China's first smart factory solution and demonstration production line for Industry 4.0 is supported by the WIA-FA technology independently developed by the Shenyang Institute of Automation, Chinese Academy of Sciences. It integrates a series of cutting-edge core technologies and is highly flexible and intelligent, but it For the sensors used, it is mainly imported products.
Sensors are used in different industrial fields, and their temperature, humidity and pH can be tolerated differently. The power consumption and size are also severely limited. For example, the extreme environment of 60 °C is a great challenge.
"Technical Roadmap for Key Areas Made in China 2025" requires that by 2020, the localization rate of intelligent photoelectric sensors, intelligent proximity sensors, medium and low-end vision sensors, MEMS sensors and chips, and optical fiber sensors should be increased to 20%. Then, where should the localization of smart manufacturing sensors in China be cut?
Domestic sensors are not inferior to foreign countries?
Are smart sensors used for imported sensors? China's intelligent manufacturing of sensors, especially industrial robot sensors, independent research and development capabilities behind the international 10 years? “I don’t think so.†Liu Yanbo, the director of Yanshan Petrochemical Information Department, a pilot unit of Sinopec’s smart factory construction, did not agree with the opinions circulating in these circles. “The basic sensors used in our smart factories are all domestic sensors. ""
However, is the situation of Yanshan Petrochemical representative?
In the central control room of Yanshan Petrochemical Refinery No. 2, the DCS (Distributed Control System) displays lined up in a black screen state. The staff who should have been staring at the screen monitoring production process were watching the training manual intently. When the production is abnormal, the system will automatically pop up the interface, and it will remain black at ordinary times, without operator monitoring. Based on the high degree of automation of production equipment operation and the refinement of production process management, the “black screen mode†of Yanshan Petrochemical Intelligent Factory has become a typical case of intelligent manufacturing in the petrochemical industry.
The operation of a smart factory is simply the collection, analysis and processing of data, and the sensors play a vital role in every part of it. “When I first arrived in the factory in the 1980s, I did use a lot of sensors imported from Japan. Today, from sensors for data collection such as pressure, temperature and flow monitoring, to various large-scale equipment and central areas involved in production and operation. The sensors of the control system have basically achieved localization," said Liu Yanbo.
In Liu Yanbo's view, the sensors produced by domestic enterprises such as Zhejiang University, Beijing and Lishi are not inferior to those of international giants such as Yokogawa and Honeywell. However, some special components, such as sensors that require high temperature and high pressure resistance, have some gaps in the reliability and stability of domestic products. However, I think this is not entirely a question of technical level. Sensor manufacturers should make more efforts in management and quality control.
For the current smart manufacturing, the sensor is not only the eyes and ears that collect data, but also the brain and heart of high-end manufacturing, process control, networking operations. Lin Yu, deputy director of the CCID IC Industry Research Institute, pointed out: "The gap between different industries is very large. For the process industries such as petrochemicals, there are fewer new high-end industrial sensors, but in the high-end manufacturing field, The localization rate of sensors is still very low."
High-end new industrial sensors still rely on imports
At the beginning of this year, China's first smart factory solution and demonstration production line for Industry 4.0 was born. The program is supported by the WIA-FA technology independently developed by the Shenyang Institute of Automation, Chinese Academy of Sciences (currently the only international standard for IEC wireless technology for high-speed automatic control applications in the world), incorporating a series of cutting-edge core technologies with high flexibility and Intelligent. But for the sensors it uses, it is mainly imported.
"In the fields of aerospace, military industry, etc., in order to achieve independent safety and control, it is possible to produce R&D and produce some high-end sensors regardless of cost. However, when applied to the industrial field, it is more cost-effective to purchase imported products at the current stage." The relevant person in charge disclosed to reporters "High-end motor, vision, force and other high value-added sensors can not be mass-produced in China, and can only rely on imports. In order to pursue the consistency and reliability of the entire system, many sensors are also required to use imported products."
