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Study on Innovative and Intelligent Field Factory
(IF7)
Phase1 Final Report
(Summary Edition)
May 2001
Contributors: The IF7 Consortium
Editor: Yuji Matsumoto/Hitachi Zosen Corporation
¥
1. Introduction
1.1 Objectives of Research
The objective of the IF7 project is to develop innovative and intelligent production system for
large-scale structure, for examples, building, ship, bridge, etc. The project aims at turning the
following seven dreams into reality:
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1) If we could build large scale objects, e.g., building, bridge and ship, in a comfortable
condition somewhat like an air-conditioned factory, ...
2) If we could easily build a temporary factory at site, ...
3) If we could decrease construction duration half as short as that of today, ...
4) If robots could assemble large components easily, ...
5) If detailed information, proactive advises and guidelines in all locations of construction sites
could be accessible by people for thinking or decision-making, ...
6) If we could have virtual dynamic construction simulation system integrated with an intelligent
planning, scheduling and performance management system, ...
7) If autonomous agents could support our decision making, ...
The seven dreams show large progress from currently nationwide construction method toward
the innovative and intelligent field factory. Field factory is relevant method that has possibility
to develop global production system. The point here is how to apply or adapt the field factory
effectively to distributed work places in a construction site.
Objectives of the IF7 project is to develop comfortable and modern construction site for
medium-rise apartment building, which satisfies both of user’s needs and contractor’s needs.
The IF7 project consists of the three works packages as follows:
Work package 1: Assembly methods for large-scale structures
In current construction method, many parts are delivered in succession to construction site,
and many various works are complicatedly and concurrently conducted. Under these
conditions, it is very difficult to realize mechanization and automation. Therefore, in this work
package, efficient construction method is developed by introduction of site plant and block
module of parts.
Work package 2: Mechanization systems for assembly of large-scale structures
In this work package, studied and developed is mechanization system for assembly line of the
new construction methods for large-scale building being studied and developed in the work
package 1. Studied is mechanization system to transport large-scale and variety of parts
efficiently and to assemble them with certain precision by utilizing technology of robot and
transportation.
Work package 3: Application of autonomous agent to construction management in field
factory
Variety of information being generated according to construction in progress is inputted into
computer. In this work package, studied is system, where agent will make appropriated
decisions and support to promote work efficiently based on the information.
1.2 Organization
As mentioned earlier, the IF7 project is composed of the three work packages.
management structure and participants are shown in Figure 1.2.1 and 1.2.2
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International Coordinating Partner
･Yuji Matsumoto : Hitachi Zosen
Executive Board
･Yuji Matsumoto : Hitachi Zosen
･Brian Atkin : KTH
･Junichi Yagi : Shimizu Co.
･Robert Wing : Imperial College
･Isamu Ishii : Kajima Co.
･Kunio Miyawaki : Hitachi Zosen
･Yoshio Maruyama : Hazama Co.
･Derek Blundell : Construct IT
･Thomas Bock : TU Munchen
･Derek Seward : Lancaster Univ.
Coordinator for the Project
To coordinate and decide overall Project matter
Regional Coordinator
･Yuji Matsumoto
(Japan)
Regional Coordinator
･Osama Moslehi
(Canada)
Regional Coordinator
･Robert Wing
(EU)
WP1
(Leader : I. Ishii)
WP2
(Leader : K. Miyawaki)
WP3
(Leader : Y. Maruyama)
WP1
(Leader : D. Blundell)
WP2
(Leader : R. Wing)
WP3
(Leader : D. Seward)
IPR Committee
Figure 1.2.2: IF7 Project Participants
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2. Research outcomes of each work package
2.1 Assembly methods for large-scale structures
2.1.1 Introduction
In the work package one, construction methods for apartment building, which is large-scale
structures, have been and are being studied. In order to improve productivity, it is necessary to
reduce volume and number of construction works on site by introducing large building modules
being assembled at pre-assemble factory, which is called site factory, and by realizing
concurrent and synchronized productions at the site factory with construction operations at the
installation area. On the contrary, in order to enhance customer satisfactions as considering
user’s needs, it is indispensable to provide living space with high degree of freedom of design.
