The client's original power distribution system was built in 2010, with serious equipment aging, and had the following problems: 1. High energy consumption, with monthly electricity costs exceeding 500,000 yuan; 2. Frequent failures, with production losses of about 2 million yuan per year due to power outages; 3. Low efficiency of manual inspection, high operation and maintenance costs; 4. Lack of real-time monitoring and data analysis capabilities, unable to optimize power structure.

Case Detailed Content

You can write detailed content of the successful case here, using Markdown format.

1. Client Introduction

Shanghai Automotive Parts Co., Ltd. was established in 2005, specializing in the production of automotive engine parts, with a plant area of about 50,000 square meters and more than 800 employees. The company mainly provides engine cylinder blocks, cylinder heads, crankshafts and other core parts for well-known domestic automobile manufacturers, with an annual production capacity of 1 million pieces.

2. Project Background

With the continuous expansion of the enterprise scale and the upgrading of production equipment, the original power distribution system gradually cannot meet the production needs, mainly facing the following problems:

1. High energy consumption: The enterprise’s monthly electricity cost exceeds 500,000 yuan, accounting for about 15% of production costs, higher than the industry average.
2. Poor reliability: The power distribution equipment is seriously aging, with production losses of about 2 million yuan per year due to power outages.
3. Low operation and maintenance efficiency: Traditional manual inspection methods have long inspection cycles and cannot detect and handle potential problems in a timely manner.
4. Lack of data support: Cannot real-time monitor and analyze power data, unable to optimize power structure.

In order to solve these problems, the enterprise decided to upgrade the smart power distribution system to improve energy utilization efficiency, reduce production costs, and enhance production reliability.

3. Solution Design

Senkuo Electromechanical provided a comprehensive smart power distribution system upgrade solution for the client, including:

3.1 System Architecture

Adopt three-layer architecture design:

• Perception layer: Real-time collection of power distribution equipment operation data through smart meters, sensors and other equipment
• Network layer: Use industrial Ethernet and wireless communication technologies to realize data transmission
• Application layer: Smart power distribution monitoring system, realizing data storage, analysis and visual display

3.2 Core Equipment

• ZK-GCK Smart Low-Voltage Switchgear: With smart monitoring, protection, communication and other functions
• ZK-PLC300 Series Controllers: Implement logic control and data processing
• Smart Meters: Real-time collection of voltage, current, power, energy and other parameters
• Smart Power Distribution Monitoring System: Realize visual monitoring and data analysis

3.3 Main Functions

1. Real-time Monitoring: 24-hour real-time monitoring of all power distribution equipment operating status
2. Intelligent Load Analysis: Analyze power load characteristics and optimize power structure
3. Fault Warning and Positioning: Early detection of potential faults, rapid positioning of fault locations
4. Energy Consumption Data Analysis: Generate detailed energy consumption reports to support energy-saving analysis
5. Remote Control: Realize remote closing, opening and other operations
6. Automated Operation and Maintenance: Automatically generate inspection reports, optimize operation and maintenance processes

4. Project Implementation Process

4.1 Demand Research and Scheme Design

The project team went deep into the enterprise site, understood the existing power distribution system situation and client needs, and formulated a detailed solution design plan, including system architecture, equipment selection, implementation plan, etc.

4.2 Product Selection and Procurement

According to the scheme design, core equipment such as ZK-GCK smart low-voltage switchgear, ZK-PLC300 series controllers, and smart meters were procured, and equipment acceptance and testing were conducted.

4.3 On-site Installation and Commissioning

During the enterprise shutdown gap, the project team carried out on-site installation and commissioning work, including:

• Demolition of original equipment and installation of new equipment
• Cable laying and wiring
• System debugging and function testing
• Integration with existing systems

4.4 Personnel Training and System Launch

Trained enterprise related personnel on system operation, maintenance and fault handling, ensuring that the system can operate and be maintained normally. After system launch, the project team conducted continuous tracking and optimization.

5. Project Achievements

5.1 Economic Benefits

• Energy consumption reduced by 35%: Saving about 175,000 yuan in electricity costs per month, 2.1 million yuan per year
• Reliability improved to 99.9%: Reducing production losses by about 1.8 million yuan per year
• Operation and maintenance costs reduced by 40%: Saving about 800,000 yuan in operation and maintenance costs per year
• Return on investment: Investment payback period of about 2 years

5.2 Management Benefits

• Realized 24-hour unattended operation: Improved management efficiency, reduced labor costs
• Established a complete energy consumption database: Provided data support for subsequent optimization
• Enhanced corporate image: Demonstrated the enterprise’s digital transformation achievements

6. Technical Highlights Analysis

6.1 IoT Technology Application

Adopted IoT technology to realize real-time collection and transmission of equipment status, solving the problems of untimely and inaccurate data collection in traditional power distribution systems.

6.2 Big Data Analysis Technology

Used big data analysis technology to conduct in-depth analysis of power data, optimize power load, reduce peak energy consumption, and improve energy utilization efficiency.

6.3 Fault Prediction and Diagnosis

Through analysis of equipment operation data, realized fault prediction and diagnosis, eliminated potential problems in advance, and reduced fault downtime.

6.4 Modular Design

Adopted modular design, facilitating subsequent expansion and upgrade, improving system flexibility and scalability.

7. Client Feedback

The client is very satisfied with this smart power distribution system upgrade, believing that the system runs stably with complete functions, achieving the expected results. The client stated that through this upgrade, the enterprise has achieved a significant reduction in energy consumption, a substantial improvement in production reliability, and a significant drop in operation and maintenance costs, providing strong support for the enterprise’s digital transformation.

8. Experience Summary

Through the implementation of this project, we have accumulated rich experience in upgrading smart power distribution systems in the manufacturing industry:

1. Deeply understand client needs: Fully understand the client’s actual needs and pain points, formulate personalized solutions
2. Focus on system integration: Ensure seamless integration of new systems with existing systems
3. Attach importance to personnel training: Ensure that clients can skillfully operate and maintain the system
4. Continuous optimization and improvement: After system launch, continuously track and optimize to improve system performance

9. Related Resources

• White Paper on Smart Power Distribution Solutions
• Product Manual for ZK-GCK Smart Low-Voltage Switchgear
• Operation Guide for Smart Power Distribution Monitoring System

Adopted ZK-GCK smart low-voltage switchgear, ZK-PLC300 series controllers and smart power distribution monitoring systems, realizing the following functions: 1. Real-time monitoring of all power distribution equipment operating status; 2. Intelligent load analysis and optimization scheduling; 3. Fault warning and rapid positioning; 4. Energy consumption data analysis and report generation; 5. Remote control and automated operation and maintenance.