XISC's groundbreaking application was recognized by the International Telecommunication Union (ITU) as one of the best use cases of AI in the steel industry at the AI for Good Global Summit on May 30, 2024.
Smart Bridge Crane System in Steel Mills
XISC's 30-meter-high steelmaking plant includes three basic oxygen furnaces, three refining stations, five ladle furnaces and five continuous casting machines. Five bridge cranes with a working range of 500 meters operate at great heights, while steel is transported at temperatures above 1,000°C.
In traditional steel production, bridge crane operations were manual, resulting in high margins of error and inefficiencies. However, XISC switched from manual calculation to artificial intelligence-supported intelligent calculation by introducing a large model-supported intelligent bridge crane planning system.
This system determines the optimum crane movement by analyzing steel production plans, bridge crane maintenance data and bucket positions. It can respond to production changes within a minute and create a new plan for the next 30 minutes. Increased the turnover rate of steel grabs, resulting in cost savings of CNY 1.2 per ton.
5G Supported Smart Belt Tracking System
The belt systems used to transport materials in steel mills operate 24/7, moving at a speed of 2 meters per second. Traditionally, these belts were manually inspected by specialized workers. However, when a belt breaks, serious production losses occur, such as shutting down the blast furnace and losing one ton of molten iron per minute.
As a solution to this problem, a smart belt monitoring solution was developed using 5G and computer vision technology. The new system monitors abrasions and deformations on rubber and steel wire composite belts in real time. It provides early warnings by detecting belt breaks in advance. After one month of learning, it reached 98% accuracy and significantly reduced the need for manual inspection.
Artificial Intelligence Inspection in a High Speed Wire Factory
At XISC's high-speed wire factory, a coil of wire is produced every minute. Previously, workers ensured quality control by manually inspecting samples with flashlights. But this method had low productivity and safety risks.
Now a cloud-based quality control system is in place. Eight industrial cameras inspect each coil in real time to check quality. This system was developed by XISC's technical team in just 10 days, and thanks to low-code AI development tools, a modular innovation ecosystem was created.
Increased Efficiency in Steel Production with the Big Model
By April 2024, XISC had deployed 23 intelligent AI applications in nine key areas, including coking, sintering, iron production, steelmaking, steel rolling and quality inspection. Reduced energy consumption per ton by 10%. Manual errors were minimized. Production processes were optimized and quality improved.
In the coming period, XISC plans to further reduce costs, improve quality and make production processes smarter with more than 60 new innovative applications.
New Era in the Steel Industry: Smart Factories
XISC's AI-powered transformation is ushering in a new era in the steel industry. With smart production technologies, automation systems and big model-driven planning, steel mills are transforming into “smart production centers”.
These developments set an example not only for XISC but also for the global steel industry. This model pioneered by XISC will continue to make steel production safer, more efficient and sustainable in the future.
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