1、 Project Background

Equipment in industries such as metallurgy, coking, chemical engineering, and steel often have characteristics such as flammability, explosiveness, and susceptibility to environmental pollution. If abnormalities are not identified and dealt with in a timely manner, it not only affects the normal production of the enterprise, but may also threaten the lives and property of surrounding personnel and the safety of the ecological environment. In addition, various types of equipment need to be regularly inspected by professional personnel to strengthen safety management. Therefore, it is urgent to promote research on inspection technology, using robots to assist or replace manual inspections, significantly reducing the labor intensity of frontline employees, reducing the risks of manual operations, achieving efficient and reliable equipment inspections, and comprehensively improving the intrinsic safety level of enterprises.

With the continuous advancement of science and technology,various typesIndustrial robots have been widely used in many fields. Faced with high-risk work environments, metallurgical, chemical and other enterprises urgently need to introduce robot technology into equipment inspection processes, in order to effectively reduce the incidence of safety accidents and promote the intelligent transformation and upgrading of enterprises. To this end, Zhiyi Era has specially developed explosion-proof wheeled inspection robots to provide enterprises with safer and more intelligent professional solutions.

2、 Industry background

In the process of gold smelting, molten slag is poured into slag bags and transported to a slow cooling field for several days or even weeks of natural cooling. This process aims to promote the phase precipitation of valuable metals such as copper and silver in slag, which is a key step in improving metal recovery rate. Traditional manual inspection of slag bags has core pain points such as high safety risks, inaccurate data, high labor intensity, and low level of digital management.

Site map of slag package

3、 Construction Goal

Build a setwithIntelligent inspection robot as the core, integrating precise monitoring of slag bag temperature field, intelligent recognition of apparent state, environmental gas safety monitoring, intelligent data analysis and early warning into an unmanned inspection system，Final implementation:

Low risk safety: Replace manual entry into high-risk areas for slag bag inspection.

Controllable cooling process: achieve precise monitoring and optimization of the cooling curve of each slag package throughout the entire process.

Digitalization of management: Establish a "digital twin" file for the entire factory slag package, allowing for one click access to all historical data. Based on big data analysis, provide scientific basis for process optimization and improve recovery rate.

four、intelligencewheeledinspectionrobotsystem

intelligenceThe wheeled inspection robot system consists of a robot body, a wireless communication base station, an autonomous charging device, and a remote control station. It can replace inspection personnel for equipment and environmental inspections, reducing their laborintensityReduce safety hazards during the inspection process and improve inspection quality.

Wheeled inspection robot

This product is an intelligent inspection robot designed specifically for hazardous and complex environments, capable of safe and stable operation in flammable, explosive, and corrosive environments commonly found in metallurgical enterprises. The robot is equipped with a four turn four-wheel drive multimodal mobile chassis, supporting independent four-wheel drive and steering. It has the ability to move laterally, turn in place, and adapt to multiple terrains, combining off-road performance with low-noise and smooth operation characteristics. It is suitable for various metallurgical scenarios both indoors and outdoors, such as sintering, ironmaking, and slag processing.

The device supports modular integration of infrared thermal imagers, gas sensors360Various detection devices such as high-definition pan tilt cameras enable multi-dimensional data acquisition and monitoring, and rely on high-precision navigation and multi-sensor fusion technology to achieve autonomous obstacle avoidance, path planning, and automatic cruising of multiple target points. With the help of a lifting gimbal and sound source positioning camera, the monitoring range can be significantly expanded and leakage points and abnormal noise sources can be accurately identified. Through real-time analysis of temperature, vibration, noise, gas concentration and other multivariate data through edge computing, early warning of equipment abnormalities is carried out, and the response speed is faster than that of human work80%The above. Robot support5G/Wi-Fi/Private network multi-mode communication ensures high-speed and low latency data transmission and cloud collaboration. Combined with digital twins and visualization platforms, users can remotely view videos in real-time, receive alarms, automatically generate inspection reports, and trace historical data, significantly improving the operation and maintenance efficiency and system intelligent management level of metallurgical enterprises.

wireless base station

Wireless base stations achieve stable interconnection between multiple base stations through optical fibers, ensuring reliable transmission of communication data and supporting robots to upload data in real-time to the upper computer at designated points. This base station is based onWiFiWireless type, coverage distance can reach200Meter, suitable for continuous monitoring and control tasks in complex industrial environments.

