What is the path forward for thermal loop systems, and how is “sustainability” at the forefront of this technology? The following article is co-authored by Peter Sherwin, global business development manager of Heat Treatment, and Thomas Ruecker, senior development manager, at Watlow. They examine four scopes to take into consideration when assessing thermal loop systems in the context of greenhouse gas emissions and their environmental impact.
Heat treatment thermal loop solutions provide several sustainability benefits, including reduced energy consumption and waste. The power controller regulates the power output to minimize energy waste, and the possible integration with renewable energy sources and circular economy principles provides a complete power solution that spans from element design to recycling and renewables. The thermal loop solutions, in combination with insulation design and materials, provide energy-efficient solutions that contribute to sustainability and reduce the environmental impact of heat treatment processes.
When discussing these systems in the context of greenhouse gas emissions and their environmental impact, it is essential to consider Scopes 1, 2, and 3, as well as the less common Scope 4:
Scope 1 (Direct Emissions): Heat treatment processes often involve the combustion of fossil fuels like natural gas, propane, or oil to generate heat. These direct emissions are attributed to the equipment used in the heat treatment process, such as furnaces and ovens. Efforts to reduce Scope 1 emissions include upgrading to more efficient equipment or adopting alternative heating technologies, like induction or electric heating systems.
Scope 2 (Indirect Emissions from Energy): In heat treatment processes and thermal loop systems, electricity is often used to power various components, such as pumps, fans, and control systems. The emissions associated with generating this electricity are considered Scope 2 emissions. To reduce Scope 2 emissions, companies can improve energy efficiency, invest in renewable energy sources, or purchase green energy from their utility provider.
Scope 3 (Other Indirect Emissions): These emissions are associated with activities throughout the value chain of heat treatment applications and thermal loop systems, such as the manufacturing and transporting of raw materials, equipment, and waste management. Companies can work to reduce Scope 3 emissions by collaborating with suppliers to improve the environmental performance of their products and services, optimizing transportation and logistics, and implementing waste reduction strategies.
Scope 4 (Avoided Emissions): In heat treatment applications and thermal loop systems, avoided emissions may come from implementing energy-efficient technologies, waste heat recovery systems, or other innovative solutions that reduce overall energy consumption and associated emissions. By quantifying these avoided emissions, companies can showcase the positive impact of their sustainability efforts on reducing their carbon footprint. Avoided emissions can also be highlighted when subcontracting heat treatment requirements to a more energy-efficient source rather than running an in-house operation. In this approach, the heat treatment process is outsourced to an external, specialized heat treatment service provider, especially if the in-house equipment is due to be lightly utilized. These service providers operate independent heat treatment facilities and offer services to multiple clients across various industries and generally run 24/7 with high utilization.
At the component level, energy savings can be realized using current technology. Advanced SCRs provide predictive load management functions and hybrid firing algorithms and contribute to sustainability by optimizing the energy usage of heat treatment processes. These SCRs offer real-time monitoring and control of energy consumption, while predictive load management systems use specific algorithms to manage peak power loads and adjust to optimize for local conditions (load shedding or load sharing). Hybrid firing systems use a combination of firing methods to control power factors and reduce the negative impact on the electrical infrastructure.
Heater design is also essential. Switching time impacts heater life with fast, modern switching modes (hybrid firing) significantly extending heater life compared to slower switching from conventional mechanical contactors.
Systems can be rapidly tested, simulated, and modeled through computational engineering. Several thermal loop systems today have improved temperature uniformity due to these methods.
Adaptive thermal system (ATS) solutions are the next frontier of thermal loop solutions. Rather than selecting the best-of-breed components — sometimes with overlapping functionality and kitting a complete solution — ATS provides a merged design between heater and control systems. ATS is already in place in several semiconductor applications, and this type of technology is looking to scale into heat treatment applications shortly.
Figure 2. Watlow Adaptive Thermal Systems ATSTM Source: Watlow
Challenges and Limitations
The initial investment in heat treatment thermal loop solutions can sometimes be higher than in traditional methods. However, this investment often leads to a significantly lower total cost of ownership and improved return on investment due to the thermal loop solutions’ increased efficiency, improved quality control, and extended life.
