Prof. Dr.-Ing. Gisela Lanza Karlsruher Institut für Technologie, wbk Institut für Produktionstechnik
Prof. Dr.-Ing. habil. Peter Mark Ruhr-Universität Bochum, Lehrstuhl für Massivbau
Jan Stindt, M. Sc. Ruhr-Universität Bochum, Institut für Massivbau
Alex Maximilian Frey, M. Sc. Karlsruher Institut für Technologie, wbk Institut für Produktionstechnik
Up to now, design and production of a concrete structure made of modules are carried out separately and subsequently. The preliminary design determines the requirements for the production, such as tolerances. If these requirements are not complied with, modules must be reworked or excluded. This can be particularly disadvantageous for the novel module construction method. Many individual modules have to be connected and correspondingly high tolerance requirements have to be fulfilled within the production processes. In this subproject a completely new approach is taken. The previously separate, consecutive processes of design and production will be coupled.
By means of this new approach, production-related uncertainties of the component properties are compensated. For example, a module produced "too long" - previously rejected according to tolerance requirements - can be equalized in the module structure by a similarly "too short" module, so that both modules are used. This way, an efficient and low-waste series production of high-performance concrete components is developed.
The geometrical deviations of bar modules are mainly caused by shrinkage of the ultra-high performance concrete (UHPC) used, which can be mitigated by heat treatment of variable duration at 80°C. The correlation between the durations of heat treatment, residual shrinkage and scattering of material properties of the UHPC is derived experimentally and statistically processed. Based on these findings, the achievable accuracy of the individual modules is evaluated by analyzing the expected node displacements.
A concept for a production system according to the flow principle and an adaptive production control is developed. By means of this system, the heat treatment can be systematically influenced in order to control the component´s properties. For this purpose, the achieved actual distributions of the scattering component properties (e.g. geometric deviations) of the batches produced at a certain point in time are determined. Subsequently, the target distributions of the next batch are determined with respect to the already assembled components and the overall structure.
This is done by the systematic tolerance-compensating assembly of the manufactured modules (isosceles, hinge connected Y-modules) to two-dimensional and statically determinate hexagonal honeycombs systems. For this purpose, a stochastic permutation approach is used for the optimal placement of modules depending on the geometrical deviations and the necessary load-bearing capacity of the modules. The design as a requirement for production is thus adapted from batch to batch - i.e. transiently - and in interaction with production. This method results in a transient interactive coupling between design and production in quasi real time, which enables tolerance-free series production (see Figure 1).
2022
[9] Stindt, J.; Frey, A.; Forman, P.; Lanza, G.; Mark, P.
Genauigkeitsgrenzen modularer Betontragwerke – Beschreibung von geometrischen Abweichungen infolge Schwinden
Beton- und Stahlbetonbau 117(5), 2022, S. 296–309. (https://doi.org/10.1002/best.202200010)
[8] Stindt, J.; Frey, A.; Forman, P.; Lanza, G.; Mark, P.
Genauigkeitsgrenzen modularer Betontragwerke – Probabilistische Bewertung der Montage mit Schraubenverbindung
Beton- und Stahlbetonbau 117(5), 2022, S. 310-323. (https://doi.org/10.1002/best.202200011)
2021
[7] Frey, A. M.; Lanza, G.
Adaptive Manufacturing Based on Active Sampling for Multi-component Individual Assembly
In Towards Sustainable Customization: Bridging Smart Products and Manufacturing Systems (pp. 372-380)
Springer, Cham
[6] Stindt, J.; Forman, P; Mark, P.
Influence of Rapid Heat Treatment on the Shrinkage and Strength of High-Performance Concrete
Materials 14(15) (DOI: 10.3390/ma14154102)
[5] Stindt, J.; Forman, P.; Mark, P.
Experimente zur Schwindreduktion von hochfesten Betonbauteilen durch Wärmebehandlung
Beton- und Stahlbetonbau (DOI: 10.1002/best.202100028)
[4] Frey, A.; Stindt, J.; Lanza, G.; Mark, P.
Geometrische Bewertung und Optimierung der Modulanordnung in Tragwerken
Bautechnik 98, 2021 (DOI: 10.1002/bate.202100027)
[3] Mark, P.; Lanza, G.; Lordick, D.; Albers, A.; König, M.; Borrmann, A.; Stempniewski, L.; Forman, P.; Frey, A.; Renz, R.; Manny, A., Stindt, J.
Industrializing precast production - adaptive modularized constructions made in a flux
Civil Engineering Design 3(3), 2021, pp. 87-98. (DOI: 10.1002/cend.202100019)
PDF
[2] Tkocz, J.:
Schnellfertigung von dünnwandigen Stabbauteilen aus Hochleistungsbeton mit gesteuerter Waermebehandlung
Dissertation, Lehrstuhl für Massivbau der Ruhr-Universität Bochum, 2021.
PDF
[1] Stindt, J.; Frey, A.; Stricker, N.; Mark, P.; Lanza, G.:
Kopplungsmethoden von Entwurf und Produktion zur toleranzfreien Serienfertigung.
In: BetonWerk International Nr. 2, 2021, S. 20-21
Link zum Artikel
2022
[6] Agustin, A.
Simulation and Optimization of Production Control through Adaptive Manufacturing
Bachelor-Thesis, wbk – Institut für Produktionstechnik, Karlsruher Institut für Technologie (KIT)
[5] Vo, V. H.
Entwicklung eines Baukastensystems für die serielle Fließfertigung von Betonfertigteile
Bachelor-Thesis, Lehrstuhl für Massivbau der Fakultät Bau- und Umweltingenieurwissenschaften, Ruhr-Universität Bochum, Betreuer: Jan Stindt, M.Sc.
2021
[4] Lorenz, R.
Tragfähigkeitsoptimierte Assemblierung von Betonfertigteilen
Master-Thesis, Lehrstuhl für Massivbau der Fakultät Bau- und Umweltingenieurwissenschaften, Ruhr-Universität Bochum.
[3] Königshofer, J.
Prozesssteuerung mittels stochastischer dynamischer Optimierung zur Vermeidung von Verschwendung in der Produktion
Bachelor-Thesis, wbk – Institut für Produktionstechnik, Karlsruher Institut für Technologie (KIT), Betreuer: Alex Frey, M.Sc.
[2] Baumbach, J.
Schwinden von ultrahochfestem Beton bei Wärmebehandlung
Master-Thesis, Lehrstuhl für Massivbau der Fakultät Bau- und Umweltingenieurwissenschaften, Ruhr-Universität Bochum
[1] Schwarz, Y.
Toleranzausgleichende Assemblierung von Betonfertigteilen
Master-Thesis, Lehrstuhl für Massivbau der Fakultät Bau- und Umweltingenieurwissenschaften, Ruhr-Universität Bochum, Betreuer: Jan Stindt, M.Sc.
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Last update: Jan 06, 2023
