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INTELLIGENT PRODUCTION LINE

Intelligent stockyard
Intelligent sintering
Intelligent coking
Intelligent iron making
Intelligent steel making
Smart bar and wire
Intelligent Seamless Pipe

Machine vision, network interconnection, data analysis, edge computing, blending model, laser radar modeling, 3D simulation and other tecnologies are used to complete automatic production scheduling, process optimization, intelligent blending and batching at raw material yards. Build data-driven visual digital-twin virtual raw material yards, use 5G technology to improve data transmission speed and stability and allow automatic raw material yard control, unmanned operation and intelligent management decision-making.

Control Automation

Unmanned Operation

Intelligent Management Decision-making

major function

Advanced planning and scheduling

Stacking 3D modeling and dynamic maintenance management

Palm Factory

Triple stack anti-collision

Intelligent mixing

Digital Twin Factory

Precise positioning and measurement

Unmanned stacker-reclaimer

economic performance

Work Efficiency Improvement Reduce manpower by about 60%

Neat and uniform material stacking Increase raw material yard utilization rate by more than 20%

Stabilize and mix mineral compositions Improving quality of mixed ore Ingredients error < 5%

Energy Saving Reduce energy consumption by about 10%

Based on process models, machine learning algorithms, a big data mining and analysis system with production, equipment, inspection, energy and environmental data as the core is built to provide digital and intelligent management over sintering process to allow intelligent sintering control, stable production and higher sintering quality and improve energy control efficiency.

Intelligent control

Stable production

Intelligent control efficiency

major function

Optimize batch calculation

Moisture control

Burning through point (BTP) control

Burning through point deviation control

Ignition control

Compositions forecast

Sintering machine tail thermal imaging

Sintering machine status identification

Intelligent optimization control over power generation using sintering waste heat

Production Effect

High quality and production

Stable raw material compositions

Stable burning through point position

Stable trolley section sintering speed

Stable mixing bunker charge level

Stable return ore bunker volume

Stable feed surface ignition effect

Lower cost

Refined batching

Automatic generation of the optimal ratio

Predictive maintenance

Key equipment for real-time machine vision monitoring

Early warning prior to fault

Complete on-site data transmission and analysis by combining IoT, machine vision technologies and on-site control. Change the situation of labor intensiveness in coking, heavy pollution and poor control using technologies such as artificial intelligence and data mining; promote "efficient, clean, low-carbon, cyclic and green" development of coking industry by improving energy utilization, energy saving and emission reduction and unmanned operation.

artificial intelligence

data mining

machine vision

Main Functions

Longitudinal temperature of coke oven Measuring robot:

Replace manual longitudinal temperature measurement and increase measurement frequency

Intelligent control system for coke oven heating:

Intelligent regulation of heating gas pressure, Reduce gas consumption by 1-4%

Intelligent coordination system for coke oven gas collector pressure:

Allow fully automatic control on the very day of production, completely eliminating smoke and fire

AI warning system for Coke Dry Quenching lifting:

Machine vision prevents unhooking, collision, red coke falling and increase recognition rate to ≥ 99.99%

Pushing ram and oven wall liner temperature measuring system:

Replace manual horizontal temperature measurement and improve heating uniformity in length and height directions. Protect oven body, improve post reaction strength of coke and effectively reduce standard temperature

Coke oven basement inspection robot:

Optimization system for coke dry quenching waste heat power generation:

Improve comprehensive efficiency of circulating fans, boilers and steam turbines; reduce self power consumption and increase net generation

Coal blending optimization system:

Improve coal blending efficiency and optimize coal blending costs

System Characteristics

Use robots in place of labors to complete inspections and measurements in harsh environments

Use AI and IoT technologies for on-site data transmission and analysis

Use expert control system to coordinate overall pipeline pressure and avoid smoke and fire

Use fuzzy control system to complete combustion control and achieve goals of energy-saving and emission reduction

Combine machine vision technology with on-site control to provide multiple guarantees for safe production

Technical Advantages

High system adaptability, allowing optimization upon completion and operation of the production line, with no need for long-time adaptation

Significant economic benefits, with about 1-4% energy consumption reduction after automatic heating

Avoid local overheating in coke oven and reduce emission, especially SO2 and NOx emission

Machine vision system recognition rate > 99.99%

Build an iron making data center using edge computing, visual analysis, superfusion and other technologies starting from core processes such as blast furnace body, feeding tracking, intelligent injection and blowing and hot-blast furnace and on the basis of industrial Internet. Develop intelligent cockpit system based on digital twinning technology and 3D modeling to allow visual and digital monitoring and control over key zones of blast furnace; allow intelligent diagnosis of equipment health and production data analysis and tracing through data analysis and integration; allow simulated production, intelligent control, intelligent decision-making and intelligent operation and maintenance in iron making through intelligent iron making module and expert model system so that stable and efficient output

Main Functions

Visual analysis of raw material particle size

Collect digital images from conveyor belt using digital image processing technology, carry out real-time calculation of particle size and analysis of distribution ofthe particles and identify material grain size and distribution to quickly provide accurate grain size information for blast furnace operators.

