Intelligent manufacturing of control valves "Industry 4.0" - Wuzhong Instrument Intelligent Factory

Digital Factory Outline

The use of CAD and PDM system, ERP and other related information systems have been appropriately popularized in many production factories at present, Wu Zhong has completed the "digital factory" skills and system after the key link of "how to make → process planning", closely following the digital auxiliary engineering of virtual prototype (VP) and virtual production (VM), providing a production process information channel, which can plan and plan the entire production process, imitate simulation and handling, and timely communicate the production information with relevant departments. Suppliers share the benefits, and then complete the virtual production and concurrent engineering to ensure the smooth progress of production.

The "Digital Factory" planning system completes the concurrent engineering of the main engine factory, production line suppliers, tooling and fixture suppliers, etc., while improving quality, reducing planning time, speeding up product development cycles, eliminating waste, and reducing the number of resources required to complete a certain task.

In addition to modeling and simulating the product development process, it is also necessary to simulate the reorganization and operation of the production system according to the changes in the product, so that the production system can understand the application performance of the system before it is put into operation, analyze its reliability, economy, quality, construction period, etc., and provide support for the optimization of the production process and network production.

The architecture of Wuzhong's digital intelligent factory covers three parts: from handling decision-making instructions, to making transaction instructions, and fulfilling control instructions, with a total of five levels: decision-making layer, application layer, transmission layer, perception layer and equipment layer, covering all aspects from enterprise management, project management, customer management, product production process management, production and processing management, assembly test to factory inspection.

Intelligent selection

Wu Zhong's appearance throws away the cumbersome and lengthy manual selection in the past and converts it to intelligent selection, which makes the efficient and accurate transformation from user needs to product needs. The new intelligent selection system of control valves is selected, and the ISO/IEC international standard accounting method is selected to meet the various needs of the active control system of the process industry for control valve products, so as to complete the quick and accurate selection.

The product has diversity and versatility, including control valves, ball valves, butterfly valves and eccentric rotary valves, etc., and supports the products of multiple suppliers, and has more than 30 million sets of common sense records, including products, specifications, equipment, data, selection rules and 889 commonly used chemical fluid physical properties library, etc., to support high-standard and high-precision selection and accounting of high-end valves under special working conditions, different valve cores and different fluid conditions, and can use B/S network architecture to complete cross-regional real-time selection.

The intelligent selection system of the control valve uses advanced image recognition skills to quickly import user needs, and selects unified and standardized selection rules for batch selection, so as to achieve fast, accurate and high-quality selection results. All accounting complies with the latest accounting specifications of international IEC control valves, combined with fluid dynamics, to form a unique set of control valve accounting theory. Integrate the professional visual accounting software LABVIEW to complete the rapid generation and invocation of the settlement method. The algorithm is transparent, which is convenient for third-party organizations to conduct certification and evaluation.

Instead of manual and expensive data entry, ABBYY FlexiCapture data collection and file processing solutions can also be actively scanned and identified, providing a full range of intelligent and accurate data extraction (ICR) for smart selection.

It can also be selected with one key, after the working conditions (at least 5 parameters) are entered, the intelligent selection is clicked with one click, and the system actively completes the accounting and selection, and the selection results include valves, matching performance organizations, matching accessories and data tables.

Digital workshop

As a pilot demonstration enterprise of intelligent production assessed by the Ministry of Industry and Information Technology, Wuzhong Appearance Company first built a digital factory of intelligent control valves, and selected the international leading three-dimensional visualization management system inside the factory, which completed the interconnection of people, machines and data, and constituted a real-time interaction between virtual and real production. As an overview of the production process, you can understand the stages of each project process. The end of digitalization is centered on quality cost and power efficiency, and based on data, covering five aspects: product data life cycle management, digital production process management, product life cycle quality management, product life cycle financial management, and personalized customization and service. It enables Wuzhong's appearance to complete the docking personalization, lean management, product planning and production integration, testing digitalization, intelligent production process management, intelligent logistics and operation and maintenance networking.

