In the field of infrastructure construction, the rapid advancement of science and technology is driving intelligent and digitalized production models to become the mainstream of industry development. However, traditional production of tunnel segments faces numerous challenges, such as low efficiency, high manual error rates, difficulties in quality control, and significant safety risks—factors that have long constrained the industry’s progress.

In response, Qingdao Hicorp Heavy Industry Science & Technology Co., Ltd. (hereinafter referred to as Qingdao Hicorp Heavy Industry), leveraging its deep expertise in engineering equipment manufacturing and unwavering spirit of innovation, has launched its 5th-generation digital and intelligent production line for tunnel segments, marking a major leap forward in industrial transformation. As a comprehensive engineering equipment manufacturer, Qingdao Hicorp Heavy Industry specializes in segment molds for shield tunneling, modular metro station components, wind power concrete tower molds, smart beam yard systems, integrated utility tunnel molds, lightweight wall panel production lines, and non-standard component manufacturing. Over the years, the company has built a strong reputation and client base by providing smart manufacturing system solutions for enterprises engaged in green, prefabricated building components.

The 5th-generation intelligent tunnel segment production line overcomes core technical bottlenecks through AI integration, enabling a fully automated and intelligent cycle of production—from mold cleaning, demolding agent spraying, rebar cage placement, mold assembly, concrete casting and vibration, rough and fine surface finishing, curing, demolding, to storage. Key features include:

• Smart Production Management System:

A SAAS platform designed for the full lifecycle management of concrete segment production, the system provides digital oversight of materials warehousing, rebar cage processing, production lines, steam curing kilns, and water curing pools. It enhances data accuracy and comprehensiveness in quality control. With a large-screen monitoring interface and BIM-integrated data center, the platform transforms factories into intelligent manufacturing hubs. Through multimodal data fusion supported by large language models, a comprehensive knowledge base is created—covering management policies, process documentation, equipment manuals, maintenance guides, and electrical diagrams—providing real-time smart Q&A support to all production roles.

Smart Manufacturing Management Dashboard

• Intelligent AI Inspection System:

This system performs full 3D scans of segment surfaces to capture geometric coordinates, including dimensions like thickness and length, as well as surface defects, cracks, and irregularities. It generates detailed inspection reports and evaluates conformity based on preset standards. The system also simulates triple-ring segment assembly to verify fit and alignment.

AI Inspection System

• Intelligent Mold Opening/Closing System:

Addressing the inefficiencies and risks of manual mold handling, the system utilizes dual six-axis robots, which has a seventh-axis to drive for full mold coverage. Equipped with a high-speed screw-driving module, it precisely controls bolt torque and rotations. Vision systems auto-detect bolt positions and adapt to different mold types, eliminating human error and fatigue-related defects.

Smart Mold Opening/Closing System

• Intelligent Rough Surface Finishing Robot”

Inspired by biomechanics, this robot mimics manual finishing motions, dynamically adjusting its blade angle relative to the concrete surface to ensure optimal contact and quality—achieving full automation in the rough surfacing phase.

Rough Finishing Robot

• Intelligent Fine Surface Finishing Robot:

Featuring multi-axis coordination and adaptive pressure-speed controls, this system guarantees uniform thickness and bubble-free surfaces. It uses a three-stage process—leveling, compacting, and precision finishing—and automatically adjusts to different segment specs, resolving issues like waviness and seams caused by manual fatigue.

Intelligent Fine Surface Finishing Robot

• Intelligent Mold Cleaning System:

This system automatically identifies mold types and executes 360° internal cavity cleaning, especially around residue-prone areas like hand holes. Configurations include:

Dual ground-rail robots for large molds

Dual ceiling-rail robots for compact layouts and retrofits

Single overhead-frame robot for lightweight needs.

Fully compatible with various segment sizes, it reduces costs and enhances production flexibility.

Mold Cleaning System

• AGV Smart Transfer System:

Meeting the demand for small-batch, multi-batch orders, this AGV system offers superior adaptability compared to traditional RGV setups. It supports flexible layouts and is compatible with diverse segment types.

AGV System

• Intelligent Demolding Agent Spraying System:

Replacing inefficient manual spraying, this system offers full 3D coverage, adapting to mold orientation and segment flow. The atomizing nozzle independently adjusts spray range and flow to ensure uniform application without waste. Compared with traditional manual operations, the system completely eliminates issues such as under-spraying and over-spraying caused by variations in human experience. Featuring a modular design, it is compatible with molds of various sizes and supports one-click switching of process parameters, significantly reducing labor dependency. This ensures consistent surface quality and improves production efficiency, providing intelligent support for the high-quality manufacturing of precast components.

Intelligent Demolding Agent Spraying System:

• Smart Intelligent Demolding-Flipping-Transfer System：

To address the inefficiencies and high risks associated with traditional manual hoisting during demolding, an innovative fully intelligent integrated demolding and transfer system has been developed. Featuring a framed structure that integrates a horizontal transfer trolley, winch lifting mechanism, and vacuum suction unit, the system enables seamless three-machine collaboration. Dual safeguards—including hydraulic mechanical lock hooks and wire rope tension sensors—ensure precise control over demolding force, effectively preventing segment dropping and mold damage.

The flipping mechanism is designed for mobility, enabling seamless integration between demolding and turnover processes. Wireless communication enables full automation of the “demolding–flipping–transfer” workflow. This system overcomes the limitations of traditional crane-based lifting methods, eliminates the safety risks of manual alignment, reduces labor requirements by 90%, and supports various segment specifications. With its high intelligence and reliability, the system sets a new benchmark for accident-free, delay-free intelligent manufacturing of precast components.

Smart Intelligent Demolding-Flipping-Transfer System：

Intelligent Pipe Insertion & Vibration Control System：

This system automates the insertion of air pipes and vibration control with PID-regulated three-phase vibration ("center mild →full mild → full strong"). It improves compaction, eliminates bubbles, and enhances concrete density—achieving fully unmanned casting operations and significantly improving workplace safety.

Intelligent Pipe Insertion & Vibration Control System：

Intelligent Safety Detection System：

To ensure operational safety along the segment production line, the company has developed a personnel safety detection system powered by AI and based on the YOLO deep learning algorithm. This system utilizes high-definition cameras and intelligent analysis modules to monitor the transfer vehicle pathways in real time. Upon detecting unauthorized personnel entry into hazardous zones, the system triggers a millisecond-level alert and immediately initiates emergency braking of the transfer vehicle. This effectively prevents potential collisions and significantly reduces on-site safety risks.

Intelligent Safety Detection System