Continuous manufacturing of thin-walled fibre-reinforced precision concrete elements for free-formed modular constructions (KoBeMo)

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The aim of this project is the fundamental investigation of interactions between process and material parameters of a continuous precision manufacturing process with integrated non-contact measure-ment for quality and process control. The manufacturing line permits the production of double-curved modular elements, which consist of thin-walled fibre-reinforced concrete with ribbed support struc-ture and integrated anchoring elements that are aligned with the directions of forces. Research find-ings of the applicants in recent years resulted in the new lightweight design of the highly resilient free-form structural components. They are produced with the help of combined concrete injection and extrusion technologies in a robot-assisted manufacturing process that includes an integrated optical measuring system. In particular, the robot-assisted process steps have to be refined in order to generate scalable fair faced concrete elements. The new manufacturing complex for precision manufacturing of the modular elements will be upgraded by interfaces for data management and the envisaged cyber-physical systems. The parameter dependent compatibility of the individual sub-processes is investigated by the determination of characteristic process and material values and their interactions. These relationships are input factors for the creation of a complete digital repre-sentation. Methods of Artificial Intelligence and “Gene Expression Programming with Free Coeffi-cients” (GEP-FC) are used to model the complex interactions. Based on these investigations, the manifold feedback effects between structural features and processing parameters can be acquired for a better understanding of the system. Thus, a fundamental basis for fast precision constructions in the future is established by an intelligent connection of CAD, robots, mechanical equipment, elec-tronic measuring, control and regulating technology. A convenient implementation can be achieved by digital mapping of the entire process from first draft to final product. Additionally, the emission and cost affecting factors of the process, like material and energy demand, are evaluated in order to es-timate the sustainability of the products. The proposed modular system follows the principle “individ-uality on a large scale, similarity on a small scale” by the use of process-specific and scalable mod-ules as a base for individual major structures. Within the research production line, scalable fair faced concrete elements are produced with targeted production times up to 15 min, element sizes of 2.5 m x 1 m, element masses up to 200 kg and tolerances in the millimetre range as goal criteria.