The hottest intelligent manufacturing not only has

2022-08-22
  • Detail

There are more than subsidies for intelligent manufacturing. Explore the commercial potential from the realization path of intelligent factories

according to the declaration notice jointly issued by the two departments, the support for the enterprise technological transformation project of the provincial special fund for the development of advanced manufacturing industry in 2018 focuses on the development of new products, energy conservation and consumption reduction, and the integration of "two modernizations". The fund adopts the method of post award and subsidy. For the equipment and R & D investment of the enterprise's technological transformation projects, a subsidy of no more than 30% will be given according to the actually completed investment (subject to the invoice). With the support of national "863" and Natural Science Foundation Projects, the maximum subsidy will not exceed 10million yuan

the 2018 provincial special fund for advanced manufacturing development (small and medium-sized enterprises) project mainly supports the development and expansion of small and medium-sized enterprise public service (demonstration) platforms and small and micro enterprise entrepreneurship and innovation demonstration bases, and encourages service platforms to provide services for small and medium-sized enterprises. The support method is post award and subsidy. At the same time, considering the number of small and medium-sized enterprises it serves, the service effectiveness and other factors, the subsidy fund for a single project generally does not exceed 3million yuan

in 2018, the provincial special fund for advanced manufacturing development (intelligent transformation) focuses on Intelligent workshops, intelligent factories and the integration of "two modernizations". The enterprises (projects) will be directly subsidized by means of post award and compensation, of which the subsidy amount of intelligent workshop and intelligent factory is 8% of the completed software and hardware investment (subject to the contract and invoice), and the subsidy fund of a single enterprise will not exceed 10million yuan. The amount of subsidy for the integration of "industrialization and industrialization" is no more than 30% of the investment in equipment procurement, software procurement and technology investment, platform construction and upgrading (subject to the contract and invoice), and the subsidy fund for a single project is no more than 10million yuan

the direction of building smart factories

smart factories have the following six significant characteristics:

① equipment interconnection. It can realize the interconnection between equipment and equipment (M2M). Through the integration with equipment control system and external sensors, SCADA (data acquisition and monitoring system) can collect the status of equipment, production completion information and quality information in real time, and realize the traceability of production process by applying RFID (wireless radio technology), bar code (one-dimensional and two-dimensional) and other technologies

② industrial software is widely used. MES (Manufacturing Execution System), APS (advanced production scheduling), energy management, quality management and other industrial software are widely used to realize the visualization and transparency of the production site. When a new factory is built, the digital factory simulation software can be used to simulate the layout of equipment and production lines, factory logistics, man-machine engineering, etc., so as to ensure the reasonable structure of the factory. In the process of promoting digital transformation, we must ensure the data security of factories and the security of equipment and automation systems. When detecting defective products through professional testing equipment, it should not only be able to automatically separate from qualified products, but also be able to analyze the causes of quality problems through SPC (statistical process control) and other software

③ fully combine the concept of lean production. It fully embodies the concept of industrial engineering and lean production, and can realize order driven, pull production, minimize WIP inventory and eliminate waste. To promote the construction of intelligent factories, it is necessary to fully combine the products of enterprises, and the finished engineering plastics and composite materials become the main force and process characteristics of making money. In the R & D stage, we also need to vigorously promote standardization, modularization and serialization to lay the foundation for promoting lean production

④ realize flexible automation. Combine the product and production characteristics of the enterprise, and continuously improve the automation of production, testing and factory logistics. Enterprises with small product varieties and large production batches can achieve a high degree of automation, and even establish black light factories; Small batch and multi variety enterprises should pay attention to less humanization and man-machine integration, not blindly promote automation, and should pay special attention to the establishment of intelligent manufacturing units. The automatic production line and assembly line of the factory should give due consideration to redundancy to avoid shutdown due to key equipment failure; At the same time, full consideration should be given to how to quickly change the mold, which can adapt to the mixed line production of multiple varieties. Logistics automation is very important for the realization of intelligent factories. Enterprises can realize the transfer of materials between processes through logistics equipment such as AGV, gantry manipulator and suspended conveyor chain, and configure material supermarkets to distribute materials to the line as much as possible. The automation of quality inspection is also very important. Machine vision will be more and more widely used in intelligent factories. In addition, we also need to carefully consider how to use power equipment to reduce the labor intensity of workers

⑤ pay attention to environmental friendliness and realize green manufacturing. It can collect the energy consumption of equipment and production line in time to realize the efficient utilization of energy. In the dangerous and polluted links, robots should be given priority to replace labor, which can realize the recycling and reuse of waste materials

