When Cranes No Longer Need Human Hands
In Ansteel Bayuquan’s steel plant, cranes now move heavy coils without a single manual command. The once labor-intensive yard now operates like it’s on “autopilot,” thanks to Schneider Electric’s industry-leading Integrated Autonomous Crane System (IACS).
The “1580 Hot-Rolled Coil Intelligent Warehouse and Unmanned Crane Project” marks a milestone in digital steelmaking. After going live, it achieved fully unmanned crane operations, cutting over 30 operator positions and improving operational efficiency by 23%, while significantly boosting safety and product quality.
Challenges in Traditional Hot-Rolling Workshops
Low Efficiency and Manual Coordination
Traditional crane operations relied heavily on human coordination through radios and manual logs. Each lift required multiple operators, leading to inefficiencies, miscommunication, and higher safety risks.
High Labor Intensity
Operators manually tracked every steel coil’s location, a demanding and error-prone task due to the unique ID and irregular storage layout of each coil.
Safety and Quality Risks
Cranes operate 15 meters above ground, while workers perform tasks below—creating constant safety hazards. Moreover, manual operation often caused surface scratches and pressure marks on hot-rolled coils, directly affecting quality and customer satisfaction.
Intelligent Solutions with IACS: Schneider Electric’s Answer
Schneider Electric introduced its Integrated Autonomous Crane System (IACS)—a complete solution comprising a customized WMS warehouse management system, crane automation, ground control, and monitoring systems.
Powered by AI-driven scheduling algorithms, IACS dynamically allocates resources and optimizes coordination across multiple cranes, reducing conflicts and ensuring seamless operations.
“The system enables dynamic scheduling across four bays and fourteen cranes, optimizing logistics flow and ensuring precision in every lift.”
— Sun Wei, Chief Engineer, Ansteel Bayuquan Hot Rolling Department
Building a Complex and High-Performance Autonomous Crane System
The IACS solution is built on Schneider Electric’s EcoStruxure architecture, integrating multiple advanced technologies for optimal performance:
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Dynamic Resource Allocation Algorithm – Acts as the “central brain,” optimizing efficiency by considering production plans, equipment status, and stacking principles.
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3D Scanning and Recognition – Gives cranes “smart vision,” enabling accurate coil identification, automated loading/unloading, and seat detection.
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Closed-Loop Anti-Sway and 3-Axis Coordination – Ensures stability and precision during motion, reducing swing and improving logistics speed.
“This solution delivers one of the most advanced autonomous crane systems in the steel industry today.”
— Song Yuehui, Steel Industry Manager, Schneider Electric Industrial Automation
From Storage to Dispatch: Achieving Full-Process Unmanned Operation
The upgraded 1580 hot-rolled coil warehouse now supports fully unmanned operations—covering coil entry, packing, leveling, transfer, sampling, and dispatch, with a daily capacity of 13,000 tons.
The system automatically assigns crane routes based on scheduling data and operates continuously 24/7, maintaining over 99% autonomous operation rate. Human error and safety incidents have dropped to zero.
Inside the control room, managers now monitor operations through digital twin models, replacing traditional paper-based communication with real-time digital management.
A Blueprint for Smart Steel Transformation
“The 1580 coil warehouse represents one of the most complex and productive storage operations in the steel sector. Our success with Schneider Electric offers a scalable model for future smart steel facilities.”
— Yang Yuqing, Production Director, Ansteel Bayuquan Hot Rolling Department
Together, Ansteel and Schneider Electric are driving the steel industry toward intelligent, green, and digital transformation, establishing a new benchmark for smart manufacturing in industrial automation.