AI solutions for the steel industry

One-stop intelligent solutions for steelmaking/continuous casting/steel rolling

UNMANNED CRANE CONTROL SYSTEM

Precise positioning, anti-swing, automatic avoidance, automatic weighing, remote control, automatic feeding and many other functions.

Unmanned crane
Unmanned Crane

TYPICAL EQUIPMENT

Unmanned crane

Intelligent control system of grab crane

The unmanned crane transformation is suitable for the scene of sludge, ore powder, coal, coke, scrap steel, waste residue, garbage and other bulk materials.

crane control system

crane remote control systems

Remote crane is applicable to all crane operation scenarios. 1) Product warehouse remote crane system 2) Steel-making warehouse remote crane system 3) Raw material area remote crane system

Unmanned Crane

Swirl Well Unmanned Crane Control System

Application scenarios such as unmanned driving in ironmaking slag pools, unmanned driving in power plant sewage slag pools, and unmanned driving in swirl well slag pools.

Unmanned Transport, AGV

Unmanned vehicle

The AGV\RGV\IGV unmanned vehicles can be driven automatically along the predetermined route without manual piloting, and automatically transport goods or materials from starting point to destination.

DBM Project of Scrap unmanned centralized control system

steel mill crane

Steel mills are one of the industries that use the most cranes. The top ten steel mills alone have tens of thousands of cranes of various types. Most of the cranes in the iron and steel plant are production cranes, which do not place much emphasis on high performance, but have almost strict requirements on reliability and failure-free rate.

The special unmanned crane equipment for the iron and steel industry realizes the automatic handling and stacking of steel plates and steel coils, which plays an important role in optimizing logistics, improving operating efficiency, avoiding human errors, eliminating personal safety accidents, improving product quality, saving labour costs, and avoiding harsh environments.  

Typical application of unmanned crane system in steel mills

Application case of unmanned crane system in slab warehouse

The slab warehouse is not only the finished product warehouse of the steelmaking process but also the raw material warehouse of the subsequent steel rolling process. It plays a crucial buffer role in the coordination of the steelmaking capacity and steel rolling capacity of the enterprise and the balance of the entire production process. There is a variety of handling tools in the slab warehouse, such as cranes, roller tables, etc., which independently or in combination complete the work of slab storage, stacking and delivery.

The traditional way of manually directing the operation of the crane has the following problems

Crane hoisting operations require the command of ground personnel, which not only poses safety hazards but also reduces the efficiency of slab handling;

The positioning accuracy is low and the operation error rate is high;

It is difficult to find slabs in the storage area;

The production management data cannot be fully synchronized with the slab information data in the storage area.

Features of slab warehouse management

1) The requirements for location division are high.

Due to the large number of slabs in the slab warehouse and the limited space in the storage area, it brings great difficulties to the division of storage locations.

2) The logistics volume is large.

The slabs put into storage include two types: cold-delivered slabs transported by automobiles and hot-delivered slabs transported by rotating rollers after continuous casting. In addition, slabs to be sold also need to be hoisted out of the warehouse by cranes through the out-of-warehouse area. The difference in business and the large number of slabs resulted in a considerable amount of logistics.

3) The business is complex.

The business of the slab warehouse includes incoming material inspection, cutting, warehousing, stacking in the warehouse, material preparation before the furnace, loading of the heating furnace, and out of the warehouse, etc. The diversity of business and the variability of logistics make business processing more complicated.

If the slab warehouse adopts the traditional crane operation method, that is, the driver operates the crane in the air with the cooperation of the ground personnel, it cannot adapt to the above-mentioned characteristics of the slab warehouse with large logistics volume and complicated business, and it is likely that the slabs in the warehouse Repeated stacking pressure, inability to connect front and rear operation procedures, slow production pace, etc., and the operating environment of operators is poor (dusty, high temperature, high altitude), limited vision, high labor intensity, and poor personal safety and reliability. In order to solve these problems and complete the crane operation accurately, flexibly and in time, the wireless system of the crane is equipped with a wireless terminal in each crane, and 5 base stations are installed in the slab warehouse. Through this system, the driver of the crane can accurately locate the position and quantity of the slab, thereby improving the working efficiency and making the production link freely.

With the development of information technology, modern iron and steel enterprises gradually adopt the crane wireless system in the slab warehouse, realize the computer to command the operation of the crane, and realize the automatic control of the operation of the crane, which has high stability, reliability and high reliability. Good scalability.

