Inverse Method for Assembly Tolerance Itervals of Cable-Stayed Bridge Based on Proactive Fault Tolerance

doi:10.12141/j.issn.1000-565X.250099

Abstract

Abstract:

To enhance construction efficiency, prefabricated and assembled industrialized construction methods are widely adopted in bridge engineering. However, on-site procedural adjustments can easily lead to assembly failures, resulting in schedule and cost overruns, which contradict the original intention of rapid construction. For cable-stayed bridge prefabricated components produced according to the original single-segment cyclic process, how to achieve assembly coordination under the adjusted dual-segment cyclic process is a key challenge when complying with overall schedule decisions. Integrating the unstressed state method and tolerance allocation approach, this paper first develops a machine learning-based inversion method for the assembly tolerance intervals of cable-stayed bridges. Then a non-negative dimensionless indicator is introduced as an independent optimization objective to characterize construction operability. Next, a GA-BPNN surrogate model combined with the NSGA-Ⅱ multi-objective optimization algorithm is adopted to conduct a trade-off optimization between structural safety and design optimality. By incorporating prior error reserves, the passive assembly tolerance ranges for various components of a cable-stayed bridge are inversely derived. Finally, integrating field-measured data from preceding construction segments, an assembly tolerance design framework for cable-stayed bridges oriented toward active fault tolerance is established. Results demonstrate that the proposed interval inversion method effectively enhances on-site operability while ensuring structural safety and design optimality. Compared with passive tolerance design, the active tolerance design approach increases the tolerance interval for the girder splicing angle of segment G2 by 1.4 times and that for the unstressed cable length of stay S16 by 2.1 times. Moreover, the active tolerance analysis framework enables adaptive adjustment in assembly failure scenarios by modifying tolerance ranges of subsequent components, thereby reducing the occurrence of work stoppages and reworks.

Key words: cable-stayed bridge, proactive fault tolerance, assembly tolerance, construction control, adaptive adjustment

CLC Number:

U445.4

WANG Xiaoming, SUN Chenjing, ZHU Chuanchao, FENG Boshun, GAO Lixiang, QIU Hongjie. Inverse Method for Assembly Tolerance Itervals of Cable-Stayed Bridge Based on Proactive Fault Tolerance[J]. Journal of South China University of Technology(Natural Science Edition), 2026, 54(2): 152-166.

Figures/Tables 25

Fig.1

Fig.2

Fig.3

Table 1

Fig.4

Fig.5

Fig.6

Fig.7

Fig.8

Fig.9

Fig.10

Fig.11

Fig.12

Fig.13

Table 2

Design domain of optimization variables"

优化变量	设计域下界	设计域上界
d $S 16 c$	230.836 5	230.912 9
d $S 15 c$	219.041 0	219.114 6
d $S 14 c$	207.334 4	207.403 0
d $S 2 c$	79.256 5	79.283 6
d $S 1 c$	72.260 0	72.284 2
d $M 1 c$	71.500 1	71.524 6
d $M 2 c$	78.154 1	78.181 0
d $M 14 c$	204.172 3	204.240 4
d $M 15 c$	215.790 7	215.865 1
d $M 16 c$	227.535 3	227.610 7

Table 2

Fig.14

Fig.15

Table 3

Tolerance intervals of stress-free parameters for strategy # 7"

无应力参量	控制参量编号	参量值	区间中点	容差半径	容差区间	与设计值的最大偏差
长度/m	S16	230.874 6	230.874 2	0.014 2	［230.860 0，230.888 4］	0.014 6
	S15	219.077 7	219.080 9	0.017 2	［219.063 7，219.098 1］	0.020 4
	S14	207.368 6	207.376 7	0.014 5	［207.362 2，207.391 2］	0.022 6
	S2	79.270 1	79.273 2	0.007 4	［79.265 8，79.280 6］	0.010 5
	S1	72.272 1	72.272 7	0.004 9	［72.267 8，72.277 6］	0.005 5
	M1	71.512 3	71.515 2	0.004 2	［71.511 0，71.519 4］	0.007 1
	M2	78.167 5	78.168 7	0.005 6	［78.163 1，78.174 3］	0.006 8
	M14	204.206 3	204.207 8	0.016 7	［204.191 1，204.224 5］	0.018 2
	M15	215.827 8	215.832 9	0.014 4	［215.818 5，215.847 3］	0.019 5
	M16	227.573 0	227.575 3	0.013 8	［227.561 5，227.589 1］	0.016 1
$拼装角度 / (°)$	G2	179.905 2	179.893 9	0.011 6	［179.882 3，179.905 5］	0.022 9
	G3	179.926 9	179.944 7	0.011 1	［179.933 6，179.955 8］	0.028 9
	Z2	179.943 0	179.952 7	0.018 2	［179.934 5，179.970 9］	0.027 9
	Z3	179.948 3	179.944 0	0.049 4	［179.894 6，179.993 4］	0.053 7

