Interface news learned at the scene that the factory is the first 5G fully connected flexible smart factory for wind power in China, and the first flexible production line for wind power assembly pulse has been built in China.
It is the information and communication industry, and OT is the industrial manufacturing industry. MOM is the core operation platform of manufacturing management, which unifies the whole manufacturing process control under a global operation model framework, and juxtaposes the management of production, maintenance, quality and inventory, so that all parts can be strengthened and upgraded independently, and at the same time, they can be closely connected and cooperate with each other.
According to the interface news, due to investment and other considerations, there is no similar smart manufacturing factory in the domestic wind power industry.
This intelligent manufacturing factory has five flexible manufacturing operation centers and two pulsating flexible production lines, which can produce 3. X-6。 X MW model, one production line can produce 800 wind turbines in 100 days.
Flexible production is a new production mode aiming at the disadvantages of large-scale production, which mainly relies on highly flexible manufacturing equipment to realize multi-variety and small-batch production methods. At present, fan manufacturing is showing the characteristics of small batch and many varieties.
The combination of mixed-flow production and flexible production can avoid process waiting and shorten product delivery cycle. Pulsating production is mostly used in aviation manufacturing field, and the assembly line can move according to the rhythm.
In the key process, Sany Heavy Industry can replace labor with intelligent robots.
Xu Peng, chief digital officer of Sany Heavy Industry Energy, said in an interview with Interface News that in the process of fan manufacturing, key processes such as material distribution, pitch control, yaw, transmission chain, cable and so on are production scenes that particularly need intelligent manufacturing.
"The manufacture of fans is not an inventory system. All manufacturing and manufacturing are signed, and materials should be distributed according to the number of sets of orders. This requires automation of material distribution. " Xu Peng said.
Wind power products require high quality. "Take the yaw and pitch system, two core components of wind power generation, as an example. They require very high assembly accuracy, and the quality of manual operation is difficult to control, which will bring great security risks. " Xu Peng said that Sany Heavy Industry Intelligent Manufacturing Factory has realized fully automatic and unmanned production units in key processes such as pitch control, yaw, transmission chain, cable and material distribution.
According to Xu Peng, the manufacturing cycle of wind turbines is long, but the delivery is urgent. If the manufacturer's efficiency and productivity can't keep up, it will be difficult to get more orders.
In addition, the era of wind power parity has arrived, and the price of the whole wind power machine is declining. If the manufacturing cost cannot be reduced and the gross profit margin of products is low, the market competitiveness will be lost.
Xu Peng said that the production of wind turbines with the same capacity in intelligent manufacturing plants can reduce the number of workers by 35%, shorten the off-line time from 3.5 hours to 2.5 hours, and reduce the defective product rate from 0.26% to 0. 14%, an increase of nearly 46%.
In the process of building an intelligent manufacturing plant, Sany Heavy Industry faces three major problems.
Xu Peng said, firstly, most of the smart manufacturing projects are the first in the industry, and they have experienced a lot of project verification and trial and error in practice.
Secondly, in addition to robots, intelligent manufacturing plants have also applied many visual technologies to realize man-machine cooperation and improve assembly accuracy, which needs to break through technical difficulties.
Thirdly, the manufacture of fans is mostly small batch and multi-variety, and the technology update iteration is fast. The production line should be compatible with different types of products and realize flexible production, which requires higher intelligent manufacturing equipment.
"Universality is the biggest challenge. In addition, it is necessary to transform the operation management system on the basis of general operation software, and this technical difficulty also needs to be overcome. " Xu Peng said.
At present, Sany Heavy Industry Smart Factory has begun to take shape. Xu Peng told Interface News that the intelligent manufacturing mode of such factories in the field of wind power is replicable and can bring experience to the development of the industry.
Sany Heavy Industry is a renewable energy sector under Sany. Sany Heavy Industry was established in 2008, mainly engaged in R&D, manufacturing and sales of wind turbines, design, construction and operation management of wind farms, and construction and operation management of photovoltaic power plants.
In 2020, Sany Heavy Industry ranked eighth among domestic wind turbine manufacturers, and is currently promoting its listing on the science and technology innovation board.