hightopo

Blast Furnace Smelting Simulation and Analysis System

In steel smelting, the blast furnace ironmaking mechanism is complex, and it‘s difficult for traditional methods to accurately perceive the internal state of the furnace. Computer-Aided Engineering (CAE) simulation technology is the core technology in the blast furnace field. Through Finite Element Analysis (FEA), the structural stress and erosion patterns of the furnace body can be analyzed; with the aid of Computational Fluid Dynamics (CFD), the flow characteristics of internal airflow and temperature fields can be reproduced, providing an in-depth analysis of physical fields and reaction mechanisms. However, due to the abstract nature of analysis results and difficulties in implementation, the value of this technology is difficult to fully realize.

Final Product Hightopo Software, based on its self-developed 2D/3D visualization graphics engine “HT for Web”, builds high-precision 3D blast furnace models that dynamically present key elements such as furnace body structure, tuyere distribution, and burden surface movement. The system deeply integrates multidimensional simulation modules, including isobaric lines, thermal loads, and isothermal lines, transforming the core blast furnace data and complex physical field data from CAE simulation calculations into intuitive visualization scenes, providing technical support for solving the blast furnace “black box” problem.

We use lightweight 3D modeling technology based on CAD drawings, aerial views, and equipment diagrams from the steel plant site. This allows us to model factory equipment — including furnace walls, hot blast stoves, and feeding and conveying systems. The appearance, texture, and structural features closely replicate the actual equipment, creating an immersive visual experience of the industrial scene.

System Analysis Isobaric Lines In the field of blast furnace smelting, isobaric surfaces and pressure contour lines on specific cross-sections are core tools for describing the spatial distribution of gas pressure inside the furnace. Among them, an isobaric surface refers to the curved surface formed by points with equal gas pressure inside the furnace at the same moment, while pressure contour lines refer to the connection of points with equal gas pressure on a specific cross-section. Both can accurately present the distribution characteristics of the pressure field and serve as key indicators for judging the stability of gas flow inside the furnace.

This system is based on real-time data collected from the furnace body sensor network, coupled with CAE pressure field simulation results for validation. It constructs real-time pressure contour lines and isobaric surface models, intuitively displaying core data such as maximum pressure and pressure range at key locations, including the furnace body, furnace waist, furnace belly, and hot blast main through a dedicated data panel. When extreme pressure points are detected in various regions, the 2D panel automatically triggers alarms and precisely locates abnormal points, facilitating a rapid response by operators.

Historical Data Playback

The system can dynamically render the gas pressure gradient distribution patterns at various parts of the blast furnace in the 3D visualization model, clearly presenting gas pressure change trends. Combined with charting tools, it visualizes historical gas pressure data for each sensor point, supports a data playback function on the 3D model, and helps operators trace back gas pressure change processes and analyze the causes of anomalies.

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Thermal Load Blast furnace thermal load is a key technical parameter in the ironmaking process, specifically referring to the amount of heat removed from the inside of the furnace body through the blast furnace cooling system per unit time. Its value directly reflects the thermal state balance inside the furnace and the energy transfer efficiency.

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Through the thermal load scenario, operators can intuitively grasp the thermal balance state inside the furnace and the airflow distribution situation. If the thermal load is too high, it means that there is local overheating inside the furnace, posing a risk of refractory material damage; if too low, it indicates insufficient reaction efficiency inside the furnace, which may involve problems such as incomplete fuel combustion and poor heat transfer effects of the furnace charge.

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Data Monitoring Display

This system uses real-time data collected by the cooling system — including inlet and outlet temperatures of the cooling medium, flow rates, and cooling wall surface area — as the core monitoring focus, employing interpolation algorithms to accurately calculate cooling wall thermal load values.

When the thermal load exceeds the set threshold, the system will automatically trigger a location alarm. By clicking the location icon in the upper right corner of the panel, the problem area can be immediately located. This provides operators with an accurate basis for timely scientific assessment, thereby avoiding refractory material failure caused by local overheating and ensuring the structural safety of the furnace body.

Isothermal Lines By collecting temperature data inside the furnace and combining it with data assimilation algorithms and 3D temperature field reconstruction technology, this system achieves precise visual positioning of the isothermal platform in the blast furnace cohesive zone, providing key support for determining the cohesive zone morphology and optimizing smelting parameters.

Data Monitoring Display

At the data display level, after the system integrates and analyzes real-time temperature data, it displays the top five temperature points ranked by location, height, angle, and specific temperature values. By clicking the interactive panel, operators can navigate directly to the target points in the 3D model, facilitating quick comprehension of high-temperature area distribution.

Similarly, based on historical temperature data, it is also possible to implement a simulation playback function for temperature changes during the blast furnace production process, thereby helping operators trace back temperature evolution trends and analyze furnace condition patterns.

Flow Field Flow field visualization is the core module for understanding the reaction environment inside the furnace, primarily encompassing three dimensions: temperature field, velocity field, and pressure field. The data originates from real-time sensing networks and CAE flow field simulation results — where the core simulation logic for the temperature field and velocity field is based on CFD technology, capable of accurately simulating gas flow trajectories and temperature gradient diffusion patterns; the pressure field combines coupled analysis of FEA and CFD, taking into account both structural loading and fluid pressure transfer characteristics, comprehensively presenting the dynamic reactions inside the furnace.

Temperature Field

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Enter your email Subscribe Based on multi-element sensing components, the system obtains real-time temperature data from various areas inside the furnace. It simultaneously applies Hightopo particle dynamic rendering technology to intuitively present the temperature gradient distribution inside the furnace. Through temperature change trends, it is possible to predict morphological changes such as upward/downward movement of the cohesive zone position and thickening/thinning of thickness, providing a data basis for adjusting smelting strategies such as burden distribution angle and blast temperature.

Velocity Field

Based on real-time gas flow data inside the furnace and referencing the airflow patterns from CAE flow field simulations, this system dynamically simulates the flow trajectories and flow velocities of gas inside the furnace. Through streamlined animations, it can clearly identify airflow dead zones, which are areas where gas flow is stagnant or velocity is too low. This prevents uneven airflow distribution from affecting reaction efficiency inside the furnace and ensures sufficient contact reaction between gas and furnace charge.

Pressure Field

The pressure field presents the pressure changes inside the furnace in the form of “a single diagram”, monitoring in real-time the pressure fluctuations at key locations such as the furnace top, furnace body, and hearth. When pressure imbalances such as sudden increases or decreases occur at the furnace top, the system will promptly issue warnings to remind operators to adjust the tuyere area and optimize the tapping rhythm.

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About HT 3D Particle System

Hightopo’s 3D particle system is designed for digital twins and simulation, consisting of particle emitters, particle properties, particle behaviors, rendering methods, particle lifecycle management, and more, achieving effects such as fire, smoke, rain, snow, explosions, dust, light trails, and magic. It has been performance-optimized on top of the “HT for Web” engine, supporting large-scale particle effects applications, supporting physical characteristics (gravity, wind force, collision) simulation, and supporting particle interaction characteristics. Particles can interact with objects in the scene through collision, adsorption, and other interactive properties, and can be applied in digital twin and simulation applications to simulate dynamic processes such as weather, fire, leakage, airflow, ocean currents, object stress, and deformation.

Heat Map To achieve a comprehensive perception of temperature distribution inside the furnace, we use the actual blast furnace dimensions as a baseline to create a 1:1 restored 3D model of the blast furnace. We then apply interpolation algorithms to spatially interpolate the discrete temperature measurement data, ensuring continuity and completeness in the temperature field presentation. By employing Hightopo Software’s heat rendering engine, temperature values are mapped into multi-color gradient heat maps. The scene supports rotation and viewing of the 3D model from any angle, allowing operators to grasp temperature distribution details inside the furnace from different perspectives.

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Additionally, the measurement point supports click interaction. Clicking on a target measurement point allows retrieval of its recent historical data, and the data will be presented in the form of a line chart visualization, clearly displaying the data change trajectory to facilitate efficient analysis.

Hearth Erosion As the core component of the blast furnace, the hearth’s erosion problem affects the blast furnace’s lifespan. Relying on our self-developed simulation analysis technology, we integrate real-time hearth erosion data with molten iron solidification data. Through in-depth integration and secondary analysis of CFD flow-state heat dissipation simulation results and FEA structural stress coupling analysis results, we dynamically generate high-fidelity hearth simulation models. The system can provide a sectioning function, allowing operators to view the erosion degree and molten iron solidification conditions of each cross-section of the hearth by adjusting the sectioning angle, enabling timely understanding of hearth erosion trends.

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The system is built with hearth erosion data as the core and temperature data as auxiliary support, combined with the actual structural parameters of the hearth. It can intuitively display the erosion depth at different angles of the hearth and the temperature distribution in corresponding areas, providing a data basis for assessing erosion risks and formulating targeted protection schemes.