Ensuring regulatory compliance is complex and time-consuming, requiring organizations to have the right people, processes, and equipment.
Future Trends
As Industry 4.0 and digital transformation continue to gain momentum and Industry 5.0 practices are implemented, heat treatment thermal loop solutions will become increasingly important. Integrating digital technology and machine learning algorithms will provide even greater control, traceability, and transparency, enabling organizations to make informed decisions based on real-time data and predictive analytics. In addition, as new materials and manufacturing processes are developed, adaptive and flexible heat treatment thermal loop solutions will need to evolve to meet these challenges and provide the necessary level of control and efficiency for these new applications.
Conclusion
Heat treatment thermal loop solutions provide several benefits over traditional heat treatment methods, including improved temperature control, increased efficiency, and improved sustainability outcomes. The integration with Industry 4.0 and data management systems, as well as the use of FMEA and OEE metrics, further help enhance the performance of heat treatment processes. As Industry 4.0 digital transformation and Industry 5.0 practices continue to evolve, heat treatment thermal loop solutions will play an increasingly important role in the future of heat treatment.
About the Authors:
Peter Sherwin Global Business Development Manager of Heat Treatment WatlowThomas Ruecker Senior Business Development Manager of Heat Treatment Eurotherm, a Watlow company
Peter Sherwin, global business development manager of Heat Treatment at Watlow, is passionate about offering best-in-class solutions to the heat treatment industry. He is a chartered engineer and a recognized expert in heat treatment control and data solutions.
Thomas Ruecker is the business development manager of Heat Treatment at Eurotherm Germany, a Watlow company. His expertise includes concept development for the automation of heat treatment plants, with a focus on aerospace and automotive industry according to existing regulations (AMS2750, CQI-9).
Rob Gilmore CEO Watlow Electric Manufacturing Company bizjournals.com
Watlow, a North American designer and manufacturer of complete industrial thermal systems, announced it has completed its acquisition of Eurotherm from Schneider Electric Company on October 31, 2022.
Eurotherm, coming from Schneider Electric Company, is a global provider of temperature, power and process control, measurement and data management equipment, systems, software and services. The company employs about 650 people worldwide, with headquarters in Worthing, U.K. and core manufacturing operations in Ledziny, Poland.
“We are excited about Watlow and Eurotherm and all we will accomplish together," said Rob Gilmore, CEO at Watlow. "This acquisition aligns with our vision of providing innovative thermal products and technologies that help increase our customers’ competitive advantage."
Watlow will establish and expand Eurotherm’s sites in Europe in order to provide a path to growth in other parts of the world including the Americas and Asia in industries such as semiconductor processing, environmental chambers, energy processes, diesel emissions, medical, and foodservice equipment.
Read more about the history of the acquisition here.
Find heat treating products and services when you search on Heat Treat Buyers Guide.com
Rob Gilmore CEO Watlow Electric Manufacturing Company bizjournals.com
Watlow Electric ManufacturingCompany, a North American manufacturer of thermal systems, will purchase Eurotherm, a global provider of temperature and power control measurement systems. The sale is estimated for the end of 2022.
“Watlow is excited to invest in this innovative product portfolio and professional team,” Rob Gilmore, Watlow Electric Manufacturing Company's CEO said. “Combining Eurotherm’s complementary controls technologies with Watlow’s focus on thermal systems, our shared engineer-to-engineer sales models and our focus on common markets will allow Watlow and Eurotherm to better serve all of our respective customers.”
Find heat treating products and services when you search on Heat Treat Buyers Guide.com
Want a free tip? Check out this read of some of the top 101 Heat TreatTips that heat treating professionals submitted over the last THREE YEARS. These handy technical words of wisdom will keep your furnaces in optimum operation and keep you in compliance. If you want more, search for "101 heat treat tips" on the website! This selection features 10 tips to meet heat treat industry standards.
Also, in this year's show issue, Heat TreatToday will be sharing Heat TreatResources you can use when you're at the plant or on the road. Look for the digital edition of the magazine on September 13, 2021 to check it out yourself!
