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Overview | Metalmaking & Casting | Rolling | Processing & Finishing | Metals MES
New Heat-Treat Facility
The Challenge: The customer, a large North American steel manufacturer, commissioned Brock Solutions to provide an automated control system for its new Heat-Treat facility. In addition to providing complete control system design and implementation, Brock Solutions was tasked with implementing a Level 2/MES solution that would synthesize production data from multiple sources, providing users with an effective diagnostic and reporting tool.

The Solution:
Brock Solutions provided complete control system design (PLC, HMI, PC) and implementation. Intuitive HMI screens allow operators to track rods throughout the entire process displaying real-time process parameters for temperatures, flows and pressures.

“Smart” PID Burner Control optimizes the temperature rise time and stability through an algorithm based on recipe, bar tracking and furnace operating parameters.

The Level 2/MES Component:
Brock Solutions’ Level 2/MES solution enabled the customer to track rods through the entire Heat Treat Process. A central database sends production information to the HMIs for the operator to view, and to the PLC system to be used for automated setup, tracking and control purposes. Bars can also be automatically rejected for non-conformance at any stage in the process. If a bar is considered invalid, for instance, the operator is immediately advised and must acknowledge the alarm and action taken. The MES database stores all event and alarm histories, enabling users to analyze and, in turn, optimize their production process.

Specific functional modules of the MES solution include:
  • Recipe Management
  • Order Release
  • Interface to existing “Sales and Information Management System”
  • SPC Analysis
  • Production History
  • Reporting & Diagnostic Tools

The Results:
The new control system enables two operators to run the entire Heat-Treat facility: one from the floor, and one from a central control pulpit. The new Level 2/MES solution, moreover, ensures that reliable data is collected and stored, and that production monitoring and reporting functionality is easy-to-use and support.