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Since the Zhejiang Provincial Department of Economy and Information Technology issued the "Notice on Further Completing the Verification and Disposal Work of Medium-frequency Induction Furnaces in the Province's Machinery Industry" in 2019, then the "14th Five-Year Plan for Emergency Management of Zhejiang Province" was released by the Provincial Development and Reform Commission and the Provincial Emergency Management Department in May 2021, and then the "14th Five-Year Plan for National Work Safety" issued by the Work Safety Committee of the State Council in April 2022 once again emphasized: Deepen the research on the theories and methods of intelligent risk perception and monitoring and early warning, and give priority to the development of information-based, intelligent and unmanned safety production risk monitoring and early warning equipment. The introduction of a large number of policies reflects the government's high expectations and requirements for industrial work safety. However, the occurrence of multiple smelting furnace accidents always reminds us that there are still many risks in the safe production and use of medium-frequency furnaces or other smelting furnaces, and safety problems occur from time to time.

In addition, there are blind spots in the monitoring of the safe operation of equipment, which makes it easy to ignore potential safety risks. There are also generally blind spots in the supervision of the work of operators in enterprises, which increases the probability of accidents to a certain extent. At present, due to the current situation of thinning market profits, small and medium-sized smelting enterprises usually cannot invest a large amount of budget in safety supervision like enterprises with an annual output value of tens of billions of yuan. These enterprises are in urgent need of improving the level of safety supervision. Therefore, it is imperative to promote the regulatory solutions of Internet of Things sensors and intelligent detection equipment.

II. Safety Monitoring Solution

The safety monitoring solution of Ruhr IoT for the smelting and casting industry conducts real-time monitoring by deploying sensors, transmits the data to the Internet of Things (IoT) platform, and carries out early warning, forecasting and emergency response, so as to safeguard production safety.
Online Monitoring: Sensors are deployed to monitor the water temperature and water pressure of the smelting furnace cooling system, as well as the changes of voltage and current signals during the working process, so as to monitor the normal operation of the smelting furnace cooling system in real time. The thickness and cracks of the furnace lining of the smelting furnace are regularly detected by the smelting furnace lining detection equipment to master the health condition of the smelting furnace lining.

IoT Platform: The monitoring equipment transmits information to the IoT platform through the IoT gateway, and then transmits the data to the management platforms on the government side and the enterprise side through the IoT platform. Through the alarm module, the monitoring data such as water flow, water temperature, cracks and thickness of the furnace wall, and the surrounding environment are used for alarm.
Emergency Linkage: Abnormal situations are pushed in real time, and the safety handling is closed-loop. The safety monitoring data is directly related to the early warning, forecasting and emergency response of emergency management, as well as the safety of enterprise production. It is of great significance to do a good job in statistics and reporting of disaster information, so that all departments can timely grasp the safety status during the furnace production process, take active and effective measures, minimize the occurrence of accidents, and ensure the safety during the production process.

III. Expected Effects

Real-time Monitoring and Early Warning: By deploying water temperature and flow monitoring equipment, furnace lining thickness and crack detection equipment, and environmental monitoring equipment, real-time online monitoring and early warning of key parameters during the smelting process can be achieved. This will enable enterprises to promptly detect abnormal situations and take corresponding measures, effectively reducing the risk of accidents.
Risk Assessment and Decision-making Support: Based on a multi-level early warning model that combines algorithms and expert experience, risk analysis and assessment are carried out. This model will provide decision-making support for enterprise managers, helping them to timely formulate corresponding disaster prevention and mitigation measures and reduce the occurrence rate of accidents.
Improvement of Work Safety Efficiency: By providing real-time monitoring and early warning functions, this technical solution can help enterprises promptly detect abnormal situations and take measures, avoiding production interruptions and production capacity losses, thus improving the work safety efficiency of enterprises.
Enhancement of Safety Supervision Efficiency and Level: With the supervision support of the industrial safety Internet of Things platform, the government can comprehensively grasp the safety situation of smelting and casting enterprises within its jurisdiction, and promptly issue early warnings and supervise enterprises to carry out rectifications. This will help improve the safety supervision level of the industry and reduce the probability of accidents.
Improvement of Economic Benefits: After implementing the safety monitoring technical solution, enterprises will obtain obvious economic benefits in terms of reducing safety accidents and minimizing production interruptions and losses caused by accidents. At the same time, by improving the safety level and production efficiency of enterprises, their market competitiveness and long-term sustainable development capabilities will be further enhanced.