1. PRODUCTION CAPACITY PLANNING
This article describes new ways of producing facade elements efficiently and at a high standard. The possibilities offered by the machines and production technologies which are currently available
were to be fully exploited. It was recognised that the combination ofa well trained staff and sensible machine technology would bode well for the success of an industrial company in the future. The production of the plant should achieve a rate of 10 pallets per hour. From this point of view, the engineers have produced a highspeed plant unlike any other.

1.2. The design and dimension of the façade products
The main purpose of the plant is to produce facade elements for industrial and commercial buildings. The elements are up to 13 m long, 2.5 m wide and, in most cases, 140, 160, or 200 mm thick. The
surfaces can be given a coloured or grey face-concrete structure, exposed aggregate, or anything else. The wall elements are provided with core insulation consisting of polystyrene insulation blocks. The sides are smooth or can also be providedwith tongue and groove. All the edges are chamfered.

1.3. The robotic formwork system
One important component of the efficient circulation system is a complex and very flexible, robot-compatible, solid-wall formwork system. The formwork profiles were made using a welding robot with the highest precision. Each compact formwork profile is fitted with two adjustable permanent magnets to stop it from shifting during the manufacturing process on the circulation plant. The formworks can be removed from the pallet later without much effort by manually deactivating the magnets.

MENTS
The number of formwork types which differ in length, height and shape was deliberately reduced to a minimum so as not to encumber the customer with a formwork system which was difficult to understand.
With the existing formworks, any length, height, or thickness of wall can be produced within the framework of the available pallet size. The formworks can be used on both sides and correspondingly both as cross formwork or longitudinal formwork depending on the dimensions of the solid wall which is being produced.
Each pallet is provided with fixed-edge formwork on one side, which can be made higher if necessary with edge formwork, depending on the wall thickness which is being produced. The two basic edge
formwork heights 140 mm (80% of the precast concrete elements) and 160 mm can be increased to 160 mm or 200 mm accordingly. The fixed-edge formworks are bolted to the pallets but can be removed and replaced whenever this is necessary. This also ensures that the circulation plant can be quickly and easily adjusted in relation to the product thickness or even the shape according to the changing market requirements in the future. The increased height of edge formwork is supplemented or removed on a manual
formwork station. Most of the solid walls have a wall height of 2 m or 2.5 m and the lengths and quantity of the cross formworks have been selected accordingly. Other cross formwork lengths are 1 m and 1.5 m. With walls of intermediate height, a telescopic metal sheet is inserted between the cross formwork and the longitudinal formwork which is fixed with a magnet box and X-Smart support angles. This system provides unlimited flexibility for the formwork concept.

1.4. The automated production concept
The length of the plant altogether is approximately 130 m and the individual pallets are 14 m long and 2.78 m wide. With a pallet loading of 20 m2 and 10 pallets per hour, approximately 350,000 m2 facade elements are produced on average per year. The pallet circulation plant consists of 18 workstations and 104 places in the rack system. The rack itself is insulated and provides the optimum conditions for fast and careful curing of the high-quality façade elements. Each rack compartment can be accessed via a segment gate
system. Every time an element is loaded or retrieved, only one of the 104 narrow segments is opened so
that the prevailing conditions in the rack for optimum curing are hardly affected. The rack-operating unit
moves along the floor

The track lies on the rack supports of the first row. All travel and lifting movements are stepless so the speed of lifting the pallets when empty is higher than the speed of lifting them when loaded. This saves energy and makes optimum use of the motor power. The pallets travel along and across on roller blocks, friction wheels and transverse elevating truck platforms as standard. Anything up to 100 kg payload and are made available by the magazine robot, are taken from the transport belt and placed directly on the pallet and then the integrated magnets are activated. The robot is also fitted with a plotting device which marks out the fittings, doors and windows.

On the two subsequent manual workstations, the formwork is extended, fittings placed and the window and door formwork placed on the pallet by hand. The handling crane is made available to the workers for this purpose.
On the two subsequent pallet stations, the pre-manufactured reinforcement is placed manually, also using handling cranes. This may consist both of individual rods and reinforcement mats. U07 is a buffer station on which the remaining reinforcement can be placed. At cycle station U08, the first layer of fresh concrete is introduced. While the concrete distributor collects the next mix from the mobile intermediate silo, the pallet switches to Station U13. The first layer is preliminary-compacted by the vibratory compactor [noise emission
less than 70 dB(A)], the second half of the fresh concrete is introduced and then the freshly concreted elements are given their final compaction. Above the pallet station U14, there is a mobile device for screeding the concrete by means of a vibrating beam.
The cycle stations U15 and U16 are used for the final inspection before the pallets are stored in the rack system or they are used as buffer stations. The rack operating unit (U18) takes the pallets with the freshly produced façade elements and transports them to a free compartment in the rack system. The heat of hydration produced and the moisture conditions create the optimum curing conditions for the elements.

