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Computer Integrated Steel Bridge Design and Construction
Summary of Responses
Summary of Responses Based on 15 responses
What is your primary area of interest/expertise:
Information Technology 1 Design 7 Fabrication (including Robotics & Welding) 6 Erection 1 Other
- Fabrication Inspection
What is your secondary area of interest/expertise, if applicable:
Information Technology 1 Design 2 Fabrication (including Robotics & Welding) 4 Erection 3 Other
- Servicing & Automation
- Eng- Shop Detail Drawings
Identify the following:
High-Payoff (short term) Opportunities For Increased Automation Gaps, Needs & Potential Obstacles to Implementing These Opportunities Electronic Submittal of Shop drawings a) ability to make designer comments during review on the electronic copy
b) ability to stamp and approve shop drawings & provide approved & current copies to required personnel
Standardize details to enhance automation a) getting all owners to agree upon common details Electronic shop drawings:streamline drwg transfer, use for mat'l takeoffs/tracking Must agree on standard file format(pdf, TIFF), authentication & protection Improve shop documentation and info flow in shop (weld proc. NDT, paint, bar codes) Educate users (ongoing process) and make available for smaller shops Information transfer/storage/retrieval for shop owners, including exchange Standard file format & protocol, insuring medium won't be abandoned in future Nondestructive testing and production monitoring for both QC and QA System cost, owner acceptance/trust in results, common stds, small shop access Automated layout for cutting, NC cutting and drilling Initial cost for new equipment is high, requires retraining of employees Electronic Submittal/Approval of Shop Drawings Liability & Security questions Combining analysis, design & geometry software together Weak link is current software Repeat elements - cleats, stairs, supports Design for repeat product IT knowledge and strategies
Data Tracking Low pay for Information Web Management Technology People Shop Layout Low Pay for Engineers
Poor or no Management Support
Communication between design software & fabricator software Computer Based design and fabrication Fabrication considerations at design stage, particularly at structural details Code requirements should be improved Autonomous Welding (less supervision by welders)
Sensor Integration Automation of Girder fit & weld CNC Is the Equipment available? Detailing software for bridges Uniform Details Varying state practices Medium and Longer term Opportunities for Automation Gaps, Needs & Potential Obstacles to Implementing These Opportunities Using shop drawings for direct production control (mat'l select, cut, weld, paint) Develop various systems; "cost" of shop errors, correcting errors found in field Flexibility to handle wide range of work (beams, I-grdrs, tubs, haunches, curves) System limits may exclude configurations and thwart innovative design concepts Workers more productive and have broader responsibilities with automation Fewer workers, older empl resist tech trng (or unable), lose knowledge/manual skills For repair & widening jobs, integrate new and existing shop drawings Major thrust in the next 50 yrs. Very labor-intensive unless "intelligent scanning" Increased automation of all welding processes, automated fit-up and assembly (web to flange and stiffener assembly) Variability of girder size and many changes in flange size is an obstacle to automation Use of electronic design info in fabrication Design software limitations. Enough interest in industry to see benefits Automated contract drawing preparation Lack of software Changed connection design Code acceptance
Columns and beams Product volumes Modular buildings Designs Failing Infrastructure Poor Scoping Lack of Timely use of resources Bridge Programs Synergistic considerations from structural design to fabrication/erection procedures - CAD/CAM 1) CAD/FEA design connecting? Not consider manufacturing effects in eng. Welding/cutting
2) E.g. welding sequence effects that significantly improve fatigue performance ????
Yes, Welding robot System Engineering for integration of Welding System Robotics for Welding Software and Hardware not able to handle submerged arc welding process Robotics for welding Conn & total CNC program @ Eng. Or shop floor Fewer plate thickness variations which could lead to more uniform designs and details. Also this could lead to more advanced plate purchasing contracts which may speed up projects. Designers wanting to "optimize" all portions of girder
Other comments, suggestions and questions:
- How does automation affect the design specification and procedures?
- "Automation" is a very generic term, so the panel must be cautious to avoid assigning inappropriate goals. Reducing labor costs with fewer, less qualified shop personnel is not applicable. Fabricators must also understand that this will be an evolutionary process, with changes, improvements and (inevitable) corrections occurring at irregular intervals. These modifications will have some negative effects on production and costs.
- We should see what is being done in the building industry.
- In order to implement Robotics in bridge building the expanded use of MIG, inner shield and or Dual Shield welding process will be required.
Appendix B | Table of Contents | Appendix D