Heat Treatment in the Era of Digital Transformation
Heat treatment has entered an era of digital transformation. With stringent standards being enforced, the industry's push towards digitalisation is less a matter of choice and more a mandate for survival and growth. In this article, Peter Sherwin, global business development manager of heat treatment at industrial heating technology manufacturer, Watlow, discusses the benefits of digitalisation and integration throughout the entire thermal loop.
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Challenges in Utilising Data for Heat Treatment
Precision and control are paramount to heat treatment processes. However, although an increase in data could offer insights to optimise processes, without proper integration and analysis tools, this wealth of data remains underutilised. Many organisations find themselves data-rich but insight-poor, unable to fully harness the power of the information they collect. This challenge is not just about collecting data — it's about translating it into actionable insights that drive decision-making and operational efficiency.
Benefits of Data Integration in Heat Treatment Processes
The benefits of integrating and harnessing data within the thermal process include increased operational efficiency, enhanced quality control, and optimised energy utilisation. So, should the industry be taking a bolder approach and accelerating the adoption of the latest Industry 4.0 methodologies? If so, how should this be approached?
The Importance of Maintaining Accuracy in Heat Treatment
Maintaining accuracy during heat treatment processes is vital to ensure components meet the required standards of stringent, compliance-led industries such as aerospace. How a material is heat treated will determine how it performs, its resistance to wear and tear, and its conformity to industry standards.
Data integration can yield measurable benefits, such as enhanced operational efficiency, tighter quality control, and optimised energy consumption. By effectively capturing and analysing data across the thermal process, businesses can uncover inefficiencies, predict equipment malfunctions, and improve product quality, all of which contribute to better performance metrics such as Overall Equipment Effectiveness (OEE).
Critical Components of the Thermal Loop
The thermal loop is at the core of the heat treatment process, comprising various components that work in unison to achieve desired outcomes.
Advanced Technologies in Heat Treatment
Advanced Silicon Controlled Rectifiers (SCRs) enhance heat treatment processes by providing predictive load management capabilities and using hybrid firing algorithms to optimise energy consumption. These SCRs manage real-time energy monitoring and control, employing algorithms that efficiently handle peak power loads and adapt through methods like load shedding or sharing. Hybrid firing techniques combine various firing approaches to better manage power factors and lessen adverse effects on electrical infrastructure.
The design of the heaters plays a fundamental role too. The fast switching of speed and frequency significantly affects the lifespan of heaters. Modern, rapid switching technologies, known as hybrid firing, can extend the life of heaters far beyond that achieved with traditional mechanical contactors. Advanced computational engineering allows for the quick testing, simulation, and modelling of these systems. Improved temperature uniformity in today's thermal loop systems is a direct result of these advancements.
Role of Temperature Sensors and Data Management
Temperature sensors are crucial, measuring the heat levels and communicating data back to the process Proportional Integral Derivative (PID) controllers, which adjust the power output to maintain the heat treatment process profile.
Finally, a robust data management system is required to record process parameters and prove process requirements were met. Modern data platforms enable the efficient collection of secure raw data and provide the replay and reporting necessary to meet the standards.
Challenges in Integrating Thermal Loop Components
The heat treatment industry is experiencing a lag in integrating the many elements within the thermal process. Each component might operate with efficiency, but the lack of synergy across the system leads to missed opportunities for performance improvement and energy savings. This disconnect poses several challenges, including inconsistent quality, and both operational and energy inefficiencies.
A lack of integration between the elements of the thermal loop leads to process inefficiencies, increased risk of quality control issues, and energy wastage. To overcome these challenges, a holistic approach to data integration is imperative, where every segment of the thermal loop, from electrical supply to process control, is designed to work as one and communicates seamlessly, enabling full optimisation of the process.
Watlow’s Approach to the Integrated Thermal Loop
Understanding the thinking that goes into choosing the right components, and putting them together, is a far greater challenge. This is where Watlow’s thermal expertise comes in. For Watlow, the underlying concept behind its entire offering of thermal solutions such as sensors and integrated power controllers, is of the thermal loop.
Benefits of a Fully Integrated Thermal Loop
When each part of the thermal loop communicates effectively with the others, the result is a streamlined, efficient process that minimises energy waste and maximises output quality. Data gathered from sensors can be used in real-time to adjust parameters, reduce energy consumption, and foresee maintenance needs, leading to enhanced operational efficiency and sustainability. Suppliers to the heat treatment industry should be taking the proactive approach needed to harness the benefits of this digital era. A merged design between heaters, sensors, PID controls, and power controllers integrated into an Industry 4.0 framework will ensure rapid system response and tight control of process parameters.
Industry 4.0 and the Future of Heat Treatment
With the march towards Industry 4.0 methodologies, the heat treatment industry must strongly consider this digital shift. The incorporation of Industry 4.0 technologies is not merely an enhancement but a necessity for those who wish to remain competitive. The benefits of a data-driven approach and integrated thermal loop ensure increased efficiency, cost savings, and improved quality, which far outweigh the costs of transition. Through this approach, heat treaters can fully realise the benefits of increased efficiency, sustainability, and compliance, securing their place in the future of global manufacturing.
