China's first prefabricated cover beam smart factory debuts, high-speed rail construction moves towards smart manufacturing

Recently, the reporter walked into the Zhengji High-speed Railway Intelligent Prefabrication Plant of China Railway Third Bureau in Qingfeng County, Puyang City, Henan Province. With the start of the intelligent production line for cover beams, through intelligent bottom mold grinding, precise fabric distribution, automatic demoulding and other processes, a 100-ton "Big Mac" on a high-speed railway bridge is ready to appear. Different from other workshops, only the sound of machines is heard here, but the busy workers are not seen.

"The overall solution for intelligent cover beam production has significantly improved the intelligence of the cover beam prefabrication production equipment and process flow. The production efficiency index has been increased by 300%, the direct operator has been reduced by more than 80%, and the operating cost has been reduced by more than 43%." Sun Maosong, executive vice president of the Institute of Artificial Intelligence of Tsinghua University, gave the answer.

On the same day, the scientific and technological achievement evaluation meeting of the project "Research and Application of Intelligent Construction Technology of Prefabricated Cover Beam" jointly organized by China Railway Third Bureau Group Co., Ltd. and Beijing Haoyunda Zhichuang Technology Co., Ltd., hosted by China Technology Market Association, was successfully held. The evaluation expert group is composed of authoritative experts in the industry such as Sun Yu, academician of the Chinese Academy of Engineering, Sun Maosong, executive vice president of the Institute of Artificial Intelligence of Tsinghua University.

Zhengji Gailiang Smart Factory has changed the traditional outdoor operation mode, realized workshop-style intelligent production, and solved the hidden safety hazards of on-site pouring. Through digital simulation and Internet of Things technology, it realizes automatic data collection, processing, self-learning, and empowers research and development, design, production, operation, etc., which fills the gap in the intelligent development of prefabricated components at home and abroad, and establishes a new model for digital transformation and upgrading. At the same time, it will make up for the shortcomings of the lack of technological innovation of prefabricated concrete products in the field of infrastructure, which will drive the industry to develop the trend of prefabricated smart factories, and solve the problems of lack of innovation awareness and innovation ability in the industry.

Cover beam intelligent factory includes cover beam intelligent production line and intelligent steel bar processing center, combined with cover beam production process. The intelligent production line is divided into intelligent grinding, automatic spraying, automatic mold clamping, precise cloth, intelligent steam curing, automatic mold opening, intelligent chiseling and other processes. This is the first cover beam intelligent production line independently developed and designed at home and abroad, which realizes the perfect combination of continuous production, intelligence, leanness and robots for the first time. The intelligent steel bar processing center integrates the leading logistics flow technology and intelligent collaboration technology, and is the first to create a linked flexible steel bar processing center. It effectively links the nine-wheel CNC arc bending machine, the intelligent bar cutting and bending robot, the intelligent CNC stirrup and plate integrated machine, the automatic steel bar straightening and cutting machine, the automatic round bending welding machine, and the intelligent small hoop bending machine. This achieves the efficient circulation of steel bar raw materials, semi-finished products and finished products, and realizes the lean, digital and intelligent management of steel bar processing and production.

During the evaluation of the results, the experts believed that after listening to the report of the undertaking unit, reviewing the materials, inspecting the production site, and after questioning and discussing, the research and development technology of the scientific and technological achievements of the "Research and Application of Intelligent Construction Technology of Prefabricated Cover Beams" project is difficult and comprehensive. It has obtained a batch of domestic technology patent authorization, has complete independent intellectual property rights, and the overall technical level has reached the international leading level. This achievement has been successfully applied in construction projects such as Zhengji High-speed Railway, providing an effective guarantee for the intelligence, informatization, greening, low carbonization and safety of the infrastructure industry.