1.5. The control concept
The production planning system operates with a CAD system and the entire production is controlled by a UniCAM system from Unitechnik, a master computer which has been developed especially for the precast concrete industry. This forms the link between the CAD system, the operator and machine control systems.
The following modules of the UniCAM system guarantee efficient production:
• Pallet allocation
• UniCAM receives the elements to be produced from the CAD system, allocates the pallets automatically and defines the optimum production sequence.
• Pallet transport
• All pallet movements and dwell times in the circulation system and the curing chamber are co-ordinated according to the product.
• NC-data generation
• UniCAM supplies the formwork robot with optimised NC data.

1.6. Production planning information management
The operator is constantly kept informed of the following via a graphics display of the system: Which pallet is located where on the plant? Is there a malfunction? When will the element be ready?
• Information management
• Documents for production and the construction site, statistical data for the management and feedbacks for the PPS system etc are output. The Unitechnik machine control systems of the circulation system and formwork robot are based on the Siemens S7 and the highest priority has been given to providing control
hardware with maximum reliability. As far as possible, the control software consists of standard modules which are already in use on a large number of plants. For service purposes, both the master computer and the plant controls can be looked after from a distance via a modem. An uninterruptable power supply (UPS) guarantees continuous operation of the computers if there is a power failure. The production manager can see all the information he needs at a glance on the control stand via the plant display. The state of the plant, the respective production times at each pallet station, disruptions and fault messages are collected centrally, evaluated and passed on. Thus bottlenecks can be determined and the plant continuously optimized and adjusted to requirements as they change. The Intranet, which is about 5 km away, is first connected to the production facility office and from there to the control stand via a router. The data flow in both directions on-line provides a rapid supply of production data and allows the production state and production values to be called up from the control panel by the head office directly.

2. HYBRID SITE AUTOMATION
The first prototypes for automated high-rise construction sites were put into operation in 1990 and 1991 by Shimizu after five years in development and a financial outlay of almost 16 million euros. Since then, 20 automated high-rise sites have been operated by different companies (Taisei, Takenaka, Kajima, Maeda, Kumagai). A hybrid high-rise construction site is understood as the semiautomated storage, transport and assembly equipment and/or robots used to erect a building almost completely automatically. It is the attempt to improve the sequencing of construction processes and construction site management by using real-time computerized control systems. This includes an unbroken flow of information from planning and designing the building through programming the robots with this data to using computers to control and monitor building operations on site.

After the foundations have been laid, the production equipment, on which the steel construction has been installed with assembly and transport robots, is covered completely with a roof of plastic film. Depending on the system, this takes from three to six weeks. Then the robots go into action. Two steel and ten concrete plants supply parts in ten-minute cycles on a just-in-time basis. This approach to supplying is not necessarily part of the system, but is due more to the lack of space around building sites in large Japanese cities. The
prefabricated parts are checked and then placed in specific depots at the foot of the building or in the building itself to be available to the robots. Once a story has been finished, the whole support structure which rests on four columns is pushed upwards by 12 hydraulic presses to the next story. Three 132 ton presses in each pillar are required to achieve this in 1.5 hours. Fully extended, the support structure is
25 meters high; retracted it measures 4.5 meters. Once everything has been moved up, work starts on the next story. By fitting out the topmost story of the high-rise as the roof at the beginning of the building process, the site is closed off in all directions, considerably reducing the effect of the weather and any damage it might cause. This system reduces labor requirements by around 30%. Future
projects are expected to achieve a labor saving of around 50%. The building consists of a remarkably high proportion of prefabricated parts. Once the foundations have been laid, the remaining construction
procedure can be described as a matter of configuring transport  and geometry. All the elements are prefabricated; only some of the fitting, joint insulation and other minor works need to be carried out
by hand. Problems with the construction arise less from the timing of deliveries of materials or from the choice of processes and/or machines but more from the need for accurate planning, from programming
the robots or from the just-in-time supply of parts.

3. CONCLUSION

The research, development and application of industrialization to construction during the last 3 decades shows that by using robotic technologies in prefabrication, on site construction and services, we
will be able to achieve customized building products at affordable construction costs and constant quality and human oriented working conditions.

 

Prof. Dr.-Ing./Univ.Tokio Thomas Bock
Chair for Building Realization
and -informatics
TU Munich, Arcisstrasse 21,
D 80333 Germany
www.bri.ar.tum.de

REFERENCES
[1] Pictures1–6, copyright, Herrmann Weckenmann, Germany
[2] Picture 7, copyright, Thomas Bock, TU Munich, Germany