原标题：“大象”也在学跳舞
一、全球重工行业首个“灯塔工厂”三一桩机的数字化转型实践
与汽车、家电等行业知名厂商相比，三一重工北京桩机工厂（以下简称为三一桩机）似乎并不起眼，但主产的旋挖钻机高擎百米、重逾百吨，称得上“钢铁巨象”了。数字化转型网szhzxw.cn
旋挖钻机俗称打桩机，用于大型基建工程的桩基开孔。这些桩基深度往往决定建筑高度。数字化转型网szhzxw.cn
2年前，这家国内三分天下有其一的旋挖钻机制造商，依托物联网、大数据和人工智能技术赋能，跻身世界经济论坛全球灯塔网络，荣膺全球重工行业首个“灯塔工厂”。数字化转型网szhzxw.cn
三一桩机从规模生产到柔性制造，破解了重工行业品种多、批量小、工艺复杂等离散化制造难题，全员劳动生产率提高85%、生产周期缩短77%，年人均产值突破千万元。数字化转型网szhzxw.cn
“以柔克刚”的三一桩机，如何玩转这些“钢铁巨象”？“举重若轻”的变化背后，对制造业数字化转型有何启示？
二、“焊接大拿”的徒弟不是人
走进三一桩机厂区，昔日挥汗如雨、满身油污的工人不见了，取而代之的120余台焊接、抓取、组装和搬运等机器人，围绕16条智能化生产线各显神通：小到分拣一块钢板，大到装配16吨重的动力头，都能轻松自如完成。数数字化转型网szhzxw.cn字化转型网szhzxw.cn
人气冷清的焊接线上，几台配备自动焊枪的机器人，正在焊接一根20多米长、8吨重的钻杆：蓝色弧光追逐着红外线靶点和轨迹，夹杂着脉冲般吱吱作响的焊接声……数字化转型网szhzxw.cn
手握15年焊枪的赵清霞，是全厂有名的“焊接大拿”。他做梦也没想到，徒弟竟是一群机器人。自己会把焊接桩机方头的看家本领，都“传”给这些“没心没肺”的“钢铁小子”。
连接钻杆与钻斗的方头，是桩机的核心部件。方头焊接质量不好发生断裂，钻斗可能掉进地下几十甚至上百米深的孔洞里，轻则影响工程质量，重则需要重新设计打孔。
此前，全厂400多名焊工中，只有赵清霞和另一名高级技工能焊接方头。“如果他俩全不在，整个生产都得停！”制造管理经理胡展鹏入厂20年，对此仍记忆犹新。
他还向记者解释说，焊接方头跟绣花差不多，主要工艺难点就是用1.2mm焊丝，环绕40mm厚、60mm宽的焊缝反复施焊上几十层，还要确保每层都不出现气泡和裂痕。数字化转型网szhzxw.cn
“每个焊层温度不同，施焊速度和节奏掌握不好，质量就难以保证。”70后赵清霞说，当年师傅就是这么教的，他也按这个套路带徒弟。
然而，这些类似于厨师口中“盐少许、油少量”的经验，经常让新手们琢磨不透，没有一年半载出不了徒。数字化转型网szhzxw.cn
赵清霞干活都穿防护服，只露出一双眼睛。赶上大热天再捂也不敢开电风扇，生怕焊缝里吹出气泡。焊工是个体力活，经常一蹲就是几个小时，腰间盘突出都成了职业病。数字化转型网szhzxw.cn
“年轻人不愿意吃这个苦，”他操着浓重山东腔说，“可技术得往下传，这不机器人都成徒弟了。”
连人都难以掌握的经验，机器人怎么能听得懂呢？
“不是简单模仿工匠的焊接轨迹。”三一桩机总经理王龙刚揭开了机器人学艺秘密：“每一条焊缝背后，都有焊枪角度、摆幅、瞬时速度、电参、温度等大量工艺参数做支撑。”
这些“心中有数”的机器人，巧用AI算法学艺，仅两个月就学会方头焊接。技术水平就连赵清霞都服气：不光效率翻倍，一次成功率达100%，个个都成了“焊接大拿”。
以前焊接一根7节长的钻杆，6个人白加黑两班顶多焊一节；现在4个人操纵8台机器人，一个白班就能全焊完。数字化转型网szhzxw.cn
经过3个月的培训，年轻技工岳千喜已能像玩游戏一样，熟练操控焊接机器人，比传统焊工轻松不少。
赵清霞教会焊接机器人后，又走上给机器人下发指令的新岗位，师徒变成人机协同的新搭档。两年前，厂里要求新岗位掌握基础的机器人编程，赵清霞第一个报名参加培训班。
有工友冲他开玩笑：“都这么大年纪了，还报名学那玩意儿？不如回家抱孩子。”数字化转型网szhzxw.cn