Solidification Line Model

The system relies on the hearth structural framework, with hearth molten iron solidification data as the core and temperature data as auxiliary support, clearly presenting the molten iron solidification range and temperature distribution characteristics at various angles of the hearth, providing an intuitive reference for optimizing molten iron solidification control strategies and avoiding aggravated hearth erosion due to uneven molten iron solidification.

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Burden Distribution Hightopo’s 3D scene supports operators in real-time observation of the dynamic process of raw materials being precisely distributed from the charging equipment into the blast furnace. Through “HT for Web” 3D visualization technology, it clearly tracks the landing positions and burden layer accumulation patterns of different raw materials such as ore and coke, ensuring that the raw material distribution status can be monitored in real-time.

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The system displays key parameters such as burden thickness and raw material distribution uniformity through 3D models and 2D data panels. When abnormalities like uneven burden distribution or raw material landing point deviation are detected, the platform immediately triggers alarms and generates optimized strategies for adjusting charging equipment angle, rotation speed, and other parameters, enabling precise monitoring of the burden distribution process.

Summary The blast furnace 3D simulation platform relies on a real-time sensing network, combined with 5G + Industrial PON dual-channel transmission, to achieve efficient data collection. The system employs dynamic 3D reconstruction technology and a thermodynamic simulation engine to realize full-domain visualization functions such as furnace body transparency adjustment and all-angle observation. At the same time, equipped with a comprehensive early warning mechanism and fault diagnosis mechanism, it can promptly identify risks such as abnormal pressure, excessive thermal load, and hearth erosion, helping enterprises achieve intelligent and efficient operation of blast furnace smelting.

Drone-Based Inspection Systems for Modern Data Centers

Drones, with their flexible, efficient, and multi-sensor integration advantages, can be used for inspecting large modular data centers, open areas, and outdoor equipment. They can precisely check the status of circuits, servers, network devices, and environmental parameters, while transmitting data in real-time. Through data-driven and intelligent analysis, they can significantly improve inspection efficiency, accuracy, and fault prediction capabilities.

Using Hightopo’s low-code digital twin tools, we have built a visualization monitoring system for the data center. This system accurately renders everything from the orderly arrangement of server cabinets to the specific locations of critical equipment, such as air conditioners and UPS in a 3D environment. It provides precise virtual navigation references that guide drone inspection routes.

During inspections, drones can automatically identify equipment labels, monitor cable connection status, and detect issues such as equipment surface damage and abnormal indicator lights, generating visual inspection reports and marking fault locations in real-time. The platform integrates multi-source data from drones, internal equipment, and environmental monitoring to build detailed three-dimensional visualization models and establish dynamic early warning mechanisms. This system effectively improves maintenance efficiency, response speed, and proactive management capabilities, providing strong support for the reliable operation of smart data centers.

Extending to the microscopic level, this platform also achieves micro-level virtual simulation of device chips. It not only digitally replicates physical characteristics at a 1:1 scale — including nanometer-level texture undulations on wafer surfaces, micrometer-level pin array spacing, and the subtle textures and cooling grooves formed by injection molding processes of packaging shells — but also clearly displays the integrated chips on circuit boards, various components, and their layouts. It can be used to simulate collaborative scenarios such as signal transmission between chips and power consumption distribution within cabinets, providing data support for overall system optimization. With these virtual models, operators can conduct performance simulations, parameter debugging, and lifespan assessment tests, thereby reducing physical testing costs and shortening chip development and verification cycles.

Hightopo Software has been focused on the web-based visualization field for over 10 years. The company has independently developed HT for Web 2D and 3D graphics rendering engines, a low-code digital twin SCADA platform, and related tools. Currently, HT for Web products has been widely applied in various industry sectors, including industrial SCADA, power and energy, digital twin factories, telecom data centers, smart transportation, smart cities, campus buildings, smart water management, aerospace and defense, providing clients with reliable one-stop digital twin solutions.

3D Visualization Enhances Modern Aerospace Launch Operations

The spaceflight system has evolved into a complex super-engineering system. As missions become increasingly complex, the industry urgently needs a more intelligent and collaborative monitoring system with improved multi-source data fusion efficiency, standardized cross-system interactions, and enhanced real-time response capabilities in physical space. Using the HT for Web (HT) graphics engine, we created a high-precision reality mapping system that enables real-time aerospace operation state perception, dynamic data analysis, and remote collaborative management. This technology is advancing aerospace engineering into a new era of intelligent operation and maintenance.

Final Product This section demonstrates three key visualizations: a monitoring simulation of the complete space shuttle launch process, precise dynamic control of the rocket recovery phase, and a technical demonstration of 2D visualization of the space shuttle lift-off process. Using the HT low-code digital twin platform, we convert complex aerospace systems and massive data into intuitive visual interfaces that overcome time and resource limitations while accurately simulating various complex and extreme launch scenarios. This technology provides space engineering professionals with advanced tools for efficient mission planning, precise risk assessment, and data-driven decision optimization.

System Analysis

Shuttle Launch Monitoring Based on Hightopo’s advanced 3D rendering technology, we accurately constructed 1:1 digital twins of the Shuttle’s external fuel tank, solid rocket boosters, and launch pad. The composite structural system, launch infrastructure, and surrounding environment of the Shuttle are reproduced with centimeter-level accuracy, creating an immersive command platform that enables the command team to break through geographic constraints and achieve efficient cross-regional collaborative decision-making.

Fuel Filling Monitoring

The system supports a first-person view interface that enables operators to monitor the level changes of fuel as it is transported from the storage ball tank to the launch pad and injected into the tank. Depending on the user’s specific data requirements, the platform can also present key indicators such as fuel refueling parameters, structural stress distribution of the external fuel tank, temperature field changes, and solid rocket booster pressure data. By comprehensively analyzing the interrelationships between these parameters, the system generates scientific launch decision support data, providing a reliable technical basis for the command team.

Dynamic simulation of equipment ignition

In the precisely constructed 3D virtual environment, we use HT 3D technology to professionally display the test workflow of the Space Shuttle’s front main engine gimbal regulator. After the test completes, the system automatically activates the hydrogen combustion unit, causing the three main engines to ignite simultaneously to generate high-energy thrust. Flame dynamics are accurately simulated by HT particle technology, providing high-fidelity visualization of vibration effects during ignition. Through the professional virtual navigation system, technicians can monitor ignition status parameters from a multi-dimensional perspective while accessing precise countdown data on the 2D data panel, creating a comprehensive integrated monitoring system.

The system interface displays real-time dynamic monitoring data of key parameters including the orbiter’s main engine thrust curve, acceleration vector, attitude angular deviation, and solid rocket booster working status. This functionality effectively identifies potential faults such as main engine thrust abnormalities, solid rocket booster combustion instability, and external fuel tank leakage. Early warnings are provided through local highlighting marks on the model, enabling technicians to quickly locate problem sources and formulate appropriate solutions.

Rocket Recovery Simulation Analysis As reusable rocket technology has become a strategic focus of global space competition, traditional monitoring systems struggle with key challenges: dynamic modeling of rocket recovery, integration of spacecraft multivariate data, and instantaneous decision-making. Using the Jupiter III reusable launch vehicle as our simulation basis, we precisely constructed a digital twin management platform for the complete rocket launch and recovery cycle.

This section highlights the digital twin rocket recovery operation and maintenance monitoring system, which accurately reproduces the actual recovery process through “digital mirroring.”

Scene Roaming

The system uses HT for Web’s GIS technology to create precise geospatial mapping, combining high-definition satellite imagery with 3D live modeling to reproduce the launch site’s topography, tower layout, and surrounding environment at a 1:1 scale. Additionally, the dynamic environment model incorporates real-time meteorological data such as wind speed and temperature, providing an accurate spatial reference for rocket recovery path planning.

Recovery Trajectory Visualization

Using HT digital twin technology, the system analyzes real-time flight data and environmental parameters to optimize the rocket’s recovery trajectory through precise simulation. During the return phase, the platform continuously monitors the flight path, analyzes atmospheric conditions, and simulates recovery scenarios across various weather conditions and flight postures. This provides a scientific foundation for trajectory adjustments.

Recovery Data Monitoring

The amount of data during the rocket recovery process is huge and complex, and HT’s 2D SCADA panel supports efficient monitoring and decision-making analysis.

■Panoramic situation panel: basic information such as rocket model, reuse times, current operation stage, recovery process node, remaining propellant, rocket external temperature, current load, etc.

■Meteorological environment information: environmental parameters such as wind direction, wind speed, temperature, humidity and visibility are monitored.

Using advanced particle dynamics simulation technology, the scene precisely captures the complex movement and interaction of numerous particles. It accurately reproduces the flame’s dynamic changes, heat diffusion patterns, and temperature gradient characteristics. This provides a highly realistic professional visualization of the entire rocket launch and recovery process.

