Solved with electrodeless welded mesh ......

2024-07-19

On August 21, 2022, the 2022 "How to systematically solve the problem of building industrialization and high energy consumption through standardized design, automated production, robot construction and prefabricated construction" released by the China Association for Science and Technology was held in Tianjin Yinfeng.

Universities and enterprises work together to create a better future with the deep integration and development of science and technology and economy. Huang Yimiao, vice president of the Institute of Intelligent Infrastructure of Hebei University of Technology, Ding Guomin, general manager of Tianjin Yinfeng Machinery System Engineering Co., Ltd., Mei Xiaobin, Liu Lijian, deputy general managers, and Hao Ruibin, technical manager, attended the meeting.

Huang Yimiao, deputy dean of the Institute of Intelligent Infrastructure of Hebei University of Technology, was entrusted by Vice President Ma Guowei to congratulate the convening of the meeting. He emphasized that intelligent manufacturing refers to the use of automated processing equipment and management software to realize the intelligent production, storage and delivery of products. The management software includes: intelligent map recognition, MES, digital twin system, comprehensive application of artificial intelligence, image recognition, digital twin, automatic control and other cutting-edge technologies, combined with automated production lines to achieve intelligent manufacturing.

In the cost of PC components, there are two main ways to improve the cost: 1. Optimize the prefabricated design, which can significantly reduce the direct production cost and transportation cost of PC components, and large-scale and automated production can effectively reduce the indirect production cost, direct production cost and transportation cost of PC components, and improve the profitability of the enterprise.

At present, the utilization level of PC factory production management software is low, and the corresponding software is not used to reduce technical personnel, management personnel, manual dismantling, drawing, manual entry of BOM coding, manual rebar re-proofing, etc., increasing management costs and other industry pain points, these problems need to be solved.

Ding Guomin first expressed warm congratulations on the convening of the meeting on behalf of the organizers. He emphasized that under the wave of vigorous development of scientific and technological innovation, the industrial cooperation model of school-enterprise cooperation has shown unique advantages in promoting the implementation of high-tech projects and the transformation of achievements in colleges and universities.

On May 23, 2022, an executive meeting was held to point out that on the basis of adhering to the principle of "housing for living, not speculation", support all localities to improve real estate policies based on local conditions, support the demand for rigid and improved housing, optimize the supervision of pre-sale funds for commercial housing, and promote the stable and healthy development of the real estate market. Affected by the epidemic, all walks of life are sluggish, and the construction industry is the same, and many people are not confident about the future. But compared with some other * data, let's analyze: per capita housing area in various countries: 39.4 square meters in Germany, 67 square meters in United States, 235 square meters in Australia, 41.76 square meters in China, from the per capita area point of view, according to their own development and needs, with the improvement of people's requirements for the living environment, the demand is still very large. In some cities, the construction industry still has a lot of room for development in the reconstruction of old urban areas, public construction projects, roads, bridges and pipe corridors. The 2035 long-term goal of the "14th Five-Year Plan" construction industry development plan clearly states that "with the goal of building a world construction power, we will strive to build a modern construction industry development system with effective market mechanism, quality ~ controllable, strong standard support and dynamic market players." By 2035, the quality and efficiency of the development of the construction industry will be greatly improved, the industrialization of construction will be realized in many aspects, the quality of construction will be significantly improved, the innovation ability of enterprises will be greatly improved, the high-quality talent team will be established in many aspects, and the overall advantages of the industry will be enhanced.

According to incomplete statistics, as of August 2021, there are more than 1,200 prefabricated factories with a scale of more than 30,000 cubic meters in China. At present, the cost of prefabricated concrete structure building is higher than that of traditional cast-in-place building, and the cost of PC components accounts for a relatively high proportion of the incremental cost of prefabricated building, which is the main obstacle restricting the promotion and development of prefabricated building. Therefore, how to reduce the cost of PC components is the key to the large-scale promotion of prefabricated buildings in the country in the future.

The cost of PC components mainly includes production costs, transportation costs, marketing expenses, financial expenses, management expenses and taxes. Compared with cast-in-place components, PC components increase the production and logistics links of the factory. Among them, the production cost accounts for a relatively high proportion, and the production cost can be divided into direct production cost and indirect production cost. Direct production costs mainly include material costs, labor costs, mold costs, etc.; Indirect production costs mainly include the amortization of intangible assets formed by the purchase of land, and the apportionment of depreciation of fixed assets such as plant and equipment. The transportation fee covers all the transportation costs of the component from the manufacturer's production to the consumer's site.

