Our process control systems provide a fully automatic process controll for melting, heating and cooling processes in thermal-metallurgical plants. They use a thermo-physical model to represent the process. The results from the process model are used to control the plant accordingly. This has got the following advantages:
· Very high and reproducible process and product quality
· Ultraflexible production
· Complete documentation of the outgoing products
· Optimization of plant efficiency depending on production conditions
· Reduction of energy consumption
· Reduction of material loss
Depending on the particular application we integrate modules of data mining and artificial intelligence into our process control systems in order to further improve process control.
Integrated in the automation structure of the plant, the process control systems belong to technological level-2-systems. Data exchange with other systems (e. g. basic automation, level-3-systems, production planning systems etc.) will be realized via network.
The visualization of our process control systems informs the operator intuitively on the current process situation and offers the possibility to act on the process, if necessary. Using applications for mobile devices the operators receive relevant information about the process even outside their control rooms.
Our process control systems provide comprehensive options for investigation of process history.
Sensitive modules, e.g. for technological and administrative modifications of the system, are password protected.
Furthermore, there is the possibility to integrate an offline-model for simulation of a production process, using the same model core as the online-model. This can be used for planning and optimization of the production process.
Due to their modular layout our process control systems can easily be adapted to modifications of plant configuration and extended in their functionalities.
With regard to application we classify our process control systems into i.a.:
· Furnace level-2 systems for reheating furnaces
· Furnace level-2 systems for heat treatment furnaces
· Level-2 systems for melting furnaces
· Level-2 systems for cooling plants