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Only fast and unbreakable丨5G full connection makes this factory stage an "elephant run"

2021.10.08

On September 27, the World Economic Forum (WEF) officially released the new list of "lighthouse factories" in the global manufacturing industry, and Sany Heavy Industry Beijing Pile Driver Factory was successfully selected, becoming the first certified "lighthouse factory" in the global heavy industry industry.

Two years ago, the Sany pile driver factory was still the same as a traditional manufacturing factory: the 40,000-square-meter factory was filled with the roar of machines, and more than 800 workers climbed up and down, covered with oil, with a monthly production capacity of only 150 units and a production cycle of up to 30 days.

Walking into today's Sany pile machine lighthouse factory, hundreds of robots are in full swing, the production cycle has been accelerated by more than 4 times, a rotary drilling rig can be delivered in 7 days, and the monthly production capacity has doubled to 300 units.

Picture丨Inside the Sany Pile Driver Lighthouse Factory

On top of the 4-fold production change of Sany Pile Crane Lighthouse Factory, it is an invisible 5G network that shows the speed and strength of elephants running in this huge heavy equipment manufacturing plant.

5G, open up the "two pulses of elephants"

On March 13, 2018, Mr. Liang Wengen, Chairman of Sany Heavy Industry, said at the 13th National People's Congress, "Sany's digital transformation will either turn over or overturn!" ”

At that time, the Sany pile driver factory, in the face of digital transformation, was as large and cumbersome as an elephant, and there were many difficulties.

As heavy equipment,Piling machineryThe production mode belongs to typical discrete manufacturing, and the processing process of each part is independent of each other, does not cooperate with each other, and the production lines cannot be connected. At the same time, the factory has a variety of production equipment, and the intranet mainly uses Wifi, old Category 5 cables, and optical fibers, and the wiring is complex, which often affects the whole body, and the deployment and adjustment cycle is long and the cost is high.

The interconnection of equipment, production and other information has become the "second vein" of this traditional manufacturing elephant.

Picture丨Inside the Sany Pile Driver Lighthouse Factory

The advent of the 5G era has allowed Sany pile machine factory to find a breakthrough. In 2019, the Sany pile driver factory renovation project was launched, fully introducing 5G technology and exploring the deep integration of 5G technology and the industrial field.

By deploying a 5G virtual private network with an uplink capacity of more than 1 Gpbs per 10,000 square meters, a single terminal of more than 300 Mbps, and a latency of about 20 ms, Sany Pile Crane Factory has fully connected 8 flexible work centers, 16 intelligent production lines, 375 production equipment, and thousands of hydropower, oil and gas meters, so that the entire industrial manufacturing process can be efficiently interconnected.

Sany pile crane factory uses 5G connection as the nerve, just like opening up the "two pulses of Rendu", coordinating muscles, bones, and brains, forming an organic whole of intelligent manufacturing.

5G Full Connectivity, Driving the "Elephant Run"

The "elephant" that has opened up the second pulse of Rendu has the basic conditions to run on the road of digital transformation, and how to run is the key to Sany pile machine factory.

Relying on the characteristics of 5G technology, such as large bandwidth, wide connection, low latency, and high reliability, many functions that cannot be realized due to the instability, slow speed, and high latency of traditional networks have been implemented in Sany Pile Driver Factory one by one.

Application 1: 5G+ device interconnection improves equipment operation efficiency

Figure丨Visualization large screen

Based on the industrial big data collected by the equipment interconnection and more than 3,600 collection points of the 5G camera, the "root cloud platform" created by Tree Root Internet calculates day and night in the background, which of the 375 equipment in the Sany pile machine lighthouse factory is in a bottleneck, which one is inefficient, and which one is temporarily redundant, and every move is under control.

Furthermore, the operation rate of pile driver equipment was successfully increased from 66.3% to 86.7% by taking measures such as reducing auxiliary operation time, optimizing production cycle and process parameters, and improving equipment load rate.

Application 2: 5G + industrial Internet to achieve unmanned operation

Figure丨Unmanned operation

Based on 5G + industrial Internet, Sany Pile Crane Lighthouse Factory has also realized unmanned operation. Taking the pile driver cutting area cutting machine as an example, before the transformation, 5 plasma cutting machines in the factory needed 5 personnel to operate on site, which not only had a poor environment on the job site, but also had a risk to personal safety.

After the management cockpit is established through the 5G + industrial Internet, only 2 people are required to inspect the 8 laser cutting machines, and the on-site situation is transmitted back in real time through 5G video and industrial Internet data, and the start, reset and edge finding operation of the processing task can be remotely unmanned, and the remote control delay is less than 10ms, so as to realize the safe and efficient unmanned operation of cutting and cutting.

Application 3: The first 5G heavy-duty AGV dual-vehicle linkage

Figure丨Dual AGV linkage based on 5G

What's more worth mentioning is that Sany Pile Driver Lighthouse Factory also pioneered a heavy-duty dual-vehicle linkage AGV based on 5G technology to solve the problem of drill pipe transportation.

Drill pipe is the core working component of the pile driver, a single rod length of 27 meters, weight 8.0 tons, in the previous production, are used "forklift" and "driving" for the transfer between the processes, low efficiency, safety hazards, how to realize the automation of this process, is one of the biggest technical difficulties in the transformation process of Sany pile driver lighthouse factory.

Figure丨Over-long and overweight drill pipe

If an AGV is used to transport drill pipes, a super-large AGV is required, which not only has high route requirements, but also has high costs and low utilization rate. However, the use of two AGVs is limited by the unreliable WIFI signal, and the communication between the two devices is delayed and cannot operate synchronously.

5G solves this problem, Sany pile crane lighthouse factory is the first in the industry to use 5G precision timing, laser slam positioning, and steering wheel dual-vehicle linkage heavy-duty AGV to realize synchronous lifting and walking of two vehicles, with a time accuracy of 10ms and a positioning accuracy of 10mm, and successfully realize the collaborative handling of ultra-long and overweight materials, which shortens the preparation time for drill pipe welding production by 50%, which is both efficient and safe.

In addition, more 5G applications are being implemented and gradually replicated within Sany Group in more than 30 subdivided scenarios in 8 categories, including manufacturing, visual management, smart logistics, equipment interconnection, smart parks, smart R&D, energy management, and smart marketing and services.

Figure 丨Ubiquitous 5G applications

At present, all 30 factories of Sany Group have been connected to the interconnection of equipment for management, and the total number of devices has been successfully reduced from 12,000 to 7,782, and the output value has increased from 75.2 billion yuan to 136.8 billion yuan, truly realizing "elephant running".

In the future, many 5G intelligent applications of Sany Pile Crane Lighthouse Factory will also achieve capacity spillover, empower industry chain partners, the industry, and even the entire "Made in China" to grow together, and effectively play the leading role of a world-class "lighthouse factory".