1SolutionBackground

The cement production plant area has complex working conditions of high temperature, high dust, strong vibration, and multi equipment linkage. The operating status of core equipment (rotary kiln, preheater, grate cooler, mill, dust collector, conveyor belt, denitrification equipment) directly determines production stability and environmental compliance.Traditional manual inspection faces the following prominent pain points:

Restricted inspection in high temperature areas: Key parts such as rotary kilns and preheaters have high environmental temperatures and limited working space, making it difficult for manual inspections to real-time grasp hidden dangers such as abnormal cylinder temperature, kiln skin detachment, and skin blockage.

Vibration and wear monitoring rely on experience: The vibration, wear, and abnormal noise of equipment such as mills and rollers require high-frequency testing by professional personnel, which is difficult to achieve24Continuous and precise control every hour.

Insufficient frequency of environmental parameter monitoring: The environmental parameters related to dust collectors and denitrification equipment mainly rely on regular manual testing, with low frequency and delayed response, which can easily lead to the risk of non-compliance with environmental indicators.

Delayed response to conveyor belt faults: sudden faults such as material conveyor belt deviation and tearing, which are detected late and respond slowly during manual inspections, can easily cause production interruptions or even safety accidents.

In response to the above pain points, Zhiyi Era has launched an intelligent inspection robot system for dust resistance, wear resistance, and kiln specific inspection based on the core inspection needs of the cement industry,Integrating three types of robot forms: rail mounted, wheeled, and explosion-proofBuild an intelligent inspection system that covers all scenarios, weather conditions, and dimensions, fully supporting the safe, stable, and environmentally friendly operation of cement production.

2、 Core productsoptional

（1） Hanging rail inspection robot

Product IntroductionThe rail mounted inspection robot can autonomously operate along a preset track and is suitable for areas such as preheaters, denitrification equipment, and conveyor belt corridors. Adopting a fully enclosed anti dust structure and wear-resistant track, equipped with high-definition visible light and infrared thermal imagers, dust sensors, and voiceprint acquisition modules, with positioning accuracy±5mm, supports horizontal, vertical, and turning paths, can24Continuous hourly inspections and real-time feedback of data to the central control platform.

Adaptation TaskMonitoring of preheater crust blockage, verification of denitrification equipment operation status, and deviation of conveyor belt/Tear detection and abnormal temperature warning for high-altitude equipment.

（2） Wheeled inspection robot

Product IntroductionThe wheeled inspection robot faces high dust scenes with open ground and scattered multiple devices, and is suitable for the surrounding areas of rotary kilns, grinding machine areas, dust collector areas, etc. Using laser technologySLAMAutonomous navigation and intelligent obstacle avoidance, equipped with heavy-duty wear-resistant chassis and anti dust sealing design, integrated with multispectral camera, vibration sensor, noise analyzer, dust concentration detector, supporting autonomous return charging.

Adaptation TaskTemperature monitoring of rotary kiln body, identification of kiln skin detachment, detection of supporting wheel wear, analysis of mill vibration and abnormal noise, detection of dust collector operating efficiency and dust concentration.

（3） Explosion proof inspection robot

Product IntroductionThe explosion-proof inspection robot meets the inspection requirements of high-risk scenarios in cement kilns and has passed national explosion-proof certification. It adopts a fully enclosed explosion-proof structure and high temperature protection, equipped with high-precision infrared thermal imaging cameras, gas sensors, and high-definition cameras. It supports dual modes of remote control and autonomous inspection, effectively ensuring the safety of operations in high-risk areas.

Adaptation TaskFull range temperature monitoring of rotary kiln body and peeling of kiln skin/Crack identification, operation status detection of grate cooler, monitoring of harmful gas concentration in kiln area.

threeScenario based deployment plan

（1） Rotary kiln and grate cooler area

◉Deployment equipment: Explosion proof inspection robot+Wheeled inspection robot

◉Core pain points: Abnormal temperature of the rotary kiln body (red kiln) is a precursor to major safety accidents. Uneven peeling of the kiln skin directly affects the service life of refractory bricks, and high temperature and wear of the supporting wheel bearings are difficult to detect in a timely manner; The uneven distribution of clinker inside the grate cooler and the leakage of material in the air chamber directly affect the heat recovery efficiency and clinker quality.

