Tolerance-free series production of high-performance concrete modules through transient-interactive coupling of design and production

本文提出了一种用于UHPC模块梁状混凝土结构设计和流动生产的交互式概念。其目的是通过耦合来克服设计和生产的实际和时间分离，智能地和交互地补偿几何、时间、工艺和材料上的不精确，并集成端到端的质量保证。通过这种方式，在流程生产中实现了高效、低浪费的模块化结构。过程中的不精确通过设计中的排列来补偿，反之亦然。一个“太长”的模块——固定的规则只是超出公差限制——可以通过模块结构中的“太短”模块来补偿。因此两者都可以使用。在准实时的生产过程中，相互补偿是随机的、瞬时的。与此同时，这种新发现的灵活性被有意用于提高生产效率。可控交互是指在结构、生产过程和时间上整体积累鲁棒性的交互（瞬时交互概念）。施工方法的效率持续提高。在第一个资助期，重点是在几何形状随机偏差的情况下，不同持续时间的热处理和选择性装配引起的收缩对结构尺寸的影响。这是研究不同类别的y模块和相关的具体尺寸的支柱，形成静定蜂窝状结构。基于从批次到批次调整热处理时间和真实尺寸的控制系统被开发，以限制收缩和产生几何上最优的结构。在第二个资助期，将考虑多个静态不确定模块系统。此外，现场模块的组装将被集成，然后授予设计和生产的预测性交互。在外部，模块形成了四个节点的墙壁，而在内部，它们根据负载分解成拓扑优化的支柱。这就产生了一个可变的、可扩展的模块化系统。交互基于模块放置现场和生产规范的耦合启发式。有意同时考虑单个或多个建筑工地。这种相互作用类似于一个模块接一个模块的施工过程，并结合了依赖于热处理和因开裂而产生的软化行为的短期蠕变。研究方法针对无批号多面制造，采用强化学习进行交互生产和同步过程控制。表演将在整体虚拟和物理真实的演示中进行验证。

An interactive concept for design and flow production of beam-like concrete structures made of UHPC modules is developed. The aim is to overcome the factual and temporal separation of design and production through coupling, that intelligently and interactively compensates for imprecisions in geometry, time, process and material and to integrate end-to-end quality assurance. In this way, efficient and low-waste modular construction in flow production is granted. Imprecisions in the process are compensated for by permutations in the design, and vice versa. A “too long” module - with fixed rules just scrap exceeding the tolerance limits - can be compensated for by a “too short” one in the module structure. And thus both can still be used. Mutual compensation happens stochastically and transiently via the production process through interactive permutations in quasi real-time. At the same time, this newfound flexibility is deliberately used to increase the efficiency of production. Controllable interaction is crated that accumulates robustness holistically over structure, production process and time (transient-interactive concept). The efficiency of the construction method is sustainably improved.In the first funding period, the focus was set on the impact of shrinkage on structural dimensions induced by heat treatments of different duration and selective assembly in case of stochastic deviations of geometry. This was investigated on Y-modules of different classes and associated specifically dimensioned struts which form statically determined honeycomb-like structures. Based on from batch to batch adjusted heat treatment durations and true dimensions a control system was developed that limits shrinkage and yields geometrically optimal structures.In the second funding period, multiply statically indeterminate systems of modules will be considered. Additionally, the assembly of modules on-site will be integrated and then grants predictive interaction of design and production. To the outside, the modules form walls with four nodes while internally they are dissolved into topologically optimal struts according to the loading. This yields a variable, scalable modular system. Interaction bases on coupled heuristics of module placement on-site and specifications for production. On purpose, single or multiple construction sites are considered simultaneously. The interaction proceeds in analogy to the module-by-module construction progress and integrates short-term creeping dependent on the heat treatment and softening behavior due to cracking. The research approach aims on lot-free multi-facetted manufacturing employing reinforcement learning for interactive production and simultaneous process control. The performance will be validated on holistic virtual and physically real demonstrators true to scale.