本文为“2022年度中国智能制造最佳应用实践奖”参评案例。本次活动将评选出2022年度，为中国智能制造领域带来突出效益的最佳实践工程，全面介绍企业推进智能制造的步骤、重点与难点、获得效益等，分享建设过程中的经验，供广大制造业行业企业学习供鉴。数字化转型网szhzxw.cn
一、企业简介数字化转型网szhzxw.cn
恒逸石化致力于发展成为国内领先、国际一流的石化产业集团之一，通过实现资源共享、产业协同，全面提升综合竞争力，目前已逐步形成“涤纶+锦纶”双纶驱动的石化产业链为核心业务，石化金融、石化贸易为成长业务，化纤产业大数据、智能制造为新兴业务的“石化+” 多层次立体产业布局。公司综合竞争优势多年位居行业前列，主要的产品包括精对苯二甲酸（PTA），参控股产能达到1,350万吨；己内酰胺（CPL）产能30万吨；聚酯（PET）切片、瓶片以及涤纶预取向丝（POY）、涤纶牵伸丝（FDY）、涤纶加弹丝（DTY）、短纤等差别化产品，参控股产能共410万吨。数字化转型网szhzxw.cn
公司自成立以来，紧紧围绕“巩固、突出和提升主营业务竞争力”的战略方针，联合战略合作方实现优势互补，不断向石化产业链上游延伸。未来，公司蓄力前行，借助文莱PMB石油化工项目实现又一次的跨越式前进。该项目是公司与文莱政府合作的一个以原油、凝析油为原料的炼油化工一体化项目，是国家“一带一路”重点建设项目，具有高度战略意义，是公司向国际产能合作、产业链一体化战略目标迈出的关键一步，同时将建设成为中文两国友好合作的典范。数字化转型网szhzxw.cn
二、企业在智能制造方面的现状
恒逸在信息化、智能制造建设方面始终走在行业前列，不断进行探索与创新，主要应用情况简介如下：数字化转型网szhzxw.cn
自2001年开始，逐步开始全面上线应用用友财务软件、OA系统、SAP系统、资金管理系统、报表系统、SCM、SRM、CRM、微商城、单锭数据流系统、营销闭环系统、TMS、仓储管理系统、共享托盘系统、全流程智能物流系统、化纤工业互联网平台、 EAM、MES、能源系统等等。其中恒逸在行业内首创的系统如下：微商城——行业内首家实现可24小时下单，提升订单处理、到货效率，为客户提供完整的金融解决方案，大幅提升客户满意度；单锭数据流——行业内首套实现单锭丝锭全生命周期的追溯与管理；共享托盘系统——行业内首创塑料共享托盘系统，通过RFID为托盘赋予信息重复利用，降低物流成本；全流程智能物流系统——2018年在行业内率先实现首个全流程智能化物流系统的落地运行，率先探索了化纤行业数字化工厂建设之路；化纤工业互联网平台——行业内首个化纤工业互联网平台，根据恒逸自身特点进行建设，有力的支撑了企业数字化建设，入选首批浙江省工业互联网平台名单，并获得2019年工信部工业互联网优秀APP解决方案。数字化转型网szhzxw.cn
通过信息化、智能制造的建设与落地，有效的实现了企业纵向“人机料法环”、横向“人财物产销”的资源整合，大幅提升企业的生产经营与管理效率，为企业数字化、智能化建设保驾护航。
三、参评智能制造项目详细情况介绍
1. 项目背景介绍数字化转型网szhzxw.cn
化纤工业是我国具有国际竞争优势的产业，是纺织工业整体竞争力提升的重要支柱产业, 也是战略性新兴产业的重要组成部分，同时也是存在产能结构性过剩，高附加值、高技术含量产品比重低等问题。随着人工智能、大数据、云计算、机器视觉等新兴技术蓬勃发展，尤其在国家《关于积极推进“互联网+”行动的指导意见》、《关于深化“互联网+先进制造业”发展工业互联网的指导意见》等纲领性文件的指导与推动下，我国化纤工业向智能制造方向发展取得积极成效，如化纤制造设备已经具有添加互联互通技术以及高速化通信网络技术数据接口能力和工业互联网传输条件。数字化转型网szhzxw.cn
