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星环科技助力沙钢集团工业互联网平台建设

2021-02-05 15:48:44 InfoQ

{"type":"doc","content":[{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"企业背景"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"沙钢集团是中国最大的民营钢铁企业。目前拥有总资产2900亿元,职工4万余名,年产钢能力超4000万吨,位居全球钢企第六位。沙钢集团是以钢铁为主,包括拥有资源能源、金属制品、金融期货、贸易物流、风险投资、大数据等板块在内的跨国企业集团,连续11年跻身世界500强。"}]},{"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":"沙钢集团积极响应国家号召,以节能减排为己任,以科技为引领,通过管理和技术变革实现钢铁工业的节能、减排与降耗,全面推进工业数字化转型创新。"}]},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"业务流程背景"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"炼钢整体场景流程是按照配料要求,先把废钢等装入炉内,然后倒入铁水,并加入适量的造渣材料(如生石灰等)。加料后,把氧气喷枪从炉顶插入炉内,吹入氧气(纯度大于99%的高压氧气流),使它直接跟高温的铁水发生氧化反应,除去杂质。除去大部分硫、磷后,当钢水的成分和温度都达到要求时,即停止吹炼,提升喷枪,准备出钢。出钢时使炉体倾斜,钢水从出钢口注入钢水包里,同时加入脱氧剂进行脱氧和调节成分。钢水合格后,可以浇成钢的铸件或钢锭,钢锭可以再轧制成各种钢材。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/fd\/fd3c288ce2c0385c26b7e8424b5d0c79.jpeg","alt":"图片","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":"图1:炼钢流程示意图"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"问题与需求"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"问题"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"1、 经过多年信息化建设,沙钢集团已具备生产、质量、采购、销售、财务等业务系统,拥有大量的业务数据,"},{"type":"text","marks":[{"type":"strong"}],"text":"各业务系统缺乏有效技术手段打通,数据无法及时融合"},{"type":"text","text":",实现应有的价值。"}]},{"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、 沙钢集团作为流程制造业,有着众多的生产控制设备与系统,设备故障无法及时发现,现阶段主要通过定期停机进行调试与维护,来保证生产的持续运行,"},{"type":"text","marks":[{"type":"strong"}],"text":"无法实时监控各设备运行状态与趋势。"},{"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、 沙钢集团目前炼钢吹炼时间在15分钟左右,在吹炼至12分钟左右时,需有一次温度和碳含量的测定来作为控制终点的参考。现阶段炼钢吹炼过程为有经验的老师傅进行人工控制,容易导致最终钢水质量参差不齐;且如今工厂年轻力量越来越薄弱,"},{"type":"text","marks":[{"type":"strong"}],"text":"炼钢过程亟需从经验化转换为标准化。"}]},{"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":"需要构建沙钢的工业互联网平台,利用大数据平台的分布式计算能力、实时流计算能力、机器学习能力,帮助企业实现如下场景:"}]},{"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":"实现业务数据的批量计算与BI可视化分析"},{"type":"text","text":",如实现公司跨年度、长周期产品销量分类统计,实现原材料库存的实时分析统计等。"}]},{"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":"实现现场工业设备的执行情况的实时监控和报警"},{"type":"text","text":",如工艺卡、开轧温度、咬钢信号等参数与状态的实时采集与流式计算分析,并进行大屏统一监控。"}]},{"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":"实现炼钢工艺过程的机器学习建模"},{"type":"text","text":"。基于加入炼钢转炉的原料条件,找出吹炼过程中供氧和造渣操作之间最佳的协调方式,以提高出钢终点温度和碳含量的命中率,保证出钢的质量,提高炼钢的生产效率,降低成本,节能减排。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":"br"}},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"解决方案"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"1、工业互联网平台设计思路"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":"br"}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/7b\/7bcb53d004487e082430f595626c294e.jpeg","alt":"图片","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数据库与Inceptor分布式计算引擎实现实时数据的毫秒级计算与全量数据的批量计算,并通过BI报表工具Polit进行可视化展示。"}]},{"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":"数据挖掘"},{"type":"text","text":":基于星环机器学习平台Transwarp Sophon,促使资深的人工智能技术专家与沙钢的业务专家进行联合建模,实现生产工业流程的模型构建与标准化。