Virtual trial assembly of large steel members with bolted connections based on multiscale point cloud fusion

Abstract

Virtual trial assembly (VTA) using 3D laser scanning as the digital carrier can overcome the shortcomings of time‐consuming and costly physical preassembly. However, its application in large steel structures with bolted connections remains limited. First, this study introduces a novel approach for acquiring multiscale point cloud data of large steel members using terrestrial laser scanners (TLSs) and hand‐held scanner (HHS). This approach considers both the global data and the local details of the steel members. Additionally, a precise registration method based on magnetic 3D targets is proposed for multiscale point clouds, which enables the registration accuracy of multisource point clouds to reach submillimeter precision. Subsequently, a novel algorithm for feature point screening is introduced, which utilizes a dichotomous point cloud grid approach to identify and extract a significant quantity of bolt holes effectively. This approach enables fully automated and fast extraction of the point cloud on the cylindrical inner surface of the holes. Finally, the bounding box and Procrustes analysis approach are employed to perform VTA using the point cloud of the cylindrical bolt holes as the assembled features. The accuracy and feasibility of the above method are verified by a down‐scale modeling experiment and project test, which provide technical support for the VTA of large steel truss structures.