Automatisierte, qualitätsgesicherte Prozesse zur Schnellfertigung adaptiver, bewehrter Betonmodule – Umsetzung in eine Forschungsanlage

Automated, quality-assured processes for the rapid production of adaptive, reinforced concrete modules - implementation in a research facility

Modular construction methods based on building blocks principle enable cost-effective and fast construction. This requires geometrically and materially precisely manufactured modules, which can be implemented and largely automated in industrial prefabrication. However, such prefabrication is not yet common and is limited to similar serial components such as railroad sleepers. In the paper, a full-scale research facility is developed that keeps the individual steps of automated production in high-precision variable and opens them up to modules of any shape. The system can be used to develop the individual process steps of shuttering, reinforcing, concreting, hardening or qualifying, and to develop the overall process in a quality-assured rapid circular manner or to test meaningful alteration (adaptivity), such as in cross-sectional dimensions or shapes. Three robots are integrated for automation. They place free-form molds and built-in parts, weld reinforcements or qualify geometrically with lasers and stereo cameras or mechanically with rebound hammers. A special curing chamber with circulating air and heating plates with direct contact to the steel formwork enables controlled heat and moisture treatments for curing times of less than an hour. A simulation model is being developed as part of the plant's digital twin, which will help to improve the robot movements.