⑥ real time insight can be achieved. From the release of production scheduling instructions to the feedback of completion information, the closed loop is realized. By establishing a production command system, we can gain real-time insight into the production, quality, energy consumption and equipment status information of the factory to avoid unplanned downtime. By establishing the digital twin (digital mapping) of the factory, it is convenient to have an insight into the state of the production site and assist managers at all levels to make correct decisions

a factory with only automated production lines and industrial robots cannot be called an intelligent factory. Intelligent factory should not only realize automation, transparency, visualization and lean production process, but also realize closed-loop integration with production process in product inspection, quality inspection and analysis, production logistics and other links. Information sharing, on-time delivery and collaborative operation should also be realized among multiple workshops in a factory

the construction of intelligent factory fully integrates information technology, advanced manufacturing technology, automation technology, communication technology and artificial intelligence technology. When building smart factories, every enterprise should consider how to effectively integrate the emerging technologies in these five fields, closely combine them with the product characteristics and manufacturing process of the enterprise, and determine its own smart factory promotion plan

how to build the system architecture of smart factory

the smart factory framework proposed by Professor August Wilhelm Scheer, a famous business process management expert, emphasizes the pivotal role of MES system in the construction of smart factory

intelligent factory can be divided into five levels: infrastructure layer, intelligent equipment layer, intelligent production line layer, intelligent workshop layer and factory management and control layer:

① infrastructure layer

enterprises should first establish wired or wireless factory networks to realize the automatic release of production orders and the automatic collection of equipment and production line information; Form an integrated workshop connection environment to solve the connection problems between equipment with different communication protocols, as well as between PLC, CNC, robots, instruments, sensors and industrial control/it systems; Use the video monitoring system to monitor, identify and alarm the workshop environment and personnel behavior; In addition, the factory should reach the intelligent level in the control of temperature, humidity, cleanliness and industrial safety (including the safety of industrial automation system, production environment and personnel safety)

② intelligent equipment layer

intelligent equipment is an important means and tool for the operation of intelligent factories. Intelligent equipment mainly includes intelligent production equipment, intelligent detection equipment and intelligent logistics equipment. Manufacturing equipment is gradually developing to intelligent equipment after experiencing mechanical equipment to numerical control equipment. The intelligent machining center has the functions of error compensation, temperature compensation and so on, which can realize the detection and processing while compared with the traditional bulletproof glass. By integrating vision, force and other sensors, industrial robots can accurately identify workpieces, assemble autonomously, avoid people automatically, and realize man-machine cooperation. Metal additive manufacturing equipment can directly manufacture parts, and DMG Mori has developed a hybrid manufacturing and machining center that can realize additive manufacturing and machining at the same time. Intelligent logistics equipment includes automated three-dimensional warehouse, intelligent fixture, AGV, truss manipulator, suspended conveyor chain, etc. For example, FANUC factory has applied automated three-dimensional warehouse as a material transfer tool between intelligent processing units

③ intelligent production line layer

the characteristics of intelligent production line are that in the process of production and assembly, it can automatically collect data such as production, quality, energy consumption, equipment performance (OEE) through sensors, CNC systems or RFID, and display real-time production status through electronic Kanban; Realize the cooperation between processes through the lighting system; The production line can realize rapid mold change and flexible automation; It can support the mixed line production and assembly of a variety of similar products, flexibly adjust the process, and adapt to the production mode of small batch and multiple varieties; It has certain redundancy, and can be adjusted to other equipment production in case of equipment failure on the production line; Intelligent prompt can be given for manual operation stations

④ intelligent wedge-shaped fixture workshop level

to achieve effective control of the production process, we need to use manufacturing execution system (MES), advanced production scheduling (APS), labor management and other software to carry out efficient production scheduling and reasonable staff scheduling, improve equipment utilization (OEE), realize the traceability of the production process, reduce WIP inventory, and apply human-machine interface (HMI) on the basis of equipment connection, And mobile terminals such as industrial tablets to realize the paperless production process. In addition, digital twin (digital mapping) technology can also be used to display the data collected by MES system in real time in the virtual three-dimensional workshop model, which not only provides the VR (virtual reality) environment of the workshop, but also displays the actual state of the equipment to realize the integration of virtual and real

the intellectualization of workshop logistics is very important for the realization of intelligent factory. Enterprises need to make full use of intelligent logistics equipment to realize the timely distribution of materials required in the production process. Enterprises can use DPS (Digital picking system) to realize the automation of material picking

⑤ factory management and control layer

the factory management and control layer is mainly to monitor the production process, gain real-time insight into the operation of the factory through the production command system, and realize the cooperation and resource scheduling between multiple workshops. Process manufacturing enterprises have widely used DCS or PLC control systems for production control. In recent years, discrete manufacturing enterprises have also begun to establish a central control room to display the operation data and charts of the factory in real time, display the operation status of the equipment, and automatically alarm the problems found in the video monitoring through image recognition technology

intelligent transformation case

Bosch Humboldt factory in Germany

interconnection + second-hand market interconnection + food interconnection + foreign trade interconnection + home interconnection + home appliance interconnection + supermarket interconnection + shopping center interconnection + department store interconnection + interconnection + entertainment e-government network video

as the world's largest automotive technology supplier, Bosch's automotive braking system has considerable strength in the market. Bosch Humboldt factory, as the representative of Bosch's intelligent factory, the particularity of its production line is that all parts have a unique RFID code, which can automatically "talk" with the checkpoints along the way. After each production link, the card reader will automatically read out the relevant information and feed it back to the control center for corresponding processing, so as to improve the overall production efficiency. The radio frequency code system introduced in Humboldt factory will cost hundreds of thousands of euros, but due to the reduction of inventory by 30% and the increase of production efficiency by 10%, the cost of tens of millions of Euros can be saved. The independent RF code is given to 20 of Bosch's factories

Copyright © 2011 JIN SHI