“学到的东西归自己，谁都拿不走。”赵清霞回应道。数字化转型网szhzxw.cn
三、生产运行不再靠“人治”
在机加中心，28岁的操作工李田华遥控着磁力吸盘，将七八十斤重的提引器坯料，稳稳当当地吊运到料台上，由机械臂自动夹装到数控机床。一整套动作下来如行云流水。数字化转型网szhzxw.cn
据李田华介绍，提引器加工精度高，允许误差仅为头发丝直径的三分之一。由于担心坯料磕碰受损，过去搬运、上料和测量主要靠人工。工人们围着机械设备爬上爬下是常态。
如今，机械臂带摄像头，机床会自动测量，机器视觉的“慧眼”遍布全厂。李田华形象地拿切菜做比喻：就像近视眼配戴高清眼镜，拿菜的手和切菜的刀都更有准了。数字化转型网szhzxw.cn
从2003年加入三一桩机，制造部经理夏闻世最头疼的事，莫过于粗重的零部件与毫米级装配精度的磨合。直到三年前，零部件生产基本靠“人治”：每道工序都离不开人，一处不到位就得返工。赶上生产繁忙，整个过程就像打乱战。
研发桩机十多年的王龙刚认为，正是这种离散化制造模式，才使该厂成为2019年集团数字化转型首批试点。如果这块最硬的“骨头”都能啃下来，其他工厂就更有把握了。数字化转型网szhzxw.cn
工程机械行业周期性较强，导致企业用工弹性过大，产能调整跟不上市场变化。三一重工决策者深知，突破行业周期困局，唯有“要么翻身，要么翻船”的数字化背水一战。数字化转型网szhzxw.cn
作为三一桩机工业互联网平台服务商，树根互联有限公司市场总经理修斌坦言，让工厂的大量“聋哑设备”学会“说话”，听从“指令”，是传统制造业启动数字化的基础。
三一重工智能制造研究院院长董明楷，把这个过程梳理为“三现四表互联”。即通过摄像头管理现场、现实、现物，采集水、电、气、油表等能耗数据，实现设备互联互通。
“要把设备连起来，结合不同的工艺和业务要求，才能把数据用好。”这位曾在西门子工业研究院工作多年的数字化专家，深谙工业软件与生产制造的融合之道。
起初，每项工艺只能采集到30多种数据。现在平均每项超过100多种。他们运用数据分类和挖掘技术搭建知识库，使三一桩机实现从刚到柔的转变。
三一桩机的数字工程师和工艺工程师利用这些数据，逐一调试、标定，建立生产知识库，让机器人得心应手地识别和处理不同尺寸的零件。
全厂每台设备的工况、每个订单的进度，包括每位工人的绩效、工厂后台的“智慧大脑”都了如指掌。5G信号打通了信息共享的“经脉”，能根据工厂实时运转情况，把订单分解到不同的产线上。
桩机物料大多都超长超重，一旦搬运时碰伤报废，损失动辄上万元。智慧物流成为数字化难点之一。数字化转型网szhzxw.cn
据王龙刚透露，他们对5G自动导引运输车采取双车联动，实现大宗物料同步搬运和自动上下料。为了提高智能化水平，下一步重点攻关运输路线的实时显示和算法优化。
装配线上的机械臂，个个都长了一双“慧眼”：借助视觉传感技术和AI算法，能快速识别、抓取和装配不同型号的工件。装配精度达到0.2mm以内，仅有两张A4纸厚。
董明楷回忆，在设备上安装高清摄像头，位置放低了生产场景拍不全，高了图片分辨率不达标。再加上机械振动、光线反射等噪声干扰，要反复调试才能选准数据采集点。
通过不断摸索，团队决定采取先拍照再修正的办法：利用图像模式识别、2D/3D视觉定位技术，精准识别工件种类和位姿，并由“智慧大脑”指导机械手平稳作业。
三一桩机数字化试点改造期间，正赶上产能从每月150台上升到200台的爬坡阶段。一直担心产量受影响的夏闻世却意外发现，产值比原来翻了一番，用工还不到过去的一半。数字化转型网szhzxw.cn
夏闻世清楚地记得，自己进厂那会儿，每月下线桩机10台左右，也就是现在一天的产量。
四、数字化不能一味做加法数字化转型网szhzxw.cn
直到今天，仍有人把制造业数字化转型，简单理解成“机器换人”，认为最理想状态就是“黑灯工厂”。
