How to manage equipment in lean digital intelligent factories
With the development of the times, the concept of Industry 4.0 and the introduction of the action plan "Made in China 2025" for the first decade of China's implementation of the strategy of building a strong manufacturing country, the traditional work mode in the industrial field has been greatly challenged, especially in ensuring profitability and long-term survival. Owners in industries such as chemical, power, transportation, and manufacturing are facing unprecedented challenges.
To achieve safe, sustainable production, operation, maintenance, and management of digital intelligent factories at low cost, it is necessary to quickly obtain basic data that is consistent with the actual state of the factory. Establishing a lean digital intelligent factory is the best way to achieve this goal. Lean digital intelligent factory is an information management platform based on data; It is a data warehouse with factory equipment basic data as its core. It is not only a platform for data integration, but also a port for information browsing and a tool for project data transfer, providing complete, accurate, and reliable basic data for the daily operation, maintenance, expansion, and repair projects of factories.
Through information lifecycle management, factory data can be continuously updated, maintained, and reused. The intelligence of basic data is an innovation in management that can improve the efficiency and management level of factories.
The technological roadmap of digital intelligent factory
The core is to achieve the digitization and intelligence of enterprise assets, and the core assets of asset intensive enterprises are equipment (devices). The application of 3D visualization dynamic equipment management is to use 3D simulation and virtual reality technology to construct industry realistic 3D simulation reality scenes based on the factory platform. Organically combine the 3D model of enterprise assets with information attributes (industry data, audio, video, and other streaming media). By adopting network-based information processing technology, the integrated monitoring and management of asset operation monitoring, operation and control, comprehensive information analysis and intelligent alarm, operation management, and auxiliary applications (maintenance, security, and environmental monitoring) have been achieved, greatly improving the enterprise's asset operation capability.
The 3D visualization dynamic equipment management platform is based on X3D extensible 3D language and component technology, which converts 3D GIS, 3D CAD, BIM, 3D factory, and 3D simulation models from different software vendors into a unified X3D real-world simulation model. The X3D real-life simulation model continuously updates 3D data and expands different types of data information, including engineering data, asset data, process automation data, monitoring data, and information system data. It can uniformly display geographic, geological, building facilities, equipment assets, automation, monitoring, surveillance, and other extended information in the space of real-life simulation to generate higher-level operational control and collaborative management.
2. Visualize the panoramic layout of enterprise assets
The 3D visualization dynamic equipment management platform provides geometric modeling of the terrain, buildings, workshop structures, facilities, and equipment of enterprise intelligent factories. It intuitively, realistically, and accurately displays the organizational relationships of various facilities, equipment shapes, and production processes, as well as the distribution and topology of facilities and equipment. Enable users to browse the entire enterprise site on their computer, as if they were physically present. At the same time, the system binds the device model with real-time, archive and other basic data to achieve rapid positioning and basic information query of equipment in 3D scenes.
3. Visual installation management
三维可视化动态设备管理平台可以对在建工程、设备安装等进行三维建模，并把三维场景与计划、实际进度时间结合，用不同颜色表现每一阶段的安装建设过程。
4.可视化设备台账管理
三维可视化动态设备管理平台建立设备台账及资产数据库，并和三维设备绑定，实现设备台账的可视化及模型和属性数据的互查、双向检索定位，从而实现三维可视化的资产管理，使用户能够快速找到相应的设备，以及查看设备对应的现场位置、所处环境、关联设备、设备参数等真实情况。
5.可视化巡检管理
三维可视化动态设备管理平台采用GPRS+PDA+RFID 技术方案，巡检任务从制定、分配、下发、接收、执行、考核等全部工作都可以远程控制、无线实时同步，从而实现巡检过程可视化、简捷化、规范化、智能化管理,使用户及时发现设施缺陷和各种安全隐患。按照巡检工作的程序，动态地收集和管理相应的数据，强化巡检计划的监控力度，提升巡检工作的管理水平。监控人员通过实时监控功能，可以掌握当前所有巡检员的状态，并可以选择任意一个在线巡检员查看实时位置和巡检信息。可以查看任意一天或一段时间任一巡线员的历史轨迹，并可动态回放历史轨迹。
6.可视化智能维护管理
三维可视化动态设备管理平台可以对企业重点设备进行在线信息采集、报警、控制等管理。
6.1采集与监控：对重点设备的温度、湿度、转速、振动、开关等实时信息进行采集和分析，当工作条件出现异常时，可及时显示、报警。
6.2异常报警处理：一种是事故报警，包括非操作引起的断路器跳闸和保护装置动作信号；另一种是普通报警，包括一般设备状态变化、遥信状态异常信号、模拟量越复限、节点或链路状态、遥控操作、保护操作、电压合格率、VQC功能、小电流接地选线等功能中的报警。系统能够对各类报警进行分类管理，自动推出报警提示及定位到三维场景相应的设备上，同时伴随着不同音响警报，并支持向指定人员手机发送报警信息，使用户及时捕获到运行风险或潜在风险。同时可通过三维动态方式指导过程处理。
6.3远程控制：可实现远程控制设备的启停、调整等，同时能在环境非正常的情况下自动或远程人为地控制各种环境调节设备（如空调、通风设备等），使工作环境恢复正常。
7.结束语
总而言之，借助数字化智能工厂平台，快速地搭建TnPM三维可视化动态设备管理应用，可显著降低资本支出和运营支出，减少因非计划停运造成的收入损失，实现数字化智能安全运营。在工厂整个生命周期内的关键工作流程中，用户大大受益于动态基础数据和其它信息系统的协作功能。数字化智能工厂的建立和应用可以提高工厂运营和维修的效率，提高工厂整体的管理水平，并在智能工厂的生命周期内为工厂节省大量的费用和资源。
消息来源/天津爱波瑞technology发展有限公司