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/16\/16a1fd68191916dd4a4e87c4b782a706.jpeg","alt":"图片","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":"图3:沙钢工业互联网平台技术架构图"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"3、数据采集实现"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","marks":[{"type":"strong"}],"text":"整体采用AIoT的边云一体架构。"},{"type":"text","text":"边缘计算端主要实现连接、处理、转发等功能,同时对设备状态、设备运维、模型等进行管理;云平台端主要实现工业大数据的存储、计算、分析、模型下发等功能,实现边端与云端一体化。"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null}},{"type":"image","attrs":{"src":"https:\/\/static001.geekbang.org\/infoq\/0e\/0e78d867b8443dcbc5a191ed3de0d7ad.jpeg","alt":"图片","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":"图4:沙钢工业互联网平台云边一体架构图"}]},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"应用成效"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"1、海量业务数据分析与展示"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"基于工业互联网平台的分布式计算能力,"},{"type":"text","marks":[{"type":"strong"}],"text":"实现了沙钢集团财务、生产等主要业务领域的大数据批量分析与展示。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"2、生产现场实时监控和告警"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"基于边缘计算和实时流引擎,"},{"type":"text","marks":[{"type":"strong"}],"text":"实现了现场工艺执行情况的实时监控和告警"},{"type":"text","text":",确保生产过程有序进行。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"3、生产操作人员人力成本减少"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"原本转炉炼钢部分从铁水入炉开始,废钢以及所有的辅料添加的时间和量都需要炉长凭经验多次作出决定,机器学习模型却可以通过预测一次做出决策,降低大量劳动成本。此外,简化了转炉炼钢流程,省去了多次添加辅料步骤、调节氧枪高度,从而减少生产操作人员,"},{"type":"text","marks":[{"type":"strong"}],"text":"降低人员投入工时每月45天。"}]},{"type":"heading","attrs":{"align":null,"level":3},"content":[{"type":"text","text":"4、产品命中率及效率提升"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"基于工业互联网平台机器学习能力,通过转炉炼钢的生产过程大数据,找出了吹炼过程中供氧和造渣操作之间最佳的协调方式,沉淀了转炉炼钢的工业生产模型,做到了标准化的炼钢生产。模型沉淀后可进行生产化参数远程实时控制,"},{"type":"text","marks":[{"type":"strong"}],"text":"可提高炼钢过程的生产效率5%;"},{"type":"text","text":"并且提高了出钢终点温度和碳含量的命中率,"},{"type":"text","marks":[{"type":"strong"}],"text":"保证了钢水的质量比人工经验生产高19~33%不等。"}]},{"type":"heading","attrs":{"align":null,"level":2},"content":[{"type":"text","text":"方案核心价值"}]},{"type":"paragraph","attrs":{"indent":0,"number":0,"align":null,"origin":null},"content":[{"type":"text","text":"星环工业互联网平台+边缘计算解决方案可满足工业行业批量计算、实时计算、机器学习等综合应用需求。主要的核心价值如下:"}]},{"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":"– 边云协同:"},{"type":"text","text":"边端快速分析响应,云端智能模型构建,边云一体化;"}]},{"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":"– 数据赋能:"},{"type":"text","text":"利用边缘计算平台高并发、高压缩比、实时写入性能强、多维查询和聚合响应快等特点,快速实现实时查询与检索、简单规则预警、组态展示等场景;"}]},{"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":"利用工业互联网平台的分布式存储、计算、分析能力,实现关联分析、复杂规则预警、人工智能分析等场景。"}]},{"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":"沙钢集团借助星环TDH和Sophon搭建的工业互联网平台,打通汇聚了各个业务环节的海量数据,通过大数据分析与机器学习工具将沉睡数据唤醒,促进了集团的业务数字化转型;同时工业互联网平台的建设,显著提高了沙钢集团炼钢工艺的质量和效率,大大减少了人力投入与生产过程中的碳排放,实现了由科技驱动的工业数字化、绿色化转型。"}]},{"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":"本文转载自:星环科技(ID:transwar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