Bridge Girder Virtual Assembly Using 3D Measurement
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Solution Overview
Problem
Current steel bridge fabrication processes, such as match-drilling, are time-consuming and expensive, requiring significant floor space and manual alignment of girders, which limits efficiency and increases costs, especially due to the need for precise hole alignment in splice connections.
Innovation Solution
The use of a 3D coordinate measurement instrument (CMI) for noncontact measurements of bridge girders to create a 3D model, allowing for the fabrication of girders with full-sized holes earlier in the process, enabling the virtual assembly of girders and custom splice plate design based on measured hole patterns, reducing the need for physical alignment and match-drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If match-drilling process is used to ensure hole alignment, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent applies preliminary action by drilling all splice holes in girders before assembly, rather than during assembly. Holes are drilled in individual girders while they are accessible and can be positioned on precision drilling jigs. The girder locations and hole patterns are recorded, and splice plates are fabricated to match these recorded patterns, eliminating the need for time-consuming match-drilling during assembly.
Solution Approach 2:
The patent uses copying by recording the precise locations of all holes in each girder using laser scanning or coordinate measurement machinery. These recorded hole patterns are then used to fabricate splice plates with matching hole patterns. This copying approach replaces the physical match-drilling process, allowing splice plates to be manufactured separately with precise hole alignment based on digital records rather than physical trial-and-error fitting.
2Manufacturing precision
If match-drilling process is used to ensure hole alignment, then manufacturing precision is improved, but loss of time worsens
Solution Approach 1:
The patent applies preliminary action by completing all hole drilling operations on girders before assembly. Individual girders are drilled on precision jigs while accessible, and hole patterns are recorded. Splice plates are then fabricated separately with matching hole patterns based on these recordings, eliminating the time-consuming match-drilling operation that would otherwise be required during assembly.
Solution Approach 2:
The patent uses copying by creating digital records of hole patterns in each girder through laser scanning or coordinate measurement. These copied patterns are used to manufacture splice plates with precisely matching hole locations, replacing the time-consuming physical match-drilling process with a parallel fabrication approach that occurs before assembly.
3Manufacturing precision
If girders are laid on sides for match-drilling, then manufacturing precision is improved, but area of stationary object worsens
Solution Approach 1:
The patent applies preliminary action by drilling holes in girders before assembly on compact drilling jigs rather than requiring large floor space for laying out multiple girders end-to-end. The drilling jigs provide precise positioning in a confined area, and girders are processed individually or in small groups rather than requiring extensive linear space for alignment.
Solution Approach 2:
The patent uses copying by recording hole patterns digitally and using them to fabricate splice plates in a controlled manufacturing area. This eliminates the need for large floor space required for physical lay-out and match-drilling operations, as the hole pattern information is transferred digitally rather than through physical positioning of multiple girders in a large area.
Data Source
AI summary
Apparatus and methods are disclosed that may be integrated into a steel bridge fabrication shop to improve steel bridge fabrication. The apparatus and methods measures aspects of completely fabricated bridge girders and virtually assembles girders in order to design custom splice plates to fit girders together. The apparatus and method further comprises of a noncontact three-dimensional coordinate measurement apparatus and methods that measures aspects of a completely fabricated girder, stores measurements as a permanent record of the girder, and combines these measurements with measurements from other girders to create a virtual assembly for a steel bridge.