The main reasons for the above four types of higher costs are:

(1) Labor costs: the labor costs of workers in each production link, including production labor costs, steel bar labor costs, repair labor costs, auxiliary labor costs, etc. The degree of product standardization is low, and special-shaped components often appear, which can only be produced by fixed mold table, and can not realize assembly operations; The steel bar specifications and spacing of PC components are not uniform, and there are leakage steel bars in the connection parts, and the stepless welded mesh machine is not used to replace manual production, and only manual binding is used, which reduces the effective working hours of workers, thereby affecting the efficiency of the production line; The utilization level of production management software is low, and the corresponding software is not used to reduce technical personnel, management personnel, manual dismantling, drawing, manual entry of BOM coding, manual rebar re-proofing, etc., increasing management costs and other industry pain points.

(2) Material cost: At present, many enterprises lack experience in prefabricated design, and only modify the traditional architectural design drawings, and the understanding of each link of the prefabricated type is not sufficient, so that the design drawings often need to be modified in the production process of components, resulting in the waste of raw materials.

(3) Mold cost: the number of mold turnover is low, usually the thickness of the steel mold template is 6~10mm, and it can be used more than 200 times in theory. However, due to the low degree of standardized design, the lack of automation and large-scale production, the reuse rate of molds in the industry is low, and the average of the general industry is about 50 times, and the corresponding mold cost is as high as 326 yuan/m³.

(4) Transportation costs: There are two main reasons for high transportation costs. First, the low loading rate of the single vehicle due to the low degree of design standardization; Second, the single transportation cost caused by the transportation distance is too long, and the general economic transportation distance is 100~150km. The distance is roughly linear with the cost, and the farther the distance, the higher the cost.

China's PC components of the steel bar specifications and spacing is not uniform, the connection parts have leakage of steel bars, in the past there is no suitable equipment to replace manual production, Tianjin Yinfeng according to the market demand, developed a stepless welded mesh machine, to fill the gap in the world, to solve the problem of China's prefabricated steel mesh automatic production. The use of electrode welded mesh machine and Gongda Yinfeng intelligent map recognition software to solve the intelligent manufacturing of PC component factories, reduce costs, reduce the cost of steel bar processing per cubic component from 95 yuan, to 18.2 yuan, 76.8 yuan per cubic meter, according to the current average annual output of 1,200 factories in the country of 30,000 cubic meters, can save 2.76 billion yuan per year, the economic benefits are significant.

Mei Xiaobin said that the problem of building industrialization and high energy consumption can be solved by using the stepless welded mesh machine and the Yinfeng intelligent map recognition software of the University of Technology: how to systematically solve the problem of building industrialization and high energy consumption through standardized design, automated production, robot construction and prefabricated construction released by the China Association for Science and Technology? Ye Ming, Secretary-General of the Construction Industry Modernization Development Committee of the Architectural Society of China, Yu Hai, Secretary-General of the Major Engineering Committee of the China Building Materials Circulation Association, relevant leaders of China Construction Technology Co., Ltd., and relevant leaders of the Fourth Public Bureau of CCCC have provided guidance on the project for many times, and have made guiding plans for the direction of research and development.

To this end, we must seize the time to promote more projects, so that more projects can be implemented, so that more users can enjoy the economic and social benefits brought by new technologies and new equipment.

Liu Lijian took Suzhou Green Construction Housing Technology Co., Ltd. and Beijing Construction Engineering Tangshan Factory as examples to make a comparison and explanation after the implementation of the project.

First, the importance of production management software applications:

With manual dismantling, drawing, manual entry of BOM code, manual rebar reproofing, etc., the annual output of 60,000 cubic meters of manual analysis. Personnel composition: 4 technicians such as dismantling and drawing, 3 MES material code entry personnel, 2 manual rebar reinforcing bar personnel, a total of 9 people.