面向未来，化纤工业下游纺织服装企业的个性化需求日趋增加，在生产批次越来多、批量越来越少、对环节柔性生产的要求越来越高的新形势下，对于连续流程性的化纤工业要在提高市场需求响应速度的同时保证产品品质的一致性，必然要求化纤企业率先解决生产过程中预测能力欠缺、人工抽检难度大等问题，构建有预测能力的数字化新型基础设施来支撑未来化纤行业的智能化、柔性化、网络化发展。与此同时，化纤工业上下游处于“信息孤岛”状态，下游面对的客户是大量中小型、高度分散的纺织服装企业，行业B2B电子商务、供应链金融、物流和客户服务等对数据互联互通的需求巨大。数字化转型网szhzxw.cn
涤纶长丝生产流程长而复杂，涵盖流程型、离线型两种制造模式。传统的生产模式具有完全依赖人工作业；产品开发周期长；产品开发、生产效率低；生产过程中损耗、能耗大；各工序作业分散，生产、产品信息采集、传递和数据汇总困难，生产运行设备多而广，关联度低，设备数据间互通互联程度低，设备状态监测、数据分析缺乏完整实时信息和数据可追溯性等弊端，成为了涤纶长丝生产进一步转型升级瓶颈。因此需对涤纶长丝生产全流程的工艺设备、工艺参数、原料信息、品质信息进行实时的监测，并通过获取的实时数据进行机理模型与非机理模型分析，从而预测原料信息差异、设备波动与产品差异之间的关联，优化生产工艺的调整，提高涤纶长丝产品品质，降低能耗和物耗。数字化转型网szhzxw.cn
工业互联网作为新一代信息技术与制造业深度融合的产物，向下连接海量设备，自身承载工业经验与知识模型，向上对接工业优化应用，为实现化纤工业全生命周期智能制造提供了系统解决方案。通过建设化纤工业互联网平台，一方面实现对化纤生产全流程的工艺设备、工艺参数、原料信息、品质信息进行实时的监测，并通过获取的实时数据进行机理模型与非机理模型分析，从而预测原料信息差异、设备波动与产品差异之间的关联，优化生产工艺的调整，提高涤纶长丝产品品质，降低能耗和物耗；另一方面，促进产业链深度融合、协同与集成应用，从而提高产业链整体效率，推进产业链的降本增效和智能化、服务化转型升级，对推动我国化纤产业向中高端迈进具有重大意义。数字化转型网szhzxw.cn
恒逸石化股份有限公司是我国化纤行业龙头企业，拥有国内先进的纤维研发生产团队、生产工艺和生产线，为了进一步提升公司化纤行业综合竞争力，推进化纤生产智能化、柔性化、网络化改造，本项目拟由子公司海宁恒逸新材料有限公司基于化纤工业互联网平台，开展现有厂区智能化改造升级，购置自动落筒线、AGV丝箱转运系统、智能外观检、丝箱平衡库、自动包装线、加弹车间智能上丝及下丝系统、加弹车间丝车平衡库及包装线、智能成品立体仓库等等自主品牌的智能化设备，合作引进浙大中控智慧制造执行系统、精细化生产管理执行系统，推广应用以客户自助下单自助服务为导向的供应链一体化系统，实现生产、物流、供应链管理和产品追溯的全流程智能化，打造基于化纤工业互联网平台的智能化工厂。
2. 项目实施与应用情况详细介绍
2.1 工艺流程概述数字化转型网szhzxw.cn
该系统是基于工业互联网平台，贯通卷绕车间、检验车间、加弹车间、仓储车间的全过程产品物流和信息流集成的智能化系统，工艺流程是从卷绕机的纱锭落筒至成品箱包的出库装车，即整个生产、检验、包装、仓储、出库过程，其中详细的工艺流程如下：数字化转型网szhzxw.cn