三一桩机也曾算过一笔账：假设购买一台60万元的设备，可替换两位人均年收入15万元的工人，两年就能回本。据此，他们提出3年收回3亿元数字化投资的目标。
随着数字化试点的推进，越来越多的人开始意识到，若完全为了机器换人而换人，既不可行也没有必要。
部件工艺所副所长尹言虎反映，对于一些特殊角度的焊缝，焊接机器人实在无能为力，只能依靠人工。
董明楷估计，三一桩机除了下料、成型等环节接近无人化，而焊接、机加、涂装、装配、物流等环节的数字化程度仅六成以上。
三年前从车企跳槽过来的智能制造所所长张雯，本想把车厂的数字化经验移植到桩机上，却遭遇了“水土不服”。
与品种多、批量小的桩机生产不同，汽车制造属于规模化生产，无需频繁转换工艺设备，计划可以直接指导生产。
“同样精确到分钟的桩机排产计划，由于不同机型生产差别过大而经常落空。”张雯深有感触地说。
三一桩机现有38种标准机型，小的挖深二三十米，大的挖深达150米。不少订单还是客户根据施工场景定制的非标型号，一年也生产不了几台。
董明楷也坦言，目前有近30种机型实现数字化生产，但对挖深超限的特殊机型，仍无法完全覆盖兼容。
显而易见，机器换人不仅存在“行不行”的技术问题，也有“值不值”的经济考量。
2021年，王龙刚接棒总经理后，一口气停掉了全厂近1/6的自动化设备，改为人机协同模式。数字化转型网szhzxw.cn
他算过这样一笔账：一台自动螺栓机成本约200万元，能抵一位年收入10万的工人干20年。与其完全靠自动螺栓机，远不如用人操纵机械臂更为高效和经济。
王龙刚认为，数字化并不是没完没了地做加法，追求所谓的“大而全”和“高大上”没必要。现在做减法就是要回归到降本增效的企业根本目标上。
一直关注企业数字化转型案例的修斌，也反对盲目追捧一些热门概念。他曾见过一家企业为了追求“黑灯工厂”，要求员工在电脑屏幕前关灯工作的滑稽场面。
在王龙刚的眼里，未来三一桩机将实现自决策，自动制定生产计划、调度工人、管理生产要素，真正打通研发、营销和服务，实现产品全生命周期的数字化。
“以后企业更多利润来源于数据，包括基于数据的服务和创新。”王龙刚坚信数据才是企业的核心优势，将成为制造业弯道超车的机会。
三一桩机的数字化转型，印证了“灯塔工厂”的意义：人让机器变得更有效率，机器让人变得更有价值。 数字化转型网szhzxw.cn
翻译：
The Elephant is Learning to Dance数字化转型网szhzxw.cn
Global heavy industry’s first “lighthouse factory” Sany pile machine digital transformation practice
Compared with well-known manufacturers in automobile and household appliances industries, Beijing Piling Machine Factory of Sany Heavy Industry (hereinafter referred to as Sany Piling Machine) seems to be insignificant, but the main production of rotary drilling rig is 100 meters tall and weighs more than 100 tons, which is called “steel giant elephant”.
Rotary drilling rig commonly known as pile driver, used for large infrastructure projects of pile foundation opening. These pile depths often determine building height.
