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The upsurge of smart manufacturing and smart factories has swept the world, changing the production and business models of many industries, and the glass deep processing industry is no exception. In the face of various smart factory concepts, Jinan LIJIANG Glass summarizes the knowledge and experience in the design and construction of smart factories to help you understand smart factories and calmly face intelligent changes.

The smart glass deep processing factory

 The smart glass deep processing factory 1

1. The smart glass deep processing factory does not mechanically connect the main processing equipment 

Some business owners believe that as long as all the host equipment is connected with the transmission station, it is a smart factory; however, in actual production, the work in process is difficult to move under this kind of mechanical connection. The reason is that the essence of the smart factory is ignored: production Beat. In the actual glass deep processing production process, the beat of each main processing equipment is different. Only through professional design, planning, and the overall scheduling of ERP and MES systems can intelligent production be realized. Jinan LIJIANG Glass fully automatic hollow glass air flotation production line can be connected to the ERP system according to the actual needs of the glass deep processing owner, to realize the accurate transmission of production data during the glass processing and the unity of deployment and production.

2. The total investment scale of the glass deep processing smart factory is closely related to the production model  

Different production scales, product types, and production shifts all affect the total investment of smart factories. Take the input cost of the film management system as an example. In the continuous production mode, the film management system is in circulation, and the capacity does not need to be too large; if the enterprise takes advantage of the difference between day and night time-of-use electricity prices, adopts the mode of cold processing during the day and tempered production at night, it is smart In terms of factory design, the capacity of the film processing system before the tempering process should be greater than the daytime cold processing output, so the input cost of the film processing system is bound to increase.

The Glass processing film management system 1

The glass processing film management system 1

3. How low is the energy consumption of the smart glass deep processing factory?

Compared with the traditional factory, the smart factory has a slight increase in electricity consumption due to the newly added film management system and in-line transmission mechanism. According to the actual calculation of Jinan LIJIANG Glass in the customer's factory, the annual production capacity is 800,000-1 million square meters of architectural glass. The hourly electricity cost of a smart factory is 60-100 USD more than that of a traditional factory. However, because of the increase in production efficiency, cutting rate, and tempering loading rate, the equipment startup time is reduced, and the annual electricity bill is saved as much as 6 to 100 million dollars .

4. Does the smart glass deep processing factory still use labor?   

Smart factories still need labor, but they require less labor and high-quality requirements. According to Jinan LIJIANG Glass’s actual calculations in the customer’s factory, a smart building glass factory with an annual production capacity of 800,000 to 1 million square meters uses about 15-20 fewer workers than traditional factories, which mainly eliminates the need for repetitive glass loading and dispatching workers. At the same time, because production is mainly coordinated and controlled by information systems (ERP, MES, SCADA), there is no manual intervention during normal production, and one person can operate and manage the operation of multiple types of equipment.

5. The glass deep processing smart factory does not occupy additional plant area

With the same output, the smart factory occupies the same area as a traditional factory; the use of a film management system and an in-line transmission mechanism to replace the loading and unloading links of multiple processes and the temporary storage area between processes, the overall area is not increased, and the area is saved. Got the trouble of finding and moving the glass. In the actual production and processing of glass deep processing, the automatic vertical glass loading machine and gantry type hollow glass loading machine produced by Jinan LIJIANG Glass can be selected, and the operating conditions and operating parameters of the equipment can be monitored in real-time through the man-machine interface. , Which can realize the pre-setting of the production capacity at that time.

6. The process layout of the glass deep processing smart factory cannot be simply imitated  

The design principles of the smart factory should follow the product production process, rationally use and configure automation equipment, connect the main processing technology and equipment, and conduct overall management. However, in the actual process design, a series of factors such as customer product ratio, product characteristics, sales mode (domestic sales or foreign sales), production capacity requirements, and power load will be comprehensively considered.

7. The existing glass deep-processing plant can be upgraded while continuing to produce   

In the intelligent upgrading and transformation of traditional glass deep processing plants, if the original equipment does not need to be moved in the transformation plan, it can be upgraded and continued to be produced under the premise of ensuring safety.

The glass tempering equipment 1

The glass tempering equipment 1

8. Tempering equipment is the core of the production rhythm of the smart glass deep processing factory

In the glass deep processing plant, the installed power of the tempering equipment accounts for half of the power of the whole plant. Therefore, in the process design of the smart factory, it is necessary to reasonably select the capacity configuration of the equipment, especially the capacity configuration of the tempering equipment, according to the capacity planning and product structure. To ensure the flexibility of production. According to actual calculations by Jinan Lijiang Glass, a smart building glass factory with an annual production capacity of 800,000 to 1 million square meters, equipped with Jinan Lijiang Glass 2800mm*5000mm double-chamber tempering equipment, processing 6mm float glass at a rate of 23-25 furnaces/hour, is making full use of In the case of production capacity, compared with traditional factories, the savings in electricity bills due to efficiency improvements can reach more than 100,000 USD.

9. Smart glass deep processing factory, can it produce glass without a film processing system?  

The smart factory temporarily lacks a sheet sorting system. It is possible to manually sort the upper and lower sheets of the glass, but this situation is only suitable for large-volume orders with a single order specification. If there are many types of order specifications, there will be a rational film system and the production cost will be lower. According to Jinan Lijiang Glass’s many years of industry experience, without a film processing system, only a single order product can be processed at a time, with a cutting rate of 82%-88%; in the case of a film processing system, optimized cutting of multiple order specifications The cutting rate is 88%-95%, which can save a lot of original film costs. In addition, the film management system can also improve the production efficiency of the production line. For example, equipment such as edging machines does not need to be adjusted frequently. Therefore, whether a film processing system is required or not should be planned according to the product structure type and capacity requirements of the factory.

10. Laser coding VS sticker label

A good product marking system makes the product identification, location traceability, and damaged patch more efficient in the entire glass production process. The laser code is not affected by high temperature and the length of time, and the paper tag code has a good recognition rate in water. Therefore, a reasonable choice of laser code or paper tag code should be based on the production process characteristics. With the development of the intelligent industry, laser codes that can be traced for a long time must be the development trend of the glass deep processing industry.

In addition, not only does the original glass sheet need to be laser-coded, in the actual glass deep processing process, the aluminum strip between the two pieces of glass is folded into an aluminum frame, and label marking is also required. The hollow glass aluminum frame bending machine produced by Jinan LIJIANG Glass can automatically print and label the folded aluminum strip according to the actual needs of the glass deep processing owner, and divide the processing order batches. At the same time, it can be equipped with USB data. The connection function can directly read the production planning table in Excel format through the computer, which is convenient for the identification of aluminum bars and aluminum frames and order records.

Aluminum Bar Automatic Coding 1

Aluminum Bar Automatic Coding 1

Automatic labeling of aluminum strips 1

Automatic labeling of aluminum strips 1

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