1）自动落筒机将纱锭从卷绕头落筒落筒至丝箱，同时本系统应用物联网技术从卷绕头获取POY纱锭的原始详细生产数据。通过上位机智能调度，自动牵引车AGV应用自动导航技术将不同生产线的丝箱搬运至指定的下一工序位置。装载POY纱锭的丝箱到达检验区域后，在自动输送线上完成人工剥丝、打结等工序，并完成自动单锭称重与智能外检检验，同时通过上位机管理系统将操作日志、检验结果等数据绑定到每个纱锭，形成产量统计、反馈、追溯等有价值的数据流。
2）完成检验工序的POY纱锭再次装载至丝箱后进入丝箱平衡库，通过仓储管理系统WMS与其它调度系统的信息互联，识别纱锭的下一个去向，包括自动包装、自动转运至加弹车间、自动装大车丝系统等。POY丝箱平衡库通过仓储管理系统WMS与包装调度系统的信息互联，识别识别纱锭的包装任务，完成POY纱锭不同的包装方式，通过上位机管理系统形成产量统计、成品入库等有价值的数据流。
3）装载原丝架的AGV通过上位机调度系统，根据生产需求实时转运不同产品至指定的加弹机。装载DTY纱锭的AGV通过上位机调度系统，实现满卷纱锭的自动落筒并从加弹车获取DTY纱锭的原始详细生产数据，转运并装载至DTY纱车，同时完成单锭信息的传递。装载DTY纱锭的纱车达到检验区，在自动输送线上完成人工剥丝、打结、织袜等工序。完成检验工序的DTY纱锭进入纱车平衡库，通过仓储管理系统WMS与包装调度系统的信息互联识别纱锭的包装任务，完成DTY纱锭不同的包装方式，通过上位机管理系统形成产量统计、成品入库等有价值的数据流。
4）完成包装的DTY成品自动输送至智能立体仓库，并与公司内部仓储管理系统WMS信息互联，根据销售订单自动出库装车。完成包装的POY成品自动输送至智能立体仓库，并与公司内部仓储管理系统WMS信息互联，根据销售订单自动出库装车。数字化转型网szhzxw.cn
2.2 建设方案
1）建设内容数字化转型网szhzxw.cn
本项目基于恒逸集团化纤工业互联网平台进行智能化改造升级，有效的集成在化纤工业互联网平台上，并链接智能化设备，包括智能落筒包装物流系统、智能外检系统、自动上下丝及自动上纸管系统、智能立体库等设备，实现全流程智能物流及产品全流程追溯；在营销端运用化纤工业互联网平台的供应链一体化应用，实现客户从商城下单、营销订单管理、智能仓储拣配、智能园区物流、到物流配送全供应链一体化管理。项目实施后，将服务配套厂区150万吨智能化环保功能性纤维的生产、检测、物流运输及销售的智能化升级。
2）总体架构数字化转型网szhzxw.cn
集团围绕化纤全生命周期管理，打造基于化纤行业特性的工业互联网平台。根据场景需求对搭建的工业互联网平台四层结构（边缘层、PaaS、IaaS、SaaS），制定相关标准并开展应用推广工作。围绕生产优化、燃煤优化、智能生产、质量优化、资源整合等方面提供平台化服务，形成多种创新模式。
3）业务框架数字化转型网szhzxw.cn
根据化纤工业互联网平台总体架构，重点从产品生命周期管理、系统层级应用、智能化功能三大维度构建功能业务框架。推广应用智能清板机器人、全自动智能纺丝落丝线、全自动智能包装线、自动智能装车机器人、基于人工智能的产品外观检验、智能立体库等智能化设备，并将智能化化装备形成的海量过程数据在有效集成MES和ERP上，形成以智能化装备和工业互联网为基础，结合快速响应的客户分层分级管理、客户征信系统、金融、物流和信息物联协同平台，实现工业大数据对产业链上下游链接，优化品质，深挖产业链价值，降低成本，提升服务价值。数字化转型网szhzxw.cn
在全生命周期管理维度，建立研发系统，实现聚酯、纺丝生产流程数据上云实时分析与工艺优化系统；信息化全面集成应用，ERP、MES系统全面建成，能够通过监控整个生产作业过程，自动预警或修正生产中的异常，提高生产效率和质量。智能化物流全面建成，实现TMS、车辆管理系统、物流系统；建立智能销售系统，建立商业智能AI，实时进行市场感知，实现销售大数据分析和个性化营销等功能。服务全面APP化。数字化转型网szhzxw.cn
