| 摘要: |
| 针对建筑师缺乏关于定制化装配式建
筑制造与装配的技术认知与研究前置等问题，
文章旨在通过面向制造与装配的设计（DfMA）
理论探索，建构适用于建筑领域的DfMA策
略。策略研究分实施基础、面向制造的设计
（DfM）和面向装配的设计（DfA）三部分，并
基于莲花之居进行实践验证以形成实施框架，
从而为建筑师提供面向定制化装配式建筑的
DfMA策略指导与设计建造流程参考。 |
| 关键词: 定制化 装配式建筑 制造设计 装配
设计 |
| DOI：10.13791/j.cnki.hsfwest.20220605 |
| 分类号: |
| 基金项目:国家自然科学基金青年项目（52108022） |
|
| Research of Design for Manufacturing and Assembly (DfMA) Strategies for the Customized Prefabricated Buildings: With Lotus House as an Example |
|
HAN Dongchen,HAN Dongchen,QU Ming,ZHU Jian,WANG Congjun
|
| Abstract: |
| Free-form buildings have sophisticated structures. They are a significant challenge
for architects, engineers, and construction workers because of the lack of affordable and feasible
fabrication and construction methods. Unlike the mass production of off-the-shelf products,
free-form structures include a high degree of customized design, manufacture and assembly of
engineered-to-order (ETO) components. ETO components require sophisticated collaboration
among project participants to ensure a smooth workflow of design, manufacturing, logistics,
assembly, and maintenance. The discrepancies in BIM capabilities among the participants
become the primary barrier to applying Design for Manufacturing and Assembly (DfMA)
approach to the building industry.
DfMA attracts a lot of interests in the Architecture, Engineering, and Construction (AEC)
industry, especially in prefabrication or off-site construction. DFMA is the combination of
Design for Manufacturing (DfM), which means the design to facilitate the manufacture of the
parts that will make up a product, and Design for Assembly (DfA), which means designing
the product to facilitate assembly. DfMA provides a new avenue for the AEC industry for the
design and builds by maintaining existing lean construction practices, value management, and
integrated project delivery (IPD). BIM collaboration is essential for the successful application
of the DfMA method in the construction industry, especially for the construction management
of project participants at different levels of BIM capability.
In the study, a DfMA framework was developed for free-form prefabricated buildings.
The DfMA framework included two parts, DfM and DfA. The DfM includes pre-programmed
engineering logics designed for mass production, manufacturing workflow, production data, and
quality control. Participants’ pre-programmed engineering logics even out the variance of BIM
application levels among the participants. The DfA handles shipping, warehousing, assembly
sequence, and quality control. The study used a design-build house in which various industry
participants have different BIM capabilities to evaluate the developed DfMA framework.
Demonstration building. The design-build demonstration project, the lotus house, is a 1 000
sf free-form residential building designated for the Solar Decathlon student competition. The house
looks like the lotus flower with 12 free-form petals. Each of the 12 parabolic-shaped exterior walls
consists of a glass-fiber-reinforced concrete (GFRC) outer shell and a glass-fiber-reinforced-gypsum(GFRG) inner shell with a cavity between the shells filled with a steel skeleton and insulation materials. The paneled walls are different in size, rendering
each unique. The roof is composed of eight double-curve, pitched composite panels with the same construction as the exterior wall panels.
Design for Manufacture (DfM). Lotus House has more than 50 highly customized ETO components, such as walls, frames, ceilings, windows,
and furniture with parabolic curves. For the convenience of transportation and onsite assembly of composite wall panels, the building includes
two assembly processes. In the first assembly process, the steel frames and GFRC are produced in an external manufacturing plant. In the second
assembly process, the insulation and the GFRG interior panels were assembled on site. The DfM process requires a highly accurate and wellorganized BIM design model to coordinate all manufacturing and assembly processes. The design team plays a leading role in creating an ETOoriented BIM mode in Revit with Dynamo to support energy simulation, structural analysis, and construction coordination. The parameterization
algorithms developed by the team were able to generate 2D shop drawings for fabrication and assembly.
Taking GFRC’s curved exterior wall as an example, the design team creates algorithms to automatically generate fabrication information to
fabricate formwork in three different approaches: 1) traditional wood formwork, 2) formwork of CNC foam, and 3) 3D printed formwork made of
carbon fiber reinforced plastic polymer. Another essential component of the composite wall panel is the curved steel frame. The BIM model can
directly generate digital documents of different formats suitable for CNC machines, steel bending machines, and large-area additive manufacturing
(BAAM) equipment. After the first assembly of the ETO components, the research uses 3D laser scanning equipment to develop precision analyses
to improve manufacturing quality. Then the qualified steel frame and GFRC panel can be completed in the first assembly. BAAM equipment
produces free-form 3D printed furniture with high precision and high speed.
Design for Assembly (DfA). The goal of the assembly process is to reduce construction costs and minimize labor use. The design team
developed a comprehensive logistics plan that includes yarding, shipping, and receiving based on the composite wall panels’ erection procedure
and physical dimensions. The design team also creates a detailed assembly sequence and installation manual using the BIM model. Computational
simulation of the assembly sequence significantly increases construction efficiency and decreases on-site risk for construction crews. The design
team also performed 3D laser scanning and precision comparison analysis to verify assembly progress and accuracy. |
| Key words: Customization Prefabricated Building Design for Manufacturing (DfM) Design for Assembly (DfA) |