Using the drawing recognition software, the BOM code and material information are exported, and the equipment is transferred to automatic production, which shortens the traditional manual working time by dozens of times, automatically recognizes and dismantles the drawing, automatically imports the BOM code, and automatically turns the sample of the steel bar. Personnel composition: 2 people who read the map and transfer BOM code, a total of 2 people.

The equipment automatically reads and processes the drawings and processes, and the production and inspection processes are all automated, and the production process uses artificial intelligence to identify and inspect, which streamlines a large number of inspectors, and the production and inventory data management is clear and accurate. Production processes and equipment management are managed by digital twin systems, which are used to digitally construct an identical entity in the digital world, so as to understand, analyze and optimize the physical entity. Digital twins are one of the keys to realizing Smart Manufacturing 2025, Industry 4.0, Industrial Internet, CPS-based manufacturing, etc. Future production orders can be deduced in advance, pain points and problems can be found and solved in advance. The digital twin system controls the whole process of equipment, prompting timely and accurate production information, equipment status, maintenance reminders, automatic shutdown and other functions.

To sum up, 300 days of production per year, 200 cubic meters of production, can save 7 technical and management personnel.

Second, the importance of the application of electrodeless soldering machine:

At present, in the production of prefabricated component reinforcement products, stirrups and trusses have been automated, but in the production of reinforcement mesh, except for very few enterprises such as Suzhou Green Building, they are also manually tied. The manual binding cost is high, the labor intensity is high, the product quality is not well controlled, and the manual binding process of mesh has not matched the automatic production requirements of the prefabricated building, which restricts the normal development of the prefabricated building.

In response to the above-mentioned industry pain points, Yinfeng Company has developed a stepless welded mesh machine suitable for the quality and standard requirements of China's steel bars, with more advanced technology and superior performance. It can automatically replace steel bars of different diameters, with automatic straightening, welding, bending and other functions, and the spacing of transverse and longitudinal reinforcements of the mesh is not restricted by 50mm multiples, and can be adjusted infinitely, which is suitable for the automatic production of steel mesh sheets for prefabricated buildings. It has the characteristics of good welding quality, significant energy saving and emission reduction effect, low labor intensity of workers, and high production efficiency.

Comparison of the cost of electrodeless welded mesh machining and manual lashing:

1. For the production cost of manual binding mesh, we have to set some parameters first. Now, let's calculate the production of 200 cubic meters per day for 300 days per year. Manual binding cost = labor cost of steel bar background blanking + labor cost of mesh binding + depreciation cost of straightening and bending equipment + electricity cost + accessories cost + straightening and bending equipment maintenance and management fee. According to this formula, we can get the following set of data:

1) Labor cost of steel bar background blanking: The steel bar background blanking adopts the method of piecework, and the unit price of piecework is 25 yuan/cubic meter. Labor cost of steel bar background cutting = 300 days * 200 cubic meters * 25 yuan = 1.5 million yuan.

2) Labor cost of mesh binding: the unit price of the piece is 70 yuan/cubic meter. Labor cost of steel bar binding = 300 days * 200 cubic meters * 70 yuan = 4.2 million yuan.

3) Depreciation cost of straightening and bending equipment: 150,000 * (1-5%)/10 years = 14,000 yuan.

4) Electricity cost for straightening and bending equipment: 15kWh * 10h * 0.725 yuan * 300 days = 32,000 yuan.

5) Straightening and bending equipment annual accessories cost: 10,000 yuan.

6) Maintenance and management fee for straightening and bending equipment: maintenance 4 times a month, 2 hours each time, and the cost per working hour is 40 yuan. 4 times * 2h * 40 yuan * 12 months = 3,800 yuan.

Total amount: 5.7598 million yuan.

2. The production cost of the electrodeless mesh welding machine, we also calculate the production cost of 300 days per year and 200 cubic meters per day, and the production cost = the operation labor cost of the mesh production line + the labor cost of truss and mesh binding + the depreciation cost of the equipment + the electricity cost + the accessories cost + the equipment maintenance and management fee. We can also get the following set of data:

1) Labor cost for mesh production line operation: The production capacity of the mesh machine is about 260 sheets, which requires 2 operators and an average daily wage of 300 yuan/person. Mesh machine operator labor fee = 300 days * 300 yuan * 2 people * 2 shifts = 360,000 yuan.

