Advantages and operation modes of intelligent unmanned steel plants

At present, with the rapid development of the 5G network, industrial network and artificial intelligence technology, the manufacturing industry will be introduced into the intelligent production stage. Intelligent robots will completely replace humans at the manufacturing site. People will completely separate from the manufacturing site and develop from production workshops to intelligent unmanned workshops.

Compared with manual work, intelligent robots have three main production advantages:

 

1) High standardization of product actions

The product action behaviour of intelligent robots has the characteristics of high precision and high standardization and is not affected by human psychological state and individual differences, so the consistency and stability of production are extremely high.

 

2) It greatly improves machine manufacturing efficiency

Intelligent robots can perform continuous manufacturing at high speed for a long time.

 

3) The manufacturing process is relatively safe

Intelligent robots are highly tolerant to adverse environmental influences, and no personal accidents were caused at the manufacturing site.

Although intelligent unmanned workshops can already allow people to leave the production site, they still require people to conduct inspections of the production site.
Conduct real-time monitoring to effectively handle issues such as production coordination, mechanical equipment failure, and safety management. in the near future
In the future, intelligent unmanned workshops will become the new standard for modern industry. To effectively cope with the challenges of intelligent unmanned workshops
Therefore, there is an urgent need to understand the construction model of intelligent unmanned workshops and deeply understand the working logic of intelligent unmanned workshops.

Edit, thereby quickly seizing the strategic advantage of intelligent manufacturing.

 

unmanned steel plants

 

1. Research on intelligentization of unmanned workshops

 

5G technology is the cutting-edge technology of artificial intelligence, virtual reality (VR)/augmented reality (AR) and the Internet of Things. It will create an era of great wisdom with high interconnectivity and deep human-computer interaction. As China’s leading future information wireless transmission technology, 5G has great development potential in promoting the development of China’s industrial Internet of Things and process control platforms such as CPM. As a new information and communication technology, 5g will become a new driving force for the innovation and development of robotics technology relying on innovative features such as high bandwidth, low latency, large capacity, and high reliability.

 

2. Research on the current situation of steel plants

 

As the most labour-intensive industry in my country, the main problems currently faced by steel companies are:

The level of automation and intelligence is low, and on-site control is mainly based on manual experience. Due to the differences in experience, level, knowledge structure and subjective initiative of on-site technicians, product quality is uneven, the scrap rate remains high, and product production Problems such as high cost and poor market competitiveness.

There are many people gathered on the workshop site and they stay for too long. Although steel companies have formulated strict safety management systems, safety hazards still exist, and casualties occur from time to time. According to incomplete statistics, 180 safety production accidents occurred in steel companies across the country in 2020. Since then, it has caused more than 270 casualties and direct economic losses of more than 500 million yuan.

On-site technicians have insufficient task arrangements and long working hours, but a considerable amount of waiting time is taken up. For example, there can be up to 5-7 cranes on a track, but for safety reasons, only 2 cranes are working on each track, the remaining 2-3 are on standby, and 1-2 are under maintenance. However, all cranes must be equipped with crane operators and be on call at any time, which results in a large amount of waste of labour costs and increases the excessive production costs of enterprise products. At the same time, due to long-term exposure to high temperature, high dust, high noise, and a strong electromagnetic environment, it is harmful to the human body. Damage was also caused.

To this end, this project proposes to use the Internet of Things, smart instruments, 5g communications, visual recognition and deep learning to transform the production workshops of steel companies into unmanned and intelligent production workshops. By adding automatic control modules control software and a visual recognition system to realize intelligent and unmanned production in steel workshops. The successful implementation of this project has greatly reduced product production costs, improved product competitiveness, reduced the impact of human factors on the production process, and achieved product quality standardization and guaranteed product quality through the automation of the production process. At the same time, it greatly reduces the time that personnel stay on site and reduces the probability of production accidents.

 

3. Conceptual framework of intelligent unmanned workshop

 

Smart unmanned workshops refer to fully automated production transformation workshops that use artificial intelligence technology, sensor technology, edge computing technology, cloud computing technology, Internet of Things technology, digital pairing technology, etc. to upgrade the traditional “man + machine” dual manufacturing model. to the single-dimensional manufacturing model of intelligent robots. At the same time, the intelligent robot and the entire manufacturing workshop can be sensed and mapped to the network space, thus completing the remote mirror monitoring of the entire intelligent robot and the manufacturing workshop. After the above-mentioned transformation of the architectural model and work logic of the intelligent unmanned workshop, since workers and managers are no longer placed on the workshop site, it is also called an intelligent unmanned workshop.