Space Shuttle Liftoff 2D Animation Using low-polygon animation technology integrated with HT’s low-code digital twin platform, we present the key components of the space shuttle, launch site, tower facilities, and surrounding environment. This approach simplifies complex space engineering processes into clear, interactive 2D animations that overcome limitations of traditional educational methods. Through intuitive visual storytelling, the system accurately illustrates the complete technical journey of the space shuttle from launch to orbital insertion.

Launch

When the countdown on the 2D page reaches zero, the system executes the launch sequence and activates the rocket engine ignition program. The engine generates a precisely calculated thrust vector that drives the Shuttle smoothly off the launch platform into a predetermined ascent trajectory. Flame dynamics in the interface are rendered through HT’s particle rendering technology, combined with accurately simulated body vibration response, providing a professional and highly immersive visualization of the launch process.

Climb and Booster Separation

This page dynamically illustrates the visual changes of the space shuttle as it traverses different atmospheric environments. As altitude increases, elements such as clouds and the ionosphere are clearly depicted. When the Shuttle reaches specific stages, the system accurately simulates the separation trajectory and attitude changes of the booster and fairing. This intuitive presentation enables viewers to easily visualize and comprehend the complex mechanisms of space flight.

Space and Orbit Setting

After entering the space and orbit setting stage, the interactive interface built by the HT platform connects with the shuttle’s power and propulsion systems’ core data in real time. It visualizes operating status through 2D charts and clearly displays key parameters such as whether the launcher has reached the target altitude and the target speed.

Once the rocket reaches the predefined orbital speed, it delivers the spacecraft into the intended orbit. During orbit insertion, the spacecraft’s control system performs precise orbital adjustments and attitude control, ensuring the spacecraft enters the target orbit accurately and maintains proper alignment with it.

Demonstration of Orbital Operation

The system reproduces the orbital movement of the spacecraft in the form of 2D animation, clearly displaying the spatial positioning of the Carmen Line, the positional relationship and functional characteristics of the Low Earth Orbit (LEO) and Geostationary Earth Orbit (GEO) regions.

Spaceflight Tips

A spacecraft enters outer space when it crosses the Kármán Line (the boundary between the atmosphere and space at an altitude of 100km). In the Low Earth Orbit (LEO) region, the spacecraft maintains a stable orbit by achieving dynamic equilibrium with Earth’s gravity. This happens when it reaches a sufficiently high horizontal velocity that creates a centrifugal effect. Here, spacecraft perform Earth observation, communication relay, and space science experiments. Meanwhile, higher orbits such as the Geosynchronous Earth Orbit (GEO) serve different functions including global communications and weather monitoring.

The Shuttle Liftoff 2D animation platform combines rendering, physical simulation, and interactive design technologies to vividly illustrate the complete space flight process. It serves as both a cutting-edge medium for sharing spaceflight knowledge and an innovative tool for science education and academic research. Through its immersive interactive experience, the platform ignites public enthusiasm for space exploration, facilitates widespread dissemination of space knowledge, and provides fresh momentum for the intelligent development of the space industry.

Summary Hightopo will continue to advance in aerospace digitization, leveraging its proprietary graphics engine while integrating cutting-edge technologies like satellite navigation and 5G communication to help aerospace enterprises build an integrated space-air-ground intelligent monitoring system. Simultaneously, we are actively supporting green space initiatives by optimizing resource allocation through digital solutions, reducing lifecycle costs, and providing momentum to drive the global space industry toward high-quality development that is “low-cost, highly reliable, and sustainable.”

Hightopo Visualization Empowers Mining Production and Management

Original link: https://medium.com/@hightopo/hightopo-visualization-empowers-mining-production-and-management-462827aa2145

With the continuous evolvement of the mining industry, traditional management methods can no longer meet the requirements of modern copper mines for efficient, safe, environmentally friendly, and refined management. Therefore, building an integrated control platform has become imperative. The Hightopo Copper Mine Integrated Management Platform — hereafter called “This platform” — has been specifically designed to address these challenges. Through information and intelligent means, it integrates management functions of various stages including mining, mineral processing, and smelting, achieving resource optimization, real-time monitoring, safety assurance, environmental protection, and process optimization, thereby enhancing the overall operational efficiency and competitiveness of the mine.

Final Project Showcase This platform, developed based on the “Hightopo” graphic engine, utilizes its powerful data visualization and real-time monitoring capabilities to achieve comprehensive integration and optimization of mine production, equipment, safety, and resource management.

This platform aims to improve production efficiency and safety, optimize resource utilization, support technological innovation and process improvements, and promote environmental protection and sustainable development. Through information and intelligent means, it drives copper mining enterprises to achieve refined management and modernization transformation.

System View Overall Management This platform uses 3D geographic models and dynamic displays to showcase a panoramic view of the mining area, including details such as mountains, rivers, and plant exteriors. The page presents monthly copper and gold production data, production progress of various mines, and daily grade data through charts and curve graphs, making it intuitive and convenient.

It supports real-time monitoring and data integration with the mine production management system, thereby enhancing management efficiency and decision-making accuracy.

3D Geographic Model of the Mining Area

The left side of the platform displays a 3D terrain model of the mining area, presenting geographical features such as mountains, plains, and rivers. It also shows detailed layouts and appearances of plants. Through dynamic light flow effects, it displays real-time changes in production activities, including equipment operation and ore transportation routes, providing intuitive on-site perception and supporting effective production scheduling and management decisions.

Mine Production Data

The dashboard on the right side of the platform displays key production data for the mine, including three parts:

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■ The first area presents the proportion and cumulative data of copper and gold production for the current month.

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■ The second area displays the daily production, monthly completion, and planned completion rate for each copper mine.

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■ The third area shows data for the past 7 days’ supply grade, production grade, and gangue grade in the form of a curve graph.

These panels provide real-time, intuitive monitoring data of production progress and quality, effectively supporting management decision-making.

Mining Dashboard The mining dashboard uses multi-dimensional data charts to monitor and display various key production and operational data in real time, including planned usage of explosives, unit consumption, drilling rig and perforation information, material consumption, and energy consumption. Additionally, the system records detailed data on mining and stripping volumes, cost statistics, changes in per-ton ore indicators, and ore quantity completion status. Other sections display production and grade testing information, provide grade comparison analysis, equipment attendance rates, GNSS monitoring information, daily ore preparation, and workforce statistics, offering real-time decision support for management.

Safety production is ensured through recording key risk point operation processes, blasting personnel information, and integrating multi-source data analysis.

Furthermore, this platform provides two theme styles — dark and light — allowing users to switch between them freely. This feature accommodates various visual preferences and enhances the interface’s readability.

Mining, Mineral Processing, and Smelting Process Flow Diagram Leveraging Hightopo’s seamless integration of 2D and 3D capabilities, this platform presents traditional 2D process flow diagrams in an innovative 3D format. Through dynamic visualizations and smooth transitions, it offers a unique and engaging experience that surpasses conventional flow charts.

The process flow diagram of the copper plant illustrates the complete production process from raw ore to high-purity copper products, divided into three main modules: mining, mineral processing, and smelting.

■ The mining process flow diagram covers steps such as drill hole perforation, explosive charging and blasting, ore transportation, and preliminary processing;

■ The mineral processing flow diagram separates and purifies the ore into copper concentrate and sulfur concentrate through stages including coarse crushing, semi-autogenous grinding, flotation, and thickening

■ The smelting process flow diagram employs steps such as crushing, heap leaching, electrowinning, and electrorefining to further refine copper concentrate into high-purity cathode copper.

Each module provides a detailed display of the various process steps and related equipment, reflecting the efficiency and precision of the entire production chain.

Mining Process

The mining process flow diagram illustrates the various steps from ore exploration to ore transportation and preliminary processing, ensuring efficient and safe ore extraction.

The mining process includes several key steps: exploration, mine preparation engineering, large and small hole drilling, large and small hole blasting, ore loading and hauling, ore chute, crushing, inclined belt conveyor transportation, copper plant flotation, and so on.

The mining process flow diagram visualization tool enhances mining safety management efficiency through streamlined charts and data analysis. By providing real-time monitoring of critical indicators and risk points, it facilitates prompt decision-making by management, ultimately enhancing workplace safety and operational efficiency.

Mineral Processing

The mineral processing workflow is a complex and precisely controlled procedure that encompasses the entire sequence from coarsely crushed ore to the ultimate production of high-grade copper concentrate.

With the Hightopo web-based graphic engine, the platform offers a comprehensive visualization of the mineral processing workflow, incorporating detailed environmental protection and safety protocols. This sophisticated tool optimizes production processes to minimize environmental impact and enhance worker safety. Through precise visual monitoring and control of each operational stage, the system ensures optimal quality and efficiency in copper concentrate production. The implementation of modular design principles, water resource recycling, and valuable by-product recovery exemplifies the platform’s commitment to efficient and sustainable modern mineral processing techniques.

