December fifth，《People's Daily》（Overseas edition）Full-page publication of Innovation China《Entering Sany Heavy Industry Beijing Pile Machine Factory——“Steel elephant”Dance smartly》One article，Explore the first in the global heavy industry“Lighthouse factory”——Sany Heavy Industry Beijing Pile Machine Factory，It is said that after its transformation and upgrading,，It represents the highest level of intelligent manufacturing and digitalization in the field of global manufacturing.。
The original report
The red drill pipe stands high.，It looks particularly bright against the blue sky and white clouds.——Outside Sany Heavy Industry Beijing Pile Machine Factory，Rows of tall Rotary Drilling Rigs are arranged neatly.，This is the main product of the factory.。Except for the Rotary Drilling Rig，The factory also produces diaphragm wall grab buckets.、Double Wheel Milling、There are more than 50 types of products in four categories of horizontal directional drilling.。These machines are often tens of meters high.、Weighing hundreds of tons.，It can be said that“Steel elephant”。
In the traditional impression，Produce such heavy equipment，Requires a lot of manpower to carry、Assemble、Welding……The process is difficult to digitize.、Intelligent connection。However, 2021，The transformed Sany Heavy Industry Beijing Pile Machine Factory was successfully selected.“Lighthouse factory”，It represents the highest level of intelligent manufacturing and digitalization in the field of global manufacturing.。
Recently，Our reporter walked into Sany Heavy Industry Beijing Pile Machine Factory, located in Nankou Industrial Park, Changping District, Beijing.，Look at the first in the global heavy industry“Lighthouse factory”Li，These“Steel elephant”How to dance smartly。
Overlooking the Sany Heavy Industry Beijing Pile Machine Factory in Nankou Industrial Park, Changping District, Beijing from the air
5G+Industrial Internet，Build a Digital Base for Smart Factory
When the reporter arrived at the Pile Driver factory,，About 10 a.m.，The roar of machinery in the factory，Production is in full swing.。Put on your safety helmet，Yin Yanhu, director of Beijing Pile Machine Technology Institute of Sany Heavy Industry, took reporters into the factory building.。
In a factory with an area of 40,000 square meters，There are 8 flexible manufacturing work centers.，16 automatic production lines，500 devices，The workers didn't see many.。Stop in front of a flexible manufacturing work center，The reporter saw，Some robotic arms are precisely grasping parts.，And then assemble；Some are robots equipped with automatic welding guns.，Welding is being carried out according to the infrared target point and track.，Sparks fly。From material preparation to welding，From painting to assembly……Each link works independently and cooperates with each other.，Be methodical。
Yin Yanhu introduced，Before the digital transformation，The factory is a completely different picture.：Parts production mainly depends on people.，Every process is inseparable from people.，If one is not in place, it has to be reworked.。Plus the parts are very“Clumsy”，The workers climbed up and down around the machinery.，Sweat like rain、It is normal to be covered with oil.。Catch up with busy production，The whole process is like chaos.。Nowadays，The factory can run smoothly with few workers.，Because of the layout of 5.GAnd industrial Internet。With 5GConnected as nerves，The factory seems to be open.“Ren and Du Meridians”General，Put the muscle、Skeleton、The brain and so on are all coordinated.，It forms an organic whole of intelligent manufacturing.。
2019 Pile Machine Factory First Deployed 5GNetwork infrastructure，Explore 5GDeep integration with industrial Internet。 At that time ，Sany Heavy Industry proposed：“Digital transformation or turning over，Or capsize”，Its determination to promote digitalization is evident.。
Relying on 5GTechnical large bandwidth、Wide connection、Low latency、High reliability, etc.，Pile machine factory successfully put 500 production equipment、Sensors and 600 water, electricity, oil and gas industrial instruments are all connected to the company's self-developed“Root cloud”Industrial Internet platform，Welding、All processes such as painting can be covered.，This is equivalent to letting a large number of“Equipment for the deaf”I learned it all“Listen”Instruction、“Say it”Information。At the same time，Through“Intelligent brain”，Orders can be quickly broken down to each flexible production line、Every work island、Each device、Every worker，From order to delivery，The whole process is driven by data.。
Take the cutting machine in the blanking area of the Pile Driver as an example.，Before the transformation，Five plasma cutting machines in the factory need five people to operate on site.，Poor operation site environment。Pass 5G+After the establishment of the management cockpit of the industrial Internet，Eight laser cutting machines only need two people to inspect.，On-site conditions pass 5GReal-time return of video and industrial Internet data，Start of machining task、Reset、The edge-finding operation and the like can be remotely implemented，Remote control latency less than 10 ms。
