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Digital Twin Management and Control Platform
1:1 Mapping of Virtual Production Lines
Get the solutionBangQi Digital Twin System creates a 1:1 digital replica of physical scenarios via 3D modeling technology. Combined with equipment simulation capabilities, it enables real-time remote monitoring and full-process remote operation & maintenance (O&M) for on-site assets. It also supports fault scenario playback and statistical analysis of operational efficiency, realizing digital management throughout the entire equipment lifecycle.
Technical Advantages
Full Lifecycle Visualization and Transparency
Through high-fidelity 3D models, physical entities (factories, production lines, equipment, etc.) and their operating status are fully mapped in virtual space, delivering end-to-end transparent visibility from design and production to operation and maintenance.
Simulation, Prediction and Optimization
"What-if" analyses and simulation tests can be conducted on production processes, equipment performance and process parameters within the virtual model. This allows proactive prediction of potential faults and evaluation of solution effectiveness, optimizing decision-making while cutting trial-and-error costs and risks.
Real-Time Monitoring and Intelligent Analytics
By synchronizing real-time Internet of Things (IoT) data, the system continuously tracks the status of physical assets and performs in-depth analysis with big data and AI algorithms, enabling fault early warning, energy efficiency optimization and performance improvement.
Remote Collaboration and Efficient O&M
Cross-regional teams can collaborate, conduct remote diagnosis and deliver on-site guidance on a unified digital twin, which drastically improves O&M efficiency and reduces costs and risks associated with expert travel and field operations.
Data-Driven Continuous Improvement
The system accumulates full-lifecycle operational data, providing a precise data foundation for product iteration, process optimization and workflow reengineering, and driving data-backed continuous improvement and innovation for businesses.
Customer Cases
A Leading Lithium Battery Enterprise
Customer Background
The factory has densely deployed production equipment and long material handling routes, with multiple types of AGVs operating in coordination. The digital twin system realizes 3D visualization of the full AGV loading/unloading process across the plant, and integrates with MES/WMS/RCS/LDS scheduling platforms. It covers automatic material handling and machine docking from the raw material warehouse to core processes including mixing, coating, rolling, slitting and winding.
Customer Pain Points
Densely arranged production equipment and long material handling paths; complex multi-AGV scheduling without unified visual management; low efficiency of manual loading/unloading that frequently causes machine idle time due to material shortage; delayed response to AGV anomalies.
Solution
A digital twin system for AGV loading/unloading is built to map the real-time position, speed, battery level, tasks and paths of all AGVs in a 3D scenario. It integrates MES/WMS/RCS/LDS scheduling data to enable automatic loading/unloading docking for key equipment such as coaters, rollers and winders. Abnormal status triggers second-level highlighted alarms with fault code push.
Key Outcomes
- Transparent material flow across the plant, with AGV coordinated scheduling efficiency improved by over 30%
- Automated loading/unloading for key processes with reduced manual intervention; full-link real-time traceability of electrode rolls from raw material warehousing to winding
- Second-level early warning for AGV abnormalities, significantly shortening O&M response time
- More stable production takt, with machine material shortage incidents reduced by approximately 45%
A Listed Company’s Polarizer Production Base
Customer Background
The digital twin platform maps in real time the full workflow of PVE warehouses, high-bay warehouses (high-temperature / curing warehouses), raw material warehouses, release film warehouses and AGV handling. It integrates WMS/MES/LDS/RCS systems to realize 3D visual scheduling of materials from warehousing to machine feeding.
Customer Pain Points
Hard-to-manage massive storage locations, opaque AGV status, low loading/unloading coordination efficiency, lagging environmental monitoring in high-temperature/curing warehouses, and slow anomaly response.
Solution
A plant-wide digital twin system is deployed covering four core scenarios: ① Dynamic simulation of material feeding from PVE warehouses to production machines; ② Real-time tracking of high-bay warehouse inbound/outbound operations and AGV routes; ③ 3D storage location inventory early warning for raw material warehouses; ④ Full-cycle traceability and environmental monitoring for release film warehouses.
Key Outcomes
- Fully transparent material flow, with machine material shortage incidents reduced by 40%
- Real-time visibility of AGV operating status, with handling efficiency improved by 22%
- Second-level alarms for temperature, humidity and cleanliness exceedances in warehouse zones, eliminating material scrapping risks
- Storage location utilization meets design targets, with precise partitioned storage for anode/cathode materials and different film types
A Leading Pharmaceutical Enterprise’s Intelligent High-Bay Warehouse
Customer Background
The digital twin platform builds a 3D real-time replica of the plant’s full material stereoscopic warehouse system, covering high-density storage racks, aisle stackers, AGVs and conveyor lines. It integrates WMS/WCS/LDS/RCS systems to realize visual intelligent scheduling of the entire "production line – high-bay warehouse – production line" material flow.
Customer Pain Points
Prominent warehousing efficiency bottlenecks; time-consuming and labor-intensive manual picking and handling; extensive storage management with maxed-out space utilization; strict GMP compliance requirements for expiry-first-out (FIFO) and batch traceability.
Solution
High-density stereoscopic warehouses are constructed to drastically boost space utilization. WMS/WCS systems are deployed for precise, visual and intelligent inventory management, and the logistics loop is closed via "goods-to-person" picking and fully automatic unmanned transfer of pallet-level materials.
Key Outcomes
- Significantly improved inbound/outbound efficiency, with peak daily throughput rising from 5,000 cases to 9,000 cases
- Full-process digital traceability, eliminating 100% of wrong shipment errors
- Informatized tracking of logistics personnel, reducing ineffective waiting and communication
- Strict compliance with batch management and expiry-first-out rules, meeting GMP requirements
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