Autonomous charging device

The autonomous charging device consists of a charging station and a charging control box, which are connected by cables and can achieve automatic charging in a safe area. It also supports manual emergency charging operations. The device adopts reliable charging electrical interlocking technology to ensure power outage in non charging or fault states, ensuring safe operation. When the robot meets the charging conditions, it can autonomously return to the charging position for wireless charging without manual intervention, and automatically continue to perform inspection tasks after being fully charged. The robot body is equipped with a wireless charging receiver, which is matched with the transmitting end of the charging station to achieve precise control through data communication.

fiveIntelligent Inspection Software Platform

Through the wheeled inspection robot software platform,canRealize remote control of robots. The platform is deployed on a remote control station and integrated into the control room, displaying real-time videos and various parameters collected by the robot. When the system detects equipment abnormalities, both the robot body and the workstation will sound and light alarms to prompt timely maintenance. Support real-time and historical alarm record storage, with the ability to query information and archive images by date and device.

core functionalityimplement

1.automated inspection

Support multiple routes and planned task settings (such as each2Routine hourly inspections and comprehensive inspections per shift, the robot automatically executes tasks according to the preset path and returns to charging.

2.AIIntelligent recognition and analysis

Equipment status recognition: based on visible light image recognition, mechanical damage such as slag package tilt, deformation, cracks, etc;

Visual state recognition: Identify whether there are abnormal phenomena such as water accumulation, smoking, and open flames on the site;

Intelligent meter reading: Automatically identify and record readings from on-site pressure gauges, liquid level gauges, and other instruments.

3.Intelligent analysis of slag package temperature field

Overtemperature alarm: set threshold (e.g.>)400℃), automatic marking and alarm;

Cooling rate analysis: The system automatically draws the time for each slag package-Temperature cooling curve. If the actual curve deviates significantly from the standard process curve, the system will issue a warning, indicating "cooling too fast" or "cooling too slow"；

Uneven cooling identification:AIAnalyze the thermal image to identify whether there is an excessive temperature gradient on the surface of the slag package, indicating the possibility of "crust" or "internal voids" that may affect metal recovery.

4.Surface state of slag packageAIrecognize

slag bagIDAutomatic recognition:OCRThe technology automatically reads the number, binds all inspection data with the number, and forms a "one package, one file".

Crack and deformation recognition: Deep learning algorithms train models to identify subtle cracks and structural deformations in the slag shell, and warn of overturning risks.

Leakage identification: Identify whether there are abnormal colored condensation or moisture marks at the bottom or wall of the slag package, and determine whether leakage has occurred.

5.Multi modal data fusion warning

Integrating infrared temperature, gas concentration, and visible light images for joint analysis to improve warning accuracy.Example warnings include the risk of high temperature and crack combination, abnormal cooling rate, and abnormal regional environment.

6.Real time monitoring and emergency linkage

Support manual remote control for close observation, and in case of emergency alarm, use sound and lightcall the policeSMSAPPpromoteWaiting for multiple ways of notificationon dutyPersonnel can also activate emergency plans in conjunction with the fire and ventilation systems in the factory area.

7.Digital Reports and Trend Analysis

Automatically generate daily, weekly, and monthly inspection reports, including inspection overview, exception statistics, and handling status.

Record historical temperature data, generate slag cooling curves, and provide data basis for optimizing slow cooling process parameters (such as spray water volume and cooling time).

8.Digital slag package archives and visualization

The platform establishes a full lifecycle digital archive for each slag package, including: storage time, initial temperature, cooling curve, all historical inspection images, alarm records, processing status, etc. Through the visualization interface of the factory map, the real-time location of all slag bags, current surface temperature (displayed in color gradient), and health status (green normal, yellow warning, red alarm) can be viewed.

six、benefit analysis

Safety benefits:

Realize intrinsic safety and eliminate the risk of personnel injury.

economic performance:

Improving metal recovery rate, even a small increase can bring significant benefits;

reduce2–3A high-risk position to reduce labor costs;

To avoid equipment damage and production interruption losses caused by the overturning or rupture of slag bags.

Management benefits:

Standardize, refine, and visualize the cooling process of slag bags.

The accumulated process big data lays a solid foundation for building a "black light factory" and achieving comprehensive intelligence in the future.

This plan is not only an automated upgrade to achieve "machine replacement", but also a strategic investment driven by data-driven process optimization. It transforms the traditional "black box" operation of slag bag slow cooling that relies on manual experience into a transparent, controllable, and optimizable modern process flow, becoming a step towards industrialization for gold smelting enterprises4.0An important milestone.