Table 3

Fig.16

Fig.17

Table 4

Fig.18

Fig.19

Fig.20

Table 5

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斜拉索编号	索力/kN		索力/kN
S16	7 086	M1	3 180
S15	6 709	M2	3 144
S14	6 091	M3	3 113
S13	5 476	M4	3 212
S12	5 152	M5	3 608
S11	4 907	M6	3 830
S10	4 701	M7	4 017
S9	4 479	M8	4 220
S8	4 388	M9	4 401
S7	4 079	M10	4 799
S6	3 744	M11	4 988
S5	3 652	M12	5 461
S4	3 510	M13	5 730
S3	3 328	M14	6 063
S2	3 316	M15	6 356
S1	3 357	M16	6 546

斜拉索编号	索力/kN		偏差/％
斜拉索编号	设计成桥	容差控制下	偏差/％
S1	3 357	3 243~3 480	-3.40~3.66
S2	3 316	3 153~3 413	-4.92~2.92
S3	3 328	3 286~3 404	-1.27~2.28
S4	3 510	3 481~3 555	-0.83~1.28
S5	3 652	3 629~3 683	-0.63~0.85
S6	3 744	3 732~3 757	-0.32~0.35
S7	4 079	4 063~4 091	-0.40~0.29
S8	4 388	4 356~4 412	-0.74~0.54
S9	4 479	4 413~4 529	-1.49~1.12
S10	4 701	4 596~4 781	-2.22~1.71
S11	4 907	4 760~5 021	-3.00~2.32
S12	5 152	4 937~5 320	-4.18~3.24
S13	5 476	5 318~5 589	-2.90~2.05
S14	6 091	5 792~6 301	-4.91~3.44
S15	6 709	6 442~6 974	-3.98~3.95
S16	7 086	6 875~7 364	-2.97~3.94
M1	3 180	3 020~3 335	-4.94~4.87
M2	3 144	2 993~3 298	-4.80~4.90
M3	3 113	3 071~3 164	-1.35~1.64
M4	3 212	3 173~3 248	-1.21~1.12
M5	3 608	3 575~3 636	-0.91~0.78
M6	3 830	3 802~3 852	-0.73~0.57
M7	4 017	4 002~4 030	-0.37~0.32
M8	4 220	4 211~4 232	-0.21~0.28
M9	4 401	4 387~4 422	-0.32~0.48
M10	4 799	4 774~4 838	-0.52~0.81
M11	4 988	4 954~5 039	-0.68~1.02
M12	5 461	5 417~5 529	-0.81~1.25
M13	5 730	5 679~5 803	-0.89~1.27
M14	6 063	5 866~6 253	-3.25~3.13
M15	6 356	6 122~6 509	-3.68~2.41
M16	6 546	6 306~6 740	-3.67~2.96

斜拉索编号	设计成桥索力/kN	调控后索力/kN	偏差/％
S1	3 357	3 352	-0.15
S2	3 316	3 308	-0.24
S3	3 328	3 290	-1.14
S4	3 510	3 486	-0.68
S5	3 652	3 634	-0.49
S6	3 744	3 737	-0.19
S7	4 079	4 086	0.17
S8	4 388	4 412	0.55
S9	4 479	4 531	1.16
S10	4 701	4 783	1.74
S11	4 907	5 021	2.32
S12	5 152	5 320	3.26
S13	5 476	5 559	1.52
S14	6 091	6 047	-0.72
S15	6 709	6 555	-2.30
S16	7 086	6 923	-2.30
M1	3 180	3 194	0.44
M2	3 144	3 164	0.64
M3	3 113	3 108	-0.16
M4	3 212	3 205	-0.22
M5	3 608	3 602	-0.17
M6	3 830	3 824	-0.16
M7	4 017	4 015	-0.05
M8	4 220	4 224	0.09
M9	4 401	4 411	0.23
M10	4 799	4 820	0.44
M11	4 988	5 017	0.58
M12	5 461	5 505	0.81
M13	5 730	5 784	0.94
M14	6 063	6 115	0.86
M15	6 356	6 307	-0.77
M16	6 546	6 371	-2.67