As we all know, manufacturing is the mainstay of the national economy, and it is the foundation of the country, the instrument of rejuvenating the country, and the foundation of a strong country. Intelligent manufacturing is born with the support of manufacturing. However, compared with the world's advanced level, China's manufacturing industry is still large but not strong, subdivided into process industries, petrochemical and other factories in terms of independent innovation capability, resource utilization efficiency, industrial structure level, information level, quality and efficiency, etc. Obviously, the task of transformation and upgrading and leapfrogging development is urgent and arduous. Further transformation and upgrading, for the process industry, intelligent factories are the only way to achieve "smart manufacturing."
01 The concept and significance of intelligent manufacturingAccording to the definition in the "Notice on Printing and Distributing Intelligent Manufacturing Development Plan (2016-2020)" (Ministry of Industry and Information Technology [2016] No. 349): Intelligent manufacturing is based on the deep integration of new generation information communication technology and advanced manufacturing technology. In the various aspects of manufacturing activities such as design, production, management, and service, it has new production methods such as self-awareness, self-learning, self-decision, self-execution, and self-adaptation.
Intelligent manufacturing system architecture
Accelerating the development of intelligent manufacturing is the only way to cultivate the new kinetic energy of China's economic growth. It is a strategic choice to seize the commanding heights of the future economy and science and technology development. It will promote the structural reform of China's manufacturing supply side, create a new competitive advantage for China's manufacturing industry, and realize a manufacturing power. Important strategic significance.
02 National background and policy proposed by intelligent manufacturingOn October 10, 2014, Premier Li Keqiang and the German Chancellor Merkel jointly issued the "China-Germany Cooperation Action Plan" during his visit to Germany, highlighting the joint efforts of the two sides in the manufacturing industry on the "Industry 4.0" plan. Cooperation between the two countries in the fields of mobile Internet, Internet of Things, cloud computing, and big data.
Premier Li Keqiang and German Chancellor Merkel
Jointly published the "China-Germany Cooperation Action Plan"
Drawing on the German Industry 4.0 plan, China quickly formulated the "Made in China 2025" plan in 2015. Along with the aging society, the labor force is reduced, the resources are scarce, the energy efficiency still needs to be improved, the consumer demand, and the objective market such as differentiated and personalized production is problematic. China's manufacturing industry is also in urgent need of transformation. It is planned to be in 2025. The manufacturing industry has completed the upgrade and transformation.
We will comprehensively improve the level of enterprise application informatization, promote the in-depth integration of informatization and industrialization, promote industrial transformation from large to strong, and substantially improve the overall quality of manufacturing industry. The labor productivity of all employees will be significantly improved, and the energy consumption, material consumption and pollutant emissions per unit of industrial added value will be significantly decline. This is a strategic road for enterprise efficiency improvement and environmental eco-friendliness.
03 Relevant industry policies between international powersThe major international countries that are fiercely competing with China's national strategy and policies have also formulated and implemented a series of national policies in the manufacturing industry. Among them, German Industry 4.0 and the US Industrial Internet are the most outstanding advanced technology concepts.
in Germany. Industry 4.0, initiated by the German government and promoted worldwide, hopes to reshape its global leading position in the industrial field, support the research and development and innovation of a new generation of revolutionary technologies in the industrial field, and solve the positive response strategies for issues such as aging. Maintaining Germany's international competitiveness. At this level, Germany's own Industry 4.0 plan is very focused on using the information industry to intelligentize and virtualize its original advanced industrial model, attaching importance to smart factories and smart production, using interconnected technologies and highly integrated, making the factory Each production module is intelligent, turning the factory into a smart factory with a self-disciplined system. A number of industrial 4.0 companies such as SAP, SIEMENS, Schneider, BOSCH and KUKA have emerged.
German Industry 4.0
In the U.S. The US government launched the "America Competitiveness Plan", in which the "National Strategic Plan for Advanced Manufacturing" is its focus. The concept of "Industrial Internet" was first proposed by General Electric Company (GE), and then joined with four other IT giants. (Intel, Cisco, AT&T, IBM) formed the Industrial Internet Alliance (IIC) to promote this concept. The main meaning of "Industrial Internet" is that in the real world, machines, equipment and networks can be connected to the big data and analysis of the information world at a deeper level, driving the two revolutionary changes of the industrial revolution and the network revolution. Building a collaborative ecosystem that leverages industrial and public infrastructure to support business transformation and social collaboration based on unified architecture, interoperability and open standards, enabling secure connectivity, control and integration between devices and people, processes and data. Thereby accelerating the growth of the industrial Internet of Things.
Other developed countries such as South Korea's "Manufacturing Innovation 3.0 Strategy", Japan's "Social 5.0", and the British "British Industry 2050 Strategy" are considering the upgrading of their own manufacturing industry, which is similar to China's "Made in China 2025". .
04 Two-in-one integration is the only wayThe integration of the two technologies is a high-level combination of informationization and industrialization. It refers to the use of information technology to promote industrialization, industrialization to promote informationization, and take a new road to industrialization. The core of integration is the support of information and the pursuit of sustainable development.
