How can steel fabrication improve productivity?

2025-03-27 15:01:51

In an intelligent factory in Xiongan New Area, a 5G-driven cutting robot cluster realizes 24-hour continuous operation, and the material utilization rate is increased to 98.7%; in a heavy Steel Structure base in Guangdong, Hong Kong and Macao Bay Area, the digital twin system increases the efficiency of process convergence by 40%; and in an assembly building project in Chengdu-Chongqing area, the modularized preassembly technology shortens the construction cycle of a single floor to 8 hours. These practices reveal that steel structure processing is undergoing a profound change of efficiency revolution.

I. Intelligent equipment cluster upgrade

Laser composite cutting workstation breaks through the traditional bottleneck. A demonstration project adopts 20kW fiber laser cutting machine, the cutting speed of 12mm thick Q355B steel plate reaches 25m/min, which is 3 times higher than the plasma cutting efficiency, and at the same time realizes bevel cutting in one go. It is equipped with a visual positioning system to control the plate positioning error within ± 0.2mm, reducing the auxiliary time by 70%.

Robot welding cluster reconstruction production beat. A bridge steel factory deployed 32 welding robots, through offline programming system to achieve multi-machine synergy, the 60mm thick plate butt weld welding speed stabilized at 35cm/min, pass rate increased to 99.9%. The application of intelligent shifter compresses the workpiece turning time from 15 minutes to 90 seconds, and improves the comprehensive efficiency by 400%.

Second, digital process chain depth integration

The BIM-CAM integration system breaks through data barriers. A super high-rise project directly converts BIM models into CNC codes, eliminating the traditional two-dimensional sampling link and shortening the processing cycle of shaped components by 60%. The intelligent nesting algorithm developed by the company has increased the utilization rate of steel plates from 89% to 96%, saving more than 8 million yuan in annual steel costs.

Virtual pre-assembly technology revolutionizes the quality inspection process. By automatically comparing the 3D point cloud data obtained through laser scanning with the design model, the 32,000 pieces of rods of a stadium net frame project have realized zero rework, and the assembly verification work that traditionally takes 2 weeks has been compressed to 8 hours, and the inspection cost has been reduced by 82%.

Third, flexible manufacturing system construction

Modularized combined production line for quick changeover. A steel structure base adopts reconfigurable tooling system, and the switching time of H-beam production line with different specifications is reduced from 6 hours to 45 minutes. Its intelligent roller conveyor system recognizes workpiece information through RFID and automatically adjusts the conveying path, increasing the efficiency of mixed-flow production by 35%.

AGV + three-dimensional storage system optimizes material flow line. A smart factory deployed 60 sets of lifting AGV, with 20-meter-high automated three-dimensional warehouse, so that the flow time of a single component is shortened from 90 minutes to 18 minutes, and the utilization rate of the site is increased by 3 times. WMS system monitors the status of 4,000 storage spaces in real time, and the accuracy rate of material preparation reaches 100%.

Intelligent optimization of process parameters

The welding big data platform breaks through the limitations of experience. A pressure vessel manufacturer collects 100,000 sets of welding parameters to build a knowledge base, and the pulse MAG welding parameters recommended by machine learning increase the welding efficiency of 25mm thick plate by 50%, while reducing heat input by 28%. The intelligent process card system it developed shortened the process preparation time from 4 hours to 15 minutes.

Precise control technology for thermoforming process. A wind turbine tower project adopts electromagnetic induction heating system with a temperature control precision of ±5℃, which improves the forming speed of Q690D steel to 1.2m/min, increasing the efficiency by 4 times compared with that of traditional flame heating, and reduces the forming stress by 65%.