How to realize intelligent management of steel structure plant?

2025-03-27 15:30:35

In a new energy battery plant in Guangdong, the digital twin system maps the equipment status of 32,000 square meters of plant in real time; the automotive parts base in Yangtze River Delta achieves a 99.99% yield rate through AI visual inspection; an intelligent storage center in Chengdu-Chongqing region realizes 300% improvement in unmanned operation efficiency. These practices reveal that the Steel Structure plant is evolving from traditional manufacturing to intelligent body, forming the management closed loop of “perception-analysis-decision-making-execution”.

I. Intelligent Equipment Health Management

Industrial Internet of Things Sensing Network

Equipment monitoring: deployment of vibration (±0.01g), temperature (±0.5℃), current (0.5 level) sensor clusters

Data Acquisition: 5G+MEC edge computing realizes 10ms response.

Practice case: a photovoltaic module factory installed 2000 sensors, equipment failure warning accuracy of 92%, MTTR shortened to 35 minutes

Predictive Maintenance System

Constructing LSTM prediction model based on equipment historical data

Achievements of a stamping workshop: spindle bearing life prediction error of ≤3%, spare parts inventory reduced by 45%.

Maintenance strategy: automatically generate work orders containing spare parts lists and maintenance programs.

Intelligent optimization of production process

Digital twin process simulation

High-fidelity modeling: 1:1 restoration of plant equipment, physical parameter error ≤2%.

Application of an automobile factory: virtual debugging to shorten the cycle of production line modification by 60% and reduce the cost of trial production by 75%.

Real-time mapping: 100,000+ data points are updated per second, realizing the synchronization rate of production status ≥99%.

Intelligent Scheduling System

Mixed integer planning algorithm integrating MES+APS

Practical effect: order delivery cycle of an electronic factory was shortened by 38%, and equipment utilization rate was increased to 89%.

Dynamic optimization: adjust the production plan every 15 minutes to cope with sudden order fluctuations.

Intelligent upgrading of logistics and warehousing

AGV cluster scheduling system

5G+Laser SLAM navigation (positioning accuracy ±5mm)

Data of a home appliance base: 200 AGVs realize 24-hour transportation and logistics efficiency reaches 150 TOs/hour.

Intelligent Obstacle Avoidance: Multi-sensor fusion technology realizes 0.1 second emergency response.

Intelligent three-dimensional warehouse

25 meters high shelves + stacker cranes (speed 200m/min)

Warehouse Optimization: AI recommends the best storage position, and picking efficiency is increased by 3 times.

Inventory accuracy: UHF RFID (read rate 99.99%) + visual review system

Fourth, energy management low-carbon transformation

Intelligent energy management and control platform

Real-time monitoring of 200+ energy metering points

Achievements of a machinery factory: Air compressor group control system saves 32% energy and 4.8 million yuan in annual electricity costs.

Demand prediction: LSTM model accuracy ≥95%, demand charge reduced by 28%.

Photovoltaic-steel structure integrated system

BIPV roof (conversion efficiency 21.6%) + energy storage system

Practical data: annual power generation of a 30,000 square meters plant is 3.6 million kWh, accounting for 45% of power consumption.

Intelligent operation and maintenance: drone inspection system detects 20,000 square meters of components per day, with 99% fault identification rate.

V. Intelligent Defense for Security Control

AI Visual Monitoring System

2 million pixel intelligent camera + edge computing box

Security protection: 18 types of risk identification accuracy ≥ 97% for people breaking in, not wearing helmets, etc.

Response speed: from recognition to alarm ≤ 0.3 seconds

Firefighting Intelligent Disposal System

Distributed fiber optic temperature measurement (±1℃) + high-pressure water mist

A chemical workshop case: the fire response time is shortened to 8 seconds, and the fire area is controlled within 0.5 square meters.

Emergency command: AR glasses real-time push escape path, evacuation efficiency increased by 60