Smelting Process

Hydrometallurgy is a crucial process for copper smelting, particularly advantageous for processing low-grade and complex ores. This comprehensive method encompasses several key stages: ore pretreatment, heap leaching, leach solution collection and purification, solvent extraction, stripping, and electrowinning. Each phase is designed to maximize copper extraction efficiency while minimizing environmental impact.

Hydrometallurgy offers significant advantages over traditional smelting methods. It efficiently processes complex ores while substantially reducing harmful emissions, aligning with environmental sustainability goals. Furthermore, its adaptable nature allows for customization to various ore compositions, thereby enhancing both economic viability and ecological stewardship in copper production processes.

Underground Mining Dashboard The underground mining dashboard professionally presents essential mine production data. It provides real-time equipment operational status, daily production summaries, and dynamic updates on underground personnel and equipment. The dashboard also includes statistical analysis of mining costs, detailed ledger information, progress reports on tunneling projects, and updates on large and medium-hole construction activities. This comprehensive tool equips mine managers with a real-time, detailed overview of production operations, facilitating informed decision-making and efficient management.

Copper production process Through the use of Hightopo’s advanced 3D engine rendering capabilities, the platform presents a sophisticated visualization of the copper mine production process. The system utilizes high-fidelity modeling and lifelike material textures to provide an accurate representation of each equipment’s intricate structure and operational status. Every component, from large-scale crushers to sophisticated flotation cells, is meticulously replicated, maintaining precise proportions relative to their real-world counterparts. This faithful reproduction enables production personnel to conduct comprehensive inspections of the mineral processing workflow, offering unobstructed views of crucial operations such as ore crushing, material transportation, and storage facilities from multiple vantage points.

The data dashboard on the right side of the platform interfaces with the server to update key parameters in real-time, such as production completion status, production organization details, and process indicator information, allowing production personnel to quickly grasp the operational status of the production system.

Summary The Copper Mine Integrated Management Platform, powered by the Hightopo graphic engine, exemplifies the advanced application of digital twin technology and visualization in copper mine management. Utilizing real-time data acquisition and 3D visualization, the platform provides comprehensive monitoring across all mining operation phases, encompassing extraction, mineral processing, transportation, and storage. It offers real-time updates on equipment status, production progress, and safety metrics, facilitating informed decision-making and enhancing operational efficiency. This system not only augments the operational effectiveness and competitive edge of mining operations but also demonstrates significant potential for driving technological innovation, optimizing resource allocation, ensuring operational safety, and promoting sustainable practices. Ultimately, it positions copper mining enterprises at the forefront of refined management practices and technological modernization.

Low-Altitude Economy Management Platform | Drone Delivery Management System

With breakthroughs in core technologies like drones and eVTOL, the applications of low-altitude economy have greatly expanded, extending from traditional areas such as agricultural and forestry plant protection and industrial line inspections to emerging fields like urban air mobility and low-altitude logistics delivery, paving new paths for the digital and intelligent transformation of numerous industries.

Final Product

Using Hightopo’s low-code SCADA platform, we developed a lightweight smart city monitoring platform for low-altitude operations. The platform enables service innovations in airspace management, smart logistics, and food delivery through route optimization, cost control, and risk warning systems. Its 3D visualization capabilities support intelligent route planning and dynamic navigation. The platform excels in essential functions including route optimization, task coordination, and risk prediction.

Control Center GIS Urban Modeling Using the low-code development platform, Hightopo builds GIS-based 3D digital twin city scenarios. These scenarios accurately recreate urban elements including terrain, buildings, road networks, and vegetation, supporting highly customizable modeling to improve the precision and efficiency of urban planning and design. It also provides high-precision ground reference information for drones, enabling precise navigation and intelligent obstacle avoidance.

Airspace Drone Monitoring Based on the global navigation satellite system, multi-source sensor fusion, and air-ground communication link technology, the system achieves comprehensive real-time monitoring of drones. It can dynamically acquire key parameters such as the drone’s spatial position, airspeed, altitude, and flight attitude. When the system identifies a flight conflict risk, it simultaneously triggers two response measures: pushing warning information to controllers on one hand, and transmitting real-time flight instructions and situational data to drone terminals on the other, helping operators adjust flight paths promptly.

Control Center Statistics This platform collects drone flight route data to optimize paths and maximize airspace efficiency. It tracks daily drone operations to streamline resource allocation and scheduling. The system also analyzes violation incidents to continually refine flight management protocols and enhance airspace security measures.

Route Management Before executing drone flight missions, route management personnel can use Hightopo’s intelligent route planning functionality to simulate and plan safe and efficient flight paths within the 3D visualization environment.

The intelligent route drawing feature provides users with convenient operation methods, allowing them to either precisely select points directly on the map or input coordinate values to easily complete the drone flight route creation. Users can flexibly set the route’s starting point, destination, and waypoints, as well as precisely configure key parameters such as flight altitude and speed.

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Route Overview The system interface allows users to view and manage various drone flight routes, including civil aviation routes. The page uses colorful flow effects to display different types of routes intuitively.

When users click on a specific route, the 3D scene displays its distribution, start and end points, average altitude, position, and other information, providing comprehensive data support for the airspace management control center.

Weather Station Alerts Before executing drone flight missions, operators check warning data from weather stations including temperature, real-time rainfall, wind direction, and wind speed to ensure drones take off under suitable weather conditions and prevent accidents caused by adverse weather.

Express Delivery & Logistics Delivery Track Monitoring The platform conducts comprehensive real-time monitoring of drone delivery logistics tasks, dynamically tracking the drone’s flight status, spatial position, and delivery progress. Based on intelligent algorithms, the system can automatically identify abnormal conditions (such as technical failures, sudden weather changes, etc.) and trigger emergency response mechanisms. Operators can intervene in real-time by sending remote commands and simultaneously push safety handling solutions to effectively avoid accident risks.

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Logistics personnel can push real-time updates to users regarding drone location and estimated package arrival time, achieving end-to-end traceability of package logistics, helping improve logistics service transparency, and optimizing user experience.

Express Logistics Data Statistics The system monitors environmental data in real-time, such as temperature, humidity, and wind speed, dynamically adjusting drone flight parameters based on environmental conditions to improve flight efficiency. The system can perform statistical analysis of warning information, precisely analyze failure causes, and provide data support for drone maintenance. Additionally, the platform automatically summarizes daily data, including drone delivery frequency, success rate, and average delivery time. The comprehensive results evaluate daily operational efficiency, supporting users in making data-driven decisions.

No-Fly Zone Monitoring The system graphically displays the No-fly zone for unmanned aircraft in an intuitive way. During drone flights, it monitors in real-time whether drones enter no-fly zones to prevent them from accessing sensitive areas.

Food Delivery Delivery Track Monitoring The entire delivery process is monitored from when the drone takes off from the merchant until the food is delivered to the pickup cabinet, ensuring safe drone delivery and enabling a timely response to potential anomalies.

Drone Queue Delivery Mechanism During peak hours, multiple drones may attempt to deliver to the same food pickup cabinet simultaneously. To avoid aerial traffic congestion and improve delivery efficiency, the platform employs real-time monitoring, intelligent scheduling algorithms, and high-speed communication technology to provide management staff with data analysis and decision support, enabling orderly drone deliveries.

Data Statistics Monitoring The platform also collects and analyzes delivery operations data, covering delivery data from various regions, delivery efficiency statistics, and equipment utilization rates. Through these data analyses, it explores potential opportunities to optimize delivery routes and strategies to improve delivery efficiency.

Advantages Traditional 2D map-based drone visualization management platforms struggle to adapt to complex scenarios and cannot meet the demands for high-precision data processing, multi-source information integration, and complex environment simulation. The Hightopo integrated 2D-3D low-altitude economy dispatch and delivery platform stands out with distinct advantages, capable of precisely replicating terrain, buildings, meteorological and other elements, providing accurate environmental data for drone flights, and significantly improving data processing precision. In terms of multi-source information integration, it can seamlessly connect with various data sources, combining weather, traffic, logistics and other information with real-time interaction, providing a comprehensive and accurate basis for dispatch decisions. It can also simulate and conduct scenario planning for complex environments and emergencies, allowing for advanced strategy development.

Moving forward, the Hightopo platform will further expand its functionality, such as integrating with intelligent transportation systems to achieve coordinated management of drones and ground traffic; explore integrated drone applications in other industries, such as agricultural plant protection and power line inspection. This will deeply empower the drone industry, promoting its steady advancement toward healthy and sustainable development, helping the low-altitude economy become a new engine for economic growth.

How to Use 3D Modeling and Drones with RFID for Smart Warehouse Stocktaking?

As logistics undergoes digital transformation, smart warehousing is evolving from passive management to proactive intelligent operations. Drone warehouse inventory technology — a key innovation in low-altitude operations — enables real-time material tracking through autonomous positioning, smart flight planning, and automated counting. This technology surpasses traditional manual inventory’s limitations in both efficiency and safety, delivering precise automated inventory management while reducing operational costs. It represents an innovative breakthrough in modern supply chain management.