The integration of two technologies means that electronic information technology is widely applied to all aspects of industrial production, and informationization has become a routine means of industrial enterprise management. The process of informatization and the process of industrialization are no longer independent of each other. They are no longer unilaterally promoting and promoting relations, but the two are intermingled at the various levels of technology, products, and management, and are inseparable from each other, and promote industrial electronics and industrial software. New industries such as industrial information services. The integration of two technologies is an inevitable outcome of the development of industrialization and informationization to a certain stage.
Starting from the integration of two
Realize "China Edition" Industry 4.0 (Made in China 2025)
At present, the intelligent factory construction in the process industry can be carried out from four aspects: technology integration, product integration, business integration and industry derivative:
1 Technology integration: the integration of industrial technology and information technology, generate new technologies, and promote technological innovation, such as MES launching and ERP system interface function expansion, industrial control network security protection products.
2 product integration: electronic information technology or products penetrate into the product, increase the technical content of the product, such as adding sensors to pumps, motors, large equipment, etc., can improve product self-diagnosis, remote maintenance and other functions.
3 Business integration: Information technology is applied to all aspects of enterprise R&D, manufacturing, operation management, marketing, etc., to promote business innovation and management upgrade. Such as enterprise flexible production, enterprise management and information transformation.
4 Industry Derivatives: New industries promoted by the integration of the two industries have formed some emerging formats, such as industrial electronics, industrial software, and industrial information services. Around the new market demand of users, the service scope of engineering companies and industrial-related software vendors will be expanded, and the work content will be further deepened and refined to meet the requirements of the owners.
05 Thoughts on the process industryFor the majority of process manufacturing enterprises, how to carry out the application point or perspective of "smart factory", personally think that we should focus on three national policy documents: "Intelligent Manufacturing Development Plan (2016-2020)", "Intelligent Manufacturing Engineering Implementation Guide" (2016-2020) and "Elements of the Intelligent Manufacturing Pilot Demonstration Project". According to the requirements, around the intelligent manufacturing model, apply new technological innovations and carry out intelligent manufacturing work. Mainly divided into the following seven aspects:
1) The overall design, process flow and layout of the factory have established digital models and simulations to realize production process data visualization and production process optimization.
2) Realize the whole process monitoring of logistics, energy flow, physical property and assets, establish a data acquisition and monitoring system, and the automatic data recovery rate of production process data reaches over 90%.
3) Adopt advanced control system, the factory self-control investment rate reaches more than 90%, and the key production links realize advanced model-based control and online optimization.
4) Establish production execution system (MES), establish models for production planning and scheduling, realize production model analysis and decision making, process quantitative management, cost and quality dynamic tracking, and integrated collaborative optimization from raw materials to finished products. Establish an Enterprise Resource Planning (ERP) system to achieve intelligent optimization of business operations, management, and decision making.
5) For projects with high safety and environmental risks, realize automatic detection and monitoring of toxic and hazardous substances and dangerous sources, and comprehensive monitoring of safety production, and establish an online emergency command linkage system.
6) Establish a factory communication network architecture to achieve process, production, inspection, logistics and other manufacturing processes, and between manufacturing processes and data acquisition and monitoring systems, production execution systems (MES), and enterprise resource planning systems (ERP) Information interconnection.
7) It has an industrial information security management system and technical protection system, and has the information security and security capabilities such as network protection and emergency response. A functional safety protection system is built, which uses a full life cycle method to effectively avoid system failure.
Only in the process plant, we continuously improve the dynamics of the production process, visualize the entire process of manufacturing and management information, and intelligentize the company in resource allocation, process optimization, process control, industrial chain management, energy saving and emission reduction, and safety production. The level of gradualization can be significantly improved gradually.
06 Process industry implementation measuresCompare the US "Advanced Manufacturing Partner Program", Germany "Industry 4.0", China's "Made in China 2025" in the process industry implementation measures (how to further realize the intelligent industry of the process industry).
6.1 Realize virtual construction and digital delivery to form a digital factory
The concept of digital delivery: based on the digital factory design system to carry out the project implementation, the 2D and 3D design data in the design process has realized the structural data integration and multi-professional coordination based on the number, and the document system matching with the digital factory design system The implementation of the tag-based non-structural data design document, the supplier document association, and the transfer of the design database to the owner as a whole. Finally, according to the owner's request, the database is handed over with the platform. Typical foreign solution vendors include AVEVA, INTERGRAPH, and BENTLEY. Domestic manufacturers include Zhongke Fulong and Beijing Bochao.
AVEVA Digital Engineering Information Management
On the one hand, all the documents and data submitted to the owner are in a unified database platform, and data association is performed, which can effectively retrieve information quickly; on the other hand, the completion of the 3D virtual factory is handed over to the owner, which is beneficial to the subsequent operation and maintenance stage. Deepen application (such as technical reform program analysis, equipment maintenance management, escape program simulation, inspection personnel monitoring, video fire monitoring platform, etc.)
