Abstract Deputy General Manager of the Sixth Design and Research Institute Co., Ltd. of Machinery Industry, professor-level senior engineer, State Council subsidy expert, China Machinery Industry Group science and technology expert, Chairman of the China Machine Tool Association Abrasives Branch Expert Committee Zhao Xinli made the title With abrasive green smart manufacturing --...
Deputy General Manager of the Sixth Design and Research Institute of Machinery Industry, professor-level senior engineer, State Council subsidy expert, China Machinery Industry Group science and technology expert, Chairman of the China Machine Tool Association Abrasives Branch Expert Committee Zhao Xinli made the title Special report on green intelligent manufacturing of abrasive tools--green intelligentization of coated abrasive production line
China's economic development model is shifting from a productivity factor to an innovation drive, from a product market to a capital market, and fully promotes the "Made in China 2025", Internet +, and "Belt and Road" strategies. China's coated abrasive industry is facing the third industrial revolution and changes in Industry 4.0 and the world economic structure, the rise of emerging countries and the opportunities and challenges brought about by the development of the Internet economy. Coated abrasives have an important strategic position in the development of the national economy, and the future coated abrasives will be intelligent manufacturing. Green smart manufacturing is a key strategic area supported by the state. It is necessary to integrate the development of the industry with the national strategy, realize the transformation, upgrading and re-engineering of the production mode of the industry, accelerate the sustainable and healthy development of the industry, and realize the green intelligent manufacturing of coated abrasives is the only way for the development of the industry.
China's coated abrasive industry, like many traditional industries in China, has experienced a period of rapid development driven by factors of production (finance, equipment, land, labor, etc.). At present, it faces severe challenges: resources are difficult to support for a long time; environmental pressures are increasing; users' demand is getting higher and higher; trade frictions between exports and other countries are increasing; industry's main products are overcapacity, labor costs are rising, and some regions are short of The market competition has intensified, the profit margin has been squeezed, and the operating expenses of enterprises have increased. The high-end products that the market urgently needs are not capable of producing due to equipment and technical reasons. All of this has forced the coated abrasives enterprises to move toward innovation drive and green intelligence transformation, in order to enhance the company's key competitiveness and reduce production costs.
The green intelligent manufacturing of coated abrasives consists of the original cloth processing system, the belt manufacturing production line system, the product conversion system, the wastewater treatment and waste gas treatment system and the packaging system in the production process. It covers the entire process and all aspects of production, technical quality and R&D, supply, marketing, and management and strategy, financial and capital operations, and resource matching and scheduling. Intelligent manufacturing through the underlying coated abrasive products, equipment, production, research and development digital construction, to achieve product digitalization, equipment intelligence, production digital, research and development of digital factories, provide rational decision-making basis for management, decision-making; secondly use the Internet of Things Technology and equipment monitoring technology to strengthen information management and services; finally coupled with green smart means and intelligent systems to build a green and modern "smart factory". Realizing informationization drives industrialization, and industrialization promotes a virtuous cycle of informationization. Achieve green smart manufacturing of coated abrasives.
   2. Brief introduction of the development of coated abrasives production and equipment in China and the development of intelligent manufacturing at home and abroad
China's coated abrasives were developed after liberation. In 1960, the widest (1000mm) flat running dry sanding cloth production line in China was built at the Shanghai Grinding Wheel Factory. In 1964, the suspension drying sandpaper sandpaper production line imported from Democratic Germany was built in Zhengzhou's China Second Grinding Wheel Factory. It is the first coated abrasive production line introduced in China. This coated abrasive production line has played an irreplaceable role in the development of China's coated abrasive industry.
From the early 1980s to the mid-1990s, China's No. 2 Grinding Wheel Factory and Shanghai Grinding Wheel Factory successively introduced a complete set of coated abrasives production lines from the Federal Republic of Germany, which enabled China's coated abrasive industry to achieve a qualitative leap. Since the end of the 20th century, the scale of production of coated abrasives in China has been continuously expanded, with numerous manufacturers and complete varieties. Today, China has become the world's largest country in coated abrasives.
By 2015, a total of 17 coated abrasives large-volume production lines and a number of fabric-based processing lines produced by Peter Schwabe Gmbh were introduced. In China, the design, manufacture and production capacity of all coated abrasive production equipment, such as original cloth processing equipment, coated abrasive production line equipment, abrasive belt conversion equipment, and automatic production line for sanding discs, have been formed in China. The digitalization and intelligence level of some equipments of abrasive manufacturing enterprises have approached the international advanced level; the equipment level of some key industry manufacturers has been greatly improved, and some of its processes and equipment levels have reached the first-class modernization level in line with international standards. However, there is still a certain gap between the overall process and equipment level of the coated abrasives industry in China and the advanced abrasives of the international abrasives, especially in the green and smart production of production technology, automation and equipment and information integration of the whole plant.
