3 hours to produce a large megawatt host|Reveal the secret of Sany Renewable Energy Chenzhou intelligent manufacturing factory

"10 days to complete the negotiation and signing, 100 days to complete the first host off the production line, and 177 days to complete the completion and commissioning. "Sany Renewable Energy Chenzhou Intelligent Manufacturing Industrial Park, which represents Sany speed, has achieved innovative results, and can complete the off-line of a large megawatt wind power main engine every 3 hours.

Sany Renewable Energy Chenzhou Intelligent Manufacturing Industrial Park is located in the high-tech industrial development zone of Chenzhou City, Hunan Province, covering an area of 455 acres, including three production lines of main engine, wheel hub and tower, the industrial park applies the advanced "three appearances and four meters" intelligent system, through the integration of "end" + "cloud" AI technology, to create visual intelligent solutions, to realize the application of a series of intelligent solutions such as smart factories, smart parks, and smart energy monitoring.

Through digital technology, the main engine factory highly integrates stations such as yaw automatic pre-assembly, brake automatic assembly, and chassis automatic flipping, which greatly reduces the difficulty of material transportation in the production process, not only improves production efficiency, but also saves plant area. The factory covers an area of 23,000 square meters, which is only the size of three football fields, and in many new machine factories in China, this area can be described as "small and exquisite". From the first impression alone, it is hard to believe that this is a super smart factory with an annual production capacity of 1,000 large megawatt units, and it only takes 3 hours to produce a host. Compared with traditional factories, the production per unit area of the factory has increased by at least 1.34 times.

Zhou Fugui (right), chairman of Sany Renewable Energy, and Li Qiang (left), general manager of Sany Renewable Energy, jointly unveiled the production line

Recently, Sany Renewable Energy Chenzhou Host Intelligent Manufacturing Production Line 2.0 was officially unveiled, and this host production line with highly integrated digital technology was unveiled. Compared with the main production line of Sany Renewable Energy Nankou Intelligent Manufacturing Factory, the "first wind power 5G smart factory in China", the factory's digitalization, intelligence and integration degree have been upgraded, and the production process has been optimized and improved by improving the accuracy of the vision system, optimizing the mechanical structure, and improving the collaboration ability between end-to-end, and the delivery time has been shortened by 30%. In addition, the main engine production line uses 2 large-tonnage AGVs for transfer, which greatly improves the production flexibility, makes exception handling and the main engine off-line more flexible, and the production unit capacity can cover 3MW-11MW.

Reliable production process is the basis of product stability. The factory has the ability to trace the whole production process, online materials throughout the process, and online management of key production data, and adopts advanced technologies such as AI intelligent quality inspection, digital twin, machine learning, and 5G to fully control the production process and ensure product quality. It is worth mentioning that under the trend of large-scale wind turbines, the weight and size of parts are also getting larger and larger, which increases the difficulty of the assembly process, and some high-strength bolts are difficult to complete by manpower in narrow spaces. Sany Renewable Energy uses robots with multi-functional grippers and vision systems to complete automatic grease, dressing and tightening of bolts, and can realize automatic detection of thread quality and grease quality, greatly improving product quality.

In the future, through automation, digitalization and intelligence, the lean manufacturing of wind power equipment will be "like a tiger". Sany Renewable Energy will continue to build a "2.0 lighthouse factory" for wind power machines, motors and blades, seek the development of "high quality, high efficiency, high flexibility and excellent cost" in wind power manufacturing, and continue to contribute leading intelligent manufacturing practical experience to the wind power industry. Actively contribute to China's realization of "carbon peaking, carbon neutrality" and the world's clean energy transition.