Radar feed surface detection

The system carries out furnace feed surface scanning and 3D modeling through mechanical scanning radar to provide reference for material distribution. Blast furnace operators adjust material distribution considering feed surface, influence gas flow distribution by changing distribution of furnace charge at furnace throat and feed surface shape so that positions and shapes of softening zones are changed, gas utilization is improved and stable and smooth operation and higher output and efficiency of blast furnace are achieved.

Automatic bunker searching and unloading by tripper car

Tripper car positioning, charge type tracking, charge level detection and fully automatic unloading are applied to allow intelligent materials management.

Analysis and Evaluation for In- telligent Hot-blast Furnace Bu- rning

Proportional extreme value adjustment method is used for intelligent analysis and evaluation of hot-blast furnace, and fuzzy thinking is applied to establish a mathematical model in sections to handle overshoot with high inertia and periodically correct fuel proportioning. Reduce excessive combustion air or gas so that hot-blast furnace is at optimal combustion state for the majority of the time.

ntelligent Slag Catch

Renovate cranes and conveyor belts and the functions and improve slag pool management system to allow unmanned operation and intelligent management of slag

ntelligent Injection and Blowing

Allow automatic safety interlock control during coal loading, stamping, injection and blowing, reladling and pressure relief, and high-precision ceramic regulating valves and algorithm models are used for coal powder injection stability control to allow stable furnace conditions and reducing coke ratio. Long-term stable coal injection rate error is less than ± 5%, resulting in increase in coal injection rate, coke usage reduction, production cost reduction and pollution reduction.

Blast Furnace Expert System

Integrate level-L2 functions such as water temperature differential heat load, hearth erosion, material distribution model, furnace type, hearth balance and hearth activity.

Economic Benefits

Gas consumption by intelligent hot-blast furnace burning system is reduced by 3% and average hot air temperature is increased by about 10°C.

Digital image processing technologies are used for analysis of raw material particle size and distribution in real-time to provide fast and accurate particle size information for blast furnace operators.

Long-term stable coal injection rate error of the intelligent injection and blowing system is less than ± 5%, resulting in increase in coal injection rate, coke usage reduction, production cost reduction and pollution reduction.

The system carries out furnace feed surface scanning and 3D modeling through mechanical scanning radar to provide reference for material distribution. Blast furnace operators adjust material distribution considering feed surface and influence gas flow distribution by changing distribution of furnace charge at furnace throat and feed surface shape so that positions and shapes of softening zones are changed, gas utilization is improved and stable and smooth operation and higher output and efficiency of blast furnace are achieved.

To allow intelligent "one-click steel making", Bestpower Intelcontrol uses independently developed converter tilting and zero-speed hovering, precise positioning of ladle cars, automatic rotating chute following, converter mouth slag level and steel flow image identification, dynamic steel tapping planning curve model and early safety warning model for steel tapping process to allow automatic "one-click steel tapping" and ensure stability, safety and efficiency during steel tapping and reduce labor intensity and reduce cost and increase efficiency for the enterprise.

Stable

Safe

Main Functions

Production Dispatching and Scheduling System

Provide automatic or manual production scheduling according to production plan received. Quickly determine the optimal production processes, paths and sch- edules for the processes in the steel making workshop.

Steel making logistics tracking system

Use advanced technologies such as wireless WiFi and RFID to complete overhead traveling crane positioning and tracking of ladle, molten iron and scrap steel ta- nk, scrap steel, steel ladle, molten steel and heat number.

Integrated Quality Management System

Accuracy of decision by quality model is effectively improved by collecting a large amount of quality related data, predicting and controlling quality of products from steel making workshop and optimizing parameters of quality decision models.

Automatic Steel Making System

Accurate control of molten steel compositions and temperature during smelting in converter, higher molten steel quality and lower production cost are achieved by building a converter smelting process model and utilizing big data analysis.

