Recently, Zhejiang Zhongcong Technology Co., LTD. (hereinafter referred to as: Zhongcong Technology) participated in the construction of a large domestic chemical group industrial universe project final acceptance meeting successfully held, which marks the first Yuan factory of Zhongcong technology in the chemical industry successful acceptance, the relevant leaders of co-construction units, Zhongcong Technology assistant President Wu Yucheng, Zhongcong Zhixin general manager Zhang Jian attended the acceptance meeting.

Zhongyuan factory solution has created a new set of production interaction methods for enterprises, which will effectively help partners achieve collaborative control and global optimization of all elements in the industrial system and production process, form a new production mode of man-machine collaboration, virtual and real mutual control, and digital integration, and lead the intelligent transformation. In the meta factory, the device has a set of process twins whose process mechanism and data performance are consistent with that of the real factory, and the employee has a twin role that continuously develops with the integral development of the production process. The process twin and the twin role combine the device portrait and personnel portrait derived from the production data to present the health of the device, production efficiency and organizational efficiency in real time. At the same time, the three-dimensional scene integrated with data and mechanism also provides an immersive interaction and training environment for employees. To help enterprises realize the visualization, transparency and intelligent management of the entire production process, and better meet the individual needs of customers, is the inevitable road to reach the intelligent completion of the future process industry.

01 Process twin of the device

Process twin is a process industrial process simulation and design platform (APEX) based on central control technology, which follows the principle of “three transmission and one reverse” and maintains the real-time mechanism model consistent with the data and process of the device. Its comprehensive prediction of temperature, flow rate, pressure, composition, heat and so on, which are difficult to measure and analyze in real time, supplements the unmeasured data needed to depict the device portrait, provides a platform for production personnel to study new processes, trial and error new operations, and reproduce abnormal working conditions, and solves the problem that traditional enterprises are difficult to predict analysis and abnormal judgment by relying on experience and historical working conditions.

In this project, the process twin accurately predicted the composition distribution of main and side reactions in different positions of the reaction section and the reflux composition distribution of the reactor in a reaction section, providing a basis for improving the quality and efficiency of the device. After the device was improved, the yield of the main product was significantly improved.

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02 Twin roles of employees

In the meta factory, the system associates production data to conduct real-time evaluation of job tasks, that is, to evaluate the safety, stationiness and compliance of the operation process and results of the job from multiple angles, provide evaluation data needed to depict personnel portraits, and form twin roles for objective evaluation of work quality. It solves the problem of less objective, more subjective, less process and more result in traditional performance evaluation of enterprises.

In this project, the twin roles of installation personnel have been integrated into the actual management process, driving employees to pay attention to the safety, stability and efficiency of the production process, mobilizing the coordination of all links of the production management system, and achieving high-quality growth of man-machine coordination.

03 Immersive training and collaborative improvement

Employees can wear VR headsets and enter the immersive virtual scene of the Yuan factory, which restores the on-site devices and control screens, and complete the opening and parking of the devices and emergency handling in both internal and external operation roles, breaking the dilemma that traditional enterprises are difficult to train with “one post and multiple capabilities” and difficult to be immersive in safety training. Employees can also wear AR helmets, and in the field operation and inspection of the device, with the help of augmented reality and process simulation technology, they can always grasp the upstream and downstream data of the equipment in front of them and the internal situation of the equipment, reducing the information asymmetry between internal and external operations in traditional production, improving the efficiency of operation collaboration, and helping field employees to fully understand the process equipment.