For the reasons, as focusing on concept of open building (SI residence), which groups building
members of apartment building into supports modules and infill modules, the work package
one aims at studying and developing concurrent prefabrication at the site factory being
synchronized with construction operations at the installation area.
2.1.2 Conceptual Design of Support System
Construction methods of support systems pertaining to the three types being proposed such as
plug-in type, coffee-table type and floor lift-up type have been studied. (Figure 2.1.2)
Figure 2.1.2: Construction Methods of Support Systems by the Three Types
2.1.3 Conceptual Design of Infill System to Enlarge Package of Infill
The concept of inner house, in which dwelling parts are planned to be flexible for user’s needs
in the future, was investigated. To put it concisely, potential changes in dwelling were predesigned, and model of apartment with changeability, was conceptually designed. The model
of apartment called Cladding Infill was specified as follows:
- Box unit is produced inside site factory;
- When box unit is lifted, almost all exterior work is finished; therefore, temporary scaffolding is
unnecessary and it is expected that a sharp shortening of construction duration is realized.
- As for interior finishing works, when box unit is installed, almost all finishing works for face of
wall, plumbing, closet, etc are finished; consequently, it is expected that construction duration
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of finishing work inside suite is also shortened; and
- Replacement and maintenance of infill requires another plan.
As shown in Figure 2.1.3, box unit is assembled in succession.
2.1.4 Considerations on Productivity of Cladding Infill Method
In case of general high-rise apartment building, if each suite has different layout of living space,
work on site becomes extremely complicated. Accordingly, prefabrication and mechanization
are disturbed. The cladding infill method, however, by each living space with different layout on
common pallet, has characteristics of productivity as follows:
①Prefabrication of suite in high-rise apartment building
Pallet being suspended from skeleton carries loads of living part. Regardless of story
and scale of building, all structures of box units can be on the same when using pallet.
Accordingly, technology pertaining to production and production line that house makers
have developed so far can be utilized.
②Industrialization of works on site
Although number of units for each suite is different, pallet of same size can be applicable
to assembly on site and lifting works. Accordingly, it becomes easy to build a series of
work line and mechanization on site.
2.2 Mechanization systems for assembly of large-scale structures
2.2.1 Introduction
In mechanization system for large-scale structure, difficult technological tasks are to transport
and assemble large-scale, heavy and various parts. Objectives of this research are to develop
intelligent and new handling equipment instead of current crane and to build mechanization
system, which has the handling equipment as key component. In this fiscal year, application of
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hybrid drive parallel arm to assembly of module in the coffee-table construction method, which
is one of construction methods being proposed in WP1, is studied as a case study. In this
case study, developed is concept of consolidated mechanization system from unloading to
installation as for three PCa parts, for examples, column, beam and slab.
2.2.2 Next-generation-oriented Handling Equipment for Heavy Loads
Next-generation mechanization system with high productivity and safety and without damage
against environment enforces to develop intelligent handling equipment instead of conventional
crane for heavy loads. Combination of wires and mechanical cylinders, which is mechanism to
utilize their excellent characteristic, was proposed to develop the intelligent handling equipment
for heavy loads. The mechanism based on the combination of wires and mechanical cylinders
is called hybrid drive parallel arm. Figure 2.2.2 shows a one-seventh model of the hybrid drive
parallel arm to study elemental technologies required to handle heavy loads. Comparing with
conventional crane, the hybrid drive parallel arm has excellent operability of controlling position,
orientation and force of objects being handled.
Figure 2.2.2: A One-seventh Model of Hybrid Drive Parallel Arm
2.2.3 Plan of Mechanization for Assembly of Coffee-table Module
(1) Plan of Mechanization System
Figure 2.2.3-1 shows image of application of handling equipment to assembly yard for
structural modules in the coffee-table construction method, which is one of construction
methods being proposed by WP1. Several hybrid drive parallel arms are hanged from double
rails. The several hybrid drive parallel arms grasp parts at the unloading area and transport
them to the assembly area. Then the several hybrid drive parallel arms install them with certain
precision.
