C008 Hot Dipping Intelligent Workshop of Baosteel Baoshan Base Cold Rolling Plant (picture provided by Baosteel).
As the core flagship subsidiary of China Baowu and the leader of China steel industry, Baosteel is facing the challenges of overcapacity, cost reduction and efficiency improvement, energy saving and emission reduction in the domestic steel industry and the "Made in China 2025" strategy. By practicing the intelligent manufacturing strategy, it strives to improve the competitiveness of cost, quality and service, form a new competitive advantage, and continue to lead the successful transformation and upgrading of China steel industry to achieve sustainable and high-quality development.
Smart factory, helping routine work "zero labor"
In the first half of 20 19, the fourth intelligent factory of Baosteel Silicon Steel Division was completed and put into operation. It is not only the experimental field for silicon steel division to promote intelligent manufacturing, but also the source of Baosteel's "one workshop" concept.
Baosteel silicon steel business division 4 th wisdom factory
Silicon steel, known as the "crown jewel of steel products", has always been a "trump card" in Baosteel's hands. The research and development process of silicon steel is extremely difficult. At that time, with the continuous improvement of competitiveness, Baosteel has attracted the attention of peers around the world, and was regarded as the first competitor of China by international steel giants, and oriented silicon steel technology was their only "secret weapon". "Even if you want to spend a lot of money to buy it, people won't sell it." Liu Baojun, general manager of Baosteel Silicon Steel Division, said with a wry smile.
"You can't always get stuck by foreign companies!" Facing the technical blockade of foreign iron and steel enterprises, Baosteel began to study the manufacturing technology of oriented silicon steel from 1997. From May 65438 to May 2008, the first roll of qualified oriented silicon steel was produced, which indicated that Baosteel had mastered the oriented silicon steel technology representing the top manufacturing capability of the steel industry through independent integration and innovation after ten years of hard work.
Nowadays, the intelligent factory with the goal of building a "future steel mill" is put into production, which indicates that the road of independent innovation of Baosteel's silicon steel is getting wider and wider. Liu Baojun said, "For silicon steel, the purpose of intelligent manufacturing is to build a new management model of" intelligent decision-making center+intelligent factory "which is highly compatible with future steel and future steel mills in the intelligent era, and realize organizational change, process reengineering and management innovation, thus forming a new brand premium ability, and making Baosteel's oriented silicon steel products develop from technological leadership to comprehensive leadership."
The fourth smart factory has achieved a leap from the traditional pyramid structure of "factory department → branch factory → operation area → team" to the network structure of "one smart decision-making center+several smart factories". Through the application of intelligent links and a large number of digital, networked and intelligent technologies, the disadvantages of segmented management of all production factors have been solved, and seamless intelligent management of the whole process has been realized; Cancel the field operation room, and the production operation will be changed from the original "machine dispersion point" to a new form of "centralized operation+abnormal intervention"; Carry out the integration of operation and maintenance, carry out post-transformation and support the new mode of "all operating rooms are centralized" with the help of intelligent diagnosis and remote operation and maintenance.
The reporter saw on the smart big screen that quality information, energy consumption indicators, order status ... can find all the information of steel coils. At the same time, the intelligent decision-making system of silicon steel introduces the demand of market users, automatically generates the optimal scheme for R&D personnel, automatically designs the production process and arranges the production plan for the manufacturing end, and finally realizes the real-time interactive service for users. The intelligent decision-making system of the whole process of market, R&D, manufacturing and customer service has been opened, and the centralized control mode has been realized, which greatly improves the on-site labor efficiency and reduces the workload of personnel.
Walking in the workshop of the fourth wisdom factory, there are no steel workers at all. 20 sets of robots, 7 sets of quality inspection, 5 sets of intelligent identification, 3 sets of automatic liquid preparation, 2 sets of remote diagnosis system and 2 sets of "zero labor" in unmanned reservoir area have been successfully developed by Smart No.4 Factory; The self-developed quality inspection and control system realizes the "AI" of quality inspection, judgment, analysis and improvement through the 40-layer neural network deep learning of more than 6,543,800 defect samples, which makes the quality control of the top-end oriented silicon steel in the fourth plant "more powerful"; Relying on the support of 5G technology, the real-time interaction of user service is realized, and the real-time online service of silicon steel products is realized.
