Industrial Equipment Digital Industry Chain Upgrade Solution

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Overview

Based on its own cloud network edge end software-hardware integration, “lean + intelligent” professional services and other core competencies, the Inspur Industrial Internet, taking Guanxing Ceramics as the application scenario, has created a demonstration application case for upgrading the digital industrial chain of industrial equipment based on artificial intelligence, with the aid of the strengths of universities and research institutes including Xi’an University of Science and Technology, and State Key Laboratory of Aviation Precision Bearings.

Background Information

The manufacturing industry is an important pillar of the national economy, and industrial “dumb equipment” occupies an important position in manufacturing production. Due to the long-term operation of “dumb equipment” under complex and harsh working conditions, its failure is inevitable. Once a malfunction occurs, it can easily cause a shutdown, and in severe cases, it can lead to equipment damage and even safety accidents. Therefore, the State Council, the Ministry of Industry and Information Technology, and the Ministry of Science and Technology have all listed the health management of “dumb equipment” as one of the development directions of national intelligent manufacturing. Under the guidance of relevant policies, the manufacturing industry has gradually realized that the safe and reliable operation of “dumb equipment” is a key factor affecting its high-quality development.

Solutions

1.Develop intelligent sensors and intelligent diagnostic technology to solve the real-time perception and abnormal state recognition problems of 2826 industrial “dumb equipment”. Three hundred and ninety-four sensors have been deployed, sixty thousand one hundred and twenty diagnosis has been made, and six hundred and two failures are identified.

2. Innovate “industrial configuration+digital twin” technology and process optimization algorithms to simulate and intelligently control ceramic production equipment and processes, achieving a 10% increase in production efficiency.

3. Develop reliable collection and accounting technologies for carbon emission data to address issues related to monitoring and accounting of corporate carbon emissions. More than 20 high energy consuming devices, such as air compressors and firing kilns, are structurally adjusted and optimized to achieve energy savings of 19.5%, resulting in a calculated reduction of 4651.73 tons in carbon emissions.

Customer Benefits

1. In terms of cost reduction and efficiency improvement for enterprises and society, predictive maintenance of equipment has reduced the workload of inspection and maintenance personnel, realizing a 55% reduction in failure rate and a 40% reduction in equipment maintenance costs. The number of equipment maintenance personnel has decreased from 80 to 60, and the annual labor cost has decreased by 3 million.

2. In terms of promoting the formation of industrial clusters and driving the development of upstream and downstream industries, a "Inspur Cloud Warehouse" is established through resource integration to collect and supply industrial clusters. The procurement cost is reduced from 30 million yuan per year to 20 million yuan per year.

3. In terms of energy conservation and emission reduction, real-time monitoring, multi-dimensional analysis, and optimization of energy consumption were carried out to achieve energy savings of 19.5%, resulting in a calculated carbon emission reduction of 4651.73 tons.

4. In terms of high-quality development and inventory reduction, the inventory management efficiency is improved, warehouse inventory is reduced, and inventory costs are reduced by 35% through the predictive maintenance of supply chain platforms and equipment.

5. In terms of promoting production efficiency improvement, a 10% increase in production efficiency and an 8% increase in the first-time pass rate of the product quality have been achieved by optimizing ceramic production equipment and processes.