Product planning

Wu Zhong built an integrated digital processing scheme for 3D planning, analysis, verification, process, production, testing, equipment and service according to the project. Including product planning according to 3D, process planning according to 3D, analysis and application, full life cycle quality management, operation guidance, equipment technology, quality inspection, production and fulfillment, and digital management services. At the same time, the construction of an advanced and large-scale control valve professional digital test center provides a solid guarantee for enterprise scientific and technological research and development.

In terms of product planning, digitalization can be completed in three aspects: 3D planning, fluid analysis simulation verification, 3D process and equipment.

Smart Production

Many of the facilities in the factory are equipped with computer monitors. This digital production information service terminal will refine and differentiate the amount of work, production process, and required information that each worker and machine tool needs to complete every day, and it is suitable for a detailed recipe. Turn on the computer, the day's work is clear, and the workers only need to operate carefully according to the requirements. ”

Wuzhong's existing processing production line includes:

1) Automatic processing line, machining center, flexible production line and processing island

2) Meet the spraying needs of small and medium-caliber valves, and transport the spraying production line according to the suspension controlled by PLC

3) To meet the spraying needs of large-diameter valves, according to the PLC control of the guide chain spraying production line

Digital equipment station, digital pressure test equipment, digital adjustment equipment;

The advanced scheme scheduling and simulation system is applied to the production plan management, and the minute-level scheduling of a single small batch of personalized customized production operations is completed through ERP + APS + production process simulation + MES. MES machining monitors, monitors, manages, and reacts to the fulfillment process of advanced scheduling outputs. The MES equipment has been visualized 3D equipment technology + station kanban + assembly operation table, and the assembly station is digitally handled according to the order; After the research and development and application of digital pressure testing equipment, the digitalization of testing has been completed for the first time in the control valve industry; After the suspension and transportation system according to the RFID identification skills, and the assembly process of the intelligent control valve, the production line assembly of a single small batch of customized products was completed.

Smart warehousing

Wu Zhong upgraded the original intelligent three-dimensional warehouse to a high-parameter three-dimensional warehouse, established an automatic catering line and laser-guided AGV, and implemented more powerful monitoring, coordination and distribution for warehousing and distribution.

Complete the automation of logistics, based on the principle of pulling down the final assembly, pull the catering through the equipment daily operation plan, the catering drives the logistics, the logistics pulls the warehouse, and the linkage operation mode of the final assembly + catering + logistics + warehousing is completed.

Digital inspection

The new factory in Wuzhong has set up a flow detection and inspection platform integrating from small flow to large flow and high pressure, which can meet the current control valve testing needs of various parameters. Through the use of digital testing equipment, a three-in-one inspection system of self-inspection of production process station + process sampling + critical inspection is established.

1) Part scale inspection planning

The process department plans the inspection specifications of the parts scale. Including detection parts, scale requirements, testing tools, testing methods, etc.

Sampling during the production process:

Professional quality inspectors conduct quality sampling inspections on parts and components in different regions;

Ability to collect data (marking barcodes, barcode information, graphic images, scans, text).

The "Quality Inspection Mobile Desk" consists of an accounting machine, a scanner, a barcode collector, a label printer, a digital camera, a wireless communication, a battery pack, and a tool cabinet.

The application software of mobile inspection station equipment includes: procurement materials into the factory inspection, flow distribution process handling, product quality process control, equipment station information service, product delivery process handling.

For different valves, the critical scale is sent for inspection:

Improve the level of control of critical scales. Measurement data is integrated with MES.

Equipped with a temperature linear compensation system, the temperature of the 3 axes of the equipment and the workpiece is actively compensated.

The resolution of the measurement system ≤ 0.1 μm, and the repeatability ≤ 0.5 μm.

Workers measure a valve part, and after the data is entered, the measurement results will be displayed on the monitor in real time. According to the requirements, if the data reaches the standard after 3 tests, the computer will actively display that the product can enter the next production process, otherwise, it will be blocked from passing. Wu Zhong's appearance of the creation of information product self-inspection procedures are appropriate and intelligent.

