Automated production line for adaptive concrete modules of high-precision

该应用程序用于多变量设备，以生产由钢筋混凝土制成的高精度部件。组件是单独的模块，在现场组装形成一个整体结构。该设施将被整合到波鸿鲁尔大学的KIB-KON测试大厅。该设施旨在探索基于流程原理的完全质量保证生产，并以很大程度上自动化，机器人辅助的方式操作。它涵盖了自动百叶窗和加固，混凝土，通过控制热处理快速硬化，几何和材料质量控制，以及感官设备和标签的过程。所有连续的过程从整体上保证质量，并通过数字整体表示（数字孪生）进行交互控制。高度可变性的几何形状，增强，内置组件，加热通过垫和热空气和质量保证与光学，热和机械过程是很重要的。研究目标是：几何和材料精度：目标是探索和扩展可实现精度的极限。目标要求是百叶窗表面的偏差≪1毫米，加固层<2毫米，部件边缘相对小于1毫米。混凝土必须具有低强度分散（标准差<2 MN/m²）。几何适应性和自由形式：模块应该是相似的，而不是相同的，并且在长度，宽度，角度，钢筋或表面等基本参数上是可变的。它们是平面或桁架状的，并且必须能够具有任意曲面的特征。模板的概念包括可调节的墙壁和内置部件，以实现弯曲的边缘。金属或非金属增强件应由机器人预制、安装、焊接或用夹子连接。整个过程和中间步骤的速度：研究的目标是将一个模块的生产时间缩短到3小时以内，包括混凝土养护。部分目标旨在开发受控热处理技术（<2小时）和适合这些的混凝土。子过程必须在速度、准确性和可实现的承载能力之间进行权衡。无缝质量保证：生产的目标是对所有相关的几何、机械和工艺参数进行无缝质量控制。将已建立的生产工程“无故障质量标准”（六西格玛，即99.99966%无故障，DMAIC）转移到建筑预制行业。设想的是光学控制（激光，摄影测量），热分析（热成像）和固定终端或机械臂的间接强度测试。链接到数字整体表示：所有制造、质量保证和标签过程都将使用数字模型实时控制、监测和监管。

The application is for a multi-variable facility to produce highly precise components made of reinforced concrete. The components are individual modules that are assembled on site to form a holistic structure. The facility will be integrated into the KIB-KON testing hall at the Ruhr University in Bochum. The facility is designed to explore fully quality-assured production based on the flow principle and to operate in a largely automated, robot-assisted manner. It covers the processes of automated shuttering and reinforcing, concreting, rapid hardening by controlled heat treatment, geometric and material quality control, as well as sensory equipment and labeling. All consecutive processes are holistically quality-assured and interactively controlled from a digital overall representation (digital twin). High variability in geometries, reinforcements, built-in components, in heating via mats and hot air and in quality assurance with optical, thermal and mechanical processes is important. Research objectives are: Geometric and material precision: The goal is to explore and extend the limits of achievable accuracies. Target requirements are deviations of shuttered surfaces ≪1mm, reinforcement layers <2 mm, component edges relative to each other <1 mm. Concretes must have low scatter in strength throughout (standard deviation <2 MN/m²). Geometric adaptivity and free form: The modules should be similar, not identical, and variable in basic parameters such as lengths, widths, angles, reinforcement or surfaces. They are planar or truss-like and must be able to feature arbitrarily curved surfaces. The concept of the formwork includes adjustable walls and built-in parts to realize curved edges. Metallic or non-metallic reinforcements shall be prefabricated, installed, and welded by robots or connected by clips. Speed in the overall process and intermediate steps: The research aims to minimize the production time of a module to less than 3 hours, including concrete curing. Partial goals aim to develop controlled heat treatment techniques (<2 h) and concretes suitable for these. Sub-processes have to be established in a trade-off of speed, accuracy and achievable load-bearing capacities. Seamless quality assurance: The goal of production is seamless quality control of all relevant geometric, mechanical and process-specific parameters. Well-established "no-fault quality standards" (Six Sigma, i.e. 99.99966% fault-free with DMAIC) of production engineering shall be transferred to prefabrication in the construction industry. Envisaged are optical controlling (laser, photogrammetry), thermal analysis (thermography) and indirect strength tests on fixed terminals or robotic arms. Link to digital overall representation: All manufacturing, quality assurance and labeling processes are to be controlled, monitored and regulated in real time using digital models.