在系统层级维度，已实现智能清板机器人、基于大数据深度学习的产品外观检验、全自动智能纺丝落丝线、全自动智能包装线、智能立体库、纱锭自动输送线，通过全流程的数据采集，进行大数据分析与决策，驱动业务运作。
在智能化功能维度，已实现能够基于能源数据信息的采集和存储，对耗能和产能调度提供优化方案，优化能源运行方式。以单锭数据流为主线，形成数据集成系统。能够基于云平台实现企业间业务的集成。上下游质量数据互通，打通产业链品质数据。5G新技术的应用。企业实现数据库的网络化集成与应用（云数据库）。数字化转型网szhzxw.cn
4）数据中台
数据中台包括两个方面，一个是数据的技术能力，另一个是数据的资产技术能力是指数据中台负责所有业务数据的采集、加工处理、服务应用等工作，是一个多技术的整合。而数据中台不仅仅是一个数据的集合，经过处理后的数据不再像蜘蛛网一样眼花撩乱，从各个业务线，业务域上的海量数据中提取核心内容，经过一定业务逻辑下的组装，还原出恒逸全链路下各个对象的行为树，同时能被灵活使用，并快速扩展。
数据中台的理念是让恒逸集团整个业务都可以共享同一套数据技术与资产，数据中台的数据源自各业务系统，为恒逸集团业务体系提供了有力的算法、数据和技术支持。在数据中台的体系之下，可以不断扩大和纳入业务版图内的各种业务数据，也都将按统一的方式接入中台系统，之后通过统一化的数据技术服务反哺业务。数据来自于业务，反哺业务，并循环往复，蕴含更大能量，形成一个数据生态，从而衍生无限的可能性。数字化转型网szhzxw.cn
5）信息安全数字化转型网szhzxw.cn
在安全运营方面提出了“ 1 +3 ”的概念，即通过“安全融入设计、自动化监控与响应、红蓝对抗与持续改进”这3个安全手段，实现“保障用户数据安全”这1个核心目标。凭着“ 1 +3 ”的强力运营管控，检测出逼近100%的内部漏洞与风险，追踪控制能力更是完全覆盖所有服务。
3. 效益分析数字化转型网szhzxw.cn
自应用该系统的自动化与数字化关键技术以来，我司传统生产流程发生了变革，通过信息化集成实现了精益管理和柔性化生产，降低了经营成本，提高了生产效率，提升了产品形象，预计可降低经营成本超3000万元/年。同时减少人为因素造成的产品降等，提升优等品率，预计降低质量损失近1000万元/年。共计产生直接经济效益超过4000万元/年。 数字化转型网szhzxw.cn
翻译：数字化转型网szhzxw.cn
This paper is a case study of “China Intelligent Manufacturing Best Application Practice Award 2022”. This event will select the best practice projects that bring outstanding benefits to China’s intelligent manufacturing field in 2022, comprehensively introduce the steps, key points and difficulties of enterprises to promote intelligent manufacturing, gain benefits, and share the experience in the construction process for the majority of manufacturing enterprises to learn from.
