EXPERT cement industry intelligent solution using the "Internet of things, big data and cloud computing" thinking, with automatic perception, intelligent decision-making, intelligent control, intelligent coordination as the core, to implement fault predict, the production of intelligence, automation, operation management informationization, scientific decision-making, improve labor condition, reduce manual intervention, improve management efficiency, reduce energy consumption, improve product quality. The intelligent construction of cement industry mainly includes intelligent equipment, intelligent control, intelligent production, intelligent logistics, intelligent management, intelligent decision-making and other aspects, so as to realize intelligent manufacturing of cement enterprises and help the transformation and upgrading of cement industry.
Overall planningCollaborative promotion
Demand traction application association
Base on actuality Customized-made
Stabilize current process system
Optimize current KPI indicator
Production organization structure
factory structure Finance/logistics/production/ sales
Equip mobile app
Convenience daily management
Open up business process
Eliminate management black hole
Realize management “visualization”
Logistic card module
The establishment of intelligent logistics system, through the integration with procurement, sales, quality and finance, realizes the management of incoming and exiting materials with few or no people on duty and automatic settlement, and reduces the management black hole in the process to the greatest extent, reduces the personnel allocation, and improves the logistics efficiency.
- Reduce staff and increase efficiency, reduce labor cost (cost)
- Facilitate customers and improve customer experience (service)
- Strengthen internal control and improve delivery efficiency (management)
- Standardize market management and improve company image (brand)
Equipment total life circle management module
Set up a unified platform for enterprise equipment management, set the equipment assets as the core, focus on equipment operation management, strengthen the equipment condition perception ability (data source: intelligent inspection instrument, the new adding vibration sensor, DCS data, vibration analyzer, automatic oil analyzer, broken belt tearing monitor). using the comprehensive analysis, early warning and diagnosis technology, combined with the preventive maintenance, maintenance management, realize the equipment fault intelligent diagnosis and maintenance decision, finally realizes the closed loop of total life cycle of equipment management, to ensure the safety of equipment, stable, long-term, full of optimal operation.
- Reduce unscheduled downtime of equipment
- Reduce spare parts inventory
- improve work efficiency
- Implement predictive maintenance
Unattended operation module
Combined with the latest computer hardware technology, software technology, electronic technology, network technology, the development of a new, hierarchical distributed open bus topology automation system, through the remote real-time data (transformer, outgoing cabinet and bus), image monitoring, remote fault location, remote control (empty, lighting), unexpected circumstances (temperature, smoke, water immersion, entrance guard) alarm processing, improve the safety and reliability of substation operation and maintenance, and gradually achieve visual monitoring, make the operation safer and more reliable. To achieve unattended, significantly reduce labor costs, reduce human error, improve production and management efficiency.
- Improve the informational automation level of enterprise security, with practical significance to ensure production.
- Save personnel, improve work efficiency, reduce workload.
- Real-time online monitoring, timely grasp the temperature change information, in case of potential accident early warning, to avoid the accident.
Production management module
Production management module adopts the technology of the Internet architecture, the production line each link of the dynamic and static data, using different interface technology unified collection, establish plant-level center database, including real-time data platform, relational data platform, unstructured data platform, combined with the different needs of the business (production, quality, equipment, energy, logistics, 3D visualization, etc.), analyze and summarize the data, integrate the functions to form a comprehensive, suitable, flexible, extensible integrated management platform,to provide real data support and reliable basis for the intelligent decision of the enterprise .
- Realizing the unification of the production data of enterprise that including personnel, finance, material, production, supply and sales;
- Complete standardized interface between enterprise software and software, hardware and hardware, software and hardware.
- Achieve enterprise management informatization, greatly improve work efficiency;
- Build the bridge between ERP system and control system
APC optimal control module
APC optimal Control module adopts model-free Adaptive Control (MFA) Control technology, which provides a new solution to solve the traditional Control problems such as multi-variable, large lag, large inertia, nonlinear, time-varying and so on. The system for cement clinker sintering process and grinding machine, pay attention to establish the dynamic balance among wind, coal and material, Multi-variable coordinated operation was used to suppress the disturbance from all directions such as raw material components, coal burning characteristics and equipment operating conditions, through the standard operation behavior to achieve a balanced operation quality, maintain stability of the whole production line and reduce the coal consumption and electricity consumption indicators, a convenient and flexible operation platform is established for the optimized operation of the device.
- Stable operation: the fluctuation range of key process variables decreases by 2 ~ 3 times, and the time of disturbance convergence is shortened
- High operation rate: strong adaptive ability, high fault tolerance
- Operation specification: strong prediction ability, more precise, timely, smooth operation, reduce personnel intervention
- Stable quality: stable working condition, smooth operation, ensure the quality of calcination
- Energy conservation and consumption reduction: comprehensive energy consumption index decreased by 2-3%;
Quality management module
It covers the quality management of the whole process of raw fuel entering the factory, production process and finished product leaving the factory, and is closely integrated with production and logistics systems. At the same time,in accordance with the need of management the system can be dynamically generate all kinds of management quality management comprehensive report according to the daily business data, implement quality traceability and quality prediction, to provide analytical means and tools for the enterprise quality management and quality improvement,.At the same time, based on the existing quality test system, extract data from it for quality management application, to realize the data integration and fusion of quality laboratory system and quality management.