2) Digital pressure testing machine

After the customized development of the integrated application of the pressure test system of the whole machine of the control valve and the MES, the active upload and final judgment of the pressure resistance and leakage test data and the online generation and delivery of the pressure test report of the whole machine were completed.

Process tracking and quality traceability

Wu Zhong uses two-dimensional code and radio frequency skills to complete the whole process of raw materials, semi-finished products, and finished the whole process of raw materials, semi-finished products, and finished the traceability of product quality.

Networked O&M

Wuzhong's appearance of the new factory in the factory operation and protection of the completion of the network, including personal operation area, leadership cockpit, equipment file handling, point inspection operation handling, maintenance operation handling, ticket handling, overhaul project handling, document approval, induction query, statistical analysis, hidden danger rectification, system management and mobile APP 13 functional modules, more than 100 business functions, can complete the cross-regional, process-based, dynamic management of various equipment of the user enterprise, with good functional transplantation and wide adaptability.

The abundant and diversified query functions in the system complete the real-time query and forward and reverse traceability of the system's underlying data and transaction data. The graphical statistics of a variety of data information have been completed, which is helpful for the decision-making analysis of the management layer.

With the equipment fault declaration (full declaration) and maintenance plan as the source, dynamically handle the information such as the processing process, processing methods and node progress of equipment faults, so that the data process is controlled, the transaction nodes are recorded, and the repair progress is monitored, which helps to speed up the handling of equipment problems. Moreover, after accumulation, we can gradually establish a common sense database for equipment fault handling, so that we can share and learn from it.

Valve point inspection specifications and plans, and each plan is associated with the corresponding valve, and the information management of point inspection task generation, program control, operation dispatch, data collection and statistical analysis and other affairs is completed.

The personal workspace is used to present all to-do transactions related to the logged-in user. Through the use of forward-looking mobile APP skills, the mobile version of the equipment management software has been developed, and some critical transaction functions are classified into the mobile terminal for user name use, which is not only convenient for users, but also shortens the transaction processing time.

Future outlook

According to Guo Wei, the director of Wuzhong's appearance informatization, in the future, Wuzhong's appearance will expand the functions of photography selection, long-distance monitoring and diagnosis, and help customers complete the "zero" inventory of spare parts.

Photography selection

The first step is to actively scan and identify the system according to Wu Zhong's appearance and text, extract the data from the user's mobile phone photos and other files, and export the data to the intelligent selection system to deal with the data entry problem; The second step is to finally complete the function of one-key selection through Wu Zhong's appearance intelligent selection system, and greatly improve the selection power.

After model selection, a lightweight 3D model is output to support users' 3D piping and other services.

Long-distance surveillance and diagnosis

In cooperation with Beijing University of Chemical Technology, relying on its dynamic equipment to monitor and confirm the channel, the long-distance monitoring and diagnosis module of the control valve was developed.

Scientific protection scheme: refer to the performance parameters of the equipment and its operation data, combined with the production status of the enterprise.

Through DCS, the equipment parameters and operation data are obtained in a read-only manner. On the premise of not interfering with the original control system and not affecting the safety of production, the equipment operation data is obtained.

According to the industrial Internet, with equipment and units as the organizational structure, the main equipment is monitored in real time, and the visualization of the whole equipment is completed in the form of plane flow chart and three-dimensional layout diagram, and all control valves and other equipment in the organizational structure are systematically analyzed

"Zero" stock of spare parts

The key point of improving the repair power of equipment and reducing the loss caused by faulty equipment is to deal with the supply of spare parts. In order to complete the user's "zero" inventory and ensure the long-term and stable operation of the user's equipment, we will build a control valve product operation database with users, build an operation service center, and build a control valve reserve for users.

Intelligent manufacturing of control valves "Industry 4.0" - Wuzhong Instrument Intelligent Factory

Intelligent manufacturing of control valves "Industry 4.0" - Wuzhong Instrument Intelligent Factory

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