Final Product Using “HT for Web” — Hightopo Software’s graphics engine — we created a smart warehouse RFID drone inventory solution. The system forms a complete intelligent management loop by monitoring all aspects of warehouse operations: material storage, asset tracking, inventory processes, and equipment operation. This solution significantly reduces labor costs and human errors while improving warehouse management efficiency. It breaks through industry development constraints and provides robust support for enterprise digital transformation.

Drone Inventory Management Traditional warehouse inventory relies on manual PDA devices for scanning or visual counting. This method is time-consuming, labor-intensive, and prone to human errors that affect accuracy. In contrast, inventory drones can autonomously plan their paths and swiftly complete inventory tasks for high-rack shelves and large areas. This automation improves efficiency by 5–10 times while enabling round-the-clock operation.

RFID Inventory Tasks

Hightopo’s smart warehouse drone inventory system seamlessly integrates RFID technology with drone systems. Using autonomous navigation drones equipped with RFID readers, the system achieves comprehensive coverage through aerial scanning while performing tasks without disrupting ground operations. This approach overcomes the efficiency bottlenecks and safety constraints of manual inventory, enabling swift automatic scanning and updating of warehouse inventory data.

Real-time 2D visualization dashboards support management decision-making. Through multi-dimensional data filtering and analysis, managers can monitor and control inventory tasks with precision — from standardized task naming and area division to real-time quantity tracking and dynamic status updates.

Drone Inventory Operation Process

When users click the “Start Inventory” button, the intelligent drone takes off automatically along preset routes and scans all RFID tags in the designated area with precision. This process reduces traditional manual inventory time from hours to minutes while enhancing data collection accuracy through intelligent recognition technology — significantly streamlining the entire operation.

Management personnel can monitor inventory distribution and item status in real-time without frequent warehouse visits, achieving full traceability and intelligent scheduling of warehouse operations. This creates a truly intelligent and automated modern warehouse management system.

Inventory Data Collection and Analysis

The drone automatic inventory system delivers real-time data collection and precise recording through advanced RFID technology. Inventory reports contain essential information — including task names and execution times — alongside key details such as RFID tag IDs, item names, planned spaces, actual quantities, current storage locations, and storage times. The system intelligently flags overdue items, enabling staff to quickly perform and maintain inventory counts while efficiently managing large volumes of data.

Drone Status Monitoring This function combines multiple sensors and data collection technologies to monitor drone operations in real time, ensuring safe and reliable task execution. The system monitors these key indicators:

■ Current Status Information: Live display of the drone’s working status, position, and key parameters including flight height, speed, and orientation.

■ Task Progress Tracking: Real-time monitoring of inventory completion progress with percentage display to help managers oversee task advancement.

■ RFID Read Data Quantity: Tracking of total RFID readings to verify complete inventory coverage.

■ Number of RFID Tags Read: Live count of successfully identified RFID tags to ensure accurate and transparent data collection.

■ Battery Status Monitoring: Continuous battery level tracking with automatic alerts when power drops below set thresholds, ensuring timely battery changes during operations.

Equipment Inspection and Alerts

The HT monitoring system features customizable drone inspection routes and schedules, allowing drones to complete inspection tasks autonomously along preset paths. During inventory checks, drones automatically identify the location, quantity, and status of shelf items while monitoring storage conditions and detecting anomalies. When the system discovers inventory discrepancies, it immediately triggers alerts and generates detailed reports — complete with locations, quantities, and supporting images — enabling warehouse managers to quickly pinpoint and address issues.

Warehouse Material Visual Management and Control Material Information Display Using Hightopo’s comprehensive chart components, the system clearly displays inventory status and transfer records for various materials. The multi-dimensional classification system organizes items across categories including fast-moving consumer goods, medical equipment, and logistics services. Real-time data analysis provides enterprises with precise inventory information, supporting informed management decisions and enhancing overall warehouse efficiency.

Inventory Dynamic Tracking The system enables dynamic inventory tracking for real-time updates and management. It precisely monitors material movement across different areas, giving users instant access to information about quantity changes, category distributions, and current material locations. This comprehensive tracking helps prevent losses from excess inventory.

Intelligent Early Warning and Alerts Hightopo seamlessly integrates its RFID management module with the warehouse alert system. The platform sends automated warnings when inventory levels approach preset thresholds, including alerts for low inventory, overdue stock, and RFID device malfunctions. These timely notifications enable management to quickly replenish stock, remove expired goods, and address equipment issues — leading to optimized inventory management and improved operational efficiency.

Material Lifecycle Management Hightopo’s smart warehouse RFID management system delivers comprehensive lifecycle management — from warehouse registration and storage positioning to requisition and outbound operations. Leveraging RFID real-time positioning technology and intuitive 3D warehouse visualization, the system offers these key functions:

■ Inbound Process: Automatically captures and records essential material details, specifications, and supplier information while assigning optimal storage locations.

■ Storage Process: Monitors inventory status in real time, provides intelligent alerts, and generates automated replenishment recommendations.

■ Inventory Process: Enables rapid RFID-based inventory counts with clear visualization of discrepancies on HT display screens.

■ Outbound Process: Streamlines operations through intelligent path planning, rapid goods location, and automatic inventory updates.

The Hightopo 3D visualization interface allows managers to monitor warehouse space utilization and material storage status clearly while performing instant queries, modifications, and deletions of material information.

Summary As drone technology evolves from military to commercial applications, it has become vital for smart warehouse management. Through precise inventory counting and real-time monitoring, drones have revolutionized both the efficiency and accuracy of inventory management. This innovation showcases the value of low-altitude technology in transforming traditional industries while pioneering new operational approaches for indoor drone applications.

The Hightopo warehouse drone inventory management system offers a forward-looking solution that combines RFID inventory, drone monitoring, anomaly alerts, and data analysis. Beyond solving immediate management challenges, it provides enterprises with a robust technical foundation for digital transformation and sustainable growth.

Smart Civil Aviation Management System

Foreword The Hightopo Smart Civil Aviation Management System (HSCAMS) is built using JavaScript and HT for Web (HT for short), a Web-based 2D/3D visualization engine. The system creates digital twins of the aircraft exterior, cabin management, cabin equipment, airplane engine, and cockpit in a sci-fi style. Various data is then integrated and analyzed using technologies such as the Internet of Things (IoT), cloud computing, big data analysis, and artificial intelligence. This allows for the establishment of a smart aircraft comprehensive management platform that is scenario-based, intelligent, and user-friendly. This platform offers managers a comprehensive and diverse management approach that includes multi-angle and multi-data management. In addition, it aims to create a green, smart, and secure civil aviation management system in the field of civil aviation.

Model Selection The system’s 3D scene showcases three distinct aircraft types and their appearance parameters:

Airbus A380: a massive, wide-body passenger airliner with four engines, designed and manufactured by Airbus for long-range flights. Boeing 787: the first ever mid-size airliner with long-range capabilities, making it a game changer in aviation history. Boeing 727: a narrow-body civilian aircraft with medium-range capabilities, developed and manufactured by Boeing in the United States.

Regarding the above models, we use virtual simulation and digital twin technologies combined with the HT for Web engine to render seamless 2D and 3D flight scenes, simulating the aerodynamic layout and geometric parameters of Airbus A380, Boeing 787, and Boeing 727, etc.

After selecting the model with the mouse, the system will show the overall shape of the currently selected plane in a roaming animation. By clicking the small triangle next to the model, a brief introduction of the current aircraft will pop up. So as to understand the history of the passenger aircraft, as well as engine other parameter information.

By connecting to the real-time data of the aircraft and its flight management system, it is possible to monitor the equipment data and passenger status in real time. This allows for sharing real-time data between the control tower and flying aircraft, which can help with pre-warning and post-event review, thereby effectively reducing the occurrence of various aviation accidents.

The 3D engine “HT for Web” is developed based on WebGL technology. It enables seamless rendering of 3D scenes and models of aircraft in the browser, as well as the creation of intricate navigation and data visualization. By accessing real-time data such as wing span, fuel capacity, and interference drag of the aircraft, HSCAMS allows for precise flight management. Additionally, it provides an immersive experience by simulating real-time flight scenes.

With Hightopo software’s all-in-one development tool, designers and programmers can collaborate on the design of view components, icons, 2D drawings, and 3D scenes for various aircraft models. This results in the rapid realization of 2D and 3D visualizations.

Aircraft Monitoring After connecting the airport monitoring data to the system, the system not only displays the real-time status of various aircraft components such as the wing, fuselage, tail wing, landing gear, control system, and power equipment, but also provides information on the aircraft’s interference resistance, fuel load, and cargo compartment load rate. This helps the tower and instrument flight control room manage flights more effectively and scientifically.

Interference Resistance Information

In addition to friction, pressure, and induced resistance, “interference resistance” is an additional resistance generated by the mutual interference of airflow between various parts of the aircraft such as wings, fuselage, and tail. When designing an aircraft, the relative positions can be effectively calculated to reduce interference resistance.