Engineering company and owner response measures
For the owner, whether it is the new factory directly digital delivery, or the existing factory to implement reverse modeling data, is a good integrated solution of the two-dimensional data file integration, which is beneficial for users to get the full life cycle efficiently and quickly. The data, maintaining good continuity, is used for the operation and maintenance management of the later factories.
6.2 Strengthening and perfecting the process plant information system
In most of the current process plant architectures, major control systems such as BPCS and SIS are more popular, but other types of information management systems that need to be designed, added, and supplemented in the later technical reforms are needed to facilitate more plant operation and maintenance. Data to support data fusion and access to isolated data or functional systems in more plants.
From EMERSON Smart Factory Architecture
For the plant information system should be integrated from two aspects: 1 horizontal data integration. Expand the informatization of all business units, form online business of each enterprise, and improve the efficiency of business operations. 2 vertical data integration. The underlying data units are maximized and quickly published to management systems for business decision making and production operations.
Especially in addition to existing production control systems such as DCS, PLC, FCS, etc., further improve the expansion management information system MIS, advanced process control APC, enterprise resource planning ERP, supply chain management SCM, production execution system MES, operator training simulation system. OTS and other functional management information systems provide a good foundation for business intelligence and decision-making automation.
6.3 OT and IT technology integration, comprehensive steering to industrial IIot and CPS
The current process manufacturing industry employs OT (OperaTIonal Technology), which includes software and hardware technologies for monitoring or controlling various types of terminals, processes and events of the enterprise, including data acquisition and automatic control technologies. For the industrial control industry, more are control systems (DCS, PLC, SCADA, SIS, OPC, FCS, etc.) and measurement and control instruments (sensors and control valves such as temperature and pressure flow level analysis).
Virtual Factory Technology System Based on Cloud Computing
Information technology and automation technology are now integrated to support smart manufacturing. By realizing the integration of the IT network and the industrial control network, it is possible to feedback and control the state of the industrial robot, and demonstrate the application scenarios of intelligent manufacturing such as realizing business visualization, flexible production, ensuring that the production line is close to zero downtime and energy efficient utilization. Enterprises can organize production economically and flexibly, enhance decision-making and control levels, and achieve optimal production quality and maximum production efficiency.
The Industrial Internet of Things (IIoT) has promoted the convergence of IT and OT. As more and more things are connected, Information Physics Systems (CPS) will become a reality, and manufacturing companies and providers of services will have to innovate and deploy these new convergence technologies at an unprecedented rate. .
For the owners and engineering companies, it is more necessary to carry out the inventory transformation of the old factory, increase the number of sensors, improve the level of automation, and increase the automation control in the new plant, increase the data acquisition sensor. Integration of factory automation and information technology, such as plant control systems (Shop Floor Control; DCS), Manufacturing ExecuTIon System (MES), Monitoring and Integration Control (SCADA), etc. Integrate SCADA to achieve data connectivity and management at the plant level.
6.4 The overall IT structure of the factory is “cloudyâ€
In the process plant, a large amount of resources exist in distributed and isolated systems, such as the DCS system of the instrument control department, the back office comprehensive security system of the electrical department, the data center of the telecommunications department, and the factory management and office systems. In the cloud computing platform, All resources are virtualized and serviced. These resources are aggregated into a virtual resource pool, and resources are allocated and combined according to the needs of business applications to achieve flat management of resources. In particular, when a single machine needs to call a large amount of resources for arithmetic processing, it can quickly improve computing power and efficiency, and has better scalability and openness.
As a new service computing model, cloud computing manages and “clouds†resources through centralized storage and computing service centers, centralized storage, and unified scheduling, which can provide services for users efficiently. Establishing a private cloud for the owners of the process plant can not only achieve unified IT resource scheduling, avoid investment waste, but also play a very important role in improving the operational efficiency of the enterprise.
6.5 Strengthening Information Security Protection of Industrial Control Network
With the integration and advancement of smart factory-related technologies to manufacturing companies, information security will penetrate into various fields. The degree of influence is not based on the degree of informationization of the enterprise, but the degree of relevance to the core data. Since industrial safety is naturally the most basic prerequisite in industrial production, information security is a new problem formed after the production network, informationization and high integration automation. With the deepening of informatization, enterprises will encounter information security problems more or less, and as the value of data continues to increase, this impact will become more and more obvious for enterprises.
Attack from the Internet
Therefore, protecting the core data security of enterprises is the general direction of all enterprises in the future. In the face of different protection needs of different enterprises, there are also different considerations: 1 using flexible enterprise-specific encryption software for data source protection; The network firewall is used for data monitoring and auditing; 3) Establish an effective industrial control information security management system, and increase the awareness and capability of enterprise data security management.
Strengthen network information security protection
07 ConclusionThe road to China's manufacturing of 2025 is still very long. By the time of the 100th anniversary of the founding of the People's Republic of China, the country can achieve the strategic goal of manufacturing a strong country in accordance with the "three steps." As a process industry in the manufacturing industry, it is also an important industrial base. There are different ways of thinking and exploring in the process of serving the manufacturing enterprises in the process industry. As long as the data sharing and interconnection are realized, on the basis of the big data platform, the road of “smart factory†that has developed its own development characteristics can be perfected.
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