This study presents an example of creating and optimizing a task sequence required in an automated remote dismantling system using a digital manufacturing system. An automated remote dismantling system using a robotic arm has recently been widely studied to improve the efficiency and safety of the dismantling operations. The task sequence must be verified in advance through discrete eventbased process simulation in a digital manufacturing system to avoid problems in actual remote cutting operations as the main input of the automated remote dismantling system. The laser cutting method can precisely cut complicated target structures such as reactor internals with versatility, but a robot and a pre-prepared program are required to deploy sophisticated motion of the laser cutting head on the target structure. For safe and efficient dismantling operations, the robot’s program must be verified in advance in a virtual environment that can represent the actual dismantling site. This study presents creating and optimizing the task sequence of a robotic underwater laser cutting as part of the project of developing an automated remote dismantling system. A task sequence is created to implement the desired cutting path for the target structure using the automated remote dismantling system in the virtual environment. The task sequence is optimized for the posture of the laser cutting head and the robot to avoid collisions during the operation through discrete event-based process simulation since the target structure is complicated and the volume occupied by the laser cutting head and the robot arm is considerably large. The task sequence verified in the digital manufacturing system is demonstrated by experiments cutting the target structure along the desired cutting path without any problems. The various simulation cases presented in this study are expected to contribute not only to the development of the automated remote dismantling system, but also to the establishment of a safe and efficient dismantling process in the nuclear facility decommissioning.

Since nuclear power plant (NPP) dismantling carries the possibility of radiation exposure from a hazardous environment, it’s important to minimize that by using a remote manipulator et al. However, due to complexity of nuclear facilities, it’s necessary for operators to increase their proficiency by operating in advance in a virtual environment. In this research, we propose a virtual manipulator system using a haptic device for NPP’s reactor vessel internals (RVI) dismantling which can realistically manipulate.

The remote dismantling system proposed in this paper is a system that performs the actual dismantling process using the process and program predefined in the digital manufacturing system. The key to the successful applying this remote dismantling system is how to overcome the problem of the difference between the digital mockup and the actual dismantling site. In the case of nuclear facility decommissioning, compensation between the virtual world and the real world is difficult due to harsh environments such as unsophisticated dismantling sites, radiation, and underwater, while offline programming can be proposed as a solution for other industries due to its sophisticated and controllable environment. In this paper, the problem caused by the difference in the digital mockup is overcome through three steps of acquisition of 3D point cloud in radiation and underwater environment, refraction correction, and 3D registration. The 3D point cloud is acquired with a 3D scanner originally developed in our laboratory to achieve 1 kGy of radiation resistance and water resistance. Refraction correction processes the 3D point cloud acquired underwater so that the processed 3D point cloud represents the actual position of the scanned object. 3D registration creates a transformation matrix that can transform a digital mockup of the virtual world into the actual location of a scanned object at the dismantling site. The proposed remote dismantling system is verified through various cutting experiments. In the experiments, the cutting test object has a shape similar to the reactor upper internals and is made of the same material as the reactor upper internals. The 105 successful experiments demonstrate that the proposed remote dismantling system successfully solved the key problem presented in this paper.