Digitization Project of Hot Rolling Workshop of Aluminum Foil Factory

In the past few years, digital technologyis booming and has become an important part of our world. Internet of Thingstechnology and artificial intelligence algorithms have brought convenience toour lives and improved efficiency, but in the manufacturing industry, manyfactories still maintain the working patterns of the past.

As a high-end aluminum foil manufacturer,Xiashun's products are widely used in food, medical, capacitors and otherfields, and its market share ranks among the top in the world. Xiashun and NICLI have been cooperating for more than ten years. In the past, we providedequipment and services to our customers, and now we help our customers todigitally transform on this basis.

Through the on-site inspection of NICLI engineers, it is found that the following problems are faced in the operationof the factory:

1. Severe working environment: The temperatureof the heating furnace motor in the hot rolling workshop is between 70-105°Call the year round, and manual inspection is difficult.

2. Unplanned downtime seriously affectsproduction: The hot rolling workshop of the strip factory is equipped with arolling mill imported from Germany with a high degree of automation and hasstrict requirements for stable operation, but the factory lacks the means tograsp the real-time status of the equipment, and it is difficult to predict thefailure of the equipment.

3. High cost of manual inspection: Thefactory has three production bases with a total area of 600,000 square meters.Arranging manual inspection in such a workshop will cost huge labor costs andtime costs.

4. Excessive spare parts occupy funds andstorage: In order to cope with emergencies in production, many spare parts arestored in the factory. However, when spare parts are needed, it is found thatsome spare parts are stored for too long and their efficacy is reduced, whileothers are lacking. spare parts.

After clarifying the customer's needs,after many consultations and discussions, NICLI finally provided a solution forthe customer through the ABB Ability™ Smart Sensor.

ABB Ability™ Smart Sensor second-generationhigh-performance motor smart sensor (hereinafter referred to as SSHP) is acondition monitoring solution that can help almost all low-voltage motors (notlimited to ABB brands) and some high-voltage motors to achieve predictivemaintenance monitoring. SSHP has built-in three-way acceleration sensor,high-frequency acceleration sensor, magnetic field sensor, temperature sensor,and acoustic emission sensor, which can automatically analyze, track and alarmthe mechanical and electrical faults of the motor.

SSHP sends the data after edge computingthrough Bluetooth - transmits the relevant data to the secure cloud platformthrough the mobile phone or gateway, analyzes the data, and displays theoverall status of the monitored equipment, the operating parameters of themotor monitoring components, and the motor through the mobile phone and webclient. The health parameters of each monitoring component and the motor faultalarm event, and the ABB dedicated server can store the historical data andstatus of the motor for fault analysis and maintenance planning, and the sensorcan temporarily store 1 month (720 groups) of data.

The system has a complete bearing database.SSHP monitors the motor speed, magnetic field and other electrical relatedinformation in real time through the magnetic field sensor. Combined with thevibration spectrum measured by the vibration sensor, it automatically tracksand calculates the running status of the bearing in the background and alarms,without the need to manually check the spectrum. . Through the three-wayacceleration vibration sensor and noise sensor, multiple analysis andverification are made on the vibration, bearing condition and lubrication stateof the motor in three directions, so as to discover the fault of the equipmentin time and reduce the false alarm of the equipment.

It can help customers achieve predictivemaintenance for almost all low-voltage motors (not limited to ABB brands), andalways bring the following benefits:

1. Shorten downtime and reduce downtime lossescaused by sudden equipment shutdowns: loss of production capacity, maintenancelabor costs, and maintenance material costs.

2. Extend the interval of plannedmaintenance, and formulate a reasonable maintenance plan according to the listof faulty equipment found by the system to avoid excessive maintenance.

3. By monitoring the list of faultyequipment, it can effectively reduce the inventory of spare parts andcontribute to the cash flow of the enterprise.

4. Avoid product quality problems caused byexcessive equipment vibration and improve product quality.

5. Rich and intelligent algorithms realizeautomatic data analysis, reduce the dependence on professional analysts, andreduce the workload of condition monitoring personnel.

6. Reduce the energy loss and componentdamage of the production line caused by the long-term excessive vibration ofthe equipment.

7. The historical data is used as aneffective data support for the customer to analyze the failure cause of theequipment, so as to avoid the continuous occurrence of similar failures.

China has always advocated intelligentmanufacturing, which is not only the general trend, but also to create morevalue for the company itself. Through this ABB Smart Sensor digitizationproject, the hot-rolling workshop of Xiashun strip Factory has realizedcomplete monitoring and prediction of key motors, making production smarterthrough technology and digital means, and bringing more benefits toenterprises. NICLI will also continue to provide our customers with reliableproducts and services, and make efforts for efficient and sustainabledevelopment goals.