Introduction
Using a SCADA system to manage the use of a fleet of industrial furnaces can make a lot of sense. Companies can use this system for the following functions:
- Control processes on site or remotely
- Interact with devices using HMI software
- Record, collect, monitor and process data
- View historical data
- Log events and data
- Generate production reports automatically
The advantages of using a SCADA system are:
- Improved data management – Operations and processing
- Increased and simplified visibility – For operators
- Greater efficiency – Uniform processes for all
- Easy handling – Centralized control
- Reduce downtime – Send instant alarms
- Simplified integration – Pre-tested and validated solution
- A unified platform – A multitude of data available on a single platform
- Automatic generation and storage of batch heat treatment reports
Operating principle
A Supervisory Control and Data Acquisition (SCADA) system is used to control a site’s industrial furnaces, as well as to collect and record data about their operations.
A SCADA system is usually supplied as software installed on an industrial PC or laptop. This is combined with temperature controllers (for simple industrial furnaces) and/or PLCs (Programmable Logic Controllers) installed for more complex industrial furnaces with several mechanical components and programmed operating sequences. It must also be linked to a HMI (Human Machine Interface), with operators using the screens to communicate with the SCADA system.
Case studies
Pyradia recently implemented a SCADA system for a world-class aeronautics manufacturer. This project involves upgrading the control architecture to automate all furnace chamber sequences, temperature control, heating profile management, production data logging and real-time equipment monitoring via a SCADA and industrial PC interface. This control and data acquisition system included the following components:
- 1 x PLC
- 1 x HMI with 10” screen
- SCADA program developed on the Movicon platform
- Movicon software license (execution)
- Installation of SCADA software and program on an industrial PC (operator interface) to display furnace commands, alarms, production data and temperature trends via historian software. This PC also enables data to be stored in an SQL database, locally on the PC, remotely on servers or in the cloud, and enables communications for backup and visualization via the network.
- Batch processing capacity
- Bar code reader
- Centralized industrial workstation
- Ethernet/IP communication network
- Remote access modules on local router (for remote customer support)
- Uninterruptible power supply (UPS) to keep the control system live to complete shutdown of the appropriate control system and data logging in the event of a power failure
- CSA-certified electrical components and panels
Batch production data for SCADA:
- Operation: Annealing, solution treatment or aging.
- Heat treatment load / batch number.
- Date of operation.
- Number of parts in batch. (Manual entry and/or barcode scanner)
- Time at which the batch is loaded into the furnace
- Forced air furnace number (Manual entry with pre-configuration)
- Soaking temperature (manual text entry and/or barcode reader)
- Start of soaking time. (PLC-triggered timestamp)
- End of thermal process time: when the parts are removed from the oven. (PLC-triggered timestamp)
Figure 1 – Processing production batch data
Figure 2 – Processing temperature batch data
Figure 3 – Processing batch data reports
Figure 4 – Example of a batch data report
Figure 5 – Example of operator interface for a Pyradia furnace
SCADA implementation service by Pyradia
Pyradia’s technical department has expertise and know-how in SCADA implementation, and a proven track record with numerous successful integrations of small and large-scale automation projects. Pyradia is a Rockwell Automation Silver Level OEMpartner.
Don’t hesitate to contact Pyradia’s Sales or Technical Service teams to find out about all the SCADA implementation options available to you.
If you have any questions ? Contact us today.