Continuous manufacturing of thin-walled fibre-reinforced precision concrete elements for free-formed modular constructions (KoBeMo)

该项目的目的是对连续精密制造过程的过程和材料参数之间的相互作用进行基础研究，并采用集成的非接触式测量来进行质量和过程控制。生产线允许生产双弯曲的模块化元件，包括薄壁纤维增强混凝土，带肋支撑结构和与力方向对齐的集成锚固元件。申请人近年来的研究成果导致了高弹性自由形式结构构件的新型轻量化设计。它们是在机器人辅助制造过程中的混凝土喷射和挤压技术的帮助下生产的，其中包括集成的光学测量系统。特别是，机器人辅助的过程步骤必须加以改进，以产生可扩展的公平面混凝土元素。用于精密制造模块化元件的新制造综合体将通过数据管理接口和设想的网络物理系统进行升级。通过确定特征工艺和材料值及其相互作用，研究了各个子过程的参数依赖兼容性。这些关系是创建完整数字表示的输入因素。采用人工智能和“自由系数基因表达编程”（GEP-FC）方法对复杂的相互作用进行建模。基于这些研究，可以获得结构特征与加工参数之间的流形反馈效应，从而更好地理解系统。因此，CAD、机器人、机械设备、电子测量、控制和调节技术的智能连接，为未来快速精密施工奠定了基础。通过对从初稿到最终产品的整个过程进行数字映射，可以实现方便的实现。此外，该过程的排放和成本影响因素，如材料和能源需求，进行评估，以估计产品的可持续性。拟议的模块化系统遵循“大规模的个性化，小规模的相似性”的原则，通过使用特定于流程和可扩展的模块作为单个主要结构的基础。在研究生产线中，可扩展的清水混凝土元件的生产时间为15分钟，元件尺寸为2.5米× 1米，元件质量为200公斤，公差在毫米范围内作为目标标准。

The aim of this project is the fundamental investigation of interactions between process and material parameters of a continuous precision manufacturing process with integrated non-contact measure-ment for quality and process control. The manufacturing line permits the production of double-curved modular elements, which consist of thin-walled fibre-reinforced concrete with ribbed support struc-ture and integrated anchoring elements that are aligned with the directions of forces. Research find-ings of the applicants in recent years resulted in the new lightweight design of the highly resilient free-form structural components. They are produced with the help of combined concrete injection and extrusion technologies in a robot-assisted manufacturing process that includes an integrated optical measuring system. In particular, the robot-assisted process steps have to be refined in order to generate scalable fair faced concrete elements. The new manufacturing complex for precision manufacturing of the modular elements will be upgraded by interfaces for data management and the envisaged cyber-physical systems. The parameter dependent compatibility of the individual sub-processes is investigated by the determination of characteristic process and material values and their interactions. These relationships are input factors for the creation of a complete digital repre-sentation. Methods of Artificial Intelligence and “Gene Expression Programming with Free Coeffi-cients” (GEP-FC) are used to model the complex interactions. Based on these investigations, the manifold feedback effects between structural features and processing parameters can be acquired for a better understanding of the system. Thus, a fundamental basis for fast precision constructions in the future is established by an intelligent connection of CAD, robots, mechanical equipment, elec-tronic measuring, control and regulating technology. A convenient implementation can be achieved by digital mapping of the entire process from first draft to final product. Additionally, the emission and cost affecting factors of the process, like material and energy demand, are evaluated in order to es-timate the sustainability of the products. The proposed modular system follows the principle “individ-uality on a large scale, similarity on a small scale” by the use of process-specific and scalable mod-ules as a base for individual major structures. Within the research production line, scalable fair faced concrete elements are produced with targeted production times up to 15 min, element sizes of 2.5 m x 1 m, element masses up to 200 kg and tolerances in the millimetre range as goal criteria.