Unmanned Crane Control System for Scrap Storage in Steel Plant

With the increase of scrap ratio in electric furnace steelmaking and converter steelmaking, the turnover rate of scrap steel is getting higher and higher, and the distribution and production circulation rhythm of scrap steel is very tight. The traditional dispatching and management mode has been difficult to adapt to the production requirements of scrap steel warehouse , has become an important factor restricting the efficient production of steelworks. The application of the 5G intelligent crane control system has greatly improved the efficiency of steel scrap production scheduling, shortened the average smelting time of each furnace by 30 seconds, and greatly reduced the energy consumption of the steelmaking process.

The scrap warehouse of a steelmaking plant consists of three scrap steel centers, which respectively feed 4 converters and 1 electric furnace in the steelmaking plant. Each steel scrap center consists of two-span factory buildings, and each span is equipped with 4 sets of 20t electric bridge cranes, a total of 8 sets, and the rail surface elevation is +17.5m. Each crane corresponds to a work station, a total of 8 work stations . A total of 24 sets of 20t electric bridge cranes are used in the entire scrap warehouse. Before the implementation of the project, the environment of the scrap warehouse was harsh and the operation was outdated, making it difficult to meet the digital and intelligent transformation of the steelmaking plant. The most important thing is that the scrap warehouse is responsible for the storage of scrap steel, raw material batching and transshipment. The scrap steel turnover rate is high and the production rhythm is very tight. Once a failure occurs, the production of the converter and electric furnace cannot be guaranteed smoothly, which will affect the normal production of steelmaking. cause hidden dangers.

In order to solve the above problems, the scrap warehouse of the steelmaking plant needs to open up the digital control of scrap storage, processing and delivery, and the unmanned operation process of the crane to realize the unmanned operation of the scrap warehouse area. Through the upgrade of the unmanned overhead crane, the unmanned loading and unloading of the scrap warehouse can be realized, the material flow can be automatically tracked, and the cross-regional informatization process can be connected between the scrap warehouse and the converter/electric furnace production, so as to reduce the number of times of scrap steel transportation, reduce logistics costs, and optimize the refining process. Batching production and scheduling of steel scrap in the steel mill area.

1) Intelligent scrap steel unloading process

First, the steel scrap unloading plan is automatically generated by the dispatching information system of the steelworks. In the second step, the smart logistics system in the factory directs the scrap steel transport vehicles to the designated loading and unloading area. In the third step, after the vehicle identification system (SRS system) detects that the vehicle has arrived at the unloading position, the manufacturing execution system (Manufacturing Execution System, MES) sends instructions to the ground control system of the unmanned overhead crane, and then forwarded by the system To the crane PLC system. Finally, the crane PLC system performs the stacking operation according to the above logistics information.

2) Unmanned operation process of scrap warehouse

The materials in the scrap warehouse are managed by an intelligent warehouse management system (Warehouse Management System, WMS) and automatic scheduling of cranes. The unmanned overhead crane system does not need manual instructions but receives WMS system instructions to complete automatic operations. It mainly performs operations such as unloading and stacking of incoming vehicles, automatic positioning of loading vehicles, automatic classification and storage of scrap steel, and intelligent batching. Automated, unmanned operation and management of vehicles.

3) Intelligent loading and transhipment process

When the SRS system recognizes that the transfer vehicle has arrived at the designated location in the loading and unloading area, the MES system will send the scrap ratio information to the ground control system of the unmanned crane, and then forward by the system to the PLC system of the crane. The unmanned crane system will use scanning and The positioning system automatically identifies the position, size and height of the vehicle, and then intelligently analyzes and generates an automatic loading program for the crane based on the above information. After the unmanned crane completes the loading operation, the transfer vehicle will transport the scrap to the production workshops of the steelmaking plant according to the logistics management and scheduling instructions.

With the continuous increase in the scrap-steel ratio of raw materials in steelmaking production in the steel industry, more and more enterprises have improved the production scheduling efficiency of steelmaking plants through the intelligent upgrade and transformation of the crane system of the scrap warehouse. The unmanned crane control system has achieved good results in many aspects such as function, efficiency, reliability and safety, and has made contributions to improving the scheduling efficiency of scrap warehouses and improving the intelligent level of production in steelmaking plants. It has a good value in technology promotion.

