Digital-Twin-Based High-Precision Assembly of a Steel Bridge Tower

Steel structures that benefit from having lightweight, ductility, and seismic behaviors are capable of improving the overall performance of civil engineering in environmental protection, project quality, process management, and ease of construction, making the procedure more feasible for builders. The application of steel structure techniques has been widely used in bridges, tall buildings, and complex projects around the world. Increasing demand for planning and design has led to structural projects upgrading in structural complexity and geometrical irregularity. However, steel structure projects are still limited by the principal disadvantage of susceptibility to deformation. Therefore, the challenges of the assembly and manufacturing process for steel structures are important. In this paper, to achieve full-loop tracking and control of the assembly and manufacturing process, we propose an integrated approach to undertake the aforementioned challenges via digital twin technology, which combines three modules: (1) deformation detection, (2) pose estimation and optimization, and (3) deformation correction and pose control. This proposed methodology innovatively merges gravitational deformation analysis with geometrical error analysis. Furthermore, the validity of this method’s implementation is demonstrated by the New Shougang Bridge project. The results show that the assembly precision satisfies the standard of less than H/4000, nearing H/6000. Moreover, the elevation difference is less than 20 mm, which satisfies the control precision of the geometric pose. The new method that we propose in this paper provides new ideas for structural deformation control and high-precision assembly, as it realizes dynamic deformation sensing, real-time deviation analysis and manufacturing, and efficient optimization of the assembly process.