At the completely automatic wharf in the fourth phase of Yangshan Port, unmanned straddle carriers convey containers unloaded from oceangoing freighters to designated yards in perfect coordination. In a manufacturing workshop, robots perform assembly work according to plan, participating in the production of robots by robots. In a smart general assembly shop, automatic spraying technology is applied for gluing and painting.
All these seemingly futuristic scenarios are now a reality in Pudong New District, Shanghai. A number of leading companies have put a smart label on the local manufacturing industry. The district is building a leading intelligent manufacturing industrial position with global influence. Intelligent manufacturing developed steadily during 2019, and the production value of high-end equipment manufacturing above designated size exceeded RMB 90 billion. By focusing on intelligent manufacturing, Pudong will continue to vigorously develop industries like robotics, computer numerical control machine tools, and marine equipment, promote the automation and smart upgrading of traditional manufacturing enterprises, and strive to achieve a high-end industrial equipment output value of RMB 120 billion.
The fourth phase of the Yangshan Deep-Water Port in Shanghai Free Trade Zone is the world’s largest unmanned container terminal, requiring only about 20 workers to manage the daily operations.
Advancing Robotics
Industrial robots are the most typical application for intelligent manufacturing. During the 4.0 era of global industry, robots are also known as the pearl in the crown of intelligent manufacturing.
Automobile manufacturing is a field where robots are widely used. At the Cadillac factory in Jinqiao Town, Shanghai, the coating workshop uses robotic spraying technology for gluing and painting, representing China’s most advanced level of car body coating. The assembly workshop has achieved barrier-free communication between machines, and between machines and people through the full application of an industrial-grade Ethernet network. It can not only support the flexible assembly of eight vehicle models, but also trace the torque information of each key fastening point through the intelligent Internet of Things system, resulting in a world-class digital assembly system.
The scale of Shanghai’s industrial robot industry ranks first in China, with domestic and foreign giants gathering in the city. As a key industrial region, Pudong has been continuously optimizing the investment environment of the robotics industry in recent years, actively introducing favorable policies on projects, funds, technology, and talent. Currently, it has formed a robotics industrial base with the largest scale and the most complete industrial chain domestically.
In September 2019, the ABB Group, one of the four largest robot companies in the world, began to build a new robotics factory and research and development base in Kangqiao Town, Pudong, which are expected to be put into operation this year. Called “factory of the future” by ABB, the factory is expected to be the most advanced, flexible, and automated one in the global robotics industry — a cutting-edge center that uses robots to manufacture robots.
SIASUN, the leading domestic industrial robot company, has gone from producing the first domestic robot, to owning the first robot production line based on locally developed technology, becoming the world’s largest robot industry base. It has carried out more than 600 major technical research projects and created more than 100 domestic firsts. The versatile robots it produces can host shows with people, paint, spray paint, and weld.
Zhangjiang High Tech Park is an important robotics industry gathering place in Shanghai. Zhangjiang has more than 150 companies engaged in the field of robotics and automation. Not only has ABB established its Chinese headquarters here, the place is also the best choice for domestic robotics companies’ headquarters, as well as a large number of startups and small and micro enterprises focusing on domestic robots, medical robots, and unmanned aerial vehicles (UAV).
Displays of ABB robots at the China International Industry Fair in Shanghai on September 16, 2020.
Two Characteristic Industrial Parks
Shanghai licensed eight characteristic intelligent manufacturing industrial parks in June 2020, two of which are located in Pudong, specializing in intelligent manufacturing and 5G industry.
Waigaoqiao Intelligent Manufacturing Service Industrial Park makes full use of the advantages of international trade facilitation in the Shanghai Free Trade Zone. With the goal of gathering industries and technologies such as precision computer numerical control machine tools, industrial automation equipment, smart robots, 3D printing, and high-precision testing, the park provides a bonded display and demonstration, logistics, parts distribution, trade agency, testing and certification, and professional training as the core services for intelligent manufacturing companies in the region, promoting the formation of a more complete and competitive industrial ecosystem. At present, it has become host to the operations of 150 companies and organizations from Germany, Switzerland, Italy, Spain, the U.S., Australia, and other countries.
Jinqiao 5G Industrial Ecological Park, based in the traditional automobile industry and focusing on new energy and the intelligent networked automobile industry, is dedicated to building a leading 5G+ future car industry cluster, which concentrates on future car communications, chips, chassis, core components, and complete vehicle research and development to build a complete 5G+ advanced vehicle industrial manufacturing chain. A number of key innovations such as the Huawei 5G Innovation Center, SAIC 5G Intelligent Connected Automotive Electronics Innovation Center, and 5G Application Innovation Center of China Mobile Shanghai Industrial Research Institute, are working to form an industrial development ecosystem of 5G+ future cars.
Automobiles are assembled on the production line of SAIC General Motors Cadillac plant.
Empowering Intelligent Manufacturing
Continuously deepening the integration and development of technologies such as 5G, artificial intelligence, and the Industrial Internet with the manufacturing industry is key to the development of intelligent manufacturing, which is triggering a soaring elevation of business innovation and acceleration of the transformation and upgrading of traditional industries. The use of emerging technology in Pudong is empowering intelligent manufacturing.
At the Shanghai 5G Application Innovation Competition held during the 2019 World Artificial Intelligence Conference, COMAC Shanghai Aircraft Manufacturing’s 5G Empowered Civil Aircraft Manufacturing Integrated Solution won the first prize. The solution combines AR technology such as machine vision and real-time collaborative interaction with traditional aircraft interior assembly scenes to improve assembly efficiency and quality. For instance, in the quality test of laying wing composite materials, it is necessary to stop for a 50-minute testing after laying for 10 minutes. Now with the combination of 5G+8K+AI technology, high-definition video can be sent back during the laying, and the background can be connected to artificial intelligence to analyze whether the laying is qualified, thereby achieving real-time detection. In the aircraft assembly process, with the artificial intelligence-guided assembly system, segment assembly can be realized and the entire assembly process can be accurately monitored.
In the Volvo Construction Equipment Company in Jinqiao, sensors are installed on equipment. Through the on-board information data monitoring screen of the operation center, the operation dynamics of the equipment working across the country can be seen in full view, even providing early warnings before the equipment malfunctions.
After Zhenhua Port Machinery Company Ltd. mastered the core technology of automated terminals, it has launched intelligent unmanned straddle carriers, automation systems, electronic control systems, automated rail-mounted gantry cranes, and other intelligent port equipment that is not only used in China, but also well-received in Europe, America, and other countries and regions along the Belt and Road.
Emerging technologies such as artificial intelligence and intelligent manufacturing are becoming a significant focus of a new round of technological revolution and industrial transformation, and Pudong is opening up new prospects in this integrated development.
LIU ZHAOHUI is a reporter with Xinmin Weekly.
