Zhou Qian Commentator: Industrial Automation Is the First Step in the Intelligent Era
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Ren Zhengfei, the founder of Huawei Technologies, is very objective in his judgment. He believes that this is an era of artificial intelligence. First, it must emphasize industrial automation; after industrial automation, it will be possible to enter informationization; only after informationization can intelligence be realized. Chinese industry has not yet completed automation, and many industrial companies cannot even achieve semi-automation.
Therefore, before exploring Industry 4.0 and industrial uninitiated, it is necessary to understand the historical origins, technical origins, and economic significance of related concepts.
Automation is the Prelude to Intelligence In the 1980s, the American auto industry was worried that it would be defeated by Japanese competitors. In Detroit, many people are looking to beat their opponents with "light out production." "Light extinguishing production" means that the factory is highly automated and the lights are turned off, and the robots themselves are making cars. At that time, this idea was impractical. The competitive advantage of Japanese car makers in that year was not in automating production but in "lean manufacturing" technology. Lean production in most cases relied on manpower.
Nowadays, advances in automation technology have made “light-out production†a reality. Japanese robot manufacturer FANUC has been able to put some of its production lines in an unattended environment and run autonomously for weeks.
German Volkswagen aims to dominate the world, this auto industry group has formulated a new production strategy: modular transverse moments. Volkswagen wanted to use this new process to produce all models on the same production line. This process will eventually enable the masses to adapt their facilities in locations around the world to produce any models needed in the local market.
Many years ago, Qian Xuesen once said: "As long as the automatic control is done, even if the components are a little inferior, the missile can hit the sky."
Today, automation will largely mimic human intelligence. Robots have been used in industrial production, marine development, and space exploration. Expert systems have achieved remarkable results in medical diagnostics and geological exploration. Factory automation, office automation, home automation and agricultural automation will become important contents of the new technology revolution and will be rapidly developed.
As a whole, China's traditional industries still have a big gap in terms of technical equipment, energy and raw material consumption, product quality, and management level compared with industrial powers. In particular, the gap in technical equipment (such as high-end CNC machine tools) has expanded. . Large-scale equipment upgrades cannot be sustained by the state; maintaining the status quo of equipment will lead to disastrous consequences. Only by applying automation technology to transform traditional industries can the company's quality be improved most effectively.
The economic take-off of Japan and Germany started here. Prior to 1986, the United States did not attach enough importance to the application of automation technology, so that it lost its dominant position in traditional industries such as automobiles, machinery, raw material industries, computers, and electronic components. Later, the United States rushed to catch up, attached great importance to industrial automation technology, and used automation technology to transform traditional industries, resulting in tremendous benefits.
The status quo of automation in various industries in China lags far behind that of industrial powers. For any enterprise, without the support of powerful and advanced automation systems, the quality and output of its products are difficult to reach the world level. Such as the welding process, the quality of the manual operation is not easy to control, and the appearance alone does not show the quality. If operated by industrial robots, the details of each process can be standardized, and welding quality and efficiency will be higher.
This is why, even if China's economic growth rate is declining, the demand for industrial automation technology in China's domestic market, especially in the manufacturing industry, will only increase. Automation technology can make "Made in China" calcium and boost China's industrial rejuvenation.
Artificial intelligence and unmanned factory unmanned factories are the result of a comprehensive upgrade of automation technology. The basic feature is that all production activities are controlled by electronic computers, and the production line is equipped with robots without workers.
The world’s first experimental unmanned factory was built in April 1984 in Tsukuba Science City, Japan. Japan is relatively lacking in manpower. Therefore, it began to value the machine very early, and took the lead in constructing an unmanned factory that can increase production efficiency.
In an unmanned plant that uses artificial intelligence, all work is done by computer-controlled robots, CNC machine tools, unmanned transport cars, and automated warehouses. People do not directly participate in the work. Workers became "commanders" and "doctors." During the day, only a few workers in the factory did some checks and revised some instructions; at night, only two or three monitors were left.
Today, unmanned factories have become quite popular in the fields of automobile and aircraft manufacturing. Almost all of these production lines are operated by robots, and people play an auxiliary role next to them.
However, it is not easy to translate artificial intelligence into industrial applications. This is a complicated system project. Unmanned factories have to break through a number of key technologies, including flexible production technologies, industrial robot control technologies, overall safety and monitoring technologies, and safety monitoring of all machine systems. The status of each robot, the status of each instrument, and any problems must be given early warning.