2) Labor cost of truss and mesh binding: After the on-site use research of Suzhou Green Building, Beijing Construction Engineering and other units, the use of welded mesh, the laminated plate steel bar binding station only needs 2 people, no need to bind the mesh, only need to tie the steel bar truss and the mesh together, and the number of steel bar binding can be controlled at 2 people. Labor cost = 300 days * 300 yuan * 2 people * 2 shifts = 360,000 yuan.

3) Equipment depreciation cost: equipment depreciation cost of screen machine = 3.2 million yuan * (1-5%) / 10 = 305,000 yuan.

4) Electricity fee: deducted from the wire used in the reinforcement binding.

5) The annual cost of accessories is 60,000 yuan.

6) Equipment maintenance management fee: the mesh machine is maintained 4 times a month, and each time it is 4 working hours. 4 times * 4h * 40 yuan * 12 months = 7,600 yuan.

Total: 1.0926 million yuan.

To sum up, 300 days of production per year, 200 cubic meters of production in a single shift, the cost of manual binding is 5.7598 million yuan, the production cost of electrode mesh welding machine is 1.0926 million yuan, and the use of automatic mesh machine can save 4.6672 million yuan compared with manual binding production.

2) Comparison of the environment of the production site

Neat and clean stepless soldering machine production site 

Messy hand-tied production site

3) Quality assurance

Compared with manual binding, the quality of automatic steel mesh production line processing is more guaranteed. From the analysis of rich experience and practice, the steel mesh is manufactured by a fully automatic and intelligent production line, and the grid size, steel bar specifications and quality are strictly controlled, which avoids the omission of manual binding and the solder joints are firm. Lashing errors and cutting corners are avoided. Its mesh has large stiffness, good elasticity, uniform and accurate spacing, and high strength of welding joints, which greatly improves the quality of components. The longitudinal reinforcement and transverse reinforcement of the reinforced mesh form a network structure, so it has good bonding and anchorage with concrete, and the load is evenly diffused and distributed, which improves the seismic crack resistance of the prefabricated component structure. According to the actual test, the welded steel mesh laid on the road can reduce the occurrence of cracks by more than 75% compared with the manual binding mesh.

Since 2006, the global manufacturing industry has invested in management software, MES system ranks second, second only to ERP system, and many domestic enterprises have gradually begun to adopt this technology to enhance their core competitiveness. According to IDC (Internet Data Center) analysis, the total market share of China's manufacturing execution system (MES) software reached 3.09 billion yuan in 2020, with a compound annual growth rate of 24.3%, a significant increase from the past three years.

When the MES system is used, a large number of BOM codes must be manually entered into the system, which increases the labor cost and difficulty of use, and affects the promotion of MES. The automatic drawing recognition and export BOM code to the MES system of the TYF digital twin system solves the problem of manual entry, reduces the cost of using the MES system, and has broad market prospects.

Quoted from data from The Paper: In 2021, the global digital twin market will be 7.47 billion US dollars, which is less than 50 billion yuan, which is still a blue ocean market. By 2025, the global digital twin market is expected to reach US$26.46 billion (168.4 billion yuan), with a lot of market space.

Let's take a look at the potential of China's digital twin market from a few aspects: (1) Smart CitiesIn 2019, the scale of China's new smart cities has exceeded 900 billion yuan, and the market size is expected to exceed 1.3 trillion yuan by 2023. (2) Smart diagnosis and treatmentIn 2020, China's smart diagnosis and treatment industry has exceeded 100 billion yuan, with a scale of more than 120 billion yuan in 2021 and is expected to reach more than 150 billion yuan in 2022. (3) Smart mobilityIn 2020, the size of China's smart mobility market was 354.7 billion yuan, and it is expected to double to 700 billion yuan in 2025.

At present, the application of digital twins in United States and Germany is mainly in the national defense and military industries, and the penetration rate of digital twins in smart cities in China is at the advanced level in the world. It can be seen that the market potential of TYF digital twin system is huge, and it has a far-reaching impact on the future economy, science and technology, and life.

The convening of this conference has promoted the transformation of scientific and technological achievements in colleges and universities, and promoted the integrated development of science and technology and economy; It has promoted the development of China's prefabricated buildings from labor-intensive production methods to intelligent manufacturing automated production methods, and has played a milestone guiding significance for the future intelligent manufacturing of prefabricated buildings.