星環科技助力沙鋼集團工業互聯網平臺建設

{"type":"doc","content":[{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"企業背景"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"沙鋼集團是中國最大的民營鋼鐵企業。目前擁有總資產2900億元，職工4萬餘名，年產鋼能力超4000萬噸，位居全球鋼企第六位。沙鋼集團是以鋼鐵爲主，包括擁有資源能源、金屬製品、金融期貨、貿易物流、風險投資、大數據等板塊在內的跨國企業集團，連續11年躋身世界500強。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"沙鋼集團積極響應國家號召，以節能減排爲己任，以科技爲引領，通過管理和技術變革實現鋼鐵工業的節能、減排與降耗，全面推進工業數字化轉型創新。"}]},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"業務流程背景"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"鍊鋼整體場景流程是按照配料要求，先把廢鋼等裝入爐內，然後倒入鐵水，並加入適量的造渣材料（如生石灰等）。加料後，把氧氣噴槍從爐頂插入爐內，吹入氧氣（純度大於99%的高壓氧氣流），使它直接跟高溫的鐵水發生氧化反應，除去雜質。除去大部分硫、磷後，當鋼水的成分和溫度都達到要求時，即停止吹煉，提升噴槍，準備出鋼。出鋼時使爐體傾斜，鋼水從出鋼口注入鋼水包裏，同時加入脫氧劑進行脫氧和調節成分。鋼水合格後，可以澆成鋼的鑄件或鋼錠，鋼錠可以再軋製成各種鋼材。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/fd\/fd3c288ce2c0385c26b7e8424b5d0c79.jpeg","alt":"圖片","title":null,"style":[{"key":"width","value":"75%"},{"key":"bordertype","value":"none"}],"href":null,"fromPaste":true,"pastePass":true}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":"center","origin":null},"content":[{"type":"text","text":"圖1：鍊鋼流程示意圖"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"問題與需求"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"問題"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"1、 經過多年信息化建設，沙鋼集團已具備生產、質量、採購、銷售、財務等業務系統，擁有大量的業務數據，"},{"type":"text","marks":[{"type":"strong"}],"text":"各業務系統缺乏有效技術手段打通，數據無法及時融合"},{"type":"text","text":"，實現應有的價值。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"2、 沙鋼集團作爲流程製造業，有着衆多的生產控制設備與系統，設備故障無法及時發現，現階段主要通過定期停機進行調試與維護，來保證生產的持續運行，"},{"type":"text","marks":[{"type":"strong"}],"text":"無法實時監控各設備運行狀態與趨勢。"},{"type":"text","text":" "}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"3、 沙鋼集團目前鍊鋼吹煉時間在15分鐘左右，在吹煉至12分鐘左右時，需有一次溫度和碳含量的測定來作爲控制終點的參考。現階段鍊鋼吹煉過程爲有經驗的老師傅進行人工控制，容易導致最終鋼水質量參差不齊；且如今工廠年輕力量越來越薄弱，"},{"type":"text","marks":[{"type":"strong"}],"text":"鍊鋼過程亟需從經驗化轉換爲標準化。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"需求"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"需要構建沙鋼的工業互聯網平臺，利用大數據平臺的分佈式計算能力、實時流計算能力、機器學習能力，幫助企業實現如下場景："}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"（1）"},{"type":"text","marks":[{"type":"strong"}],"text":"實現業務數據的批量計算與BI可視化分析"},{"type":"text","text":"，如實現公司跨年度、長週期產品銷量分類統計，實現原材料庫存的實時分析統計等。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"（2）"},{"type":"text","marks":[{"type":"strong"}],"text":"實現現場工業設備的執行情況的實時監控和報警"},{"type":"text","text":"，如工藝卡、開軋溫度、咬鋼信號等參數與狀態的實時採集與流式計算分析，並進行大屏統一監控。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"（3）"},{"type":"text","marks":[{"type":"strong"}],"text":"實現鍊鋼工藝過程的機器學習建模"},{"type":"text","text":"。基於加入鍊鋼轉爐的原料條件，找出吹煉過程中供氧和造渣操作之間最佳的協調方式，以提高出鋼終點溫度和碳含量的命中率，保證出鋼的質量，提高鍊鋼的生產效率，降低成本，節能減排。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":"br"}},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"解決方案"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"1、工業互聯網平臺設計思路"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":"br"}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/7b\/7bcb53d004487e082430f595626c294e.jpeg","alt":"圖片","title":null,"style":[{"key":"width","value":"75%"},{"key":"bordertype","value":"none"}],"href":null,"fromPaste":true,"pastePass":true}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"num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Hyperbase NewSQL數據庫與Inceptor分佈式計算引擎實現實時數據的毫秒級計算與全量數據的批量計算，並通過BI報表工具Polit進行可視化展示。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"（3）"},{"type":"text","marks":[{"type":"strong"}],"text":"數據挖掘"},{"type":"text","text":"：基於星環機器學習平臺Transwarp Sophon，促使資深的人工智能技術專家與沙鋼的業務專家進行聯合建模，實現生產工業流程的模型構建與標準化。