Figure 2.2.3-1: Plan of Mechanization System for Assembly of Coffee-table Module
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Primary specifications of transportation equipment being used here are shown as follows:
- Mass being handled: 3.0[ton],
- Movable extent:φ500×3500[mm]×(±)10[deg],
- Distance between rails: 2000[mm],
- Mechanism of travel: this is the same method as hoisting double-rail crane,
- End-effector: this is available for parts of column, beam and slabs
(2) Design of Prototype of Hybrid Drive Parallel Arm
Based on required specifications of transportation equipment, prototype of hybrid drive parallel
arm was designed.
C3W4 with rod that can be expanded and contracted is selected as
mechanism of hybrid drive parallel arm. In this fiscal year, work envelope and attitude, where
each link does not interfere with other at certain section of columnar work envelope, are simply
calculated by Excel. Extents pertaining to work envelope and attitude were finally calculated
and generated power was calculated by the software, which was developed to analyze
mechanism. Figure 2.2.3-2 shows overview of transportation equipment being designed based
on results of the analysis.
Figure 2.2.3-2: Bird-eye View of Prototype of Hybrid Drive Parallel Arm for Three ton
(3) Examination of End-effector for Assembly of Coffee-table Module
Hybrid drive parallel arm can transport and position PCa parts without workers. Then, endeffector is required to grasp and hold parts, directly. Capacity of the hybrid drive parallel arm
depends on capacity of the end-effector. Workability of end-effector to load and unload parts
and easiness of end-effector to detach and attach have serious influence on cycle time of
transportation and efficiency of work pertaining to PCa parts. Accordingly, end-effector to
handle PCa parts of column, beam and slab was examined by putting its work conditions,
composition, kind and specifications in order. Figure 2.2.3-3 shows idea of end-effectors for
each part. Pictue2.2.3 shows the state of experiment to erect frame of four columns and four
beams by the prototype machine.
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Figure 2.2.3-3: Idea of End-effector to Transport Coffee-table Modules
Picture 2.2.3: Model of End-effector and State of Assemble of Module
2.3 Application of Autonomous Agent to Construction Management in Field Factory
2.3.1 Introduction
Autonomously agent-oriented construction management has been studied to support efficient
construction practices in construction methods, which have been studied in the work packages
one and two.
A variety and large amount of information is generated as a variety of
construction works subsequently proceeds, and is stored in many computer systems. The
autonomously agent-oriented Construction management will effectively supports decision
making based on a variety and large volume of information. Virtual and real-field construction
information management system (hereafter called V&R-Coms) was proposed as system to
support site manager.
It is expected that the V&R-Coms will be able to reduce load of
information processing to site personnel.
2.3.2 Outline of V&R-Coms
Figure 2.3.2-1 shows overview of V&R-Coms. V&R-Coms is composed of Cyber Concurrent
Engineering (CCE), Cyber Manufacturing (CM), POP construction management system and
extranet production system (EP system). Enterprise core business information system is core
information system for all company that is composed of ERP （ Enterprise Resources
Planning）, APS (Advanced Planning and Scheduling) and schedulers.
Figure 2.3.2-1: Various Information Systems of V&R-Coms and Simulator
Figure 2.3.2-2 shows composition of testbed. Information on plan of program of work being
made by CDPM is transmitted to Quest (3D-CG production line simulator) to simulate virtual
construction. Works by equipment and robots are simulated by Envision (3D-CG work plan
simulator). AutoCAD generates three-dimensional data being required to simulate. Data of
production (performance, progress, parts, etc), which were generated by Quest, are input data
into the POP construction management system. As for information managed by the POP
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construction management system, information required by the headquarters or outside
suppliers is processed again by the EP system and is transmitted to the headquarters or
outside suppliers.