Introduction to the enterprise数字化转型网szhzxw.cn
Hengyi Petrochemical is committed to developing into one of the leading domestic and international petrochemical industry groups. By realizing resource sharing and industrial synergy, Hengyi Petrochemical comprehensively improves its comprehensive competitiveness. At present, it has gradually formed a petrochemical industry chain driven by “polyester + nylon” as its core business, and petrochemical finance and petrochemical trade as its growth business. Chemical fiber industry big data, intelligent manufacturing for the emerging business of “petrochemical +” multi-level industrial layout. The company’s comprehensive competitive advantage has been in the forefront of the industry for many years. The main products include refined terephthalic acid (PTA), and the ginseng holding capacity has reached 13.5 million tons. Caprolactam (CPL) production capacity of 300,000 tons; The company has a total production capacity of 4.1 million tons, including PET slices, bottle slices, polyester preoriented silk (POY), polyester drafting silk (FDY), polyester elastic silk (DTY), staple fiber and other differentiated products.数字化转型网szhzxw.cn
Since its establishment, the company has closely focused on the strategic policy of “consolidating, highlighting and enhancing the competitiveness of the main business”, united with strategic partners to realize complementary advantages, and continuously extended to the upstream of the petrochemical industry chain. In the future, the company will make great strides forward with the help of Brunei PMB petrochemical Project. This project is a refinery and chemical integration project with crude oil and condensate oil as raw materials cooperated by the company and the government of Brunei. It is a key construction project of the “Belt and Road” of the country and of high strategic significance. It is a key step of the company towards the strategic goal of international production capacity cooperation and industrial chain integration, and will be built into a model of friendly cooperation between China and Brunei.
The status quo of enterprises in intelligent manufacturing数字化转型网szhzxw.cn
Hengyi has always been at the forefront of the industry in informatization and intelligent manufacturing construction, and has been constantly exploring and innovating. The main applications are as follows:
Since 2001, Gradually began to fully online application of Yonyou financial software, OA system, SAP system, fund management system, report system, SCM, SRM, CRM, micro mall, single ingot data flow system, marketing closed-loop system, TMS, warehouse management system, shared tray system, the whole process intelligent logistics system, chemical fiber industry Internet platform, EAM, MES, energy systems, etc. Among them, Hengyi’s first system in the industry is as follows: 数字化转型网szhzxw.cn
Micro Mall — the first one in the industry that can place orders in 24 hours, improve the efficiency of order processing and arrival, provide customers with complete financial solutions, and greatly improve customer satisfaction; Single ingot data stream — the first set in the industry to realize the traceability and management of the entire life cycle of single ingot silk ingot; Shared tray system — the first plastic shared tray system in the industry, through RFID tray information reuse, reduce logistics costs; Whole-process intelligent logistics system — In 2018, the first whole-process intelligent logistics system was put into operation in the industry, and it took the lead in exploring the construction of digital factory in the chemical fiber industry; Chemical fiber industrial Internet platform — the first chemical fiber industrial Internet platform in the industry.
Built according to Hengyi’s own characteristics, it has strongly supported the digital construction of enterprises. It has been selected as the first batch of industrial Internet platforms in Zhejiang Province and won the outstanding APP solution of Industrial Internet in 2019 by the Ministry of Industry and Information Technology.数字化转型网szhzxw.cn
Through the construction and implementation of informatization and intelligent manufacturing
Through the construction and implementation of informatization and intelligent manufacturing, the enterprise effectively realizes the resource integration of vertical “man-machine material process” and horizontal “human property production and marketing”, greatly improves the production, operation and management efficiency of the enterprise, and escorts the digital and intelligent construction of the enterprise.数字化转型网szhzxw.cn
Detailed introduction of intelligent manufacturing projects数字化转型网szhzxw.cn
Introduction of project background
Chemical fiber industry is an industry with international competitive advantages.
It is an important pillar industry for the improvement of overall competitiveness of textile industry, and an important part of the emerging industries of strategic importance. It is also a problem of structural excess capacity, low proportion of high value-added and high-tech products. With the booming development of emerging technologies such as artificial intelligence, big data, cloud computing and machine vision, especially under the guidance and promotion of programed documents such as the Guidelines on Actively promoting the “Internet Plus” action and the Guidelines on Deepening the “Internet Plus Advanced Manufacturing” Development of Industrial Internet, China’s chemical fiber industry has achieved positive results in the direction of intelligent manufacturing. For example, the chemical fiber manufacturing equipment already has the ability to add interconnection technology, high-speed communication network technical data interface and industrial Internet transmission conditions.数字化转型网szhzxw.cn
Facing the future, the personalized demand of textile and garment enterprises in the downstream of chemical fiber industry is increasing day by day.
