RoFab-4iDM: Robotic Fabrication of Tunnel Services using Industry 4.0 for Intelligent Distributed Manufacturing

**_Robotic Fabrication of Tunnel Services using Industry 4.0 for Intelligent Distributed Manufacturing (_**_RoFab-4iDM) addresses safety and productivity problems that occur when fabricating customised mechanical and electrical (M&E) installation bracketry within rail and infrastructure tunnels._

**_RoFab-4iDM will radically improve productivity and worker safety by integrating survey, inspection, machining and additive manufacturing operations within an integrated, autonomous "survey-\>design-\>manufacture-\>install" system._**

**_South Korean partners will apply this technology automating metal pipework repairs within tunnels._**

We will combine conventional test techniques with machine learning (ML) and artificial intelligence (AI) to create a digital control environment capable of assessing and designing welds, fabrication, machining and additive manufacturing without human decision-making.

**_Innovating to solve real-world problems: Improve worker safety; saving UK taxpayers £16,000 per km_ tunnel built.**

RoFab-4iDM has immediate application for tunnelling projects including HS2, capturing benefits of autonomous robotics, while forming tunnel structures using conventional, cost-effective, precast concrete (PCC).

No other system of this kind is available.

**The issue:**

Rail tunnel M&E services are fitted to racking bolted to inserts cast into PCC tunnel sections. Installation tolerance build-up (due to 'roll' of PCC sections) means inserts are often out of position. Safety rules forbid welding and deter drilling new inserts inside tunnels. Therefore, many brackets need bespoke adaptions.

**Our proposal:**

RoFab-4iDM will combine tunnel design models with as-constructed 3D survey data, using AI to automate design and manufacture of customised bracketry. Each bracket will precisely suit the as-installed inserts, enabling fast robotic installation.

* **Precisely determine as-installed position of each insert** - automated scanning rig survey creates digital 3D representation.
* **Position-specific, customised standard bracket design** created by AI using digital twin.
* **Fabricate bracketry offsite** -- autonomous, adaptive robotic fabrication.

The project integrates proven techniques/technologies with a novel digital twin. The demonstrator will develop the digital twin integration from TRL5 to TRL7\.

**Further markets:**

**_Enhancing construction productivity by creating a method for off-site mass manufactured components that are cost-efficient and bespoke._**

Bridging the variance between designed ideal/predicted dimensions and as-installed would accelerate wide adoption of pre-manufactured products on construction projects.

**_Autonomous repair to regulated standards within hazardous environments._** Applying RoFab-4iDM technologies to other sectors will provide a solution for welding/AM within hazardous environments, avoiding disruption from having to move damaged components to a repair workshop. Future development would be to combine all stages into a **survey-\>design-\>manufacture-\>install** platform, with applications in any industry that requires assessment, repair and remanufacture of steel materials, including rail and civil nuclear decommissioning.