On a huge visual screen in the middle of the factory.，You can see the real-time situation of each machine.，Which one is in the bottleneck?、Which one is inefficient?、Which one is temporarily redundant，Every move is under control.。Even the operation of all Pile Driver products of Sany Heavy Industry in various places is clear at a glance.。
5G+Industrial Internet，Build the digital base of the smart factory。“Although we can't see it with the naked eye.，But‘Root cloud’The industrial Internet platform is computing day and night.。”Yin Yanhu said， Before ，Different production systems are independent of each other，Become an island of data，It is difficult to manage。Now，“Root cloud”The platform calculates and analyzes the industrial big data collected by multiple data collection points in the factory 23000.，Can be for each operation、Matching optimal parameters for each model，Optimize the production process。Dynamic identification and performance analysis of 30 high-value machining centers，Optimize key parameters such as speed and load，Machine tool productivity increased by 5 percent%Above。
“ Arm ”“ Eye ”“Scud”，Assist“Flexible intelligent manufacturing”
Except for the invisible.“Neural network”，There are still visible in the factory.“ Arm ”“ Eye ”“Scud”……
As heavy equipment，The production mode of Piling Machinery is a typical discrete manufacturing.，Variety、Small batch、The process is complex。The bigger challenge is.，The work piece is big, heavy and long.，For example, the longest of more than 170 kinds of drill pipes is 27 meters.，The heaviest of more than 20 power heads is 16 tons.。
Yin Yanhu introduced，Based on this situation，Self-developed production control system of pile driver factory，Through the application of modular technology，Disassembly of the product into individual parts or modules，And each module is designed independently.、Assemble、Testing and maintenance，Make the automatic production line under the condition of minimum investment according to different orders、Quick adjustment of working conditions，Realize mixed production of multiple products。
Intelligent production workshop in Sany Heavy Industry Beijing Pile Machine Factory
Look in the direction pointed by Yin Yanhu.，When processing different models，The robotic arm does automatically pick the most suitable tooling fixture.。How does the mechanical arm achieve rapid recognition?、What about grabbing and assembling different types of workpieces?？ Original ，“ Clever ”Yes“ Arm ”，Can't live without“Wise eye”The help of。
Machine vision system，It is ubiquitous in the factory.“Wise eye”。With the help of 2D/3DVisual sensing technology、AIAlgorithm and high-speed 5GNetwork，The pile driver factory has realized the adaptive welding of intelligent industrial robots in large equipment.、In-depth application in high-precision assembly and other fields。
The road of digital transformation is not achieved overnight.。Before，When the team installs an HD camera on the device，The position is lowered, and the production scene is not complete.，Raise the resolution of the picture and it is not up to standard.，Plus the mechanical vibration.、Noise interference such as light reflection，Repeated debugging is required to select the right data acquisition point.。Through continuous exploration，The team decided to take photos first and then correct them.，Pattern recognition using image、2D/3DVisual positioning technology etc.，Accurately identify the type and pose of the workpiece，Again by“An intelligent brain”Guide the smooth operation of the manipulator。
Got it“Wise eye”After，The factory solved it“Unmanned assembly of 16-ton power head”“40mm thick、Multi-layer single-pass continuous welding of drill pipe square head with a width of 60mm”And many other difficult problems.。Some workers make an analogy：“It's like putting on high-definition glasses.，The hands that hold the vegetables and the knives that cut them are more accurate.”。
Now，Pile machine factory can produce more than 50 models.，“Flexible intelligent manufacturing”The level of global leadership，Let“ Elephant ”Dance smartly。Factory orders come from all over the world.，Sometimes，Non-standard models customized by customers according to construction scenarios，We can't produce a few in a year.，But smart factories can still“Calm”Take orders。From“Gang”To“Soft”The transformation of，Bring the potential of production into full play。Compared to before the transformation，The output value of the pile driver factory has doubled.，Overall production equipment operating rate from 66.3％Up to 86.7％，Mean time to failure reduced by 58 percent.5％。
In the factory，The reporter also found，There are many QR codes on the ground.。“This is a confessionAGV（Automated Guided Vehicle/ 'target='_blank' style='color:blue;'>Transport Vehicle）For car identification。”Yin Yanhu said，The intelligent factory also applies the logistics intelligent scheduling system.，The system generates a picking task list for the production plan based on the production process.，The three-dimensional warehouse carries out the picking work synchronously，The logistics robot sends the material to the corresponding station，Real-time data transmission of the whole process。“In this way，From warehousing of raw materials to delivery of finished products，The whole process can realize production automation.，Picking efficiency increased by 75 percent%，Picking cycle reduced from 2 days to 4 hours。”