Figure 2.3.2-2: Composition of Testbed System
2.3.3 Model of Construction Method: Coffee-table Construction Method
Figure 2.3.3 shows apartment building of sixteen stories under construction for a case study.
In the case study, one floor is partitioned into eight modules.
One story of building is
composed of eight coffee-table modules, three floor modules, and two staircase modules.
In the case study, it is supposed that one floor is constructed in two days. Accordingly, it is
necessary to produce four modules a day.
One coffee-table module is produced in forty-five
minutes at site factory.
Figure 2.3.3: Apartment Building for Case Study
2.3.4 Research on Virtual Construction Site
Figure 2.3.4 shows model of site factory being developed in work plan simulator (Envision).
Table 2.3.4 shows results of simulation.
Figure 2.3.4: Simulation Model of Site Factory
Table 2.3.4: Results of Simulation of Site Factory
In the case 1, results of this simulation show about ninety minutes that is big larger than target
figure. Position of the hybrid drive parallel arm at the beginning of work, allocation and order of
jigs are changed.
Time to load and assemble and speed of travel of the hybrid drive parallel
arm and rails are improved. Consequently, it could be confirmed from results of simulation in
the case 5 that assembly within forty-five minutes could be attained.
2.3.5 Development of Automatic Design System regarding Site Factory
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In this research, problem to design site factory is regarded as three interactive problems of
arrangement planning, path planning and work allocation and is solved as follows:
(1) Problem of arrangement planning: This is problem to decide number and layout of rails and
number of the hybrid drive parallel arms at site factory;
(2) Problem of path planning: If several hybrid drive parallel arms can efficiently travel on each
rail, time to finish work is shortened; this is problem of path planning of the hybrid drive
parallel arms; and
(3) Problem of work allocation: this is problem to allocate efficient works to each hybrid drive
parallel arm.
The developed ADSS is a system that calculates the practically optimum solution to address
such convergent issues by modeling with arrangement planning, which is a high-order issue,
as the race and with solution of the issue consisting of path planning and work allocation,
which are low-order issues, as individuals, and applying originally-devised Multi-Species
generic algorithms.
Examples of automatic design system of site factory are shown in Table 2.3.5 and Figure 2.3.5.
Parts consist of column, beam and slab. Maximum number of the hybrid drive parallel arms is
six. Maximum number of rails at the unloading area and the assembly area is five, and at the
buffer area is seven.
Figure 2.3.5 shows that species with lower degree of fitness can
gradually increase in its degree of fitness by changing plan of layout. Table 2.3.5 shows that
the layout 1 has the same plan as the layout 3. The layout 1 still remains at the initial layout. It
can be regarded that the layout 1 is excellent as for time, cost and area being used. In fact,
the plan of layout 1 is comprehensively good.
It can be seen from the graph that species,
which finally includes individual with higher degree of fitness, is species including individual
with the lowest degree of fitness at the beginning.
Table 2.3.5: Output of ADSS
Figure 2.3.5: Transition of Max Fitness
2.3.6 Construction Information Management System for Virtual Production (POP
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Construction Management System)
First, process of business management is defined, considering the coffee-table construction
method. Second, designated are items of management to be handled by each department
corresponding to each stratum of management and to be collaboratively processed by
departments belonging to each enterprise.
In this case study, management pertaining to
progress, parts, inspection and performance is focused on as theme of management. Flow of
information on production, which is back and forth between each stratum of management in
process of business management based on designated items of management, are put together
from the viewpoint of download system and upload system. Moreover, transition of interface
for each user to process information is defined.
These are definition of requirements to
develop construction management system. Based on the definition, in fact, prototype of the
POP construction management system, which is integrated with Quest simulator, was
developed.
2.3.7 Extranet for Construction Information Management
Developed were the three interfaces as follows:
1) Interface for driver of trailer,
2) Interface for department of production management in the headquarters, and
3) Interface for department of shipment and department of production plan in PC factory.
