Analysis on the Progress and Insufficiency of China's Equipment Automation

In recent years, China's equipment automation has made considerable progress. There have been breakthroughs in petrochemicals, metallurgy and other industries. However, there are still many problems in the main problems of China's equipment automation, such as: low self-innovation capabilities, lack of independent intellectual property rights. There is a gap in product performance and it is difficult to enter major projects.

China's equipment industry has achieved a lot of major achievements. In terms of power generation equipment, it completed 90 million kilowatts in 2005. By the end of 2005, the country’s total installed power generation capacity reached 50.841 million kilowatts, a year-on-year increase of 14.9%. The nation’s power generation capacity reached 2,474.7 billion kwh, a year-on-year increase of 12.8. %; The total electricity consumption of the whole society was 246.98 billion, a year-on-year increase of 13.5%; by 2010, the installed capacity of the country will reach 650 million kilowatts. China's power generation equipment has formed independent industrial capabilities represented by Harbin Power Station equipment, China Dongfang Electric and Shanghai Electric. Among the more than 200 sets of 200,000 kilowatts of thermal power units in operation, domestically produced generators account for 70% and more than 40 sets. In the 600,000-kilowatt thermal power unit, domestically-made generators account for more than 25%. On the basis of digestion and absorption, it has been able to produce 600MW subcritical, supercritical and ultra-supercritical coal-fired power stations. It is capable of mass production of 1000MW large-scale thermal power units, 1000MW large-scale nuclear units, 700MW large-scale hydropower units, and large-scale gas turbines and large-scale Circulating fluidized bed boiler.

In terms of petrochemical equipment, the one-million-ton ethylene equipment and large-scale PTA equipment have become the centerpiece of the revitalization of petrochemical equipment. It represents the highest level of petrochemical equipment in the world today. In 2005, China’s ethylene production capacity was 9 million tons/year, and it is expected that in 2010 China’s ethylene demand will reach 25 to 26 million tons, while the production capacity can only reach 14 million tons, which can only meet 55% of domestic demand. By 2010, China will need to add about 800 sets of 800,000 to 100,000 tons of ethylene equipment. China has been able to provide complete equipment for 10 million tons of kerosene, 3 million tons of hydrofining and 1.5 million tons of hydrocracking units. China's own design and manufacture of 6000 meters of electric-driven desert oil drilling rig, large-scale ethylene engineering major equipment (including ethylene cracker, polyethylene and polypropylene devices, etc.), 300,000 tons of ammonia equipment key equipment, large-scale urban coal gasification equipment and other large equipment It is also widely used in national key projects.

In terms of metallurgical equipment, China has been able to produce 1700 hot continuous rolling, 1780 cold continuous rolling, 3500 medium and heavy plate rolling, and other internationally-advanced hot and cold continuous rolling mills, slab casters, large-scale liquid pouring machines, 4063 cubic meters. Blast furnace, 6-meter coke oven, 2 million-ton large-scale open-pit mine equipment, and large-scale rough lead smelting Ailong furnace, fuming furnace, roaster, etc., advantage manufacturing companies have the first heavy machinery plant, the second heavy machinery plant , Shanghai Heavy Machinery Factory, Shenyang Machinery Factory, Taiyuan Heavy Machinery Factory.

In numerical control equipment, China's numerical control technology began in 1958. After 50 years of extraordinary development, China's domestic CNC equipment has made substantial progress in R&D and industrialization. By 2003, the domestic market share of domestic CNC machine tools It has reached 50%, and the popular model equipped with a domestic CNC system has also reached 10%. China has laid the foundation technology of numerical control technology, formed Huazhong CNC, aerospace numerical control and other numerical control system production plant, Lanzhou Electric, Huazhong CNC servo system, servo motor production plant, Beijing, a machine, Jinan, a machine and other CNC host production plant.

In recent years, China's equipment automation has also made significant progress in power generation equipment automation systems, HOLLIAS-MACS, HOLLIAS-PLC, HOLLIAS-PADS and other distributed open control systems, fieldbus open control systems, power station distributed control systems and other major equipment The automation system breaks through a large number of technical difficulties, such as real-time data replication technology, data shunting and interception technologies, intelligent fault diagnosis technologies, and integration technologies of furnaces, machines, and stations, and makes the system from the level of technology to the architecture, from Hardware performance to software. The functions and other aspects have reached the advanced level of imported similar products. MACS also passed the IE-level nuclear safety certification. The system defeated many multinational companies in the 600MW unit, successfully won the bid for 4 projects, and achieved good results in nuclear power. Application performance.