At present, China's coated abrasives are improving and developing the direction of advanced coated abrasive products manufacturing technology and supporting a full set of coated abrasive equipment. Automatic control of coated abrasive production line equipment, precise control of coating (including ray thickness measurement), research on integrated measurement and control technology, development and research of original cloth processing equipment, automation of belt conversion equipment, digital research and development, super hard The development of special production lines for materials (synthetic diamonds and cubic boron nitride) coated abrasives and the development of special production lines for polymer film coated abrasives are facing urgent needs.
In the intelligent manufacturing of coated abrasives, the internationally leading famous coated abrasives enterprises are in the leading position in the intelligent manufacturing of coated abrasives. They are characterized by: digitization and automation of production equipment, and realization of digitalization and management of production operation management. It is currently building a system-wide intelligent manufacturing and service system characterized by the creation of big data and cloud computing. At present, China has partially realized the automation of key production equipment or production lines in some key enterprises, and partially informatized and digitized in production management. It has just started in the digitalization and informationization of production and operation of the whole system, and is characterized by big data and cloud computing. The entire system of intelligent manufacturing and service systems has begun to take action.
   3. The main content of the intelligent manufacturing of coated abrasives
Green intelligent manufacturing of coated abrasives in accordance with the concept of green intelligence, including the establishment of a digital factory model for the production of coated abrasives, and the automatic batching system, abrasive belt processing line, coated abrasive manufacturing line, coated grinding System simulation was carried out with conversion production line, waste gas treatment system and production line system integration and intelligent monitoring system. Apply the concept of digital workshop to realize the digital management of the whole process of planning, production and operation of the coated abrasive workshop. Abrasive product information runs through the design, manufacturing, quality, logistics and other aspects to achieve full life cycle management (PLM) of coated abrasives.
The improvement of the production process by the green intelligent manufacturing of coated abrasives, through the establishment of the production control system, resource management system, energy management system, product traceability system and video monitoring system of the digital workshop, the process of coating the abrasive workshop is realized. Integrated optimization of production, management, monitoring, logistics, etc., using network technology, big data technology to achieve enterprise intelligent management and decision-making, comprehensively improve enterprise resource allocation optimization, operation automation, real-time online optimization, production management refinement and intelligent decision-making Scientific level.
To realize the green intelligent manufacturing of coated abrasives, the automation and digitization of coated abrasives production is the basis of informationization and intelligent manufacturing. Automation, digitization and informationization are the basis and main components of intelligent intelligent manufacturing. Green is a must for modern belt factories.
The green intelligent manufacturing of coated abrasives is from the automation, digitization, through intelligence and information to the wisdom, to achieve the deep integration of industrialization and information. Automation and digitization are just the predecessors of intelligence. Based on digitalization, we will drive automation with information technology, promote informationization through automation, and seek improvement from intelligence. The biggest difference between automation and intelligent intelligent manufacturing is the establishment and analysis of databases.
The overall application architecture of intelligently coated abrasives intelligent manufacturing can be constructed as intelligent equipment production inspection control layer, communication layer, platform layer and application layer.
Intelligent equipment production inspection and control layer, including production process equipment automation and digitization, to achieve intelligent and optimized production and product technology quality control, such as: raw material processing, batching and conveying system technology equipment; original cloth processing technology equipment system; belt manufacturing Line equipment and process inspection and control support equipment system; supporting environmental protection and energy security equipment system; automatic control and online detection and control system for production lines supporting energy management and safety and fire protection and industrial hygiene inspection and equipment systems. The intelligent equipment production inspection control layer is also responsible for identifying objects and collecting information.
The communication layer is responsible for transmitting various types of information from the cognitive interaction layer to the application service layer through the basic bearer network, including the communication network under the triple play, the Internet, the satellite network, the wide-area network, etc., and the network transport layer can be upgraded to meet Different transmission requirements in the future. The communication layer mainly focuses on the transmission of data initially processed by the sensing layer via various types of networks, and the communication layer involves various network technologies such as interworking and self-organizing communication of different network transmission protocols.
The platform layer is responsible for dividing the data resources of the intelligent sanding belt factory to build a cloud-based mine data center and constructing a production integrated monitoring platform.