The core equipment in unmanned factories is industrial robots. After nearly half a century of rapid development, robotics technology has become more mature. It has been widely used in many industrial fields, such as automobile manufacturing, machinery manufacturing, electronic devices, integrated circuits, plastic processing, etc. Large-scale production companies are involved in the application of industrial robots.
Industrial robots and other automation technologies represent high-end applications for industrial automation, and ultimately achieve industrial intelligence, unmanned, and there is still a long way to go.
The systematic integration of industrial value chains is the key to industrial unmannedness. The industrial value chain mainly includes several parts such as product design, production planning, production engineering, production execution and services. These were previously implemented separately. Today, various new technologies integrate these separate parts. The future of manufacturing is to find the best combination of these technologies and learn to use them as a complete system. In this way, the overall advantages of the integrated system can be obtained, thereby promoting a significant increase in manufacturing efficiency.
To do this requires the integration of all the high-tech tools of the manufacturer's head, which is a test of comprehensive technical capabilities.
From "smart eyes" to "sage"
If the key to industrial unmannedness lies in the system integration of the industrial value chain, which lies in intelligent manufacturing, then the core of intelligent manufacturing is from "smart eyes" to "sage".
In the future, the manufacturing industry must be oriented toward more and more refined, humanized, and individualized development. It is inevitable that it will move toward unmanned production and smart manufacturing. This depends on smart manufacturing. Its core competitiveness is faster and more accurate. The core of smart manufacturing is “intelligenceâ€, which means quick and accurate information acquisition and fast and accurate information processing. As the match between martial arts masters, the fight is "hands and feet and body methods", and "eyesight" and "trick" is the core key.
The system integration of industrial value chain requires the combination of vision and image technology. It is to install a pair of super “intelligent eyes†for industrial equipment. In the future, industrial production will be centered on "smart eyes", equipped with thousands and thousands of devices, and commanding various "hands, feet, and bodies" to achieve "deep perception, intelligent decision-making, and automatic execution." "To become a "sage."
Imagine that in an electronic product manufacturing plant, the size of various chips and components has been reduced from a few millimeters to tens of micrometers to tens of micrometers. The welding and assembly of components are guided by the robot under the guidance of the vision system. Operation, as the size and quality of the device are reduced by several hundred times, the assembly speed is greatly increased, hundreds of operations can be completed per second, and the production efficiency is increased by a factor of 100.
The vision system realizes multi-angle stereo imaging. The combination of large-scale millimeter-level imaging and ultra-precise micron-level imaging enables the entire system to simultaneously acquire image information in real time, and comprehensively complete target positioning, accurately measure, and issue precise motion instructions. Once a solder joint of a product has a problem, such as a qualified soldering area of ​​2 μm, it actually reaches 0.85 μm. This will increase the impedance of the signal transmission and cause the operating frequency to fall below the normal range. The vision system immediately guides Inspect the robot and remove the waste to the branching process for repair. Each imaging unit in the assembly plant monitors various environmental indicators and integrates all image data and other data into a central information server. The problem was found, and the hidden troubles were eliminated immediately. The system was operating at a fast speed.
Smart manufacturing requires “fast and accurate†visual imaging for smart identification, smart measurement, smart detection, and smart interconnection.
The intelligent identification is to find the target for the next operation. The target identification needs to find the key features from a large amount of information. It needs to quickly converge the massive information. The degree of intelligence is required to be high. Accuracy and reliability are the keys, depending on the accuracy of the smart measurement. . Complete on the basis of measurement.
Intelligent detection, according to the degree of deviation between the measurement results and the target, to determine whether the pass, but the test is often not the result of a single index comparison, the need for comprehensive analysis of multiple information and multiple indicators to determine.
Smart interconnection, or Internet of Things (IoT), is based on big data. Data interconnection is like a person's brain neuron. When information and nodes exceed a certain number, autonomous learning and autonomous creative abilities can be produced. A large part of industrial big data originates from visual imaging. When massive data of images are collected and interconnected in multiple nodes, and people, equipment, production materials, environment, and technology are interconnected, deep learning, intelligent optimization, and intelligent prediction will be derived. Other innovation capabilities show the true power of big data and smart manufacturing.
Low-cost product customization The German industry has divided the historical process of the 200-year industrial revolution into four phases: the mechanized industrial revolution marked by the steam engine 1.0, which has resulted in the liberation and dramatic increase of human strength; and the electrification industry marked by electricity. Revolution 2.0 realized a large-scale assembly line operation and created a new model for mass production of standardized products. The Automated Industrial Revolution 3.0 marked by microelectronics and computers realized proceduralized automated production. It not only freed physical labor but also partially took over mental labor. ,Industry enters the less-humanized; Industry 4.0 is in-depth promotion to the two major directions, the product is customized, the manufacturing end is intelligent, unmanned.