Figure 2.3.7: Transition of Interface for Driver of Trailer
Figure 2.3.7 shows example of transition of displays for driver of trailer.
Following ②
information on shipment, information on shipment is downloaded from database of production
plan at the department of production management in the headquarters to PCa factory. In the
PCa factory, based on the information on shipment, PCa parts being shipped on that day are
confirmed and loaded on trailers. The information on shipment is transmitted via forwarding
agency from the PCa factory to driver concerned. The driver checks if parts being loaded are
consistent with the information on shipment and goes to her/his destination. After arrival to
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inspection area in construction site, the driver is present at inspection by site manager
concerned. Results of inspection are transmitted via POP system to manager engaged in
program of work on construction site.
3. Promotion of IF7 Global Linked Research and Opening to the Public and
Popularization of Research Results
This project was recognized as the tenth international cooperative research of IMS by ISC in
May 1997.
To proceed the IF7 global linked international joint research project, EU element, which is one
of the influential elements, has made in efforts to get research fund from ESPRIT. The EU
foresaw to gain the research fund from ESPRIT in June 1998, and the FutureHome Project
started formally in December 1998. The kick-off meeting was held in Greece in January 1999.
Almost all the partners of EU and Japan gathered and attended the kick-off meeting.
Executive Board Meeting (TV conference) was held in July 1999, and the second international
conference has been held in Madrid in September 1999. Participants made presentation of
their research activities in this conference. In addition, further joint research was examined in
sectional committees by work packages.
The third international conference was held in Kyoto in September 2000 to exchange
information on research results between EU and Japan. There were especially brisk opinions
on technology pertaining to earthquake-resistant and earthquake-free. In March 2001, IMS IF7
international open day was held in Tokyo, and presentation in academic society and press
release of research results were done to open results of the IF7 international joint research to
the public. (Picture 3)
Picture 3: Third IF7 International Conference (Left) and IF7 International Open Day (Right)
4. Conclusion
IF7 Project is one of the international collaboration researches of IMS Program. Research
activities of each work package carried out by the IF7 Project are described in the following.
WP1: Assembly methods for large-scale structures
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As focusing on concept of open building (SI residence), Three types of construction methods of
support systems were proposed such as plug-in type, coffee-table type and floor lift-up type
have been studied. As for infill part of SI apartment housing, infill system to enlarge package
of infill part and conceptual design of cladding infill system has been conducted and were
finished. Pre-assemble at site factory and installation method at floor being constructed, which
were production method of the infill unit, have been examined. Consolidated system of infill
unit in addition to support, which has been proposed so far, has been developed as SI housing
construction method.
WP2: Mechanization systems for assembly of large-scale structures
As for transporting and assembling materials of column, beam and floor of coffee-table
modules based on the hybrid drive parallel arm, which was developed as next-generationoriented method to handle heavy materials, concept of mechanization system including support
system with censor as central part has been developed. In addition, usability of the concept
regarding materials of column and beam has been examined and confirmed by the prototype
machine.
WP3: Application of autonomous agent to construction management in field factory
Virtual and real-field construction information management system (V&R-Coms) was proposed
as system to support site manager. Virtual field of building construction site, where hybrid
drive parallel arms were applied to assemble modules of coffee-table at site factory, and its
availability of V&R-Coms were examined.
In the study on construction information
management, prototypes pertaining to POP system and extranet production system were
developed.
Using these prototype systems, basic functions of construction information
management system for construction site were made clear.
In the study on cyber-agent,
appropriate composition of rails to transport at site factory and function to make path planning
of hybrid drive parallel arms were developed.
Innovation in the construction field is being achieved by moving from "construction" to
"manufacturing." To accomplish this revolutionary transformation, innovation is essential in
three fields -- assembly methods, mechanization systems, and information technology for
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supporting the production process.
IF7 Project has developed an innovative new proposal concerning the technologies required.
With new technologies now being developed at an increasingly accelerated pace, the results of
this research will no doubt be put into actual practice in the very near future.
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