◉Inspection tasks and implementation:

The explosion-proof inspection robot travels along the track of the rotary kiln barrel and is equipped with an infrared thermal imaging device to scan the temperature field of the barrel,AIRecognition“Red Kiln”High temperature point, warning of the risk of refractory brick detachment; Combining high-definition visible light visual analysis to examine the morphological changes of kiln skin.

The wheeled inspection robot moves on the ground and uses acoustic imaging technology to monitor abnormal vibrations and frictional sound sources of the supporting wheels and belts, and determine the wear trend of the supporting wheels; Monitoring the temperature field of the grate cooler chamber through infrared thermography to identify“Red River”Phenomenon, auxiliary cooling air volume adjustment.

（2） Preheater and Denitrification Equipment Area

Deployment equipment: Rail mounted inspection robot

◉Deployment equipment: Rail mounted inspection robot

◉Core pain point: PreheaterC1-C5Crushing and blockage are prone to occur inside the level tube and cyclone tube, and manual cleaning faces the risk of high temperature and falling from heights; Traditional inspections cannot be carried out“Collapse material”Effective early warning. The ammonia escape or uneven ammonia spraying of denitrification equipment directly affects environmental standards, and there is a leakage hazard in the ammonia water storage tank area.

◉Inspection tasks and implementation:

Autonomous cruising along the high-altitude orbit, dual spectrum pan tilt monitoring penetrates the dust to monitor the temperature field of the preheater cone and the outer wall of the discharge pipe,AIPredict the risk of crust blockage and achieve early warning before material collapse.

Infrared thermal imaging monitoringSCR/SNCRUniformity of temperature field in the reaction zone, assisting in optimizing the amount of ammonia injection; Explosion proof robots are equipped with ammonia gas sensors to monitor real-time leaks in the ammonia storage tank area and injection system.

（3） Grinding machine and dust collector area

◉Deployment equipment: wheeled inspection robot

◉Core pain point: Grinding machine (vertical grinder)/During ball milling, there is significant vibration and abnormal gear meshing noise, making traditional manual inspection difficult to quantify; The damaged bag of the dust collector leads to excessive dust emissions, directly affecting the environmental protection red line, and the fault location is difficult to quickly locate.

◉Inspection tasks and implementation:

Autonomous navigation inspection of the grinding mill workshop, equipped with acoustic imaging devices and pickups, accurately locates the sources of abnormal noise in the main reducer and grinding roller bearings, and achieves early fault warning.

Inspect the ash hopper and clean air chamber of the dust collector, and monitor the real-time changes in dust concentration in the clean air chamber in combination with the dust concentration sensor,AIDetermine the location of bag damage to ensure dust collection efficiency and emissions meet standards.

（4） Material conveyor belt area

◉Deployment equipment: Rail mounted inspection robot+Wheeled inspection robot

◉Core pain points: long belt corridors, high dust concentration, and difficulty in manual inspection; Belt deviation, tearing, and roller jamming are the main hazards leading to production stoppage and fire.

◉Inspection tasks and implementation:

The rail mounted inspection robot walks along the top of the belt corridor,AIReal time visual monitoring of belt deviation, laser contour technology for identifying longitudinal tears; Infrared thermal imaging captures the temperature of the roller bearings and provides early warning for high-temperature rollers.

The wheeled inspection robot inspects along the ground belt section,AIVideo analysis identifies the accumulation of materials at the drop point, warns of material leakage and blockage accidents, and ensures the continuous and stable operation of the conveying system.

FourValue of the plan

Safety ValueReplace manual entry into high-temperature, high dust, and high-risk areas, reduce inspection safety hazards, and achieve intrinsic safety;

Production value：24Uninterrupted hourly inspections reduce unplanned downtime of equipment60%Above, ensure continuous and stable production;

Environmental ValueReal time monitoring of environmental parameters such as dust concentration and denitrification efficiency to ensure compliance with emission standards and avoid environmental penalty risks;

Cost valueReduce the frequency of manual inspections, lower the cost of operation and maintenance personnel, and extend the service life of equipment;

Management ValueUnified data management and intelligent analysis, realizing digitalization and intelligence of operation and maintenance, and improving the efficiency of factory management.