We incorporate real-time resistance data into the HSCAMS. A red triangle with an exclamation mark will appear when the resistance is too high, making it convenient for the ground control tower to detect problems in a timely manner and contact the crew to confirm flight safety. The system’s historical records can also be used to optimize future aircraft designs.

Fuel Capacity Information

An aircraft’s fuel capacity can be categorized into three groups: maximum fuel capacity, minimum fuel capacity, and takeoff fuel quantity. The maximum fuel capacity is the greatest amount of fuel that the aircraft can carry while still ensuring safe flight. Minimum fuel capacity refers to the amount of fuel that the aircraft can carry after arriving at the destination airport, which should be sufficient to allow the aircraft to fly for 30 minutes at holding speed over the airport. Takeoff fuel quantity refers to the total amount of fuel carried by an aircraft for a flight’s mission.

This system combines sensors, 5G, and other technologies, and display the capacity data on 2D panels of the Hightopo visualization system, helping relevant personnel to monitor fuel consumption at all times. By adjusting the flight speed appropriately to make the actual fuel consumption as close as possible to the theoretical minimum value, it can also achieve cost reduction, carbon emissions reduction, and other purposes.

Cargo Information

HSCAMS utilizes Hightopo’s robust charts, graphics, and design elements to display information about general cargo, chemicals, overweight items, fresh goods, and more in a more user-friendly manner. By integrating real-time data from the cargo hold with data from the ground passenger and cargo transportation service area, it can also enhance airport loading and unloading efficiency.

The cargo loading capacity is a crucial indicator of an aircraft’s performance. For instance, the Airbus A380 has a maximum cargo capacity of 66.4 tons. The indicator is primarily restricted by weight, volume, door size, and floor load capacity. The system retrieves the loading capacity data of the aircraft model in the 2D panel and shows the current cargo hold load rate in percentage. Additionally, the 2D panel can also support unmanned monitoring of the cargo hold and fire warning.

Cabin Management The Airbus A380, colloquially known as the “giant” of the skies, is the largest commercial passenger airliner in the world. Many A380s boast exceptional onboard entertainment such as fitness rooms, bathrooms, restaurants, and bars, providing passengers with a fun and enjoyable experience while flying. A unique feature of this aircraft is its two-story cabin and luggage compartment, which are separately displayed in the system. This provides a visual representation of the cabin structure, layout, and facilities and equipment, which correspond one-to-one with their actual locations and numbers, maintaining consistency with the actual aircraft.

The cabin is divided into three classes — first class, business class, and economy class — based on the size and comfort of the seats. Once connected to the ticketing system, different seat types, including selected, remaining, and VIP seats, are color-coded for easy differentiation.

Passenger Information

The system supports displaying passenger information such as name, class, boarding number, available mileage, etc., so that flight attendants can make more reasonable arrangements for passenger service.

Cabin Equipment Management

Clicking on the cabin equipment will take you to the details page, where you can view related information such as passenger volume, flight information, system parameters, and more.

In terms of design, we utilized a futuristic wireframe pattern and implemented a transparent shell for the aircraft. This allows for easy visual inspection of the cabin equipment by maintenance personnel, providing a clear view of the overall layout and structure. By integrating device data into the system, faults can be promptly detected, ensuring a safe flight. Additionally, by integrating passenger information data, the distribution of passenger nationalities can be viewed through small flashing dots on a world map located in the upper right corner, so as to help flight attendants provide personalized service to customers.

Aircraft Equipment View

Clicking on the Aircraft Equipment View will automatically remove the aircraft’s transparent mask. By clicking on the internal equipment again, the equipment name and its properties will be displayed. Our system uses the virtual simulation technology of Hightopo software to create a 3D interactive model of the aircraft that is based on its actual appearance. This high-precision model helps maintenance personnel to grasp flight data through real-time data-driven operations.

Equipment Self-check

Monitoring device data is a way to supervise processes as they happen, while equipment self-checks serve as reminders before a process begins. The HSCAMS interface’s 2D panel can scroll to show the current safety system status, and it includes an intelligent warning analysis feature. If the system data exceeds the set threshold, the relevant information will be highlighted in the list to remind maintenance personnel to promptly check the equipment’s health status.

Aircraft System Presentation

In this page, the Flight Management System (FMS) is capable of automating flight missions. The Aircraft Health Management System (AHMS) includes monitoring, diagnosis, and evaluation of the aircraft’s health status. The Air Data Inertial Reference System (ADIRSP) measures various factors such as the aircraft’s position, speed, trajectory, wind direction/speed, and attitude. The Information System (IS) provides flight, maintenance, cabin, and operational information. The Integrated Modular Avionics (IMA) is based on core computing, RTOS, and on-board networks that support system interconnection and data communication. The Communication System (CNS) is primarily used to maintain two-way voice and signal contact between the aircraft and ground navigation controllers, dispatchers, and maintenance personnel. The Display System (CDS) provides pilots with an integrated monitoring and cockpit display control system to enhance situational awareness.

Engine The aircraft engine generates thrust to propel the aircraft forward. In HSCAMS, for instance, the TRENT 900 specification engine can be viewed from all angles through four methods: section, airflow, disassembly, and reset.

The TRENT 900 turbofan engine is composed of a compressor, a combustion chamber, a high-pressure turbine (which drives the compressor), a low-pressure turbine (which drives the fan), and an exhaust system. The diagram in the center of the page illustrates the working conditions of the high-pressure turbine blades. The Trent 900 engine has 70 high-pressure turbine blades, each of which is capable of generating nearly 600 kilowatt-hours of power. The 2D panel on the right displays the changes in engine pressure and temperature using line charts.

On the airflow page, the system presents the propulsion efficiency of various turbojet engines. This includes values for inlet airflow, aerodynamic load, thermal load, centrifugal load, and other indicators. The inflow and outflow airflow are differentiated with red and green arrows.

The software enables visualization of the engine’s internal structure by breaking down its components and displaying their names, including hollow structure fan blades, titanium alloy honeycomb cores, honeycomb interlayers, and superplastic formed wide-chord fans. It also allows for detailed viewing of each individual part after disassembling the engine. By connecting to IoT data of the components, the current status of each part can be monitored and visualized, enabling global monitoring from a macro to micro perspective.

Cockpit The cockpit of a civil aviation plane is a complex and highly technical environment. It is here that pilots control the aircraft, monitor its systems, and communicate with air traffic control and other aircraft. The cockpit is designed to be ergonomic and intuitive, allowing pilots to quickly and accurately make critical decisions in real-time. Modern cockpits are equipped with advanced technologies such as digital displays, GPS navigation, and automated systems to enhance safety and efficiency.

Flight instruments in the cockpit are divided into three main categories: navigation, communication, and flight control. Navigation instruments guide pilots to navigate correctly during flights, while communication instruments maintain communication between the aircraft and the ground. Flight control instruments allow pilots to control the aircraft’s attitude and speed. On the cockpit page of this system, different flight information can be displayed by clicking on different displays, which will then pop up the corresponding 2D panel.

The Engine Indicating and Crew Alerting System (EICAS/ECAM) is utilized to monitor and present engine status and crew alerting information. The Flight Management System (FMS) is utilized to enter and validate flight plans, control speed, and more. The Multi-Function Display (MFD) provides a visual interface that can be utilized for integrated flight information, engine monitoring, and flight parameter configuration. The Navigation Display (ND) displays the current aircraft heading information on a three-dimensional map.

Aviation navigation refers to the various systems and equipment used in aircraft during flight, including flight computers, radar, inertial navigation, celestial navigation, and global satellite positioning. These systems provide continuous, safe, and reliable technical services for airborne aircraft. On the cockpit display, it shows the three-dimensional position and speed of the aircraft, as well as provide important information such as heading and attitude.

Summary The Hightopo Smart Civil Aviation Management System (HSCAMS) uses 3D visualization and virtual simulation, as well as big data, cloud computing, and other technologies. This allows users to view a 3D interactive model of the aircraft and access operating data, helping relevant personnel to analyze flight data in real-time. Users can gain a comprehensive understanding of the aircraft’s working conditions and the status of various systems through device self-checks, aircraft system displays, and engine, cockpit, and other page operations. This results in increased flight reliability, reduced costs, and simplified maintenance. It also includes information on aircraft fuel capacity and engine operating curves, leading to digitization and more environmentally-friendly flight within the general aviation industry.