Under the new situation of more and more production batches, fewer and fewer batches, and higher and higher requirements for link flexible production, the continuous process of chemical fiber industry should improve the response speed of market demand while ensuring the consistency of product quality. It is necessary for chemical fiber enterprises to take the lead in solving problems such as lack of forecasting ability and difficulty of manual sampling in the production process, so as to build a new digital infrastructure with forecasting ability to support the intelligent, flexible and networked development of the chemical fiber industry in the future. 数字化转型网szhzxw.cn
At the same time, the upstream and downstream of the chemical fiber industry are in the state of “information island”. The customers facing the downstream are a large number of small and medium-sized and highly dispersed textile and garment enterprises. And the industry B2B e-commerce, supply chain finance, logistics and customer service have a huge demand for data connectivity.
Polyester filament yarn production process is long and complex, including process type, off-line two manufacturing modes.
The traditional production mode is completely dependent on manual work. Long product development cycle; Low product development and production efficiency. Large loss and energy consumption in the production process. Various processes are scattered, production and product information collection, transmission and data summary are difficult, production and operation equipment is numerous and wide, the correlation degree is low, the interconnection degree between equipment data is low, equipment condition monitoring, data analysis lack of complete real-time information and data traceability and other drawbacks. Become the bottleneck of further transformation and upgrading of polyester filament yarn production.
Therefore, real-time monitoring should be conducted on the process equipment, process parameters, raw material information and quality information of the whole process of polyester filament filament production. And mechanism model and non-mechanism model analysis should be carried out through the real-time data obtained. So as to predict the correlation between raw material information difference, equipment fluctuation and product difference, optimize the adjustment of production process and improve the quality of polyester filament filament products. Reduce energy and material consumption.
As the product of the deep integration of the new generation of information technology and the manufacturing industry
As the product of the deep integration of the new generation of information technology and the manufacturing industry. The industrial Internet connects massive equipment downward, carries the industrial experience and knowledge model. And connects the industrial optimization application upward, providing a system solution for the realization of intelligent manufacturing of the whole life cycle of the chemical fiber industry. Through the construction of chemical fiber industry Internet platform, real-time monitoring of process equipment, process parameters, raw material information and quality information of the whole process of chemical fiber production can be realized on the one hand. And mechanism model and non-mechanism model can be analyzed through the real-time data obtained. So as to predict the correlation between raw material information difference, equipment fluctuation and product difference, and optimize the adjustment of production process. Improve the quality of polyester filament, reduce energy consumption and material consumption;
On the other hand, it is of great significance to promote the deep integration, synergy and integrated application of the industrial chain. So as to improve the overall efficiency of the industrial chain. And promote the transformation and upgrading of the industrial chain through cost reduction and efficiency improvement. As well as intelligent and service-oriented transformation and upgrading of the industrial chain. Which is of great significance to promote China’s chemical fiber industry to move towards medium-high-end.
Hengyi Petrochemical Co., Ltd. is the leading enterprise in the chemical fiber industry
Hengyi Petrochemical Co., Ltd. is the leading enterprise in the chemical fiber industry, with domestic advanced fiber research and development production team, production process and production line. In order to further enhance the comprehensive competitiveness of the chemical fiber industry of the company. And promote the intelligent, flexible and networked transformation of the chemical fiber production. This project is planned by the subsidiary Haining Hengyi New Material Co., Ltd. based on the chemical fiber industry Internet platform. 数字化转型网szhzxw.cn
Carry out intelligent transformation and upgrading of existing factory areas. And purchase self-owned intelligent equipment such as automatic drum dropping line, AGV wire box transfer system, intelligent appearance inspection, wire box balancing library, automatic packaging line, intelligent wire loading and unloading system of ammunition workshop, wire car balancing library and packaging line of ammunition workshop, intelligent product three-dimensional warehouse, etc. Cooperate with the introduction of Zhejiang University Control intelligent manufacturing execution system and refined production management execution system, promote the application of customer self-service ordering and self-service oriented supply chain integration system, realize the intellectualization of the whole process of production, logistics, supply chain management and product traceability. And build an intelligent factory based on the chemical fiber industry Internet platform.