Automatic Tapping System

Independently developed converter tilting and zero-speed hovering, precise ladle car positioning, automatic rotating chute following, converter mouth slag lev- el and steel flow image identification and dynamic steel tapping models and other technologies are used to allow automatic steel tapping from converter, stable, safe and efficient steel tapping from converter, lower labor intensity and cost and higher efficiency.

Visual Recognition System

Real-time on-site images collected by industrial cameras and recognition processing technologies are used for automatic identification of labels to allow corres- pon dence of production process parameters to quality status and develop producthealth records, allow accurate tracking of products and ensure integrity of p- roduct file information and material flow.

Intelligent Energy Control

Provide factories complete intelligent transformation plan for energy instruments and instrument data collection plan to allow real-time data collection and ener- gy application process monitoring.

Centralized Steel Making Control Center

Technologies such as fault diagnosis, remote monitoring, video surveillance, automation, intelligent and unmanned operations are used to allow centralized cont- rol and unified management of operating rooms in steel making area and production information data sharing and interflow.

Tconomic Benefits

The visual recognition based "visual inspection system for slag level at converter mouth" independently developed by Bestpower Intercontrol has been included in the list of intelligent devices recommended by Intelligent Manufacturing Alliance for Steel Industry and is a key automatic steel tapping inspection technology.

In converter ladle car positioning, laser ranging technology and software redundancy algorithms are used for reliable and accurate positioning of ladle cars.

Application of converter tilting and zero-speed hovering technologies allows smooth operation during the automatic steel tapping from converter.

Economic Benefits

The 150t automatic converter tapping control system of Jingye Group allowed automatic feeding, unmanned operation at high position and interlock with subl- ance system within a week since going into operation, with automatic converter tapping accuracy up to 0.3, 24-minute smelting cycle and automatic oxygen lan- ce control accuracy within 5 mm.

On the basis of superfusion technology, artificial intelligence technology, Al visual analysis and big data analysis, applying multiple intelligent algorithms, "One-line & One-room" intelligent control system is developed, and digital and intelligent solutions that cover visual recognition systems, KPI statistical systems, quality management systems, status monitoring systems, energy management systems and rod and wire tracking systems are developed to allow visual production process, optimal process parameters, optimal product quality and controllable process costs.

Efficient

Safe

Green

Technical Advantages

Steel heaping inspection

Using with high-speed cameras and optimized algorithms, allow quick recognition of single-frame images, with recognition rate within 25 ms. From image collection to detection of steel-heaping prediction alarm signal and transmission to PLC, it takes less than 180 ms.

C-type hook number and tilt status recog- nition

Identify type-C hook number through visual recognition or RFID identification, and complete automatic tracking of wire coils in collection area through hook number identification. Apply edge detection, contour recognition and other technologies to determine presence of type-C hook tilting and reduce production accidents.

Status monitoring system

Provide multiple analysis tools to analyze rolling data, and provide warning against abnormalities during production to allow operators to know current production status and optimal equipment operation status.

3D digital twin

Realistically present on-site scenarios, synchronize data of basic automation, quality control system, status monitoring system and energy control system, monitor production anomalies and provide support for auxiliary operations.

Electronic labeling

The electronic labeling system based on mobile devices such as mobile phones and PADs allows maintainers to provide equipment maintenance information feedback, eliminate misoperations caused by human error and protect safety of personnel and equipment during equipment maintenance. Quantify workload of maintenance personnel and develop reasonable maintenance pian.

Quality Control

Create risk assessment model for quality influencing factors, explore variable control ranges, find optimal process parameters, conduct quality traceability analysis and assist process management personnel in improving quality and optimizing production processes.

Main Functions

Visualize production line operation and equipment status

Optimize process control parameters

Optimize energy management and analysis

Predict and trace equipment and quality anomalies

Zero interval rolling

Adaptive optimization of micro-tension loop

Laying head positioning

Through-water cooling model control

Intelligent control of flying shear optimization

Fully automatic control of cooling bed and collection area

3D digital twin

Steel heaping inspection

C-type hook number and tilt status recognition

Electronic labeling

Through the deep mining of the strip production process data, the hidden information of the production process is found, and the production trend is predicted in advance to prevent quality problems. It provides strong support for equipment maintenance, process monitoring, quality improvement, production process adjustment, etc. in the process of strip production.