Enhancing Efficiency in Aluminum Manufacturing with Digital Twin Technology

In the context of the digital transformation of the manufacturing industry, aluminum factories are actively exploring innovative ways to improve production efficiency and management levels. Digital twin technology, with its unique advantages, has constructed an accurate and efficient production management system for aluminum factories. This article takes the application of Hightopo Software’s low-code digital twin platform in an aluminum factory as an example to deeply analyze the practice and effectiveness of this technology in the entire aluminum production process.​

System Construction and Visual Presentation​ The aluminum production process is complex, involving multiple key links such as desulfurization, denitrification, smelting, casting, dust removal, degassing, and wastewater treatment. Hightopo Software’s low-code digital twin platform realizes a comprehensive presentation of the aluminum production process flow through a 2D SCADA visualization system. By using the platform’s icon library and panel library and adopting a graphical, drag-and-drop configuration method, a visualization interface suitable for aluminum factories can be quickly built without writing a large amount of underlying code, greatly improving the system construction efficiency.​

(I) Page Style Design​ Considering different usage scenarios, the 2D SCADA pages of the aluminum factory are designed with two style color schemes: a dark color system for night shift duty and a daily white minimalist style. The switch button adopts a fused new mimetic design style, adding a three-dimensional sense, and light blue accents increase visual vitality, enhancing the user operation experience.​

(II) Data Monitoring and Maintenance​ Through the visualization system built on this platform, users can monitor and maintain the entire system according to the industrial operation process of aluminum production, achieving real-time visual management of the production process.​

Technical Principles and Key Monitoring Points for Production Processes​ (I) Desulfurization​ Technical Principle: The desulfurization process is based on chemical reaction principles. Desulfurizers such as limestone slurry are sprayed into the flue gas to react with sulfur dioxide, generating harmless gypsum and thus reducing sulfur dioxide emissions. Limestone slurry is made by mixing limestone powder with water and is used to absorb sulfides in the flue gas. The absorption tower, as a key device, promotes full contact between the gas and the absorbent to achieve the removal of harmful components.​

Monitoring Key Points: With the 2D SCADA visualization interface, key data such as the flow rate and concentration of the desulfurizer are monitored in real-time. Once the data is abnormal, the system quickly issues an alarm, and the staff can adjust it in a timely manner to ensure that the desulfurization reaction is in the best state, reducing pollutant emissions and practicing the concept of green production.​

(II) Denitrification​ Technical Principle: The common selective catalytic reduction (SCR) technology is adopted. Under the action of a catalyst, reducing agents such as ammonia react with nitrogen oxides to reduce them to nitrogen and water.​

Monitoring Key Points: The 2D display closely monitors core indicators such as the temperature in the reactor and the ammonia injection volume, precisely controlling the reaction process to ensure that the denitrification efficiency is stably up to standard and helping to achieve environmental protection goals.​

(III) Sintering​ Technical Principle: In a high-temperature environment, aluminum ore powder and appropriate additives undergo complex physical and chemical changes in the sintering machine, gradually fusing and consolidating to form sintered blocks, laying the foundation for subsequent processes.​

Monitoring Key Points: The 2D page strictly controls key elements such as sintering temperature and atmosphere. It monitors subtle fluctuations in parameters such as temperature, pressure, flow rate, and concentration in real-time. Once factors that may affect the sintering quality are detected, it promptly feeds back to the operators to ensure the production quality of sintered blocks. Hightopo’s large-screen SCADA uses red-yellow gradients to represent temperature changes and fine particles to simulate the material transportation process, visually presenting the production status.​

(IV) Casting​ Technical Principle: In the casting link, liquid aluminum cools and solidifies, transforming into aluminum products of various shapes and specifications.​

Monitoring Key Points: Hightopo’s SCADA large screen monitors key parameters such as mold temperature and aluminum liquid flow rate in real-time and in detail, closely paying attention to the cooling process to ensure uniform and stable cooling and prevent quality problems such as cracks and deformations in aluminum products due to uneven stress, ensuring the quality of aluminum products.​

(V) Dust Removal and Degassing​ Technical Principle: Technologies such as bag dust removal and electrostatic dust removal are used to remove dust in the production process, and special technologies are used to remove harmful gases such as hydrogen dissolved in the aluminum liquid to purify the production environment and protect equipment and product quality.​

Monitoring Key Points: The page monitors the operating status and key parameters of purification equipment comprehensively and continuously. Once the equipment parameters are abnormal, it immediately issues a warning to remind the staff to maintain and adjust in a timely manner, ensuring a clean production environment and creating conditions for improving the quality of aluminum products.​

(VI) Wastewater Treatment​ Technical Principle: The wastewater generated in the aluminum production process, if discharged directly without treatment, will cause serious harm to the environment. The wastewater treatment process makes the wastewater meet the discharge standards through a series of physical, chemical, and biological treatment methods, which is a key step for aluminum factories to achieve green and sustainable development.​

Monitoring Key Points: Operators can master the details of the operation of each link and equipment in the wastewater treatment process in real-time through the screen, precisely adjust key parameters such as the dosage of chemicals and the water flow rate, and ensure that the wastewater treatment effect is stably up to standard.​

Advantages Compared with Traditional SCADA Software​ Compared with traditional SCADA software such as InTouch/lFix/WinCC, Hightopo’s Web-based platform is more in line with the trend of the transformation from C/S to B/S. Its rich multi-element visualization components and fast data binding methods are convenient for quick creation and deployment, and can realize real-time data monitoring based on Web services and multi-user access on the server side. This platform has broad application prospects in many fields such as water systems, power systems, petroleum, and chemical engineering, and can provide 2D, 2.5D, and 3D clear and beautiful visualization services.​

Conclusion​ The application of digital twin technology in aluminum factories, through Hightopo Software’s low-code digital twin platform, has achieved accurate presentation, real-time monitoring, and efficient management of the entire aluminum production process. From the technical principles and monitoring key points of each production link to the advantages compared with traditional SCADA software, this technology has demonstrated significant effects in improving the production efficiency of aluminum factories, ensuring product quality, and achieving green production. With the continuous development of digital technology, digital twin technology is expected to play a greater role in the aluminum industry and other industrial fields, promoting the continuous progress of the industry towards intelligence and greenness.​

Utilizing Digital Twins in Steel Manufacturing

Digital twin technology plays a key role in the progressive digitalization of the process industry for increasing competitiveness and sustainability. Digital technologies are transforming the industry at all levels. Steel has the opportunity to lead all heavy industries as an early adopter of specific digital technologies to improve sustainability and competitiveness.

Hightopo’s core product, HT for Web, uses WebGL technology under the hood, offering users a new, immersive way to visualize, plan, educate and stimulate the steel processing and the whole steel plant. Integrate data into one single web application, which covers 3D digital twin monitoring system, process SCADA, and data board, enabling users to get real-time data and break data silos.

3D Digital Twin

It seems like Digital Twins are everywhere in manufacturing today, but what exactly is a Digital Twin? A Digital Twin is an exact representation of a production process. It allows for easy and quick visualization of all the characteristics that go into a process. Hightopo uses the web front-end visualization framework, HT for Web to build Digital Twins that truly match the production process, and corresponds 100% with the real process. From raw materials to finished products, accounting for every step in between — even if the data lives in different mills or data systems. By analysing such data and monitoring it in a real-time manner, this system leads to reduced cost, risk, and waste.

Raw Material Transportation

After the raw materials are unloaded from the wharf, they are transported to the raw material yard by belts. HT connect data sourced from various IIOT sensors, and real-time rendering the data on a 3d data pannels. HT 3D engine supports the roaming of simulated drones or pedestrians, and enables browsing the raw material factory in all directions without dead ends. Therefore, in the dispatching centre, staff can grasp all angles of the tens of thousands of square meters of raw materials, each piece of equipment, the entry and exit of various raw materials, and the usage in real-time.

Sintering Process

Sintering is an agglomeration process of fine mineral particles into a porous mass by incipient fusion caused by heat produced by combustion within the mass itself. Iron ore fines, coke breeze, limestone and dolomite along with recycled metallurgical wastes are converted into agglomerated mass at the Sinter Plant, which forms 70–80% of iron-bearing charge in the Blast Furnace. Leveraging 3D animation, users can intuitively view the equipment and materials of the process production line, such as sintering machines, annular coolers, etc.

Blast Furnace Visualization

Blast furnace visualization technology is a new technology for monitoring charging and smelting conditions in blast furnace and for guiding blast furnace operation. HT 3D modeling digital twins according to the actual blast furnace, detailed modelling of an entire furnace shell, pipes, etc. Through the special designed, translucent furnace shell, visualize inside of the blast, temperature data etc.

Data panels extend from 3d model are connected with real-time data sourced from sensors located across the equipment, intuitively to monitory the work conditions of pipelines and equipment. Visualize various kinds of data such as CO, CO2 mass fraction, coke ratio, gas flow rate, furnace top pressure, and gas permeability parameters in real-time, and supplemented by a line graph. real-time display of the real-time data change trend of furnace top cross temperature measurement so that operators can timely understand the airflow in the furnace changes in distribution and furnace conditions, and timely detection of abnormal conditions in the furnace, so as to actively control the operation of the blast furnace.