- Achieve the full coverage of the enterprise quality management network, to ensure the quality of the entire production process is controllable, in the control, under control
- Achieve early warning prediction of the quality management , transform quality management from after-event management to beforehand preventing.
- Establish a rapid response mechanism to prevent the occurrence and expansion of quality events
- Complete quality data precipitation, to achieve the whole process of traceability for quality analysis
- Establish quality big data model, realize data analysis and statistics, solve quality control bottleneck, and realize sustainable improvement
Energy source management module
Energy source management module adopts energy efficiency analysis + energy control to carry out the management from two levels: process improvement and management of energy efficiency. Through the high-precision data acquisition device, monitor the operation, production capacity data and production parameters of key equipment, analyze it in different forms, different methods after collecting a large amount of data, understand the production trends and energy consumption to achieve the gradually reduction of energy consumption costs and the continuous improvement of the lean management level.
- Provide energy efficiency analysis tools: explore the best energy efficiency operation mode of each process operator, and refine operation management.
- As a professional tool: to help analyze the economy of system (or equipment) operation and determine the best time for system maintenance or replacement of spare parts from an energy efficiency perspective.
- As an online management tool: supervise the no-load and light-load operation of the equipment, strengthen the field management.
- Provide tools for production scheduling department: online automatic analysis of load rate and operation efficiency of the system and major energy-consuming equipment, judge/avoid non-economic operation, and provide data support for rational scheduling and production arrangement. It usually saves 3%-8%.
Security management module
Cement enterprises adhere to the policy of "safety first, prevention first, comprehensive treatment" for production, Security management involves in the production process of each link, take a variety of effective measures to ensure safe production, safe production management is the primary link of enterprise safety, economic production
- Safety specifications, safety inspection, safety rectification, safety management, safety training, safety assessment, safety document management, etc.
- No safety helmet, no tooling, alarm and record of intrusion of dangerous and key personnel.
Environment protection management module
Manage the policy related to environmental protection, provide upload, download, delete, add description functions for documents; Responsible for the relevant contents of eia projects, internal and external environmental audit, sewage declaration, monthly meeting of environment protection, environmental standards, environmental inspection, rectification and document management. Through acquiring online monitoring equipment data, monitor and display environmental protection data, alarm and record smoke monitoring of the key parts; Set up environmental protection input expense ledger, record environmental protection input cost in detail.
AI video monitoring module
Combined with the new or existing cameras, the use of AI (artificial intelligence) technology can automatically identify the invasion of personnel, smoke, no helmet, no tooling, flap valve valve position, blocking, over temperature warning real-time monitoring and automatic alarm.
- Big data display: real-time data, dynamic display
- Video patrol: manual video patrol and automatic video patrol
- Production condition video linkage: equipment start-stop video linkage, equipment condition abnormal video linkage
- Intelligent image recognition: personnel invasion, alarm without safety helmet, smoke alarm in electrical room
3D factory module
3D factory fuses the "physical space" and "virtual representation" together, through the sensor acquiring all real-time data of "physical space" in the process of manufacturing ,
3D integrates and display more analysis, simulation, exercise,training and monitoring functions in “Virtual representation” environment. Make production simulation in the virtual environment seamlessly integrate with the production in the real world, and the flexible advantage of the virtual factory is utilized to promote the real production.
- It provides an intuitive, synchronous, precise, collaborative and intelligent working environment for the production and operation of the factory
- Using Internet of things positioning technology to link with video,access control system, real-time monitoring personnel operation safety
- Through the use of intelligent operation, electronic fence technology to build a safe construction environment to ensure the safety of construction
- Through the integration of equipment management and 3D simulation, 3d visualization equipment management is realized
ERP (Enterprise Resources Planning) Enterprise Resources Planning system is a management platform which is built on the basis of information technology and provides systematic management ideas for Enterprise decision making and staff to make decisions. ERP is a kind of enterprise management information system that can provide real-time information integration across regions, departments and even companies. ERP is not only a software but also a management idea, which realizes the integration of internal resources and external resources related to the enterprise. Through the software to the enterprise's people, financial, material, production, supply and marketing and the corresponding logistics, information flow, capital flow, management flow, value-added flow and so on closely integrated to achieve resource optimization and sharing.
What value does it bring to customers
Improve the level of enterprise intelligence
Improve enterprise productivity
Improve corporate management
Reduce business operating costs
Smart cement construction content
The fourth industrial revolution characterized by full digitalization has already begun. Intelligent manufacturing, cloud computing, big data, Internet of Things, Industry 4.0 and other new technologies are subverting the production operations and competition methods of manufacturing companies at all levels
Customer trust is our driving force