RoFab-4iDM: Robotic Fabrication of Tunnel Services using Industry 4.0 for Intelligent Distributed Manufacturing

** _使用工业4.0智能分布式制造的隧道服务机器人制造（_**_RoFab-4iDM）解决了在铁路和基础设施隧道中制造定制机电（M&E）安装支架时出现的安全和生产力问题。rofab - 4idm将通过集成测量、检测、加工和增材制造操作，在一个集成的、自主的“测量-设计-制造-安装”系统中，从根本上提高生产率和工人的安全性。_**** _韩国合作伙伴将应用这项技术自动化隧道内的金属管道维修。_**我们将把传统的测试技术与机器学习（ML）和人工智能（AI）相结合，创建一个能够评估和设计焊接、制造、加工和增材制造的数字控制环境，而无需人工决策。** _创新解决现实问题：提高工人安全；每建造一公里隧道可为英国纳税人节省1.6万英镑。**RoFab-4iDM可立即应用于包括HS2在内的隧道工程，利用自主机器人技术的优势，同时使用传统的、具有成本效益的预制混凝土（PCC）形成隧道结构。没有其他类似的系统可用。**问题：**铁路隧道机电服务安装在机架螺栓上，嵌入到PCC隧道部分。安装公差累积（由于PCC部分的“滚动”）意味着插入件经常不在位置上。安全规定禁止在隧道内焊接和钻孔新的镶件。因此，许多支架需要定制适配。**我们的建议：**RoFab-4iDM将把隧道设计模型与已建成的3D勘测数据结合起来，利用人工智能自动化设计和制造定制支架。每个支架都将精确地适应已安装的插入件，实现快速机器人安装。** *精确确定每个插入件的安装位置** -自动扫描钻机测量创建数字3D表示。** *位置特定，定制的标准支架设计**由人工智能使用数字孪生创建。** *在现场制造支架** -自主，自适应机器人制造。该项目将成熟的技术与新的数字孪生技术相结合。演示者将开发从TRL5到TRL7的数字孪生集成。**进一步的市场：**** -通过创造一种成本效益和定制的非现场大规模制造组件的方法来提高建筑生产率。_**弥合设计理想尺寸/预测尺寸与实际安装尺寸之间的差异，将加速预制产品在建筑项目中的广泛采用。** _在危险环境中按照规定的标准进行自主维修。_**将RoFab-4iDM技术应用于其他行业将为危险环境中的焊接/增材制造提供解决方案，避免因必须将损坏的部件移动到维修车间而中断。未来的发展将是把所有阶段结合成一个“勘察-设计-制造-安装”的平台，应用于任何需要评估、修理和再制造钢铁材料的行业，包括铁路和民用核退役。

**_Robotic Fabrication of Tunnel Services using Industry 4.0 for Intelligent Distributed Manufacturing (_**_RoFab-4iDM) addresses safety and productivity problems that occur when fabricating customised mechanical and electrical (M&E) installation bracketry within rail and infrastructure tunnels._**_RoFab-4iDM will radically improve productivity and worker safety by integrating survey, inspection, machining and additive manufacturing operations within an integrated, autonomous "survey-\>design-\>manufacture-\>install" system._****_South Korean partners will apply this technology automating metal pipework repairs within tunnels._**We will combine conventional test techniques with machine learning (ML) and artificial intelligence (AI) to create a digital control environment capable of assessing and designing welds, fabrication, machining and additive manufacturing without human decision-making.**_Innovating to solve real-world problems: Improve worker safety; saving UK taxpayers £16,000 per km_ tunnel built.**RoFab-4iDM has immediate application for tunnelling projects including HS2, capturing benefits of autonomous robotics, while forming tunnel structures using conventional, cost-effective, precast concrete (PCC).No other system of this kind is available.**The issue:**Rail tunnel M&E services are fitted to racking bolted to inserts cast into PCC tunnel sections. Installation tolerance build-up (due to 'roll' of PCC sections) means inserts are often out of position. Safety rules forbid welding and deter drilling new inserts inside tunnels. Therefore, many brackets need bespoke adaptions.**Our proposal:**RoFab-4iDM will combine tunnel design models with as-constructed 3D survey data, using AI to automate design and manufacture of customised bracketry. Each bracket will precisely suit the as-installed inserts, enabling fast robotic installation.* **Precisely determine as-installed position of each insert** - automated scanning rig survey creates digital 3D representation.* **Position-specific, customised standard bracket design** created by AI using digital twin.* **Fabricate bracketry offsite** -- autonomous, adaptive robotic fabrication.The project integrates proven techniques/technologies with a novel digital twin. The demonstrator will develop the digital twin integration from TRL5 to TRL7\.**Further markets:****_Enhancing construction productivity by creating a method for off-site mass manufactured components that are cost-efficient and bespoke._**Bridging the variance between designed ideal/predicted dimensions and as-installed would accelerate wide adoption of pre-manufactured products on construction projects.**_Autonomous repair to regulated standards within hazardous environments._** Applying RoFab-4iDM technologies to other sectors will provide a solution for welding/AM within hazardous environments, avoiding disruption from having to move damaged components to a repair workshop. Future development would be to combine all stages into a **survey-\>design-\>manufacture-\>install** platform, with applications in any industry that requires assessment, repair and remanufacture of steel materials, including rail and civil nuclear decommissioning.