 

4. Unmanned operation logic of workshop

 

4.1 Overall operation logic of the workshop

 

The intelligent unmanned workshop consists of three parts: a production control system, an edge computing control system and a remote monitoring control system. Among them, the production operating system is mainly composed of robots and corresponding production devices and is mainly responsible for sensing and controlling the processes on the production line. The edge computing control system mainly provides on-site computing capabilities for factory equipment. The remote monitoring and control system mainly consists of remote monitoring platforms, and monitoring It is composed of robots and management robots. It mainly monitors the on-site conditions of the production workshop in real-time and implements corresponding restrictions on industrial production activities when necessary.

4.2 Operation of production operating system

 

The production operation system is the backbone of the intelligent unmanned workshop. Its core role is to manufacture qualified products according to production task requirements and quality standards. The production operation system is mainly composed of industrial robots, production processes and some other auxiliary equipment. Its auxiliary equipment generally includes raw material supply, factory ancillary facilities, workshop environment, etc. Each manufacturing process has supporting industrial robots to form a production line, and its workers use auxiliary equipment to perform production operations according to work instructions. The core of intelligent unmanned manufacturing technology is the industrial Internet of Things. After intelligence, all manufacturing devices are connected, and the production line Workers can work autonomously under the Internet. For electronic devices with a fixed spatial distance, wired connection methods are used to achieve more efficient transmission effects, while for electronic devices that require frequent activities, wireless connection methods are mainly used to achieve faster transmission functions.

4.3 Edge computing system operation

 

Edge computing technology is the brain of the intelligent unmanned workshop. Its core role is to provide on-site computing power for the manufacturing process, helping industrial personnel complete manufacturing process decision-making and ancillary equipment scheduling, as well as upstream and downstream cooperation between various processes.

The advantage of using edge computing technology is that it can save a lot of long-distance sending current and perform delay-free and non-blocking calculations that are closer to the actual engineering reality. According to different uses, boundary computing systems can be classified into operational automation robot computing control systems and factory collaborative computing control systems. The boundary computing control system for operating automated robots mainly supports the production process decision-making and auxiliary equipment scheduling of operating automated robots.

Factory collaboration and edge computing control systems mainly support collaboration between processes. The production process decision-making process combines all the production data of a process, including manufacturing process data, equipment status data, raw material supply data, manufacturing environment data, product information data, product quality inspection data, manufacturing time data, number of failures, etc., through The operating instrument is directly transmitted to the boundary operation control system of the operating instrument. After real-time calculation and processing, it is transmitted back to the operating instrument, and the operating instrument performs corresponding production actions accordingly.

The process of using auxiliary equipment is to input the data required by the auxiliary equipment into the computing system in the work to complete on-site calculations, and then use the cooperation between the production line and the computing system to complete the overall calculation, thereby achieving the correct configuration of the auxiliary equipment. The main process of business process collaboration is to transmit the actual situation of each process in the production line to the production line collaborative edge accounting platform, and then analyze the mid-upstream and downstream time matching within the process through the production line collaborative accounting system, and schedule the actual situation of each process in a timely manner. Execution time, thus achieving a high degree of consistency in production time within the process. After coordination problems occur, remote systems can also intervene.

4.4 Remote monitoring system operation

 

The remote monitoring production management system is the external brain of the intelligent unmanned workshop. Its core function is to conduct real-time monitoring of workshop conditions and intervene in the manufacturing process when necessary. Among them, real-time monitoring of workshop scenes is mainly completed by monitoring robots, and external interference in the production process is mainly completed by monitoring robots. With the remote monitoring platform as the background centre, a large number of virtual pictures of the workshop are received and displayed, including robot pictures and production processes. Pictures and overall pictures of the workshop.

The peripheral interference of the remote monitoring system mainly faces working robots, as well as unexpected non-programmed states and technical failures that cannot be handled in the edge computing system. Specific intervention methods include warning, error correction, shutdown, maintenance, restart, etc. In actual operations, enterprises can also use the monitoring technology of the Internet of Things to monitor their own links. Make full use of the advantages of all aspects of the Internet of Things to effectively monitor your own products or construction. The intelligent monitoring system of the Internet of Things is based on
The PC server is the centre. At this time, the advantages of wireless or wired are fully utilized to transmit the data information in the sensor and save it in time.

The emergence of intelligent monitoring systems based on Internet of Things technology must be due to its unique advantages.

On the whole, it can use mechanical technology, automatic monitoring technology, electronic information and other technologies to organize and optimize the structure, thereby guiding the system to complete the operation. While completing the operation, it can reasonably monitor each unit so that each unit can be overall effective. Carry out work more efficiently, improve overall efficiency, achieve the purpose of unification, and better complete daily work needs.

Intelligence has been applied to various fields, and the construction model and operation of unmanned workshops in intelligent steel plants are products of the development of the times. They are more in line with the development trend of modern information data and have many beneficial functions, which are conducive to the Real-time monitoring of work progress reduce labour costs and improve work effectiveness.

Article source: China Journal Network official account

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