Talking about the future, Liu Baojun said that in the intelligent manufacturing blueprint of silicon steel division, a new network organization of "an intelligent decision-making center+several intelligent factories" has been built. Silicon steel intelligent decision system developed by Silicon Steel Division is the "CPU" of its intelligent manufacturing. Intelligent decision-making system covers the whole life cycle of products from market, research and development, manufacturing to user use, and opens up the data interaction among laboratories, manufacturing sites and user use. The organic combination of "one intelligent decision-making center+multiple intelligent factories" has truly realized the new PDCA "intelligent decision-making" process in the whole process of silicon steel product market, R&D, manufacturing and users. The fourth smart factory is one of several smart factories that have been put into operation in advance.
Baosteel silicon steel business division 4 th wisdom factory
Go further. On the basis of the construction of the fourth factory, the third, second and first intelligent factories of Silicon Steel Division are being planned and implemented, while the product structure optimization project of non-oriented silicon steel will build the fifth intelligent factory with higher quality, further explore and enrich the connotation of intelligent manufacturing, and then bring great reform potential.
Cloud storage, unmanned vehicles, smart ports and logistics can all be so smart!
In terms of smart logistics, Baosteel started earlier. In recent years, we have focused on tackling key problems in unmanned warehouses, less-manned port machines, intelligent garages, vehicle dispatching, and unmanned frame vehicles, and achieved remarkable results. The intelligent control of the whole process is realized, such as the finished products leaving the dock warehouse, the intelligent dispatching and unmanned transportation of frame cars, the unmanned storage of finished products warehouse and the intelligent remote operation of port machinery. Jiang Wei, Assistant Minister of Transportation of Baosteel, summarized it as "cloud storage, unmanned vehicles and smart ports".
According to Jiang Wei, Baosteel has built two unmanned intelligent finished product warehouses, covering an area of about 60,000 square meters respectively, which are the largest unmanned warehouses in China. "Unmanned intelligent warehouse has experienced more than ten years of technical research, during which unmanned warehousing technology has been optimized and upgraded many times. By using wavelet saddle arrangement and maximizing the use of three-dimensional storage space through machine learning, the storage area is increased by more than 25% and the labor productivity is increased by more than 70%. The automated operation rate is greater than 99.7%, and the average single-roll operation time is 3 minutes and 30 seconds, which is already lower than the manual operation time. "
Baosteel Baoshan Base Manufactured Products Automated Intelligent Warehouse (Phase I)
Jiang Wei mentioned that Baosteel's intelligent warehouse played an important role during the epidemic. In the 60,000-square-meter intelligent finished product warehouse (Phase I), the unmanned crane accurately transports the silver finished steel coil by using the "steel claw", and closely cooperates with the unmanned heavy-duty frame truck that followed, and continuously transports the finished steel coil to the all-weather finished product terminal. In this unmanned warehouse, intelligent operation has effectively improved the logistics efficiency. Every day, 65,438+10,000 tons of steel coils are turned around here and sent to all parts of the world. In the intelligent logistics control center of finished products, only a few operators, wearing masks and sitting separately, can complete the logistics monitoring of the whole factory.
Baosteel Baoshan base product logistics intelligent management and control center
The unmanned heavy-duty frame car driving in Baoshan base of Baosteel has become a beautiful scenery. Jiang Wei said that Baoshan Iron and Steel has been exploring and researching in the field of driverless driving since 20 15. At present, it has taken the lead in realizing industrial operation in the iron and steel metallurgical industry, and realized the unmanned application of the whole logistics chain with unmanned warehouses and intelligent terminals. Unmanned frame vehicle adopts multi-sensor fusion technologies such as magnetic nail positioning, global navigation satellite system positioning, inertial navigation, etc. "It can identify the surrounding environment, avoid obstacles, make action decisions at any time as needed, and complete free driving, car-following, lane changing, parking, frame crossing, parking and other operational strategies to achieve high-precision and intelligent autonomous navigation and unmanned driving."