In the metallurgical equipment automation system, the Metallurgical Automation Research Institute has been able to independently develop and fully master the large-scale hot rolling rolling mill drive AC speed control system technology, and overcome the high-power cross-converter design theory and manufacturing technology, to pay the frequency converter hot strip mill transmission speed Control and anti-torque technology, handed over eight technical difficulties such as frequency converter hot strip mill load observation and control technology, and at Panzhihua Iron & Steel 1450 Hot Continuous Rolling, Chuanwei 950 Hot Continuous Rolling, Beitai 850 Hot Continuous Rolling, Jianlong 1780 Hot Link Successful application of rolling automation system.

In the petrochemical equipment automation system, SupconDCS, WebfieldECS and other major equipment automation systems, the comprehensive use of device modeling technology, advanced control technology, intelligent control technology, equipment optimization technology, fault diagnosis technology, data mining technology and related process technology, successfully solved the large-scale The optimization and control of major equipment such as oil refineries, large-scale chemical plants, and large-scale petrochemical plants; also developed Multif series multi-function meters, Superfield series of smart transmitters, and eventually formed a complete set of major equipment automation systems. At present, the system has sold more than 4,000 sets, which has a market share of 57% in this field and has become the most widely used control system in the country. In the bidding with many large foreign companies, they have repeatedly won the bid.

In the light industrial equipment automation system, Kunming Ships implemented the silk machine automation system at the Yunnan Honghe Cigarette Factory. The system uses image recognition technology to identify impurities in fast-passing tobacco through high-speed video capture. The recognition rate reaches 84%, and accuracy is only once. A percentage point in the United States. The system has made breakthroughs in special detection technology. It uses infrared technology to quickly determine the moisture of tobacco shreds, uses nuclear radiation technology to determine the weight of tobacco shreds online, and uses ray to quickly determine the particle size of shredded tobacco. All detection precisions have reached the international advanced level. These key technologies were successfully applied on the new 8000 kg/hour wire making machine, making the Honghe Cigarette Factory the top three in the world: overall automation level, per capita physical labor productivity, and single brand sales. The system has been widely used in domestic large and medium-sized cigarette factories.

The main problems existing in China's equipment automation are the low capability of independent innovation and the lack of independent intellectual property rights. The specific performance in domestic high-end automation products is scarce, and the market competitiveness is not strong. In 2004, China's domestic control system was 3240 sets, accounting for 61%, but the domestic market share of high-end control systems only accounted for 5%; and domestic smart transmitters that were equipped with equipment automation systems had a market share of 27% in 2004. However, the high-end smart transmitters are less than 5%; they are particularly suitable for complete sets of special control systems or complete sets of special optimization systems for large and medium-sized equipment. In 2004, the market share of domestically produced systems reached 30%, but domestic high-end complete sets of special control systems or optimization systems are almost Zero.

There is a gap in product performance and it is difficult to enter major projects. Most of China's control systems have a large gap with foreign advanced products due to their high reliability, high stability, and high environmental adaptability, as well as digitalization, intelligence, and integration. At the same time, due to government understanding, domestic control It is very difficult for the system to enter key equipment, core equipment, and main equipment of major projects in China. Most of them are monopolized by foreign control systems. For nuclear power equipment, 25 sets of home-made control systems have been used in Qinshan Nuclear Power Station, Daya Bay Nuclear Power Station, etc., but all of them are external nuclear power units. Another example is the use of petrochemical equipment in large-scale refineries, large-scale chemical plants, and more than 3,000 applications, but less than 50 applications have been applied to core equipment.

The "strong middle and weak ends" control system is very serious. The main control system in the domestic equipment automation system has strong R&D strength, sufficient input funds, rich technical results, and high product quality. However, as the two ends of the control system transmitter and actuator, long-term input serious shortage, research and development power is thin, low product quality, China's own design and manufacture of smart transmitter in the domestic market share is only one-tenth of foreign products This is especially true for smart actuators. With the characteristics of miniaturization, digitization, intelligence, integration, and networking, high-precision, high-reliability, and high-accuracy are the goals of small size, light weight, low cost, and low power consumption. There is a big gap.

Utilities large-scale equipment automation control system is very backward. Public large-scale engineering equipment refers to large-scale engineering machinery equipment, large-scale mining machinery equipment, large-scale port engineering equipment, large-scale traffic engineering equipment, and large-scale urban engineering equipment. For a long time, insufficient capital investment, weak research and development forces, and lack of modern control theory and methods. , technology integration. China has designed and manufactured large-scale excavators, large-scale pavers, large-scale loaders and other major equipment. Most of the control systems are provided by foreign countries. China's own design and manufacture of large-scale injection molding machines, large-scale integrated machine tools and other major equipment, complete sets of automated systems are provided by foreign countries. These factors have seriously affected the rapid development of China's equipment manufacturing industry.