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Development of the part firing system

Heat treatment

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In this article, I would like to talk about the experience of implementing the task of creating a control system for furnaces for roasting metal products.

According to the initial technical specifications, the parts had to be smoothly heated according to the ramp function at a given interval, then kept at a certain temperature and cooled down smoothly (thermostating).

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For this, it was necessary to develop a program that runs on the PLC110 Oven controller, and a SCADA visualization program (Masterscada from InSAT), which will control the process. Along with this, a DBMS had to be created and implemented in the SCADA system to receive data from the firing process to generate detailed reports.

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The controller configuration was quickly created, taking into account the existing developments related to a smooth increase in temperature. Then a visualization program was executed in Masterscada using the C# language to create order entry forms. A DBMS was also developed and implemented in SCADA. The firing process was debugged on simulators.

In the process of work, the terms of reference were regularly updated. New functions required by the Customer were identified, which had to be implemented into the project "live". It turned out that the temperature should be regulated by minimum and maximum (by delta). The reporting system should contain both graphical and textual information about the firing process, capture both the time interval before the start of the process, and after. The location of the furnaces was constantly changing (the Customer could not decide on the numbering).

It is obvious that the solution of this problem constantly "flowed" and became seriously complicated.

One of the last requirements was that each product should be able to choose its own firing program, and different products with different temperature requirements would be placed in the same furnace. But titanium alloy is not equal to copper. And if one product improves, then the other will be clearly damaged and sent to marriage. This argument was not heard.

There were also difficulties with the selection of the width of the fields in the order entry forms. Each time the operator insisted on his field width, the next time he entered it, it returned to its original position.

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In addition, for a long time it was not possible to adjust the PWM control of the heating element (to select PID coefficients), since it depended on the completeness of the furnace load, and the loaded furnace was not provided for testing. The acceptance process is delayed.

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Unfortunately, this work, 90% completed, was not completed/accepted properly.

Link to YouTube video about this work

#heattreatment #subdvscada #thermostating #rampfunction #Masterscada #PLC110OWEN #burningprocess #PID #Shimregulation

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