting points evenly arranged on both sides of the center of gravity of the pipe assembly unit; the pipe assembly unit is equipped with a guide device to restrain the horizontal sway during the lifting process.

7. The method according to claim 1, characterized in that, The preset accuracy range mentioned in step S4 is: the plane position deviation does not exceed ±3mm, the elevation deviation does not exceed ±2mm, and the levelness deviation does not exceed 1mm / m.

8. The method according to claim 1, characterized in that, The adaptive correction adjustment mentioned in step S4 is achieved by a fine-tuning hydraulic cylinder group, which has translational degrees of freedom in the X, Y, and Z directions and a displacement resolution of 0.01 mm.

9. The method according to claim 1, characterized in that, The "one item, one code" system described in step S5 uses QR codes or RFID electronic tags. By scanning with a mobile terminal, design data, processing data, testing data, and installation guidance information of the pipe assembly unit can be obtained instantly.

10. The method according to any one of claims 1 to 9, characterized in that, The mobile intelligent manufacturing center and the fixed prefabrication plant mentioned in step S2 produce together: standard pipe sections and integrated supports are produced in the mobile intelligent manufacturing center, while large equipment modules and irregular components are produced in the fixed prefabrication plant and then transported to the site.

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