The application layer is responsible for the establishment and analysis of the database, including the whole plant ERP system, OA system and other management systems such as digital informationization of the whole plant. In combination with strategic management and control, business management innovation is required to realize the command and dispatch of coated abrasive manufacturing and production safety inspection. Business applications such as intelligent decision-making in production and operation, monitoring and forecasting of resource management systems.
The system of green intelligent manufacturing of coated abrasives is as follows:
Figure 1 Based on the intelligent green manufacturing system of information coated coated abrasives
Figure 2 Sub-assembled abrasive green intelligent manufacturing project subsystem
Coated abrasives produce green intelligent manufacturing production management system adopts advanced digital factory concept, based on relevant data of product life cycle, using real-time, information integration, decision-making, improvement and other informational means to complete product from order to finished product Effective management of the entire life cycle. Coated abrasive production process, including original cloth processing production line, abrasive belt manufacturing production line, product conversion line and auxiliary subsystem (waste water and waste gas treatment, production packaging line); and production management system, energy management system, production video monitoring system The environmental monitoring system is effectively integrated to design a digital factory and intelligent logistics system for the production and processing of coated abrasives.
Figure 3 Coated abrasives production green intelligent manufacturing digital factory production system integration map
Figure 4 Production energy management system with coated green plastic intelligent manufacturing
The coated abrasive belt production workshop adopts the advanced digital factory concept design, based on the relevant data of the product life cycle, using real-time, information integration, decision-making, improvement and other informational means to complete the product from order to finished product life. Effective control of the cycle. 
Figure 5 coated abrasive green intelligent manufacturing production management system
The implementation of green smart manufacturing of coated abrasives is a systematic project. As a new or existing coated abrasives enterprise, different implementation strategies can be adopted. Its implementation covers the planning, design, technical transformation, construction, production, management, monitoring, etc. of traditional enterprise operations. It is efficient, safe, environmentally friendly in the whole process and operation, and tightly integrated between business, finance and management. Efficient collaboration of processes. It involves manufacturing line equipment and process inspection and control support equipment systems; supporting environmental protection and energy security equipment systems; supporting energy management and safety and fire and industrial hygiene testing and equipment systems. Construction of ERP systems, OA systems, etc. The intelligent manufacturing of coated abrasives is highly informationized, automated and efficient, and one of the ultimate goals is to achieve intelligent optimal production and operation.
Taking the design of a domestic enterprise as an example, this paper introduces the exploration of green smart manufacturing implementation of coated abrasives.
First of all, in accordance with the concept of green manufacturing of coated abrasives, according to the concept of the whole life cycle, the design, construction, operation and maintenance of the plant. Provide digital assets to businesses. The system of Figure 1 - Figure 5 was built. Second, green smart manufacturing is implemented in accordance with the characteristics of coated abrasives.
(1) Digital original cloth processing production line:
The original cloth treatment of coated abrasives includes: a cloth inspection machine, a hydraulic double-winding machine, a singeing desander, a full-width cleaning machine, a dip tenter, a squeegee and a batching process. .
Figure 6 Digital original cloth processing production line
(2) Digital coated abrasive manufacturing line: The manufacture of coated abrasives includes: uncoiler, printing machine, primer machine, gravity and electrostatic sanding machine, glue preparation system, drying temperature control ventilation system, glue filling machine, winding machine, curing furnace and other process equipment.
Figure 7 Digital coated abrasive production line
(3) Digital coated abrasive product conversion line Coated abrasive product conversion line includes: boring machine, slitting machine, edging machine, belt press, belt cutting machine, belt coating machine and other equipment.
The digitally coated abrasive belt conversion equipment adopts man-machine interface to realize the interaction between human and machine. Each equipment controller adopts a small PLC to communicate all the PLC network and the coated abrasive product conversion line workstation. According to the production task information sent under the digital workshop management system, the machine operation plan is automatically formulated, and the control task is completed by the PLC. The equipment status, operating parameters, product type, quantity and other information in the production process are transmitted to the product conversion line workstation in real time.
Figure 8 Digitally coated abrasive production conversion line
(4) coated abrasive life cycle information management system The product life cycle includes product demand information collection, product design, product manufacturing, and product market lifecycle management. Create detailed, intuitive, and actionable digital product information to identify and resolve critical issues.
The coated life cycle information management system uses MES information technology as the means, adopts advanced automatic control technology, bar code technology, RFID technology, and uses modern production management concepts (such as TPS, TQM, OEE, LEAN, etc.) as the theoretical basis. It covers the whole process of the production of coated abrasives, realizes the information management of the life cycle of coated abrasives, and provides a complete solution for the production management of coated abrasives.
