#1ONREL Transforming ENERGY INDUSTRIALIZED AND ROBOTIC CONSTRUCTION ADVANCES IN TERRESTRIAL CONSTRUCTION AND OPPORTUNITIES IN SPACE CONSTRUCTION NASA NAVEEN KUMAR MUTHUMANICKAM STACEY ROTHGEB SHANTI PLESS JERRY DAVIS#2ONREL Transforming ENERGY Intro Please contact Naveen Kumar. [email protected] for the PowerPoint version of this presentation. NAVEEN KUMAR MUTHUMANICKAM RESEARCH ENGINEER INDUSTRIALIZED CONSTRUCTION INNOVATION (ICI) NREL SHANTI PLESS SENIOR ENGINEER INDUSTRIALIZED CONSTRUCTION INNOVATION (ICI) NREL STACEY ROTHGEB SENIOR ENGINEER INDUSTRIALIZED CONSTRUCTION INNOVATION (ICI) NREL JERRY DAVIS LAB PROGRAM MANAGER PARTNERSHIP DEVELOPMENT NREL#3ONREL Transforming ENERGY Overview of Presentation TERRESTRIAL CONSTRUCTION 1. Background 2. Trends & Sample 3. ICI efforts at NREL 4. Future Avenues (NREL ICI,) (Glimpses of past projects + Systems approach) (Modelling & Simulation, Deployment, Commercialization) (Robotics for Systems Integration/outfitting in buildings) SPACE CONSTRUCTION#4ONREL Transforming ENERGY National Energy Technology Laboratory Pacific Northwest National Laboratory Lawrence Berkeley National Laboratory SLAC National Accelerator Laboratory Lawrence Livermore National Laboratory Sandia National Laboratories Idaho National Laboratory Background NRELS goal is to deliver a ZERO CARBON ECONOMY (*2050) through research, innovation and strategic partnerships Ames Argonne National Laboratory Laboratory Brookhaven Laborat Princeton Plasma Physic pry National Re Energy Labo Los Alamos Nati NRELS Building Technologies Program (BTP) focuses on enabling EFFICIENT BUILDINGS AND BUILDING TECHNOLOGIES to contribute to a Zero Carbon Economy through clean energy interventions in buildings Laboratory Sandia National Laboratories Savannah River National Laboratory Industrialized Construction Innovation (ICI) team within NRELS BTP focuses on developing technologies to enable ADVANCED BUILDING CONSTRUCTION (ABC) to accelerate the decarbonization of the U.S. buildings sector#5ONREL Transforming ENERGY Background National Renewable Energy Lab (NREL) in Colorado Cold Climate Housing Research Center (CCHRC) in Alaska United States#6ONREL Background Transforming ENERGY ONREL Transforming ENERGY INDUSTRIALIZED CONSTRUCTION INNOVATION Integrating energy, decarbonization and circular economy strategies into Onsite automated construction Onsite Additive Construction Construction Traditional Industrialized Construction Offsite Prefabrication Decarbonize existing buildings Deploy clean buildings Climate Goals (2050 | 2070)#7ONREL Transforming ENERGY Volume at speed Background + new buildings and retrofits (Quality) volume at (optimal) speed Efficient, Functional, Affordable, and Appealing Efficient production through industrialization and robotic automation#8ONREL Transforming ENERGY Computational Capabilities Modelling and simulation capabilities to support Product Optimization Process Optimization Data Analytics Background Traditional Construction Industrialized Construction Innovation Demonstration Capabilities Testing and demonstration capabilities to support Prototype Projects Thermal Simulations Airflow Simulations Daylighting Simulations Energy Simulations Hygrothermal modeling Design for Manufacturing & Assembly Factory Information Modelling Process Modelling Multi-modal Data Collection (Camera, LiDAR, EMUs) Machine Learning based post processing (Computer Vision, Object Detection, Classification) TRL 1-3 Research Materials Research Small scale Projects Large Scale Projects at NREL+ labs TRL 4-6 Research with SBIR/STTR partners (startups and small businesses) TRL 7-9 research + Path to commercialization of technology with large scale partners#9ONREL Transforming ENERGY Offsite Prefabrication Background Traditional Construction Industrialized Construction Onsite Automation Prefabrication material handling Site Preparation Earthmoving Road building Crushing and Screening Construction Additive Deposition Material Handling Assembly Manipulation Outfitting Subtractive Tech. Material handling Navigating & Placing Manipulation Surveying Navigating & Scanning Retrofitting Navigating & Scanning Material Handling Manipulation#10ONREL Transforming ENERGY Background MODES OF ROBOTIC CONSTRUCTION Industrial Robotic Arms Rovers Quadrupedals Drones#11ONREL Transforming ENERGY 3 Smart Controls Integration and Commissioning Modularization of MEP Systems Background UT 5 Solar Plus Storage, Distribution Design and Integration HABITABLE BUILDINGS = FUNCTIONAL BUILDINGS FIGURE 11 An Ideal NZE Modular Housing unit for multifamily buildings as an output of DfEEinIC methodology by NREL and partners. 