Two years ago, with the help of the Internet of Things, big data and artificial intelligence technology, this company, one of the three manufacturers of rotary drilling RIGS in China, joined the World Economic Forum’s global Lighthouse Network and was awarded the first “lighthouse factory” in the global heavy industry.数字化转型网szhzxw.cn
From large-scale production to flexible manufacturing, Sany pile machine has solved the difficult problems of discrete manufacturing in heavy industry, such as variety, small batch and complex process. The labor productivity of all employees has increased by 85%, the production cycle has been shortened by 77%, and the annual per capita output value has exceeded 10 million yuan.
How to play with the “steel giant elephant” of the Sany pile machine “with soft and tough”? What are the enlightenments for the digital transformation of manufacturing industry behind the change of “lifting the weight as if it were light”?
Welding Dana’s apprentice is not a person
Walking into the Sany Pile machine factory, the workers who used to sweat like rain and covered with oil disappeared. Instead, more than 120 robots such as welding, grasping, assembling and handling, etc. showed their unique abilities around 16 intelligent production lines: from sorting a steel plate to assembling a 16-ton power head, they could all be completed easily and freely.
On the popular welding line, several robots equipped with automatic welding guns are welding a 20-meter-long, 8-ton drill pipe: blue arcs of light chase infrared targets and tracks, mixed with a pulse of creaking welding sound…
Zhao Qingxia, who holds the welding gun for 15 years, is the famous “welding master” in the factory. He never dreamed that his apprentices turned out to be a group of robots. He will put the welding pile machine square skills, are “pass” to these “heartless” “steel boy”.数字化转型网szhzxw.cn
The square head connecting drill pipe and drill bucket is the core component of pile machine. If the welding quality of the square head is not good, it will fracture, and the drill bucket may fall into the underground holes dozens or even hundreds of meters deep, which will affect the quality of the project in light cases, and it will need to redesign the drilling.
Previously, only Zhao Qingxia and another senior technician could weld square ends among the more than 400 welders in the factory. “If they’re both gone, the whole production will stop!” Hu Zhanpeng, manager of manufacturing management, has been in the factory for 20 years and still remembers it.
He also explained to reporters that welding square head with embroidery
He also explained to reporters that welding square head with embroidery, the main process difficulty is to use 1.2mm wire, around 40mm thick, 60mm wide weld repeatedly welding dozens of layers, but also to ensure that each layer does not appear bubbles and cracks.
“The temperature of each welding layer is different, the welding speed and rhythm are not good, and the quality is difficult to guarantee.” Zhao Qingxia, who was born in the 1970s, said that the master taught him this way, and he also guided his apprentices according to this routine.
However, these “little salt, little oil” lessons, as chefs call them, often confuse the novice, who can’t get out for more than a year.数字化转型网szhzxw.cn
Zhao Qingxia works in protective clothing, showing only one pair of eyes. Catch up with hot days again cover also dare not open the fan, for fear of blowing bubbles in the weld. Welder is a physical work, often squatting for hours, lumbar disc protrusion has become an occupational disease.
“Young people don’t want to suffer from this,” he said in a thick Shandong accent. “But you have to pass on the skills. The robots have become apprentices.”
How can a robot understand an experience that is difficult for humans to master?
“It’s not just copying a craftsman’s welding track.” Wang Longgang, general manager of Sany pile Machine, revealed the secret of robot learning: “Behind every weld, there are welding gun Angle, swing, instantaneous speed, electrical parameters, temperature and a lot of other process parameters to support.”
These “knowing” robots learned how to weld square ends in just two months using AI algorithms. 数字化转型网szhzxw.cn
The technical level even Zhao Qingxia is convinced: not only doubled the efficiency, a success rate of 100%, all have become “welding master”.
Before welding a 7 section long drill pipe, 6 people white and black two shifts welding at most one section. Now four people operate eight robots, which can be welded in a single day shift.
After three months of training, Yue Qianxi, a young technician, is able to skillfully control welding robots like playing games, much easier than traditional welders.
After teaching welding robots, Zhao Qingxia took the new post of giving instructions to robots. And became a new partner of man-machine collaboration. Two years ago, Zhao was the first to sign up for a training class that required new positions to master basic robot programming.
