Automated production line for adaptive concrete modules of high-precision

该应用程序用于生产由钢筋混凝土制成的高精度部件的多变量设备。这些组件是单独的模块，在现场组装，形成一个整体结构。该设施将整合到波鸿鲁尔大学的Kib-Kon测试大厅中。该设施旨在探索基于流程原则的完全质量保证的生产，并在很大程度上自动化、机器人辅助的方式运行。它涵盖了自动模板和加固、混凝土浇注、通过受控热处理进行快速硬化、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的，并通过数字整体表示(数字孪生)进行交互控制。在几何形状、增强材料、内置组件、通过垫子和热空气加热以及通过光学、热和机械工艺进行质量保证方面具有很高的可变性是很重要的。研究目标是：几何和材料精度：目标是探索和扩大可达到的精度范围。目标要求是遮挡表面偏差≪为1 mm，加强层偏差为2 mm，部件边缘相对于彼此的偏差为1 mm。混凝土必须始终具有低的强度离散性(标准偏差&2 MN/m？)。几何自适应和自由形式：模块应该是相似的，而不是相同的，并且基本参数是可变的，如长度、宽度、角度、钢筋或表面。它们是平面或桁架状的，必须能够以任意曲面为特征。模板的概念包括可调墙和实现弯曲边缘的内置部件。金属或非金属钢筋应由机器人预制、安装和焊接或通过夹子连接。整个过程和中间步骤的速度：这项研究的目标是将模块的生产时间减少到3小时以下，包括混凝土养护。部分目标是开发可控热处理技术(&lt；2小时)和适用于这些技术的混凝土。必须在权衡速度、精度和可实现的承载能力的情况下建立子进程。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。将完善的生产工程“无故障质量标准”(六西格玛，即99.99966%无故障)转移到建筑行业的预制。设想的是光学控制(激光、摄影测量)、热分析(热成像)以及对固定终端或机械臂进行间接强度测试。链接到数字整体表示：所有制造、质量保证和贴标过程都将使用数字模型进行实时控制、监控和监管。

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.