Do not simply think that using a robot to replace the streamlined operation of the shop workers in the production workshop is a smart factory, or the industry is unmanned.
True intelligent manufacturing and industrial unmanned far more than this. They are the exploration of manufacturing companies from the single product manufacturing to the smart manufacturing ecosystem and the transition to products and services. Through intelligent, unmanned transformation, the cost of individual production of customer-specific products can become the same as the cost of mass production.
The advanced stage of combining traditional industrial production with modern information technology is that every production link in the factory is clearly visible and highly transparent, and the entire workshop runs quietly and efficiently. Industrial robots and other automation equipment not only cooperate with each other, but also Global employees, customers, and smart analytics dynamic systems collaborate.
The transformation of information technology has realized the intelligent manufacturing of products, and the greater change is the production organization mode: by analyzing the historical purchase volume of customers and the data of medium and long-term needs, the production time and quantity can be independently arranged according to the output capacity, and the account managers, Operators and raw material suppliers "string" on the same information chain.
The future factory, that is, the unmanned smart factory, represents the high-efficiency park: the problems of defective products, downtime, waste, and waiting all disappear. Factory managers and CIOs (Chief Data Officers) work together to ensure that data is seamlessly integrated with production, IT and manufacturing, with each rotation of each machine, every cutting of every tool, and every component of the global delivery chain. Every time you transport, you can see everything.
Establishing System Advantages and Addressing International Challenges The unmanned industrialization is essentially a microcosm of industrial manufacturing's intelligentization and high-end production. The premise is that industrial automation continues to leapfrog and upgrade. Stepping into Industry 4.0, we must first go through 2.0, 2.5, and 3.0. In the meantime, think about whether a company or a team can grasp these tools of the information revolution to overcome the fortress of the Industrial Revolution.
After the intelligent transformation of the manufacturing industry, the personnel structure will shift from the pyramid of the primary line of industrial workers to the more and more trapezoidal transformation of the middle skilled workers. The "unmanned factory" is not entirely unmanned. It is the pursuit of a kind of organic interaction and balance between people and machines.
In recent years, the domestic labor-intensive "million factory" has become more and more close to Boli and even zero profit. Enterprises and governments often look at industrial informatization and unmanned people based on cost pressures and the “machine-for-agent-driven-industry-upgrade†perspective. What should really be considered in depth is how to use smart equipment to change the process of production, solve the problems of the manufacturing cycle, cost, and the entire process flow, and make the products more competitive, so as to realize the transformation and upgrading of the entire system.
The transformation and upgrading of manufacturing industry, in addition to the highly-focused industrial 4.0 in China, or the deep integration of informatization and industrialization, there is also a dimension of globalization.
At the macro level, the government is advancing the “going out†strategy and encouraging some Chinese traditional manufacturing industries with advantages to shift production capacity overseas; at the micro level, large domestic manufacturing companies highly emphasize the need to create international companies.
However, the deep integration of informatization and industrialization will inevitably impact the global thinking of domestic companies. The Industry 4.0 model can basically be unmanned, and the unmanned industrialization will surely impact the global manufacturing industry. Whether it is the same in the United States, Europe, China, or Southeast Asia or South Asia, the gap based on labor costs has disappeared, and the manufacturing structure of the entire world will be rewritten and refreshed.
Industrial 4.0 or Made in China 2025 will bring a new era of “sweepingâ€. Under the new circumstances, how can globalization be promoted and what advantages be used to achieve globalization?
The intelligent transformation of manufacturing has become the consensus of the government and entrepreneurs. "Machine Substitution" promotes industrial innovation, upgrades, and automation. It is necessary to comprehensively consider the six major groups of robot technology inventors, entrepreneurs, industrial capitalists, application pioneers, base attendants, and industrial organizers in the process of policy formulation and implementation. The actual needs. Integrate resources and seek innovation breakthroughs at the system level (system framework, development direction).
Industrial upgrading for smart manufacturing is not an upgrade of a single technology or even an industry. Instead, it reshapes the entire industrial system with new operating methods and closer industrial interaction. This transformation upgrade is not as simple as upgrading several production lines or designing a new generation of products. It puts forward higher requirements for the ability to grasp the industrial global (ie top-level design) from the system level. The informatization and unmanned transformation and upgrading of China's manufacturing industry in the future is to create a “full-chain†ecological environment and industrial system, establish systemic advantages, and respond to international challenges.
(Original title: Industrial unmanned technical origin and economic prospects)