One workmate joked to him: “At his age, to sign up for that? Might as well go home and hold the baby.”
“What you learn belongs to you. No one can take it away.” Zhao Qingxia responded.
Production operation no longer depends on “man rule”
In the machine processing center, Li Tianhua, a 28-year-old operator, remotely controls the magnetic sucker and lifts the blank of the lifter weighing 70 or 80 jin to the material platform. Where it is automatically clamped into the CNC machine tool by the mechanical arm. The whole thing flows like a stream.
According to Li Tianhua, the extractor has a high processing accuracy, allowing an error of only one third of the diameter of the hair. In the past, handling, feeding and measuring mainly relied on manual labor because of worries about billet damage. Workers climbing up and down machinery is the norm.
Now, the robot arm has a camera, the machine tool will automatically measure. And the “smart eye” of machine vision is all over the factory. Li uses the analogy of chopping vegetables in a vivid way: just as a nearsighted person wears high-definition glasses. The hands holding vegetables and the knife are more accurate.数字化转型网szhzxw.cn
Since joining Sany pile machine in 2003, Xia Wenshi, manager of manufacturing department, has been most troubled by the running-in of heavy parts and millimeter-level assembly accuracy. Until three years ago, the production of parts was largely a “human operation” :. Every process involved a human being, and a failure had to be reworked. Catch up with the busy production, the whole process is like disruption war.
Wang Longgang believes that it is precisely this discrete manufacturing mode that makes the factory become the first batch of pilots of the group’s digital transformation in 2019.
Wang Longgang, who has been researching and developing pile machines for more than 10 years, believes that it is precisely this discrete manufacturing mode that makes the factory become the first batch of pilots of the group’s digital transformation in 2019. If the hardest bone can be cracked, other factories will be more confident.
Construction machinery industry is more cyclical, leading to enterprise labor flexibility is too large. Capacity adjustment can not keep up with market changes. Decision makers of Sany Heavy Industry know that the only way to break through the industry cycle is to “turn over or turn over” the digital battle.
As a service provider of Sany Piling machine industrial Internet platform, Xiu Bin, general manager of Shugen Internet Co., LTD., said frankly that it is the foundation for traditional manufacturing industry to start digitization to let a large number of “deaf and mute equipment” in the factory learn to “speak” and follow “instructions”.
Dong Mingkai, director of intelligent manufacturing Research Institute of Sany Heavy Industry. Described the process as “three present and four table interconnection”. That is, cameras are used to manage the site, reality, and objects. And collect energy consumption data of water, electricity, gas, and oil meters to realize device interconnection.
“It takes connecting devices and combining different processes and business requirements to make good use of data.” The digital expert, who worked for Siemens Industrial Research Institute for many years. Knows how to integrate industrial software and manufacturing.
At first, only 30 kinds of data could be collected for each process.
Now the average is more than 100 each. They use data classification and mining technology to build knowledge base, so that Sany pile machine to achieve the transformation from rigid to soft.
The digital engineers and process engineers of Sany pile machine make use of these data to debug and calibrate one by one. And establish the production knowledge base, so that the robot can easily identify and deal with parts of different sizes.
The working condition of every equipment in the whole factory, the progress of every order. Including the performance of every worker, the “intelligent brain” in the back of the factory are well understood. The 5G signal opens up the “meridian” of information sharing and can split orders into different production lines based on the real-time operation of the factory.
Most materials of pile machine are over long and overweight. Once they are damaged and scrapped during handling, the loss will be tens of thousands of yuan. Intelligent logistics has become one of the difficulties in digitization.
According to Wang Longgang, they have adopted a two-vehicle linkage for 5G autonomous guided transport vehicles to realize synchronous handling of bulk materials and automatic loading and unloading. In order to improve the intelligence level. The next step focuses on the real-time display and algorithm optimization of transportation routes.数字化转型网szhzxw.cn
The robot arms on the assembly line have a pair of “smart eyes” :
using visual sensing technology and AI algorithms, they can quickly identify, grab and assemble different types of workpiece. The assembly accuracy is less than 0.2mm, and only two A4 sheets of paper are thick.
