A digital twin factory behind a piece of paper
2024-04-17
After the raw materials entered the factory, the robot cut the packaging wire and used a robotic arm to lift 250 kilograms of wood pulp raw materials and put them into a pulp crusher. After the production line starts, personalized orders customized according to customer needs begin production. Pulping, copying, cutting, packaging... The entire process of paper production is unmanned, and each operation is converted into data, which is updated in real-time on the large screen of the intelligent control center. Once an abnormality occurs in a certain link, even if there is only a slight change in temperature and humidity, the model algorithm will issue a warning. This is a scene that the reporter saw in the "Digital Twin Factory Construction" scene built by Mudanjiang Hengfeng Paper Co., Ltd. (hereinafter referred to as Hengfeng Paper). Previously, this scene was selected for the list of excellent intelligent manufacturing scenes in 2023. Intelligent production lines assist enterprises in accelerating production transformation. Hengfeng Paper Industry is located in Mudanjiang City, Heilongjiang Province, China. It produces ten series of products including thin printing paper, household paper, and food packaging paper, with a comprehensive market share of one-third in the domestic market. It has more than 200 customers worldwide and covers five continents. "In 2001, Hengfeng Paper Industry began its informatization construction and has been continuously promoting the deep integration of manufacturing technology and information technology for more than 20 years. Through the application of new generation information technologies such as big data, Internet of Things, robots, visual inspection, artificial intelligence algorithms, and digital twins, our production capacity has increased nearly five times compared to the beginning of informatization construction, and personnel have decreased by a quarter." Xu Lu, Digital Director of Hengfeng Paper Industry, introduced. The PM16 production line is the pioneer machine in the construction of digital twin factories, which was the earliest to implement intelligent transformation and digital transformation. Through the intelligent placement project of finished products independently developed by the enterprise, the production line can automatically package and transmit, and connect with the bundling machine to achieve automatic bundling. In the temporary storage area, unmanned forklifts can carry out intelligent storage and transportation planning in three-dimensional space, achieving two-layer stacking. With the help of a quality management system, the production line can conduct real-time online inspections, achieving full traceability of quality in both forward and reverse directions. The staff introduced that the raw materials had arrived before, and the workers had to open the packaging and manually put the wood pulp board into the pulp crusher. Nowadays, in new scenarios, workshops have achieved full lifecycle intelligence in personnel, machines, materials, methods, and environmental production. With the gradual advancement of digitalization, humans have gradually shifted from looking at machines to looking at data. The reporter walked into the intelligent control center for "looking at data", which is like the "brain" of a company. In the workshop, the status of 21 production lines is displayed in digital form on the large screen, with real-time updates on pre production preparation, whether energy meets startup requirements, the latest lower roll data, and the current number of machines in storage. The healthy and stable operation of equipment is crucial for improving production efficiency and cost control in enterprises. In the construction scenario of digital twin factories, monitoring personnel do not need to conduct real-time inspections because the fault prediction and health management system can use sensors to collect and process critical data such as vibration and temperature of equipment, achieving real-time monitoring and early warning of equipment, and ensuring timely maintenance of equipment. Objective
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