By Sonia Rani, Content Writer
 

In the era of rapid technological advancement, the specialty steel industry is undergoing a remarkable transformation. Intelligent manufacturing and auto- mation are revolutionizing production processes, enhancing efficiency, and setting new standards for quality and safety. From electric hoists in steel production workshops to precision gears for automotive manufacturers, the integration of advanced technologies is driving unprecedented growth and innovation. This article explores how smart factories are becoming the cornerstone of modern industrialization, paving the way for a future where productivity and sustainability go hand in hand.

Electric hoist, the “lifting mechanism” in the crane.In the production workshop of DAFANG CRANE,all kinds of electric chain hoists are being sent to various places in a hurry. In the past 20 years, relying on the road of “new industrialization”, the number of “gourds" sold by DAFANG CRANE has risen from 10,000 units per year to 40,000 units per year.

Automation upgrades boost production efficiency

Looking upstream from the small hoist at the downstream end, the specialty steel and new materials industry chain shows a thriving production of bearings, gears, and other components. On the path to advancing new industrialization at full speed, this region has played the "trump card" of specialty steel and new materials, becoming a national demonstration base for new industrialization.

If you disassemble an electric hoist, its core components are quite simple: motor, reducer, drum device, and hook. However, the seemingly simple reducer is composed of more than 40 parts, which determine the smooth operation of the lifting equipment. In the past, it took four processes, four workers, four loading and unloading operations, and four transitions to turn a single part from a rough blank to a finished product, which was time-consuming and labor-intensive. With automation upgrades, not only has unmanned operation been achieved, but the processing time for a single part has also been reduced from 28 minutes to 14 minutes, saving 16.56 yuan per part.

Building a Smart Workshop for New Industrialization

In the special steel production workshop, the electric hoist produced by DAFANG CRANE is constantly running in the air, which facilitates the production of special steel and witnesses the emergence of a new industrial model-the "lighthouse factory".

Accelerating the forging of new productive capabilities is evident in this workshop. The entire process, from raw materials being transported from the ship to the blast furnace, to being pressed into products, can be digitally collected, analyzed, and scored. The factory has developed a digital brain, the "Smart Center", which has successfully predicted 17 potential accidents, with the breakdown results matching the system's predictions exactly.

The modernized workshop completely overturns the traditional image of a steel plant. The vast hot rolling workshop, previously dependent on 69 on-site heavy labor and harsh environment positions, now only requires two workers on site thanks to AI technology. Workers receive system alerts and quickly identify and resolve issues, such as a damaged QR code on a steel raw material during transportation, within minutes.
Notably, the new intelligent workshop also uses AI for autonomous product design and development. Originally, developing a new product took 13.6 days, but with deep AI involvement in the design process, it now takes only 5.9 days.

Pursuing the Next "Unmanned Factory"

The intelligent specialty steel factory has become highly sought after by downstream enterprises and a designated material supplier for many automobile brands. One automotive manufacturing company uses steel from this smart factory for some of its precision-forged gears. "Perfect engagement of four bevel gears forms a differential, allowing cars to turn corners," explained the company's general manager. This critical safety component for driving was previously limited to 2,000 units per day but can now produce 20,000 units, with the second phase expected to exceed 30,000 units.

This tenfold increase is attributed to the automated production line. In the mold processing workshop, starting the machining program with a single click produces a set of level 3 precision gear molds in six hours. On the gear finishing production line, gantry robots operate at high speed, completing the precision finishing of 400 bevel gears in half a day. "Increased speed, improved precision, and reduced transmission gaps between gears meet the low-noise requirements of new energy vehicle powertrains." To achieve higher quality development, the company is planning to create an "unmanned factory."

The second phase of the new "smart workshop" is about to be operational. Previously, stacks were limited to five layers with safety risks; now, with the 'Steel Intelligence Hub,' they can go up to twelve layers, saving space and ensuring first-in, first-out material handling. Inside the factory, palletizing robots shuttle back and forth, automatically weighing, storing, cutting, and sorting steel billets, which emerge as qualified billets. These billets are sent to the newly launched "cold-warm combined forging production line," reducing the completion time of precision-forged parts from eight days to just one. This advancement further enhances the path of new industrialization for the company.

With continuous advancements in automation and intelligent manufacturing, the specialty steel industry is setting new benchmarks for efficiency and precision. The transition towards unmanned factories not only enhances production capabilities but also ensures higher quality and safety standards. As these innovative practices become more widespread, the industry is poised to meet the growing demands of modern technology and sustainable development. The future of specialty steel manufacturing looks brighter than ever, driven by relentless innovation and a commitment to excellence.