In May 2018, Unitoon accepted “The IoT intelligent monitoring project of aggregates processing system in Wudongde Hydropower Station”, which, in accordance with ‘Sinohydro Bureau 7 Co.,Ltd.’, was to intellectualized reconstruct “Wudongde Aggregates and Concrete Project”. Advanced technologies such as the internet of things, big data, mobile internet, data mining etc. was added into intelligent management of stone production line, helping to increase production efficiency, reduce operation costs, higher safety production factor.
Sinohydro Bureau 7 Co.,Ltd., borned in 1965, is one of the wholly-owned subsidiaries of Power Construction Corporation of China with two-billion-yuan registered capital, the total assets of the enterprise has exceeded 30 billion yuan. The company has over 10 professional contracting qualifications, such as special grade of general contracting qualification for national water conservancy and hydropower project construction and level one of general contracting qualification for municipal public engineering construction.
Wudongde hydropower station is located on the mainstream of Jingshajiang river, which is at the junction of Luquan county, Yunnan province and Huidong county, Sichuan province. This hydropower station is the most upstream cascade power station in the lower reaches of Jingshajiang river(the other three hydropower stations are Baihetan, Xiluodu and Xiangjiabei). It is a major hydropower project built in the lower reaches of Jingshajiang river during the twelfth five-year plan period. Wudongde hydropower station is the fourth hydropower station in China and the seventh hydropower station in the world, which has reached the rank of ten million kilowatts.
The sand and aggregate crushing and screening production line of Wudongde hydropower station, which covers an area of around 90,000 square meters (equals to 12 standard football fields), is the main sand and aggregate processing base of Wudongde power statioin project. It mainly offers products to the commercial mixing station built by hydropower station for its own use. The design capacity is 1000 t/h and the outcomes mostly are secondary aggregate concrete and tertiary aggregate concrete, which satisfy the requirements of enigneering concrete for power station besides the dam.
Wudongde project is a typical existing line reformation project, of which the biggest difficulty is the existing production and equipments cannot be influenced, meanwhile, intelligent reconstruction must be implemented. Facing these problems, Unitoon has found some coping methods.
Problem 1 : Time
Difficulty: Reformation of the project cannot affect the routine production line.
Method: Under the circumstances of poor working environment, Unitoon team works between 7 a.m. to 11 a.m. ( while operation time of the production line is 11 a.m. to 7 a.m. next day). All the staffs live under the same roof and eat at the same table, together with production line workers. The project has taken two months to be finished, and no influence has been made.
Problem 2: Equipments
Difficulty：It is more difficult to add sensors on the existing equipment.
Method: After field research, Unitoon has made a detailed euqipment upgrading plan, which includes installing proper sensors on the equipment in a proper way and then collecting vital data for later control and analysis.
Problem 3: Field wiring
Difficulty: The situation on site is complex, and the wiring diagram should be adjusted according to the actual condition.
Method: Senior engineers have been dispatched, cooperating with field workers. Proper wiring circuit and better wiring plan has been implemented.
As to the software upgrade.
In accordance with customer-specific requirements, Unitoon offers six subsystems, including Intelligent Distributed Control System, Spare Parts Management System, Cost Analysis Management System, Intelligent IoT Monitoring Center, “Unitoon JiZhi” Webpage, “Unitoon JiZhi” Smartphone.
Intelligent Distributed Control System (DCS)
In order to keep the original control cabinet, a console in the sub-control room is used to control the equipment operation, which is to avoid the existing production system being influenced.
Load of production line automatically collaborative and optimized. The equipment could be remotely controlled by virtual start and stop buttons. The equipment working status and alarm messages could be monitored intensively. Equipment failure could be found instantly and troubleshooting time is saved. When emergency happens, the equipment will shut down automatically.
Spare Parts Management System
Spare parts and easily damaged parts of the main and auxiliary equipment could be intelligently managed. Stock-in and stock-out operation, demand forecasting are designed to effectively controlled and track the storage/logistics/using condition of spare parts, which provides an integrated and clear spare parts management system to the custmer.
Cost Analysis Management System
According to the information of production line capacity, integrated energy consumption, easily damaged equipment consumption, system of production cost index and assessment index is designed and statistical reports will be generated. The distribution of production cost could be clearly known, and thus control level of production cost about the sand and aggregate processing system could be increased.
Intelligent IoT Monitoring Center
Combined with the existing signal panel in the monitoring center, signal linkage could be realized. Splicing display of the screen could be done if needed. Staffs could obtain equipment operation data, alarm messages through the big screen. Video monitoring could also be achieved.
'Unitoon JiZhi' Webpage
The functions of 'Unitoon JiZhi' Webpage contain equipment production monitoring, history query, cost analysis mangament, spare parts management, material scheduling, maintenance log etc.
To satisfy the requirements of staffs in different positions, on the basis of different application fields, production supervision application system of production run and equipment status, after-sales service system of maintenance and fault management, professional analysis system of data analysis are classified, which make 'Unitoon JiZhi' Webpage be truly useful to mining management.
'Unitoon JiZhi' Smartphone
'Untioon JiZhi' Smartphone is made up of three modules, including production analysis, equipment supervision and event record, by which the mining manager could quickly understand the overall operation situation of the production line.