2 1 Envelope Infiltration Control Envelope Thermal Control#12NREL Transforming ENERGY 14 3 6 9 8 Background Building as a system of systems STRUCTURES MECHANICAL ELECTRICAL 8 12. Boiler Plant 16. Main board PLUMBING 21. Water storage tank 20. Water supply pipes 1. Fuselage 2. Cockpit 11. Chiller Plant 15. Power supply I I 19. Grey water return 10. Air valves I 14. Conduits I pipes 9. Ducts 13. Artificial Lighting 17. Drainpipes 10, 11, 12,13 9 -Years of development *Standardized -Standardized components MECHANICAL CONTROL SYSTEMS 1 10. Flap Control System 11. Aileron Control 13. Landing Gear I System I I 14. Wheels 1 12. Spoiler Control System I AVIONICS 3. Winglet STRUCTURAL 8. Footing 7. Foundation 4. Flaps 5. Slats I 6. Spoiler 7. Aileron 8. Stabilizers 6. Slabs 5. Beams 4. Columns ENGINES 9. Turbine 17, 19 20 11,12,21 -Months of development - One-off outputs -Less standardized -Customized components- ARCHITECTURAL 3. Windows 2. Interior walls 9,10,14,15 I A 1. Envelope assembly 5 6 1 2 7,8 3 Muthumanickam, N.K. (2021). Multidisciplinary Design Optimization Framework For Multi-Phase Building Design Process - Technology Demonstration Using Design Of Office Building And Robotically 3D Printed Habitat [Doctoral dissertation, The Pennsylvania State University]. PSU Electronic Thesis and Dissertation for Graduate School Repository. https://etda.libraries.psu.edu/catalog/24577nxm78 I I#13ONREL Transforming ENERGY BOLDT узинам MARK FEE ĐC DT Trends BUILDINGS: COMPLEX MULTI-SYSTEM ASSEMBLIES $ Source: https://constructionblog.autodesk.com/mark-III-construction-manufacturing/#14ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: BUILDING COMPONENT PRODUCTION Source: https://www.consigli.com/wp-content/uploads/2017/02/Lean-03-1.jpg#15NREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: BUILDING ASSEMBLIES 650 Source: https://www.asti.com/productization-a-vision-for-industrialized-construction/#16ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: ONSITE ASSEMBLIES AlionEnergy Alion Source: https://www.nytimes.com/2013/10/15/business/energy-environment/putting- robots-to-work-in-solar-energy.html#17ONREL Transforming ENERGY 131. OX Trends INDUSTRIALIZED CONSTRUCTION: OFFSITE MULTI-SYSTEM ASSEMBLIES 8 9 1119 8 7 6 5 4 76 5 4 3 dry 2 skim dry tape & bed plumbi Source: https://www.bdcnetwork.com/blog/epic-rise-industrialized-construction#18ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: IN-SITU CONSTRUCTION Source: https://www.popularmechanics.com/technology/infrastructure/a26252/3d- printer-build-house-mit/#19ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: ONSITE AUTOMATION Source: https://www.archdaily.com/779906/new-construction-robot-lays-bricks-3-times- as-fast-as-human-workers#20ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: ONSITE AUTOMATION Source: https://www.archdaily.com/779906/new-construction-robot-lays-bricks-3-times- as-fast-as-human-workers#21NREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: ONSITE AUTOMATION GUDEL Source: https://www.youtube.com/watch?v=jA9IJDZuYNK#22ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: ONSITE AUTOMATION Source: https://www.youtube.com/watch?v=qBvuZ-tUFIA#23ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: ONSITE AUTOMATION FUE ACCEES CANVAS Source: https://www.canvas.build/#24ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: REMOTE ACCESS Source: https://www.ribaj.com/products/q-bot-invests-2-million#25ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: RETROFIT AND RENOVATION Source: https://www.woodworkingnetwork.com/technology/robots-repair-veneer- imperfections-georgia-pacific#26ONREL Transforming ENERGY Trends INDUSTRIALIZED CONSTRUCTION: FAULT DETECTION Source: https://www.uasvision.com/2022/01/19/apellix-gets-nondestructive-testing- drone-patent/#27Penn State Project Samples - NASA 3D Printed Mars Habitat Challenge NASA Virtual Construction Level Mars THIN ATMOSPHERE COLD TEMPERATURES LOW GRAVITY Actual Construction Level Earth#28Penn State Project Samples - NASA 3D Printed Mars Habitat Challenge NASA Model Slice Translate Simulate Axis 3 Axis 4 Axis 5 Axis 2 Axis 1 Construct Axis 6 Ж Scenario 2 X Scenario 1 Muthumanickam, N. K., Duarte, J. P., Nazarian, S., Memari, A., & Bilén, S. G. (2021). Combining AI and BIM in the design and construction of a Mars habitat. In The Routledge Companion to Artificial Intelligence in Architecture (pp. 251-279). Routledge. https://doi.org/10.4324/9780367824259-17#29Penn State Project Samples - NASA 3D Printed Mars Habitat Challenge NASA Model Slice Translate Toolpath A Toolpath A efault start oode 628 Home extruder GL 215 F10 M207 690 M32 Turn off can Absolute positioning Extruder in absolute moder H90 850 Activate all used extrGGLE 10 MAGH TO $210 13 692 E4 Beset extruder position 12 Wait for all used extraders to reach tempere 13M109 TO 210 14 Layer counts 995 15 LATER 16 107 1763 F5000 X148.295 88.100 20.000 16 TEPE EMERT 1961 F1840 108.816 87.460 0.04117 MAL VITA SAAT IN Toolpath B Toolpath B Default start code 628 Rome extruder G1 215 F100 H107 630 M92 Turn off fas Absolate positioning Extruder in absolute mode M90 960 Motivate all used extruder 10 M10 TO 8210 11 692 E Reset extrader position 12 Wait for all used extruders to reach tempere 15 HAS TO 8210 14 Layer counts 998 15 LATERIO 16 MA37 1763 F50 x108.295 88.100 20.000 18 TYPE SHIRT 1901 F1800 X108.816 87.460 0.04117 sonian VELA 141 14 Simulate Manufacture ↑ Structural performance Complex Robotic Maneuvers Robotic vibrations at turns Concrete deformation (Less shape accuracy) Muthumanickam, N. K., Duarte, J. P., Nazarian, S., Memari, A., & Bilén, S. G. (2021). Combining AI and BIM in the design and construction of a Mars habitat. In The Routledge Companion to Artificial Intelligence in Architecture (pp. 251-279). Routledge. https://doi.org/10.4324/9780367824259-17#30Penn State Project Samples - NASA 3D Printed Mars Habitat Challenge NASA Design Variables: • Angle of taper Material consistency (Concrete mixing ratio) Lou Deformation of concrete beads when printed without supports due to shifting of center of gravity Muthumanickam, N. K., Duarte, J. P., Nazarian, S., Memari, A., & Bilén, S. G. (2021). Combining AI and BIM in the design and construction of a Mars habitat. In The Routledge Companion to Artificial Intelligence in Architecture (pp. 251-279). Routledge. https://doi.org/10.4324/9780367824259-17#31Penn State Project Samples - NASA 3D Printed Mars Habitat Challenge NASA ABB Challenges: • Over-extrusion at edges/corners/junctions Design Variables: • • Fillet radius at edges/corners/junctions Robot speed at corners Muthumanickam, N. K., Duarte, J. P., Nazarian, S., Memari, A., & Bilén, S. G. (2021). Combining AI and BIM in the design and construction of a Mars habitat. In The Routledge Companion to Artificial Intelligence in Architecture (pp. 251-279). Routledge. https://doi.org/10.4324/9780367824259-17#32Penn State Project Samples - NASA 3D Printed Mars Habitat Challenge NASA Flame Resistant 40/2018 ABB Muthumanickam, N. K., Duarte, J. P., Nazarian, S., Memari, A., & Bilén, S. G. (2021). Combining AI and BIM in the design and construction of a Mars habitat. In The Routledge Companion to Artificial Intelligence in Architecture (pp. 251-279). Routledge. https://doi.org/10.4324/9780367824259-17#33Penn State Project Samples – NASA 3D Printed Mars Habitat Challenge NASA Muthumanickam, N. K., Duarte, J. P., Nazarian, S., Memari, A., & Bilén, S. G. (2021). Combining AI and BIM in the design and construction of a Mars habitat. In The Routledge Companion to Artificial Intelligence in Architecture (pp. 251-279). Routledge. https://doi.org/10.4324/9780367824259-17