Detailed introduction of project implementation and application
Process overview数字化转型网szhzxw.cn
Based on the industrial Internet platform, this system integrates the whole process of product logistics and information flow of the winding workshop, inspection workshop, ammunition workshop and storage workshop. The process flow is from the falling of the spindle of the winding machine to the unloading and loading of the finished product case and bag. Namely the whole process of production, inspection, packaging, storage and warehousing. The detailed process is as follows:
1) The automatic dropping machine will drop the spindle from the winding head to the silk box.
Meanwhile, the system applies the Internet of Things technology to obtain the original detailed production data of POY spindle from the winding head. Through the upper intelligent scheduling, the automatic tractor AGV uses the automatic navigation technology to move the silk boxes of different production lines to the designated position of the next process. After the silk box loaded with POY spindle arrives at the inspection area. The processes such as manual stripping and knotting are completed on the automatic conveyor line. And automatic single spindle weighing and intelligent external inspection are completed. At the same time, the data such as operation log and inspection results are bound to each spindle through the upper computer management system to form a valuable data stream such as output statistics, feedback and traceability.数字化转型网szhzxw.cn
2) After the completion of the inspection process, the POY spindle will be reloaded into the silk box and enter the silk box balancing warehouse.
Through the information interconnection between the storage management system WMS and other scheduling systems. The next destination of the spindle will be identified, including automatic packaging, automatic transfer to the ammunition workshop and automatic loading of the trolley silk system. Through the information interconnection between the storage management system WMS and the packaging scheduling system. The balance library of the POY silk box can identify the packaging tasks of the spindle, complete the different packaging methods of the POY spindle. And form the valuable data stream of output statistics and finished products warehousing through the upper computer management system.数字化转型网szhzxw.cn
3) AGVs loaded with raw wire racks transfer different products to the designated refueling machine in real time according to production requirements through the upper computer scheduling system.
The AGV loaded with DTY spindle realizes the automatic dropping of full-rolled spindle through the upper computer scheduling system, obtains the original detailed production data of DTY spindle from the loading truck, transfers and loads it to the DTY yarn truck. And completes the transmission of single spindle information. The yarn truck loading DTY spindle reaches the inspection area. And completes the manual stripping, knotting, knitting and other processes on the automatic conveyor line. Complete the inspection process of DTY spindle into the yarn truck balance library. Through the information interconnection of storage management system WMS and packaging scheduling system to identify the spindle packaging task. Complete the different packaging methods of DTY spindle. Through the upper computer management system to form output statistics, finished products into the warehouse and other valuable data flow.
4) Complete the automatic delivery of packaged DTY finished products to the intelligent three-dimensional warehouse, 数字化转型网szhzxw.cn
And connect with the company’s internal storage management system WMS information, automatic delivery and loading according to sales orders. Complete automatic delivery of packaged POY finished products to intelligent three-dimensional warehouse. And connect with the company’s internal storage management system WMS information, automatic delivery and loading according to sales orders.
Construction Scheme
1) Construction content
This project is based on Hengyi Group’s chemical fiber industry Internet platform for intelligent transformation and upgrading, effectively integrated on the chemical fiber industry Internet platform, and linked to intelligent equipment, including intelligent drum packaging logistics system, intelligent external inspection system, automatic silk loading and unloading and automatic paper tube loading system, intelligent three-dimensional library and other equipment, to realize the whole process of intelligent logistics and product process traceability; At the marketing end, the supply chain integration application of the chemical fiber industrial Internet platform is applied to realize the integrated management of the whole supply chain from the shopping mall placing orders, marketing order management, intelligent warehousing and sorting, intelligent park logistics and logistics distribution. After the implementation of the project, we will upgrade the production, testing, logistics, transportation and sales of 1.5 million tons of intelligent environmental functional fibers in the supporting plant.
2) Overall architecture数字化转型网szhzxw.cn
Focusing on the whole life cycle management of chemical fiber. The group builds an industrial Internet platform based on the characteristics of the chemical fiber industry. Formulate relevant standards and carry out application promotion for the four-tier structure (edge layer, PaaS, IaaS, SaaS) of the industrial Internet platform built according to scene requirements. Platform services are provided for production optimization, coal optimization, intelligent production, quality optimization and resource integration, and various innovation modes are formed.