Different from automobile manufacturing、Garment production and other industries，In order to adapt to the special needs of the pile machine factory，Many functions of digital transformation are specially customized.。For example，The drill pipe is the core working part of the pile driver.，Length of single section pole: 27m，It weighs 8 tons，In previous production，It's all adopted“Forklift”“Driving”Carry out inter-process transfer，Low efficiency、There are great potential safety hazards。For this reason，Factory's first two-Vehicle linkage logistics robot，Based on 5GHeavy-load logistics robot based on positioning and laser，The synchronous lifting of two vehicles can be realized.、Synchronized travel，The positioning accuracy is less than 10 mm，Easily complete the automatic distribution and loading and unloading of ultra-long heavy materials。
These logistics robots come and go freely.，It's in the factory.“Scud”。“Our automatic welding line materials are all handled by logistics robots.，The area of the drill pipe buffer zone is reduced from 200 square meters to 80 square meters.，The production preparation time for drill pipe welding is also reduced from 17 minutes to 8 minute.5 minutes。Got it‘Scud’，Efficient and safe。”Yin Yanhu said。
The old master brought out the robot.“Apprentice”，Man-machine collaboration is more efficient
Faced with so many complex processes，Robot on duty，Is it comparable to the craftsmanship of the old master?？Yin Yanhu told reporters with a smile.：“Don't worry at all，These robots have also become old masters.‘Apprentice’Where's。”
Take the example of a welder.，The traditional welding method has high labor intensity.、Low efficiency，The pile driver factory has collected tens of thousands of welding records from welding engineers.，Form a digital model of the welding proces，Parameterize the mature welding experience of the engineer，Compile it into the robot welding program，Let craftsman technology be inherited between man and machine。
Before ，There is a workstation that requires high skills.，If the welder is not skilled enough，The welded product is easy to break in use.，Therefore, this link has been by two veteran workers.“Operate the knife”。The qualified rate of the products made by the old master is higher.，But there will inevitably be mistakes.。Now it's replaced with robots.“Apprentice”，With the help of the old master's experience，Output is more stable。The factory also brought in outside welding experts.，Guide and verify the optimization of these parameters.，The production process is upgraded and iterated by detecting the welding effect.。In everyone's eyes，Today, many of the machines in the factory have become“The brain is smart、A quick-witted engineer”，Become Experienced“Old master”。
The machine runs efficiently，Workers also perform their duties。
The reporter met Xu Jianlei in the factory.。Before digital transformation of the factory，He is a welder.；Nowadays，He became a robot commissioning engineer.，Responsible for on-site robot programming、Debugging、Exception handling and technical support for automation equipment。For example，Some equipment has been running for a long time.，A slight deviation will occur.，At this time, he needs to optimize the program.。
“I heard that the factory is going to be digitized.，The first reaction of most of our workers is concern.，I'm afraid I'm out of work.。”Xu Jianlei said frankly，I also worried about the future development.，Later, he took part in the training.、Keep learning，Welders from the front line，Became“People who watch robots.”，Worry then disappears。In a factory of 40 thousand square meters.，Walking twenty or thirty thousand steps a day is for Xu Jianlei“Standard configuration”，But he likes his job.。“The factory has become intelligent.，Our workers have also made progress in their studies.。In the past, I only knew a single welding job.，Now I have learned to operate the automatic production line.，Skills have improved，Income has also increased.，The future is more promising。”Xu Jianlei said。
In fact，Pile machine factories do not pursue complete unmanned in the process of digital transformation.。Yin Yanhu explained，Construction machinery industry has strong periodicity.，As a result, the employment flexibility of enterprises is relatively large.，The number of recruits varies in the off-peak season.；In addition，In the past, workers worked hard.，The working environment also needs to be improved.。After digital transformation，Traditional hard work、Dangerous work no longer requires manual operation，The labor intensity of workers is reduced.，And that work comfort is improved，The performance and quality of products will also be improved.。From these angles.，Digital transformation is necessary.。But，Digital transformation is inseparable from improving production efficiency.、The core of cost reduction，If some processes are more suitable for man-machine cooperation，Then it is still to retain manual posts.。The data shows，At the pile driver factory，Labor productivity of heavy workpieces increased by 85% under man-machine cooperation%，Production cycle time reduced by 77 percent%。
Nowadays，Many digital experiences of Sany Heavy Industry Pile Machine Factory have achieved capacity spillover.，Continue to empower industry chain partners and industries。
