Process control, engineering mathematical models, data alignment, equipment monitoring and vision AI — five product families that fully automate and digitalize cold rolling operations.
Universal process control software for cold rolling with high reliability, high efficiency, high scalability and high maintainability
Integrates line PLCs, DCS, standalone equipment and production management control systems, providing functions such as data acquisition, processing and setup.
A universal process control software product for cold rolling independently developed by Baosight. Easy to extend, excellent to maintain and flexibly customizable, it is highly generic across cold rolling and hot rolling.
It provides feature-complete, safe and reliable process control solutions, forming the foundation of intelligent production and lean management on the line.
All task modules run stably around the clock throughout the year, keeping the line running without stoppage and the system operating fault-free.
High-frequency data is rapidly acquired, saved, archived and aggregated, with control signals delivered at a latency of 100 ms to meet the demanding real-time requirements of production control.
Highly coupled base task modules form a stable foundation, while upper application modules are decoupled from each other, enabling flexible module combinations and custom configurations for redundant system expansion.
Built on the Baosight iplat platform, it provides intuitive visualization of operating status; one-click start/stop and automatic backup of critical data make daily operation maintenance-free.
Widely applied to tandem mills, single-stand mills, continuous annealing, galvanizing, tin plating, color coating, pickling and recoiling/packing lines, it delivers the complete cold rolling flow through automated control, information integration and digital management. It also provides data services and integration that coordinate with applications such as smart manufacturing, giving the line an accurate information foundation for intelligent production and lean management.
Application track record: All major production bases of Baosteel Co., plus domestic steel groups such as Maanshan Steel, TISCO, Xinyu Steel, Shougang, Ansteel, HBIS, Shagang and Hongwang, and overseas customers including Indonesia's Hongwang and India's JSL — comprehensive process control solutions are provided for entire cold rolling plants, cold rolling mills or processing lines.
Product track record: China 200+, Indonesia 3, India 8, Japan 1 (the electrical equipment supply contract for the twelve-high precision rolling mill of Mingdao Metal Co., Ltd.), and Thailand 1.
High-accuracy setup models with intelligent self-learning, stable and reliable
Establishes rolling models, flatness setup models and dynamic rolling-gauge-change models for stable, efficient, high-quality mill production.
Developed from the production process knowledge of cold rolling mills accumulated across long-term projects and integrated with Baosight's cold rolling gauge control approach, it is a mathematical model solution that satisfies the process requirements of modern cold rolling mills.
The setup calculation models combine classical rolling theory with engineering experience, while the self-learning models employ intelligent algorithms, giving the models self-learning capability.
The setup calculation models cover the rolling model, flatness setup model, dynamic rolling-gauge-change model and rolling engineering specifications for each material grade. Combined with Baosight's control approach, the setup values are accurate, fully ensuring efficient and stable automatic mill production.
Real-time rolling data is automatically collected, and intelligent model algorithms give the rolling and flatness setup models self-learning capability, improving the accuracy of setup values for each material grade.
Based on Baosight's independently developed software platform, it offers excellent stability, reliability and extensibility, making subsequent specification expansion and maintenance very easy.
Suitable for producing a broad range of flat products — ordinary carbon steel, tinplate substrate, high-strength steel, ultra-high-strength steel, electrical steel and stainless steel. Combined with Baosight's control approach, it effectively raises the fully automated production level of large cold rolling mills, completes production process setup accurately and efficiently, and helps enterprises build intelligent, green and high-quality lines.
Delivering a digital product with full-dimensional, full-scale, meter-level granularity
Accurately maps the entire production flow to the physical positions of the actual strip, ensuring correlation among the data of every process.
By making production process data, quality data, energy/environment data and other management data transparent and visible, it provides steel enterprises with a full-dimensional, full-scale, meter-level-granularity digital product — the "Digital Coil".
From pickling–tandem rolling to continuous annealing, galvanizing and color coating, it strongly supports the digitalization and intelligence of every line at the data level.
It can supply high-quality data services to upper-level applications.
Integrates data from different sources — production processes, energy consumption and environmental protection, and equipment operating status — into a unified dataset.
Using the coil as the carrier, it tracks the production data of strip through each process in real time, ensuring timely and accurate data alignment.
Builds physical-object data models and an inter-process data ecosystem, resolving the challenges of insufficient secondary-data accuracy and cross-process data integration.
An advanced manufacturing approach that fuses digital technology with steel production — data is collected, analyzed and applied during production to achieve real-time monitoring and optimization of the process. Widely applied to the digitalization and intelligence of pickling–tandem rolling, single-stand mills, pickling, continuous annealing, galvanizing, color-coating/skin-pass and electrical steel lines. Building on existing lines, it develops and deploys diverse applications including smart rolling, virtual plants, digital cold-loading plants, green low-carbon development and integrated safety & smart management.