Steel mill based on unmanned crane intelligent raw material warehouse solution

As an important hub for logistics connection and production rhythm control in the steel production process, the raw material warehouse of the cold rolling plant is the basis for informatization, unmanned and intelligent construction of the factory. The in-depth integration of human cranes and intelligent raw material warehouse management platforms will fundamentally change the operation mode of raw material warehouses, realize unmanned lifting of cranes and intelligent scheduling of raw material warehouses, which can improve production efficiency, reduce production costs, and promote the circulation of production information is of great significance.

1. Current status of raw material warehouse

There are 3 cranes in the raw material warehouse of a cold rolling factory, which are used for the operation of steel roll-in, loading, and delivery in the cold-rolling raw material warehouse. The hoisting objects of the crane are mainly steel coils, which are hoisted by special spreaders, and there are other auxiliary tasks. When the steel coil is sent to the raw material warehouse by train, the material collector confirms the steel coil and sends and receives information, the driver of the crane lifts the steel coil into the warehouse and waits for the unit to produce the steel coil. Manually mark the winding order of the coils or direct the driver of the crane to lift the steel coils to the saddle of the unit to provide raw materials for the production of the unit. Crane drivers have long working hours, high labour intensity, low operating efficiency in the storage area, prone to equipment failure and loss of coil data and information.

2. Unmanned crane system solution

On-site analysis is carried out according to the status quo of the raw material warehouse. The purpose is to build an intelligent raw material warehouse platform based on the unmanned crane. The unmanned crane and the intelligent warehouse management system are composed of the information domain and the physical domain. The physical domain consists of a number of measurement devices, feedback devices, and actuation devices. These elements have communication capabilities, perception capabilities, and command execution capabilities. With the warehousing and logistics management (WMS) system as the core to receive and issue instructions, the entire raw material storage area realizes unmanned operation. The specific plan is as follows:

1) Among the three cranes on site, 1-1#, 1-2# and 1-3# equipment are driven by conventional rotor cutting resistance. This transformation will use two cranes 1-1# and 1-2# Change to frequency conversion automatic cranes, and consider the safety interlocking of 1-3# with the other two cranes when in use.

2) The intelligent system of the crane is added to the crane to realize the unattended and automatic operation of the crane.

3) Add the WMS system module to realize the coil management function in the stacking area, and perform data interaction with L3 (factory manufacturing execution system).

4) The train flatbed car is equipped with a special steel coil saddle, and the crane automatically completes the operations of unloading and storing steel coils from the train.

5) The crane automatically completes the loading operation of the walking beam saddle of the cold rolling line.

6) Temporary remote operation requirements require manual work; 7) Safe physical isolation and electronic fences in the raw material storage area.

8) Adaptive modification of cold rolling L3 system, logistics railway transportation command system and L1 (basic automation) system.

9) Set up industrial control system network security measures.

The intelligent transformation of the raw material warehouse of the cold rolling mill is mainly the unmanned transformation of the crane and the construction of the WMS system. The main workflow of the raw material warehouse is the storage of raw steel coils and the loading and unloading of raw steel coils through the walking beam. Other operations of the automated crane (slinging belt, rolling belt, equipment and other remote, manual lifting, remote operation by people in the control room, auxiliary personnel are needed on site, raw materials are transported and discharged by car) are operated by manual remote control conduct.
The automated operation process can be divided into the train unloading process, the raw material storage acid rolling mill process, and the storage process. These three processes can be synchronized according to needs. The material loading process is given priority, followed by the train unloading process, and the warehouse storage has the lowest priority.

3. Smart devices

The unmanned crane and WMS system integrate advanced sensing, wireless communication, intelligent optimization and other technologies. The intelligent transformation of the raw material warehouse is divided into transportation vehicle tracking, product warehouse scheduling, warehouse storage location coordinate management, product work order control, and interface A series of functions such as communication compatibility, automatic loading and automatic delivery. The WMS system intelligently dispatches the steel coil transportation tasks in the logistics system through different interfaces, sends the operation tasks to the unmanned crane, and the unmanned crane completes the lifting task.

The intelligent raw material warehouse solution based on the unmanned crane realizes the 24-hour unmanned operation of the raw material warehouse, improves the operating efficiency of the crane, reduces the labour intensity of the workers and the equipment failure rate, and realizes the visualization and informatization of the raw material warehouse, Intelligent management.

With machine vision as the core, DBM can provide intelligent equipment R&D, manufacturing and transformation services such as unmanned factories in the metallurgical industry and other industries, machine vision, and robot application design.

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