Equipment

Process monitoring

Quality improvement

major function

Production process monitoring

Quality warning

Quality assessment and analysis

Control accuracy analysis

Defect distribution analysis

Defect correlation analysis

Plate type analysis

Production planning optimization

Shearing optimization

Data statistics analysis and report

LOGISTICS

Intelligent Warehouse and Unmanned Crane

Intelligent Rail Transportation System

Intelligent Warehouse and Unmanned Crane

Intelligent Rail Transportation System

Technologies such as AI recognition, anti-swing control, positioning system and 5G wireless transmission and 3D intelligent warehouse management system are used to allow intelligent warehouse dispatching and management and unmanned crane operation. Current situation of traditional cranes and warehousing relying on manual operation and command is changed to reduce labor costs, significantly improve warehousing and logistics efficiency, reduce material loss and allow unmanned, information-based and intelligent warehousing

AI identification

Anti-swing control

Positioning system

System Composition

Crane dispatching system

Intelligent warehouse management system

Intelligent expansion module

Automatic crane system

Ground management system

System Characteristics

Intelligent database management system is a 3D operating terminal with 1:1 live display

Intelligent warehouse management system applying modular design, with high scalability

Parameterized settings for device configuration and dispatching rules, allowing independent decisions by users

The system integrates functions such as intelligent algorithms, time path optimization, auto- matic obstacle avoidance, virtual two-layer saddle, multi-axis linkage

System interface optimization design, easy operation, high efficiency, easy use and maintenance

Economic Benefits

Increase storage area utilization by ≥ 25%

Reduce operators 4 persons/crane

Improve worke fficiency Reduce labor intensity Eliminate safety hazards

Achieve zero lifting loss Reduce internal friction in enterprises Reduce costs and increase efficiency

Use of information technology and intellectual technology in logistics management

Cases

To present, the intelligent warehouse management system of Bestpower Intercontrol has been used in 45 storage areas, and over 100 cranes have been renovated and put into use.

Intelligent rail transportation system utilizes technological and management innovations such as unmanned operation, intelligent dispatching, environmental perception, big data analysis, production simulation and intelligent equipment to connect the most closely correlated links between corporate logistics systems and production systems and achieve driverless operation, intelligent dispatching systems, digital production management and intelligent equipment operation and maintenance. Application of this system has solved problems such as transportation personnel aging, difficulty in recruitment and lagged informatization of production systems, bringing "green" economic benefits such as personnel reduction, efficiency increase, safe production, energy conservation and consumption reduction and has become a popular trend in corporate rail transportation systems development in the future.

Main Functions

Unmanned operation system

Intelligent dispatching system

Environmental awareness system

Big data analysis system

Intelligent O&M system

Production simulation system

Intelligent Equipment

5G+ vehicle-ground communication system

Key Technology

Precise vehicle control technology

Production simulation technology

Dynamic path planning technology

Industrial wireless communication technology

Fusion positioning technology

3D HMI technology

Environment perception technology

Intelligent equipment technology

Technical Advantages

Break barriers, allow information connection and 3D technology display

Online data management, real-time record transmission

Automatic update of vehicle status

Online equipment status monitoring, proactive push of maintenance information

Intelligent planning for dispatching, help production decision-making and management

EQUIPMENT

Intelligent perception products

intelligent robot

Anti-Sway System

Intelligent perception products

intelligent robot

Anti-Sway System

The Electronic Anti-Sway Control System of Bestpower eliminates the load swing during acceleration or deceleration of the crane, ensuring safe and efficient crane operations, and preventing damage to goods during transportation. With additional features such as record keeping, backup, 3D simulation environment, and IP67 industrial connectors, users are provided with a more intuitive and convenient production experience.

The Electronic Anti-Sway Control System is suitable for the following types of cranes:

Overhead Bridge Cranes (OHBC)
Rubber-Tyred Gantry Cranes
Rail-Mounted Gantry Cranes
Ship-to-Shore Container Cranes (STS)
Grab Ship Unloaders Cranes (GSU)
Slewing Cranes (as per requirements)

Economic benefits:

Improved productivity of the crane system, with a long-term productivity increase of 8%
Reduced damage and prevention of accidents
Simplified crane structure, achieving full/partial automation of the system, resulting in a 2% increase in throughput
Extended service life of the crane system, reduced wear on drivers, and lower energy consumption
Simplified controls for the crane operator, reducing the impact of experience limitations

Order information:

BPI-SC Electronic Anti-Sway Control System

Name	Model
Anti-Sway Controller	BPI-SC-1200
Anti-Sway Controller	BPI-SC-1200-DP
Anti-Sway Controller	BPI-SC-1500
Anti-Sway Controller	BPI-SC-1500DP
Camera Sensor	BPI-SC-Sensor-210
Camera Sensor	BPI-SC-Sensor-300