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Shanghai Electric's Innovative Use of Industrial AI

In a groundbreaking shift toward enhanced efficiency and reliability, Shanghai Electric has successfully integrated industrial artificial intelligence (AI) into its production processes for heavy-duty gas turbines. This leap signifies a departure from mere pilot programs into the core operations that underpin the manufacturing of high-performance energy equipment.

Gas turbines are often likened to the “crown jewels” of modern industrial devices. Therefore, the implementation of AI not only refines the intricate production of their components but also ensures consistent performance throughout their operational lifespan. Shanghai Electric, with its deep-rooted engineering expertise, utilizes AI to transform the way turbines are made and maintained.

Key Applications of AI in Gas Turbine Manufacturing

Flexible Blade Production

A vital aspect of the manufacturing process is the flexible production of turbine blades. Given the diverse dimensions and intricate designs of these blades, the ability to adapt is crucial for suppliers. Shanghai Electric employs AI-driven automated systems equipped with vision technologies, digital twins, and robotics to facilitate the efficient manufacturing of various blade models. This advanced approach allows for seamless transitions between different designs, enhancing production capabilities significantly.

Using 3D imaging and AI, the systems can accurately identify and position randomly stacked blade precursors with an extraction accuracy exceeding 99.99%. Furthermore, the production line integrates scheduling, execution, and quality management systems, effectively creating a continuous workflow from loading and processing to final packaging. This can operate fully automated or switch to independent machine functioning, thus ensuring seamless production continuity.

AI-Enhanced Quality Control

Quality assurance is paramount in the production of substantial energy devices. Turbine rotors, which are critical to the operation of these turbines, require exceptional quality for safe functionality, particularly in welding processes. Shanghai Electric has developed an AI-based vision terminal that integrates AI technology with robotic control and welding expertise, allowing for real-time monitoring of the welding process to detect potential quality faults.

Equipped with a specially designed end-effector, the collaborative robot arm adjusts itself automatically during the welding cycle. Through 5G connectivity, images are analyzed, and quality control results are transmitted within seconds, creating a feedback loop that enhances process optimization and quality traceability. This capability transforms practical manufacturing experiences into valuable digital knowledge.

Data-Driven Operations and Maintenance

The application of AI extends beyond production; it also encompasses the long-term operation and maintenance of power plants. Shanghai Electric’s intelligent SIMPLE platform collects data from over 60 turbine units that have collectively surpassed a million operational hours. It integrates AI with extensive knowledge of gas turbine operation principles, enabling continuous parameter monitoring, dynamic performance optimization, and early warnings of potential faults.

Leveraging cloud collaboration with edge systems, the platform harmonizes design and operational data into a cohesive decision support process. This allows for proactive service actions before failures occur, alongside remote collaboration tools that enable experts to provide real-time technical assistance from any location using augmented reality annotations.

Future Prospects for Shanghai Electric

Looking ahead, Shanghai Electric aims to further enhance data integration throughout the gas turbine lifecycle, utilizing feedback to improve design, production processes, and post-sale services. As the company expands into additional global markets, it remains committed to refining these solutions through practical implementation. The ultimate goal is to provide power plants with reliable equipment performance, timely service support, and cost-effective operations over the long term, laying the groundwork for future international expansion in the gas turbine sector.

With its innovative approach, Shanghai Electric exemplifies how industrial AI not only promotes technological advancement but also supports sustainable and efficient energy production to meet growing global demands.