Baosteel unmanned heavy frame car
At present, there are two unmanned cranes, three unmanned port cranes and six unmanned frame trucks in Baosteel Steel Automation Terminal, which has realized unmanned transportation and loading from the warehouse to the terminal, with an annual working capacity of more than 4.5 million tons.
According to Jiang Wei, the automatic terminal management and control system is a transportation flow control system based on edge calculation, which tracks the operation information of vehicles, port cranes and frame vehicles in the area in real time, dynamically balances the resources of vehicles, roads, warehouses and terminals in the whole port area, and realizes upstream and downstream linkage. At present, the only advanced equipment commercially used in the grocery terminal in China has realized unmanned fixed-point loading. "One person can control more than two port machines, which reduces the staffing by more than 50% and reduces the labor intensity of employees. Everyone said,' Let the drivers of port machines bend over for generations'. "
It is reported that in the future, Baosteel will continue to expand in the fields of AI control of ex-factory logistics, unmanned locomotives of process railways, unmanned port machines, and unmanned transportation of steel products in factories, and intelligently "paint" the future.
Intelligent manufacturing empowers business and becomes a global steel industry leader.
Shen Liming, senior manager of operation improvement department of Baoshan Iron and Steel Company, told the reporter that as early as 20 14, Baoshan Iron and Steel Company began to explore intelligent manufacturing, set up a virtual team, and began to pilot hot rolling, the core link of steel manufacturing. 20 15 Baosteel organized the system planning and strategic layout of intelligent manufacturing to further promote intelligent manufacturing.
In Shen Liming's view, intelligent manufacturing will subvert people's understanding of traditional iron and steel enterprises, and it is a main road for the transformation and upgrading of iron and steel enterprises. "If you don't seize this opportunity, you will be eliminated. It is precisely because of this profound understanding of the great significance of smart manufacturing that Baosteel has gone all out to explore and strive to become the first' crab eater' in domestic steel enterprises. "
Shen Liming also mentioned that under the background that intelligent manufacturing has become one of Baosteel's key strategies, Baosteel Academia Sinica established the Intelligent Manufacturing Research Institute on 20 17. More than 95% of the R&D team are masters and doctors, who are committed to developing key bottleneck technologies and achieving the ultimate product quality and production efficiency in the steel field. Bao vision technology is one of them, that is, Baosteel's hot high-speed wire surface detection technology. The purpose is to realize the intelligent control of product surface quality in the whole process of steel manufacturing. At present, this technology has been widely used and popularized in the industry.
Needless to say, the purpose of intelligent manufacturing is to improve quality and efficiency, empower merchants through intelligent means, improve the operational efficiency of various businesses, and at the same time liberate employees from the scene, further improve the working environment and working conditions, and effectively protect employees' occupational health. For example, if Baosteel builds an intelligent production line for continuous casting of thick slab, the unit capacity will increase by 10%, the labor productivity will increase by 30%, the energy consumption per ton of steel will decrease by 12%, the quality will increase by more than 30%, and the processing cost will be reduced by 25%. After intelligent transformation, Baosteel Hot Rolling Company's 1580 intelligent production line also achieved a 7.6% decrease in process energy consumption, a 15% decrease in rejection rate and an increase in labor efficiency 1 1%.
Standing in a new historical position, Baosteel will continue to vigorously promote reform and innovation and green intelligent manufacturing, actively integrate into global value chain, industrial chain and supply chain, accelerate the cultivation of "China brand" and "golden signboard" leading the digital transformation of the global steel industry, and make greater contributions to making China Baowu a global steel industry leader.
(Editor: Tang Xiaoli, Han Qing)