Smart Galvanizing Line with Centralized Monitoring & Production Data Analytics System

Smart Galvanizing Line with Centralized Monitoring & Production Data Analytics System
 

WUXI WONDERY INDUSTRY EQUIPMENT CO., LTD. has transformed traditional galvanizing operations through comprehensivemonitoring and data intelligence. The system's is a centralized dispatch center featuring a 32-screen video wall constructed from 100-inch 4K displays with 60,000-hour MTBF reliability. This command center provides real-time visualization of all 14 production lines simultaneously, with picture-in-picture capabilities allowing detailed inspection ofspecific process while maintaining overall situational awareness.

Data acquisition extends far beyond basic temperature and pressure readings. Each production line incorporates 9 strategically placed cameras (Hikvision or Dahua 4MP models) covering critical points from raw material entry to finished product dispatch. These visual records integrate with process data—including zinc temperature profiles, gas consumption rates, chemical concentrations, and production speeds—creating comprehensive digital twins of each production batch. Advanced analytics identify correlations between process parameters and product quality, enabling continuous optimization.

The production management software represents another innovation. Built on SQL Server with custom-developed interfaces, the system generates 27 distinct report types including real-time production dashboards, shift performance analyses, predictive maintenance schedules, and environmental compliance documentation. Data retention policies ensure 10-year accessibility for quality traceability, while secure interfaces allow controlled access for supply chain partners. The system's predictive capabilities analyze historical data to forecast maintenance needs, chemical consumption trends, and production bottlenecks with 85% accuracy.