3) Business framework数字化转型网szhzxw.cn
According to the overall framework of the chemical fiber industrial Internet platform. The functional business framework is mainly constructed from three dimensions: product life cycle management, system-level application and intelligent function. Promote the application of intelligent plate cleaning robot, automatic intelligent spinning thread, automatic intelligent packaging line, automatic intelligent loading robot, artificial intelligent-based product appearance inspection, intelligent three-dimensional library and other intelligent equipment, and the mass process data formed by intelligent equipment in the effective integration of MES and ERP, forming intelligent equipment and industrial Internet as the basis. Combined with the rapid response of customer hierarchical management, customer credit system, finance, logistics and information and things cooperation platform, the industrial big data can connect the upstream and downstream of the industrial chain, optimize the quality, dig the value of the industrial chain, reduce the cost, and improve the service value.
In the whole life cycle management dimension, the research and development system is established to realize the real-time analysis and process optimization system of polyester and spinning production process data on the cloud;
Informationization is fully integrated, and ERP and MES systems are fully built. Which can improve production efficiency and quality by monitoring the entire production process and automatically warning or correcting anomalies in production. Intelligent logistics has been fully completed, and TMS, vehicle management system and logistics system have been realized. Establish intelligent sales system, establish business intelligence AI, real-time market perception, sales big data analysis, personalized marketing and other functions. Services are fully app-based.
At the system level, it has realized intelligent plate cleaning robot, product appearance inspection based on deep learning of big data, automatic intelligent spinning thread, automatic intelligent packaging line, intelligent three-dimensional library and automatic spindle conveying line. Through data collection of the whole process, big data analysis and decision-making are carried out to drive business operation.
In terms of intelligent functions, it has been able to provide optimization schemes for energy consumption and capacity scheduling and optimize energy operation mode based on the collection and storage of energy data information. Single ingot data stream as the main line, the formation of data integration system. It can realize the integration between enterprises based on the cloud platform. Upstream and downstream quality data interworking, through the industrial chain quality data. The application of 5G new technology. Enterprise database network integration and application (cloud database).
4) Data center数字化转型网szhzxw.cn
The data center includes two aspects, one is the technical capability of data. The other is the technical capability of data assets. The data center is responsible for the collection, processing, service application and other work of all business data. Which is an integration of multiple technologies. The data center is not only a collection of data. And the processed data is no longer giddily like a spider web. The core content is extracted from the massive data of each business line and business domain. And the behavior tree of each object under the constant and free full link is restored through the assembly under certain business logic. Which can be flexibly used and rapidly expanded.
The idea of data center is to enable the whole business of Hengyi Group to share the same set of data technology and assets. The data source of data center is from each business system, which provides powerful algorithms. Data and technical support for the business system of Hengyi Group. Under the system of data center. All kinds of business data that can be continuously expanded and incorporated into the business domain will be connected to the middle desk system in a unified way. And then feed back to the business through unified data technology services. Data comes from the business, feeds back to the business, and repeats, containing more energy. Forming a data ecology, thus derived infinite possibilities.数字化转型网szhzxw.cn
5) Information security
In the aspect of security operation, the concept of “1 +3” is put forward, that is. The core goal of “ensuring user data security” is realized through three security means of “integrating security into design. Automatic monitoring and response, red and blue confrontation and continuous improvement”. With the strong operation control of “1 +3”, close to 100% of internal vulnerabilities and risks are detected. And the tracking control ability is fully covering all services.
Benefit analysis
Since the application of the automation and digital key technologies of the system. The traditional production process of our company has changed. Through the integration of information technology, lean management and flexible production have been realized. Which has reduced operating costs, improved production efficiency and enhanced product image. It is estimated that the operating costs can be reduced by more than 30 million yuan/year. At the same time, reduce product degradation caused by human factors, improve the rate of excellent products. And is expected to reduce the quality loss of nearly 10 million yuan/year. Total direct economic benefits of more than 40 million yuan/year.数字化转型网szhzxw.cn
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