Steel Making Process

The molten pig iron is treated by preparative equipment to separate impurities such as sulfur and phosphorous, then further refined by removing carbon with the use of a steel converter. Once the impurities are removed by these methods, the viscose substance remaining is known as “steel.”

HT enables digital visualization of the whole process of steelmaking, keeps tracing vital data and displays it on the 3d in realt-time. Enables intelligent decision-making, and interactive integration of information systems in each line.

Continuous casting

Using an overhead crane, a ladle of liquid steel is transferred from the BOS Plant to the casters, where it is poured — or teemed — into the casting machine and shaped by water-cooled copper moulds of varying sizes depending on the final product to be made.

HT powerful 3d render engine1:1 photo-realistic modelling physical equipment and display vital data on the data panel. The 2D panel seamlessly work on 3d environment.

Rolling

Rolling is the process by which billets are converted into sheets with thicknesses ranging from less than 1 mm to 400 mm.

Product

A 3d animation to simulate the final product, wire rods. Through the high-precision digital twin models and data integrated from sensors, supplement data such as current, actual operation, and line speed etc.

Shipping

HT engine integrates the smart vehicle terminal and vehicle management system, enabling vehicle scheduling, vehicle tracking, operation monitoring and transportation performance. The 2D panel accesses information such as the total number of vehicles, total weight, etc., to guide the driver to carry out goods. Assist in solving the problems of low visibility of steel logistics management, inability to scientifically and rationally carry out transportation stowage, high vehicle emptying rate, and low transportation efficiency.

Steel Manufacturing Process SCADA

Compared with traditional configuration software such as InTouch/IFix/WinCC, Hightopo’s Web-based platform is more suitable for the general trend of C/S to B/S transformation. The multi-element rich visualization components and fast data binding methods are available for rapid platform creation and deployment.

Data Board Data Visualization

With the maturity of computer technology, the information construction of iron and steel enterprises has developed rapidly. At the same time, the explosive growth of data in iron and steel enterprises becoming a new challenge for enterprises.

HT comes with powerful visualization components, such as line charts, pie charts, bar charts, tables, etc. Brings great value to enterprises to manage the big data and visualize it for sharper insight.

Cross-platform (Mobile Device UI)

Mobile device HT for Web cross-platform feature ensures users access the data on anywhere, at any time. Mobile device access breaks the boundaries of time and space, enables stakeholders to understand production dynamics through mobile phones in real-time, and be aware of production changes. This greatly improved the work and management efficiency of the steel plant.

Conclusion The easiest way for people to understand information is through images. Hightopo visualization solution seamlessly combines 2d graphic and 3d models together, offering a unique, immersive way to visualize vital data.

From the three-dimensional structure of the iron and steel mill to each detailed production line, presents data in a unified manner, and intuitively reflects the information of each piece of equipment, which is conducive to the monitoring of the steel production line equipment and timely detection of equipment problems. Engineers can uncover the root cause of problems and find the data that corresponds to these problems, even if the data lives in different and disconnected sources.

The Role of Digital Twins in Optimizing Waste-to-Energy Conversion Through Incineration

In recent years, the amount of waste in urban areas, in particular, has increased dramatically due to population growth, urbanisation and lifestyle changes. As a result, the importance of intermediate treatment facilities to reduce the volume of waste, such as incineration plants, has emerged as pressure increases on the remaining capacity of final disposal sites.

Hightopo takes waste incineration power generation as the research object, and exploits the self-developed visualization product, HT for Web(mentioned as HT below), to visually demonstrate WtE(Waste-to-Energy) incineration equipment process. Simulate the smoke and dust emissions from the waste incineration power station, as well as the treatment technology, technological process, environmental conditions and machine failures. Visually display the execution progress of waste incineration, the operation status of equipment, the control status of flue gas pollutants, etc., and facilitate the visual management of WtE(Waste-to-Energy) incineration plants.

WtE(Waste-to-Energy) incineration is the process of direct controlled burning of waste in the presence of oxygen at temperatures of 850°C and above, coupled with basic mechanisms to recover heat and energy and more sophisticated mechanisms to clean flue gas, utilise wastewater, and assimilate diverse streams of waste.

HT uses 2D configuration diagrams to popularize the working principle of waste-to-energy generation. Staff can more intuitively see the working status and detection information of each system, including the fermentation time of the waste pit, the negative pressure of the waste pit, the residence time and temperature of the stocker, furnace, boiler, combustion chamber and steam turbine, etc. Click “Configuration Process” in the scene to drill down and switch to a different process. The visualization flowcharts of different dimensions will meet the business demands of managers and operators.

Digital Twin Simulates Main Process 1. Waste pit for the storage of waste before it is fed into the furnace

Adopt indoor positioning, vehicle positioning, and sophisticated IoT device, data which indicated car location on the platform can be collected. By RESTful APIs or WebSocket, communicate the data to the front end for visualization and display. Utilize multiple algorithms to calculate data such as waste volume, waste crane status, precrusher status, etc.

1. Incineration furnace operated at a temperature over 850ºC

After the waste enters the incinerator, it is fully burned at high temperature. By combining the temperature measurement system, the system counts the furnace temperature, boiler feed water temperature, flue gas temperature and steam temperature in the incinerator, and monitors the operation status of the slag treatment system and the fly ash treatment system. Ensure that the fuel combustion energy in the furnace meets the needs of the boiler, maintain the safe and economical operation of the boiler, and maintain the stable operation of the incineration system.

1. Heat recovery and power generation

One of the objectives of WtE incineration is to recover energy from waste combustion heat by generating steam. Most steam is sent to a steam turbine and then used to generate electricity.

The steam conditions of boilers significantly affect the output of power generators. It is desirable to design systems that incorporate high-temperature and high-pressure steam boilers. Therefore, HT visualization highlights the current steam temperature and pressure to empower maintainers and staff to get a comprehensive view of the current status, as well as the water-steam cycle, turbine spin speed, power generation efficiency.

1. Flue gas cleaning system typically includes a bag filter;

Bag filters are used to remove air pollutants from flue gas through filtering. An alkali agent such as lime powder and powdered activated carbon is injected into flue gas before it passes through the bag filter. Air pollutants, except NOx, can be removed through the following mechanisms.

To monitor flue gas, dust, HCl, SO2, and NOx must be measured continuously. And for HT, the data panel will update in real-time to display the data.

1. Ash discharge and treatment

Quality of bottom ash and APC residue (fly ash) should be checked for loss on ignition (LOI) and harmful substances before reclamation or other treatment. The most common method of treatment is reclamation in a controlled landfill site.

HT simulates the whole process and uses data to trigger 3d models as well as the 2d data panel. Exploit digital twins technology, stakeholders can get a comprehensive overview of each progress; get shaper insight on each process and monitor key data. Leverage the development with a good sense of sustainability.

Advantages & Disadvantages The main benefits of MSW incineration are volume reduction and disease control, and it is a practical way to treat MSW in 1.2 Historical background and main features of WtE incineration Waste incineration began because of the need to control outbreaks of disease and reduce the rising volume of waste that resulted from continuous population growth in towns and cities large or populated cities as it can be localised in an urbanised zone. WtE incineration also offers the added benefit of using waste as a resource to produce energy. This form of incineration also decreases carbon emissions by offsetting the need for energy from fossil fuel sources and reduces methane generated from landfills if used as an alternative to landfilling.

However, the introduction of MSW incineration has its own barriers, such as (1) high costs to construct and operate incinerators, (2) insufficient income from waste disposal and energy sales to cover all costs, (3) the minimum amount of feedstock required for operations, which could potentially divert waste away from the 3Rs, and (4) risks to human health.

In above use cases, we can see how HT help to minimise the disadvantages and empowers the WtE incineration for its digital transformation.

HT Web 3D Visualization Solution

Hightopo solution offers to view the 3D digital model anytime, anywhere, thanks to HT’s B/S structure, all the content are live on the web. During the construction process, the company avoided the traditional manual count and review of work quantities, and it used the model to view the equipment and pipeline schedules, which became an important basis for preparing the construction budget and completion settlement. Meanwhile, it carried out the lifecycle management of project assets through the model to improve the operational management efficiency of enterprises.

Hightopo visualization solution enabled a mobile display and VR display of the 3D model, making it easier to view the equipment and pipeline properties with an immersive view, as well as improving communication with each stakeholder.

Conclusion Companies are gradually adopting digital twins to manage their most critical assets. In return, digital twins are helping monitor and identify ways to become more efficient, prevent downtimes, and even plan for the future. As in the case of WtE incineration plant, Hightopo digital technology help to inform decisions on whether to be reduced, recycled and made harmless to the environment.

Hightopo 3d visualization solution also offers the possibility of improving energy sales, reducing the cost to construct and operate incinerators, and energy savings or simply being more efficient at the storage of renewable energy. Related research demonstrates that digital twins can indeed help companies to repurpose their sense of sustainability and take it to a plausible level. In the end, development with a good sense of sustainability is key for corporations to thrive while limiting their environmental footprint.