Application track record: 120+ deployments in China and Indonesia cumulatively, including two lines already in operation at Guangzhou JFE.
Consolidating the requirements of production, process, quality, equipment, visualization and production management — it builds a unified production management system, introduces advanced process technology and equipment, implements total quality management, applies IoT for real-time equipment monitoring and maintenance, uses big-data analytics to optimize production flows, and presents production data in real time through visualization to support business decisions.
Applied to the two lines of the Guangzhou JFE cold rolling plant, it achieves an advanced upgrade of quality traceability and production management through full-process data alignment and visualization.
Upgrading with intelligent technology for superior equipment monitoring
Leverages existing equipment components and combines them with advanced big-data analytics to monitor equipment operating status in real time.
An inspection-support system designed for industrial equipment monitoring. Combined with the production environment and advanced big-data analytics, it rapidly identifies potential faults and anomalies.
Equipment reliability and service life are greatly improved and maintenance costs effectively reduced, safeguarding the continuity and stability of production.
Two new push functions have been added: abnormal equipment status and maintenance information can be pushed to the SaaS system, and can also be emailed to equipment owners, proactively reaching the relevant personnel with anomaly and maintenance alerts.
Maximizes the use of existing equipment and components with no additional hardware investment.
Provides a flexibly editable rule and algorithm library — choose between Expert Mode (preset advanced algorithms and optimization strategies) and Custom Mode (freely adjust or write proprietary rules to meet business needs).
Real-time data acquisition combined with big-data processing and machine-learning algorithms builds an online diagnostic model that automatically identifies equipment anomalies during production and raises alarms immediately, preventing failures before they occur.
Regularly monitors the operating status of major equipment (vibration, temperature, current, etc.) to detect potential faults early and avoid sudden downtime.
When equipment anomalies occur, data analysis quickly pinpoints the root cause, shortening repair cycles.
Applies IoT technology to centrally monitor distributed equipment from remote locations, facilitating centralized management and resource allocation.
Combines big data and machine-learning algorithms to build models that predict problems a device may face in the future, enabling more refined maintenance planning.
As an equipment monitoring system integrating equipment management, rule libraries, equipment history, equipment health trend analysis, inspection planning and fault reporting, it has been put into service on the following lines.
Enabling unmanned production with simultaneous gains in efficiency, yield rate and operating rate
Adopting AI algorithms such as CNN, it performs highly efficient and accurate recognition of dimensions, shapes and defects on the surface of cold-rolled material.
Based on advanced artificial intelligence technology and machine-vision principles, it builds network models with convolutional, pooling and fully connected layers, appropriately tuned and optimized from common architectures such as ResNet and VGG. It is an intelligent inspection and automatic precision control system developed specifically for cold rolling production.
Strongly supports cold rolling enterprises in product quality assurance, production efficiency improvement and production process optimization.
Strictly complies with steel industry association and relevant regulatory requirements, keeping inspection processes and management systems compliant and helping enterprises easily meet regulatory standards.
Inspection results are fed back to the cold rolling line control system in real time; once quality issues or dimensional deviations are detected, parameters such as roll force and rolling speed are adjusted immediately, efficiently raising the yield rate and operating rate.
Quickly corrects problems during production to prevent sustained output of large quantities of defective material; compared with traditional post-process inspection and adjustment, it drastically shortens production adjustment cycles and improves efficiency across the entire flow.
Simple and intuitive operation with flexible, convenient operating templates; inspection flows can be freely customized, and business upgrades and extensions are completed efficiently and quickly.
On cold rolling lines, the vision-AI inspection product monitors strip surface quality and dimensional condition throughout the entire process. From the moment the incoming strip enters the mill, defects such as scratches, pinholes and oxide scale are detected in real time, while dimensional parameters such as thickness and width are precisely measured. Taking automotive-grade cold-rolled strip as an example, problematic strip can be quickly identified and intercepted, ensuring that all strip flowing to downstream processes such as automotive manufacturing is qualified and safeguarding the quality and performance of the final automotive components.
Previously, staff judged the centering of incoming coils during coil-up by eye; fatigue and carelessness late at night could cause coils to topple, be scrapped or even lead to production accidents. After adopting Baosight's vision-AI inspection and adjustment models, the line automatically confirms the positions of the reel and the coil's inner circumference and, linked with the PLC system, achieves precise automatic coil-up — the entry section has realized unmanned production and the line operating rate has improved significantly.
A plate-centering vision inspection system has been deployed on the Miebach welder of Baosteel cold rolling line C122, automatically detecting the plate position with high precision before welding to improve weld quality and operating efficiency.
