Development of a consistent digital process chain from an adaptable modular bridge design to intelligent additive manufacturing utilising cyber-physical systems

由于计算机辅助设计和增材制造的稳步发展，今天已经有可能描述和分割一系列复杂的结构，并在高度自动化的情况下用高性能混凝土制造它们。除了目前这些技术的探索性应用之外，在可预见的未来，桥梁建设一定可以从这些技术不断增加的灵活性和性能中受益。然而，目前的连续施工方法在设计上受到限制，主要是保守的施工思想和制造技术，没有充分利用扩展的设计自由。这在很大程度上是由于这样一个事实，即所需的高规划工作是手动执行的，或者仅在单个的、不相关的子步骤中自动执行。应对这一挑战的一个很大程度上尚未开发的潜力在于以数字化连续的方式设计整个流程链，从而实现从桥梁系统设计到分段和机器人辅助制造的跨尺度连接。这大大降低了详细说明和必要调整的成本，并为能够对关键制造和测试数据做出动态反应提供了基础，以便调整尚未制造的设计部分。通过网络物理系统（CPS）的一致应用，实现了设计过程与质量控制和管理生产的紧密耦合。

Thanks to steady advances in computer-aided design and additive manufacturing, it is already possible today to describe and segment a range of complex structures and to manufacture them with high-performance concretes under a high degree of automation. Beyond the current, exploratory applications of these techniques, it must be possible in the foreseeable future for bridge construction to benefit from the ever-increasing flexibility and performance of these technologies. Current approaches to serial construction, however, are limited in design to predominantly conservative construction ideas and fabrication techniques and do not take full advantage of the expanded design freedom. This is largely due to the fact that the high planning effort required for this is carried out manually or is automated only in individual, unrelated sub-steps. A largely untapped potential for meeting this challenge lies in designing the entire process chain in a digitally continuous manner so that a cross-scale link is achieved from the design of the bridge system to segmentation and robot-assisted manufacturing. This significantly reduces the costs for detailing and necessary adjustments and provides the basis for being able to react dynamically to critical manufacturing and test data in order to adjust the parts of the design that have not yet been manufactured. A close coupling of the design processes with quality controlled and managed production is realised by the consistent application of cyber-physical systems (CPS).