Automated production line for adaptive concrete modules of high-precision

高精度自适应混凝土模块自动化生产线

• 批准号: 501824812
• 金额: --
• 依托单位: Ruhr-Universität Bochum
• 依托单位国家: 德国
• 项目类别: Major Research Instrumentation
• 财政年份: 2022
• 资助国家: 德国
• 起止时间: 2021-12-31 至 无数据
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/501824812?language=en
• 关键词: Automated; production; line; adaptive; concrete

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.

该应用程序是一个多变量的设施，以生产高精度的钢筋混凝土制成的组件。这些组件是在现场组装以形成整体结构的单个模块。该设施将被整合到波鸿鲁尔大学的KIB-KON测试大厅。该工厂旨在探索基于流动原理的完全质量保证的生产，并以机器人辅助的方式进行大规模自动化操作。它涵盖了自动模板和加固、混凝土浇筑、通过受控热处理快速硬化、几何和材料质量控制以及传感设备和标签的过程。所有连续的过程都是整体质量保证和交互式控制的数字整体表示（数字孪生）。几何形状、增强材料、内置组件、通过垫和热空气加热以及光学、热和机械工艺的质量保证方面的高度可变性非常重要。研究目标是：几何和材料精度：目标是探索和扩展可实现的精度的极限。目标要求是百叶窗表面的偏差<1 mm，加强层<2 mm，构件边缘相对于彼此<1 mm。混凝土必须具有低强度分散（标准偏差<2 MN/m²）。几何自适应性和自由形式：模块应该相似，而不是完全相同，并且在基本参数（如长度、宽度、角度、钢筋或表面）上可变。它们是平面或桁架状的，必须能够具有任意弯曲的表面。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。金属或非金属钢筋应预制、安装，并通过机器人焊接或通过夹子连接。整个过程和中间步骤的速度：该研究旨在将模块的生产时间最小化到3小时以内，包括混凝土固化。部分目标旨在开发受控热处理技术（<2小时）和适用于这些技术的混凝土。必须在速度、准确性和可实现的承载能力之间进行权衡，建立子流程。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。生产工程的完善的“无故障质量标准”（六西格玛，即DMAIC 99.99966%无故障）应转移到建筑行业的预制。设想在固定终端或机械臂上进行光学控制（激光、摄影测量）、热分析（热成像）和间接强度测试。链接到数字化整体表示：所有制造、质量保证和标签流程都将使用数字模型进行真实的实时控制、监控和监管。