High-precision detection and lofting system for large-scale steel structure industrial components has become a critical aspect of modern manufacturing, particularly in the field of large-scale steel construction. This paper discusses the determination of the workpiece coordinate system and the transformation principles between the measuring coordinate system. It also explores the methods for marking key points such as screw holes and template orientation lines on the workpiece during the processing of large-scale steel structures.
Accurate measurement and precise layout are essential for ensuring product quality. As the use of elbow technology becomes more widespread and quality management systems are established, there is an increasing demand for direct dimensional inspection and high-precision layout. For instance, in the production of maglev railway components, these techniques play a crucial role in improving the accuracy of inspections and reducing repair rates. This system significantly enhances production efficiency and is an important technological component in modern factories.
Currently, many domestic manufacturers still rely on traditional tools like calipers and rulers for inspecting large industrial components. The layout process often involves using specially designed platforms and common warps, which not only lack precision but are also influenced by human factors, leading to unreliable results. Moreover, different sizes of components require various platforms with grid lines, increasing costs and reducing efficiency. Therefore, there is a clear need for a stable and accurate sub-millimeter-level detection and layout method.
This paper introduces a joint development project focused on the application of high-precision detection and layout systems in large-scale steel structure industrial components, specifically in the Anhui Wuhu Yangtze River Bridge construction. The system demonstrates exceptional accuracy, with a maximum workpiece size measurement error of 0.15 mm and a loft position error of 0.35 mm. This achievement lays a solid technical foundation for computer simulation assembly and the transformation of actual workshop assembly processes.
The system is composed of a high-precision industrial control network, two total stations or electronic theodolites, specialized data communication equipment, and advanced computer software for data processing. Hardware includes measuring piers equipped with centering devices, embedded underground communication lines, and intelligent multi-user serial cards for real-time data transmission. Specialized tools include hole center locators, dotting devices, line stakers, and measuring targets, all designed for accurate measurements and layout tasks.
Software functions include real-time data communication, instrument orientation, coordinate calculation, parameter computation, and report generation. These features enable automatic processing of horizontal angles and zenith distances, coordinate transformations, and geometric inspection calculations. The system allows for flexible layout of point positions and template orientation lines, independent of traditional platform grids.
The system's working principle involves real-time data transmission from total stations to computers, where coordinate transformations and layout calculations are performed. The workpiece coordinate system is determined based on feature points, and transformations between coordinate systems ensure accurate measurement and layout. This approach enables efficient and reliable detection and layout of large-scale components, regardless of their size.
Through experimental validation, the system has demonstrated impressive accuracy. Using a Soka Total Station with 2" angle measurement accuracy, the average layout accuracy reached ±0.35 mm, while hole position detection achieved ±0.25 mm. These results confirm the system’s effectiveness in improving the precision of industrial measurements and layout tasks.
In conclusion, this high-precision detection and lofting system represents a significant advancement in the field of large-scale steel structure manufacturing. It not only improves product quality and reduces rework but also enhances production efficiency, making it a valuable tool for modern industrial enterprises.
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