Research And Practice On The Construction Of Smart Factories In Steel And Metallurgical Enterprises Based On Digital Twin

Currently,the manufacturing industry is increasingly becoming the focus of global economic development,and the industrialization path of high production capacity,high speed,high consumption,and high pollution is no longer sustainable.Iron and steel metallurgy includes discrete production stages and continuous production stages,belonging to a mixed metallurgical industry dominated by continuous type,with a wide variety of raw material sources,complex processes,long processes,harsh working conditions and high safety risks.Researching the application of Digital Twin to the field of intelligent steel manufacturing,establishing an intelligent digital factory,and achieving real-time monitoring and precise control of production processes,scheduling optimization of energy and material flows,and full life cycle management of equipment and products through high-fidelity mapping of industrial entity processes in the information space,as well as real-time interaction between Digital Twin virtual representations and physical entities,to improve the production quality and efficiency of the entire steel industry,ensure the safe and stable operation of the entire production process,and transform and upgrade from traditional manufacturing to intelligent manufacturing and green manufacturing is an inevitable trend of today’s era.This paper views the whole intelligent factory system as a living intelligent complex large system.Firstly,aiming at an old long steel and metallurgical enterprise with a large aged amount of inventory information systems,it studies and proposes an appropriate "OCE" type octopus intelligent factory system architecture and physical layout for lage-scale remote intelligent operation management and centralized control by hierarchical intelligent control theory,to solve the skeleton construction problem;Secondly,the research is carried out in accordance with Digit Twin three major construction processes of the Data Phase,Modeling Phase,and Service Phase of the digital twins in the steel and metallurgical industry:(1)Data Phase.Research large-scale,highly concurrent,multi-source,heterogeneous production data integration in the production process of the steel and metallurgical industry,support the aggregation and flow of data,and solve the neural smooth problem of information transmission.(2)Modeling Phase.The Physical Model,Knowledge Model,and Data Model,which are crucial to the modeling of Digital Twins,have been studied and practiced with the example of building a geometric digital information foundation for the entire plant,optimizing the full cost batching of pre-ironmaking,and intelligent transportation and logistics tracking of steel billets throughout the entire process based on machine vision.(3)Service Phase.Based on the above research,this paper introduces the practice of Digital Twin service phase of operation management center "O" by taking metallurgical major safety risk supervision and production scheduling management as examples;Introduces the practice of the Digital Twin service phase of the four control centers "C",namely,iron making,steel making,rolling steel,energy environmental and public auxiliary,with operational navigation,regional navigation,and factory navigation;Introduces the practice of the Digital Twin service phase of on-site human-machine collaboration "E" by taking long steel robot demonstration plant line as example,and evaluates and verifies the overall construction effect of intelligent factories using the Centralized Index and Unmanned Index.After nearly two years of research and practice,the Digital Twin oriented intelligent plant construction project for iron and steel metallurgical enterprises has achieved the expected design goals for various functions of the system.The Concentration Index increased from 39.79% before construction to 76.96%,and the Unmanned Index increased from 34.51% before construction to 58.13%.This not only significantly improved the production efficiency of the enterprise,but also freed employees from a large number of 3D(Dirty,Difficult,Dangerous)positions,reducing safety risks and improving the work environment of employees,This research practice has helped the case project achieve good economic benefits and social demonstration benefits for the construction of intelligent factories in the steel and metallurgical industry,and has conducted beneficial exploration for the construction of intelligent factories in the steel and metallurgical industry.