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/16\/16a1fd68191916dd4a4e87c4b782a706.jpeg","alt":"圖片","title":null,"style":[{"key":"width","value":"75%"},{"key":"bordertype","value":"none"}],"href":null,"fromPaste":true,"pastePass":true}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":"center","origin":null},"content":[{"type":"text","text":"圖3：沙鋼工業互聯網平臺技術架構圖"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"3、數據採集實現"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","marks":[{"type":"strong"}],"text":"整體採用AIoT的邊雲一體架構。"},{"type":"text","text":"邊緣計算端主要實現連接、處理、轉發等功能，同時對設備狀態、設備運維、模型等進行管理；雲平臺端主要實現工業大數據的存儲、計算、分析、模型下發等功能，實現邊端與雲端一體化。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/0e\/0e78d867b8443dcbc5a191ed3de0d7ad.jpeg","alt":"圖片","title":null,"style":[{"key":"width","value":"75%"},{"key":"bordertype","value":"none"}],"href":null,"fromPaste":true,"pastePass":true}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":"center","origin":null},"content":[{"type":"text","text":"圖4：沙鋼工業互聯網平臺雲邊一體架構圖"}]},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"應用成效"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"1、海量業務數據分析與展示"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"基於工業互聯網平臺的分佈式計算能力，"},{"type":"text","marks":[{"type":"strong"}],"text":"實現了沙鋼集團財務、生產等主要業務領域的大數據批量分析與展示。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"2、生產現場實時監控和告警"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"基於邊緣計算和實時流引擎，"},{"type":"text","marks":[{"type":"strong"}],"text":"實現了現場工藝執行情況的實時監控和告警"},{"type":"text","text":"，確保生產過程有序進行。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"3、生產操作人員人力成本減少"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"原本轉爐鍊鋼部分從鐵水入爐開始，廢鋼以及所有的輔料添加的時間和量都需要爐長憑經驗多次作出決定，機器學習模型卻可以通過預測一次做出決策，降低大量勞動成本。此外，簡化了轉爐鍊鋼流程，省去了多次添加輔料步驟、調節氧槍高度，從而減少生產操作人員，"},{"type":"text","marks":[{"type":"strong"}],"text":"降低人員投入工時每月45天。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"4、產品命中率及效率提升"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"基於工業互聯網平臺機器學習能力，通過轉爐鍊鋼的生產過程大數據，找出了吹煉過程中供氧和造渣操作之間最佳的協調方式，沉澱了轉爐鍊鋼的工業生產模型，做到了標準化的鍊鋼生產。模型沉澱後可進行生產化參數遠程實時控制，"},{"type":"text","marks":[{"type":"strong"}],"text":"可提高鍊鋼過程的生產效率5%；"},{"type":"text","text":"並且提高了出鋼終點溫度和碳含量的命中率，"},{"type":"text","marks":[{"type":"strong"}],"text":"保證了鋼水的質量比人工經驗生產高19~33%不等。"}]},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"方案核心價值"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"星環工業互聯網平臺+邊緣計算解決方案可滿足工業行業批量計算、實時計算、機器學習等綜合應用需求。主要的核心價值如下："}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","marks":[{"type":"strong"}],"text":"– 邊雲協同："},{"type":"text","text":"邊端快速分析響應，雲端智能模型構建，邊雲一體化；"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","marks":[{"type":"strong"}],"text":"– 數據賦能："},{"type":"text","text":"利用邊緣計算平臺高併發、高壓縮比、實時寫入性能強、多維查詢和聚合響應快等特點，快速實現實時查詢與檢索、簡單規則預警、組態展示等場景；"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","marks":[{"type":"strong"}],"text":"– 智能分析："},{"type":"text","text":"利用工業互聯網平臺的分佈式存儲、計算、分析能力，實現關聯分析、複雜規則預警、人工智能分析等場景。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"沙鋼集團藉助星環TDH和Sophon搭建的工業互聯網平臺，打通匯聚了各個業務環節的海量數據，通過大數據分析與機器學習工具將沉睡數據喚醒，促進了集團的業務數字化轉型；同時工業互聯網平臺的建設，顯著提高了沙鋼集團鍊鋼工藝的質量和效率，大大減少了人力投入與生產過程中的碳排放，實現了由科技驅動的工業數字化、綠色化轉型。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"本文轉載自：星環科技（ID：transwarp-sh）"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"原文鏈接："},{"type":"link","attrs":{"href":"https:\/\/mp.weixin.qq.com\/s\/JqdlKXfV5YeY9IZgUtmBXg","title":"xxx","type":null},"content":[{"type":"text","text":"星環科技助力沙鋼集團工業互聯網平臺建設"}]}]}]}