Digital-Intelligent Shuangliang | AI Leading Precision Intelligent Manufacturing, Anchoring New Quality Productive Forces, Building a Global Benchmark for Advanced Photovoltaic Capacity
At the critical juncture when the photovoltaic industry is moving from "scale expansion" toward "high-quality development," intelligent manufacturing has become a key variable determining enterprises' core competitiveness. Shuangliang Silicon Materials (Baotou) Co., Ltd., Shuangliang New Energy Technology (Baotou) Co., Ltd., and Hengli Crystalline Silicon New Materials (Inner Mongolia) Co., Ltd. have successively been recognized as Advanced-Level Intelligent Factories of Inner Mongolia Autonomous Region, building an intelligent manufacturing matrix covering "monocrystalline silicon pulling — wafer processing — PV module manufacturing," and setting a new industry benchmark for the digital-intelligent transformation of PV manufacturing.
Grounded in an industrial internet architecture, Shuangliang has built deeply integrated, secure and reliable digital infrastructure, achieving facility-level industry leadership.
At the industrial network level, Shuangliang took the lead in adopting an F5G all-optical network architecture in the PV manufacturing field, replacing traditional Ethernet with a GPON passive optical distribution network, deploying core OLT with dual-link redundancy design, and achieving physical isolation between the production network and the office network. The all-optical network increases data transmission speed several times, reduces the probability of misoperations and data errors by over 80%, and greatly shortens network fault recovery time.
At the data governance level, Shuangliang built a data middle platform supported by Yonyou, adopting a hybrid architecture of data lake and data warehouse. Through industrial gateways and SCADA platforms, protocols such as OPC UA and Modbus are uniformly accessed, aggregating real-time data from MES, ERP, WMS and thousands of underlying devices. The data middle platform breaks down data silos across multiple systems, achieving full-chain data connectivity and precise traceability from procurement to production to sales, with system data accuracy reaching 100%.
At the security protection level, Shuangliang has built a defense-in-depth security system: firewalls are deployed at the boundary to resist external attacks, bastion hosts on the operations side control permissions and audit all internal operations, and core process parameters are encrypted with AES during storage and transmission, reducing data leakage risk by at least 80%.
In the monocrystalline silicon pulling stage, the factory deploys industry-leading 1600-type monocrystalline furnaces, achieving remote control and comprehensive monitoring through a centralized control system, raising the equipment numerical control rate to 97% and the key equipment connection rate to 96%. Shuangliang's independently developed monocrystalline thermal field reduces oxygen content to 12 ppm, with power consumption 16% lower than the industry average. In the machining stage, the MES manufacturing execution system realizes full-process work-order-driven, paperless operations from crystal rod cutting to inspection, sorting and blanking, improving per-capita equipment management efficiency by more than 6 times.
In the module production stage, Shuangliang built the industry's most advanced automated module production line, integrating core processes such as vision-guided high-speed string welding, AI layout, vacuum lamination and automatic framing. The entire line requires only a few operations personnel, with one module produced every 18 seconds. AI artificial intelligence centralized control recognition systems are used from string welding to EL inspection, achieving a product yield of 99.9%. Automation reduces unit packaging cost by nearly 40% and labor costs by 75%.
Shuangliang deeply embeds large models, machine learning and digital twins into the entire production process, driving the leap from automated to intelligent manufacturing, and deeply embedding artificial intelligence technology throughout production.
In production scheduling, the APS advanced planning and scheduling algorithm model, combined with parameters such as monocrystalline furnace operation data, pulling cycles and changeover cycles collected in real time via IoT, automatically completes monocrystalline furnace specification allocation and workshop scheduling optimization, shortening the planning cycle by 70% and improving plan issuance efficiency by 30%.
In equipment operation and maintenance, the EAM system relies on IoT edge cloud and center cloud collaboration, based on fault tree models, intelligent spot checks and inspection rules, to achieve intelligent equipment fault identification and automatic anomaly warning; combined with time-based preventive maintenance and performance-based preventive maintenance models, it automatically generates repair plans and preventive maintenance strategies, achieving the shift from reactive repair to predictive maintenance.
In quality control, the monocrystalline silicon rod electrical performance automatic grading system achieves overall grading and dispatching through fully automatic inspection and the MES system; after completion, processing efficiency increased by 50% and the defect rate decreased by 20%. The quality traceability project leverages the data middle platform to integrate data from ERP, WMS, MES and IoT, achieving full-process production quality information traceability from raw material entry to finished product shipment, with traceability efficiency reaching 100% and above.
Shuangliang integrates energy saving and carbon reduction into the entire intelligent manufacturing chain, has built an industry-leading energy-carbon management platform, responds to zero-carbon factory cultivation policies, and achieves green growth through technological innovation.