From the "Technical Roadmap for the Key Fields of Made in China 2025", we can see some clues. Intelligent manufacturing core information equipment ranks among the top ten key areas. The new industrial sensor's near-term goal in 2020 is to occupy the market for intelligent photoelectric sensors, intelligent proximity sensors, low- and medium-end vision sensors, MEMS sensors and chips, and fiber-optic sensors. The rate is increased to 20%.
"Industrial sensors are the key factors to test whether a country's industrial system is perfect." Yang Chao, who has provided intelligent manufacturing solutions for many domestic auto, home appliances, machine tools and other manufacturing companies, has more say. "Industrial robots, production lines, reaction vessels, CNC machine tools, the basis of intelligent manufacturing of standardized equipment and non-standardized equipment are all integrated by many sensors." Yang Chao told reporters, "In the early days, most of China's intelligent manufacturing equipment It is imported from abroad and has a high cost. Later, after the introduction and digestion of domestic equipment companies, independent production was realized. However, in order to facilitate the selection and stability of equipment operation, the sensors generally use the original products.
"The prices of these imported sensors are naturally high. For example, a pair of laser monitoring sensors from SICK in Germany will cost 7,000 to 100,000 yuan. However, compared with the price of the overall equipment, it still accounts for a relatively small share." Yang Chao said. “In fact, the application of a wide range of imported sensors, such as Bonner, Omron's vision module, Yike, Phoenix encoders, and similar domestic products. But compared to civilian use, the industrial environment requires more sensors. From the perspectives of stability, accuracy, operational safety, etc., the localization rate of sensors in the smart manufacturing solutions I contacted is still very low."
Intelligent manufacturing of sensors needs to increase localization rate
Industrial sensors for intelligent manufacturing offer more stringent requirements in terms of accuracy, stability, shock resistance and impact resistance than in consumer applications such as consumer electronics. "Industrial control must ensure zero error. The sensor must not only communicate in real time, but also be accurate enough. The 'loss of bag' in the civilian field is absolutely intolerable." Lin Yu said, "The sensor is applied in different industrial fields. The temperature, humidity, and pH that can be tolerated also have different individual requirements, and the power consumption and size are also severely limited. For example, the extreme environment of 60 ° C is a great challenge."
Industrial sensors are not only demanding in terms of performance, but also very versatile. According to Yang Chao, from the functional point of view, industrial sensors are divided into different categories such as photoelectric, thermal, gas sensitive, force sensitive, magnetic sensitive, acoustic sensitive, and humidity sensitive. Taking industrial robots as an example, several important sensors involved include: three-dimensional vision sensors, force torque sensors, collision detection sensors, safety sensors, welded seam tracking sensors, and tactile sensors.
In the face of the complex status quo, where should the localization of smart manufacturing sensors in China be cut? Yang Qifeng, assistant to the president of Xinsong Robot Central Research Institute, advised reporters not to pursue large and complete, but to develop a class of sensors for specific application needs and concentrated advantages. “With a force sensor we need to use, the single price is as high as 100,000 yuan.â€
Yang Qifeng said, "The force sensor is a sensor used to detect the interaction between the robot's own force and the external environmental force. There are still many new types of sensors that need to be used in industrial robots. Although there are no large-scale applications, It has become an inevitable trend of industrial development. In the immature market segments, there are more opportunities for Chinese enterprises, so it may be laid out in advance."
At the same time, smart manufacturing is defining a new industrial IoT space that leverages MEMS technology. Lin Yu said that the industrial Internet of Things-driven MEMS industrial application will bring huge emerging markets. Bosch, STMicroelectronics, Lou's Electronics, Ying Meisheng and other international MEMS leading companies have already targeted this application field.
"In fact, we can't just limit our eyes to the production of the sensor itself." Lin Yu suggested, "For hardware, the application software of industrial sensors is equally important. For now, the overall layout of the industrial ecology is more operational. Sex."
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