Driven by the "Dual Carbon" goals guiding the transformation and upgrading of the manufacturing industry, a globally leading 3C electronics production enterprise, in collaboration with GETECH's Dual Carbon team, has successfully advanced the "Smart Factory Energy-Carbon System + HVAC AI Intelligent Control" project at its Shenzhen production base. This initiative not only represents the company's proactive response to national policies on energy conservation, carbon reduction, and dual transformation in manufacturing but also marks a significant milestone in the implementation of its digitalization and greenization strategy.

As China’s "Dual Carbon" policies deepen, the manufacturing industry faces dual pressures of energy conservation, carbon reduction, quality improvement, and efficiency enhancement. As a globally renowned 3C electronics manufacturer with the world’s top product sales for four consecutive years, the company’s Shenzhen production base urgently needed to establish an energy-carbon management system compliant with the national Level 4 Intelligent Manufacturing Maturity Standard.

The project focused on building a "Unified Smart Factory Energy-Carbon Management Platform," integrating cutting-edge technologies such as AI algorithms and digital twins to achieve end-to-end refined management of energy usage and carbon emissions. It specifically targeted intelligent optimization of high-energy-consumption systems like HVAC, aiming to set a new industry benchmark for energy-carbon management.

During project implementation, the team faced multiple complex challenges. As an industry leader embarking on a comprehensive digital transformation, the complexity extended beyond technology to include system integration, data governance, and standard compliance. Key difficulties included:

Large and Dispersed Data Volume: Required integrating over 40,000 energy data points covering electricity, water, cooling/heat, nitrogen, compressed air, and other mediums, posing significant data consolidation challenges.

Complex System Coordination: Needed to interface with multiple platforms, including production systems and photovoltaic systems, to achieve data interoperability and system synergy.

High Technical Integration Demands: Required deep integration of AI algorithms, mechanistic models, and actual equipment control to achieve real-time optimization and automatic adjustment.

Stringent Standard Compliance: Needed to meet national Level 4 Intelligent Manufacturing Maturity certification requirements while ensuring international compliance to support the company’s global business expansion.

The project team advanced implementation with a "Platform + Algorithms + Data" trinity architecture:

Build a Full-Scope Sensing Network to Solidify the Data Foundation

Deployed nearly 400 smart electricity meters, water meters, and flow meters, dozens of chiller units and auxiliary equipment, and end air handling devices. Efficiently integrated over 40,000 energy data points to establish a comprehensive IoT sensing network covering HVAC and air compression systems, laying a solid data foundation for refined energy management.

Break Protocol Barriers with AI-Powered Data Governance

The platform is compatible with over 95% of mainstream industrial protocols, including MQTT, Modbus, Siemens S7, and BACnet. Enabled "plug-and-play" device integration through an intelligent protocol conversion engine, resolving protocol isolation issues. Innovatively applied automated AI data governance tools to significantly enhance data quality and availability, providing high-quality datasets for AI optimization algorithms.

AI Intelligent Algorithms Drive Energy Efficiency Leap

Deployed self-developed AI energy-saving optimization algorithms in 4 HVAC rooms and 4 air compression rooms. The algorithms integrated advanced mechanistic models and global optimization technologies like deep reinforcement learning to achieve unattended intelligent operation of cluster control systems. Precisely regulated the coordinated operation of nearly 400 end air conditioning units’ air-water systems, achieving a 20% energy saving rate post-deployment.

Forward-Looking Carbon Management for a Scalable Platform

Initially built a carbon asset management module to lay the data foundation for future carbon inventory and carbon trading. The platform’s highly flexible architecture offers strong scalability, enabling seamless integration of more energy types and management scenarios to meet the company’s evolving green needs.

Through the dual drivers of "Energy-Carbon Management + AI Intelligent Control," the project not only achieved energy conservation, carbon reduction, quality improvement, and efficiency enhancement for the company but also provided a replicable and scalable smart energy solution for the broader manufacturing industry, demonstrating the powerful role of technological innovation in green manufacturing.

Enhanced Economic Benefits

Annual cost savings reaching several million RMB.

Annual energy cost reduction exceeding RMB 3 million.

Converted policy benefits: Met Level 4 Intelligent Manufacturing standards, securing municipal smart manufacturing subsidies of several million RMB.

Key system optimization: AI dynamic regulation of HVAC systems reduced energy consumption by 20%.

Achieved Refined Management

Upgraded management granularity: Full-chain digitization.

Panoramic carbon-energy monitoring: Integrated 40,000+ device points, achieving 100% online monitoring of energy consumption and carbon emission data.

Intelligent diagnostics for efficiency: Automatically generated 15+ customized energy-saving solutions, continuously reducing energy consumption per unit product.

Operational efficiency leap: Reduced manual input for energy-carbon management by 70%, improved anomaly response time to minutes.

Supported Green Development

Breakthrough in green competitiveness: Supported global expansion.

Precise carbon emission control: Automatically generated carbon emission reports compliant with ISO 14064 standards, improving carbon accounting efficiency by 90%.

Empowered global compliance: Assisted Chinese manufacturing enterprises in expanding overseas, enhancing the global competitiveness of national manufacturing.

Industry benchmark effect: Achieved comprehensive carbon emission monitoring and management, improving green competitiveness and sustainable development capabilities.

The company’s representative stated: "With national development and market changes, digitalization, intelligence, and low-carbonization have become imperative trends for manufacturing enterprises. By implementing the Smart Factory Energy-Carbon System + AI HVAC optimization application, we have enhanced our intelligent manufacturing level, realized digital-intelligent and low-carbon development, responded to national policies, and elevated our core competitiveness."

In the future, as more enterprises join the digital low-carbon transformation, such projects will become a vital engine for high-quality industry development, empowering the group’s industries toward an intelligent and sustainable future!