As Mr. Tung recalled, installing high-definition cameras on the device made it too low to capture all the production scenes and too high to reach the resolution standard. In addition to mechanical vibration, light reflection and other noise interference. It is necessary to repeatedly debug to select the correct data collection point.数字化转型网szhzxw.cn
Through constant exploration, the team decided to take photos first and then correct the method:. Using image pattern recognition, 2D/3D visual positioning technology, accurately identify the type and position of the workpiece. And the “intelligent brain” guided the smooth operation of the manipulator.
During the digital pilot transformation of Sany piling machine. It is catching up with the climbing stage from 150 units per month to 200 units. Xia Wenshi, who had been worried about the impact on output, unexpectedly found that output had doubled and the number of workers employed was less than half.
Xia Wenshi clearly remember, when he entered the factory. The monthly line pile machine about 10, is now a day’s output.
Digitization can’t just add up
Until now, some people still regard the digital transformation of manufacturing industry as simply “machine replacing man”. And believe that the optimal state is “black light factory”.
Sany piling Machine has also calculated an account: if you buy a 600,000 yuan equipment. You can replace two workers with an average annual income of 150,000 yuan. And you can pay back the cost in two years. Accordingly, they set a target of recovering 300 million yuan of digital investment in three years.
As digital experimentation continues, more and more people are realising that it is neither feasible nor necessary to replace people entirely for the sake of machines.
Yin Yanhu, deputy director of the Institute of Component Technology, said that for some welds with special angles, welding robots can do nothing but rely on manual labor.数字化转型网szhzxw.cn
Dong Minghai estimated that Sanyi piling machine is almost unmanned except for the feeding and forming links, while the digital degree of welding, machining, painting, assembly, logistics and other links is only more than 60%.
Zhang Wen, the director of the intelligent manufacturing Institute, who was transferred from an automobile company three years ago, wanted to transplant the digital experience of the automobile factory to the piling machine, but encountered “not suitable for the soil”.
Different from pile machine production with many varieties and small batches, automobile manufacturing belongs to large-scale production, without frequent conversion of process equipment, and planning can direct production.
“The production scheduling plan of pile machine, which is accurate to minutes, often falls through due to the huge difference in production of different models.” Zhang Wen said with deep feeling.
There are 38 standard types of Sany piling machine, small digging depth of 20 or 30 meters, big digging depth of 150 meters. Many orders are customers according to the construction scene customized non-standard models, a year can not produce a few.
Richard Tung also admitted that there are nearly 30 models of digital production, but it is still not fully compatible with the special models that dig deep beyond the limit.
Obviously, there is not only a technical question of whether the machine can be replaced, but also an economic question of whether it is worth it.
In 2021, after Wang Longgang took over as general manager, he stopped nearly 1/6 of the automation equipment in the whole factory and changed it into man-machine collaboration mode.
He calculated that an automatic bolt machine costs about 2 million yuan, which is enough for a worker with an annual income of 100,000 yuan to work for 20 years. Rather than completely rely on automatic bolt machine, it is far more efficient and economical to employ people to operate the mechanical arm.
According to Wang Longgang, digitization is not endless addition, and it is unnecessary to pursue the so-called “large and comprehensive” and “lofty”. Now do subtraction is to return to the enterprise’s fundamental goal of reducing costs and increasing efficiency.数字化转型网szhzxw.cn
Xiu Bin, who has been concerned about the digital transformation of enterprises, also opposes blindly pursuing some hot concepts. He once saw a farcical scene in which a company, in pursuit of a “black light factory”, required its employees to work with the lights off in front of a computer screen.
In Wang Longgang’s eyes, the future Sanyi piling machine will realize self-decision-making, automatic production planning, labor scheduling, management of production factors, really get through research and development, marketing and service, and realize the digitalization of the whole life cycle of products.
“More profits will come from data, including data-based services and innovation.” Wang Longgang firmly believes that data is the core advantage of the enterprise, will become the manufacturing industry curve overtaking opportunities.
The digital transformation of Sany Pile machine confirms the meaning of “lighthouse factory” : people make machines more efficient, and machines make people more valuable. 数字化转型网szhzxw.cn
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