Figure 9 Coated abrasive product life cycle management system
Figure 10 Flow chart of the whole process of coated abrasive tools
According to the market demand, the product order is determined. After the enterprise obtains the order information, the production management department converts it into the corresponding raw material formula, inputs the formula to the formula automatic management system, and determines the order of the recipe cycle and the order of the recipe according to the quantity and urgency of the product demand. The preparation and batching system determines the raw materials to be prepared at the current production according to the prompts of the production management information system, and performs the operation of the system by the preparation and batching system. In addition, the status and statistical data of the preparation batching system are transmitted by the touch screen through the Ethernet form into the central control room centralized control system, realizing the function of real-time monitoring, preservation and historical data query of important data. The on-site kanban information is managed by the central control room production management and kanban management software, and displays the production schedule information of batches, order numbers, and shift groups of materials.
Prepare the material to automatically input the recipe code information into the control system. The PLC control system can intelligently identify the recipe, quantity and station for each feeding, so that the material can be intelligently tracked. The system establishes communication with the intelligent control line control integrated system of the central control room. In the control integration system, the “batch management system†screen displays, intelligently monitors the running status of each device in the batching system, and at the same time conveniently records the material conveying situation, and the production report is easy to query.
The original cloth processing process, the coated abrasive production process, and the conversion process can dynamically monitor the real-time and historical data of the process parameters, equipment operating parameters, and the online equipment fault diagnosis system through the respective digital information tube systems. So that maintenance personnel can find the equipment that runs the unstable production line in time and repair it in time. All these informationization means realize dynamic and intelligent tracking of information such as product order number, product specification and quantity.
After the coated abrasive products are off the assembly line, the finished product quality inspection management system checks the quality of the products, and the products that meet the requirements are transported to the packaging area for packaging. At the same time, the quantity, specifications and reasons for failure of the batch of products are not qualified. Information is transmitted to the central control room as a basis for production improvement, sales and shipment.
The products that have passed the inspection enter the factory warehouse management system after entering the product information, and are connected with the enterprise ERP system for the relevant management personnel to call and view.
When shipped, the digital logistics management system ensures product safety and arrives at the customer on time. When the customer is using, if the problems in the use of this product will be traced through the after-sales service system, including quality analysis and production traceback, the problem will be found and the production will be improved.
Due to space limitations, other content of coated abrasive green smart manufacturing is not repeated here.
In short, the implementation of green smart manufacturing of coated abrasives is generally implemented in the following processes: 1.) Resource allocation and use of digitization and intelligent wisdom; including the establishment of an ERP system for the belt factory, the establishment of a multi-plant network system, to achieve the full Optimized configuration and use of plant resources. 2). Green and intelligent production equipment; including supporting environmental protection and energy security equipment systems; automatic control and online detection and control systems for production lines supporting energy management and safety and fire and industrial hygiene testing and equipment systems. The equipment of the belt production line has intelligent control functions, including detection and online control of various process parameters, product product life cycle management, safety, traceability and energy saving technology, etc., and the source of these functions must pass through the abrasive belt. The establishment of the production line sensor extends the generated message device end to the end-to-end enterprise link architecture of the IT data center to realize the intelligentization of the belt production line equipment. 3). Production automation and digitization and green intelligence; refers to the whole process equipment and auxiliary supporting functional equipment of coated abrasives to realize automation and digitization and green manufacturing, and achieve the goal of green intelligentization through integration. 4). Management system digital information and green intelligence; including automation system management, resource management system, OA system and energy management management system. Realize the digital informationization of the whole plant management. In terms of energy and green energy management, digitally realize the cycle of green product life cycle management from resource, material, design, manufacturing, waste recycling to recycling, green value-added application of ICT, and cooperation in green supply chain Management, green process management and intelligent environmental monitoring, etc., to help upstream and downstream manufacturers and customers create green products that are environmentally friendly. 5) The plant operates green and intelligent, and realizes the green intelligent manufacturing of coated abrasives.
   5. Conclusion
China's coated abrasives enterprises should actively meet and face the opportunities and challenges brought by the "Made in China 2025", Internet +, and "Belt and Road" strategies, and accelerate the implementation of coated abrasives manufacturing from automation, digitization, and through intelligentization. The informatization to the intelligentization of green intelligent manufacturing, the deep integration of industrialization and informatization, and the realization of green and intelligent manufacturing of coated abrasives are the only way for the development of China's coated abrasive industry.
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