Compliance Issues? Try On-Site Gas Generation
On-site gas generation may help resolve compliance issues. Growth and success in thermal processing may have resulted in you expanding your inventory of reducing atmosphere gases. If you are storing hydrogen or ammonia for Dissociated Ammonia (DA), both of which are classed by the EPA as Highly Hazardous Materials, expanding gas inventory can create compliance issues. It is now possible to create reducing gas atmospheres on a make-it-as-you-use-it basis, minimizing site inventory of hazardous materials and facilitating growth while ensuring HazMat compliance. Modern hydrogen generators can serve small and large flow rates, can load follow, and can make unlimited hydrogen volumes with virtually zero stored HazMat inventory. Hydrogen is the key reducing constituent in both blended hydrogen-nitrogen and DA atmospheres—hydrogen generation (and optionally, nitrogen generation) can be used to provide exactly the atmosphere required but with zero hazardous material storage and at a predictable, economical cost.
(Nel Hydrogen)
Inspection Mistakes That Cost
Rockwell hardness testing requires adherence to strict procedures for accurate results. Try this exercise to prove the importance of proper test procedures.
A certified Rc 54.3 +/- 1 test block was tested three times and the average of the readings was Rc 54 utilizing a flat anvil. Water was put on the anvil under the test block and the next three readings averaged Rc 52.1.
Why is it so important that samples are clean, dry, and properly prepared?
If your process test samples are actually one point above the high spec limit but you are reading two points lower, you will ship hard parts that your customer can reject.
If your process test samples are one point above the low spec limit but you are reading two points lower, you may reprocess parts that are actually within specification.
It is imperative that your personnel are trained in proper sample preparation and hardness testing procedures to maximize your quality results and minimize reprocessing.
(Young Metallurgical Consulting)
Where You Measure Matters
Eugene Gifford Grace (August 27, 1876 – July 7, 1960) was the president of Bethlehem Steel Corporation from 1916 to 1945. He also served as president of the American Iron and Steel Institute and sat on the board of trustees for Lehigh University, of which he was an alumnus. One of his famous quotes is as follows:
“Thousands of engineers can design bridges, calculate strains and stresses, and draw up specifications for machines, but the great engineer is the man who can tell whether the bridge or the machine should be built at all, where it should be built, and when.”
If you check out the additional accomplishments of Mr. Grace, you will see that he was a successful and smart person. Maybe all of us are not capable of reaching such breadth of vision as he articulated above, but as heat treaters, do we simply accept the specification given? Or do we stop to ask if the specification has been properly determined?
With modern computer added stress analysis (FEA), we have at our fingertips a way to move beyond both the “guess and test” and the “copy the historical spec” methods of determining the case depth. Within “guess and test,” of course there are scientific guesses and scientific wild guesses. If you are using a wild guess, chances are that the field is the test lab!
Figure 1. Metallurgical mount holding a cross-section of the steel gear.
Especially for carburized components, deeper case is more time in the furnace, and thus more expensive. I continue to wonder why, if even back in the 1950s, thousands of engineers were available who could calculate stresses and strains and thus set a quantitative foundation for a case depth, in 2019, so few people take advantage of modern technology to optimize the cost of their products.
If you are not ready to take this big step toward design optimization, maybe you would consider always using effective case depth, based on hardness and thus linked to tensile strength, instead of total case depth, which is not linked to any durability or strength criteria.
Figure 1 shows the metallographic cross-section that was used to measure the hardness. Each white pin point is a Knoop 500 gram hardness indentation. The cross-section of the gear was mounted in black epoxy resin. Figures 2 to 4 show the data collected to determine the effective case depths to the common Rockwell C 50 criteria.
Figure 2. Knoop 500 gram hardness data converted to Rockwell C at the tooth flank.
Figure 3. Same data but for Root position.
Figure 4. Same data as shown in Figure 3, near surface information easier to see.
The effective case depth is the depth where the hardness dips below HRC50. For Gear Tooth Flank A, that value was 0.85 mm. For another gear from the same lot, it was over 1.08 mm. But for the root areas, between the teeth—the high-stress area, the effective case depths were only 0.45 and 0.65 mm, respectively. Figure 3 shows the same data as Figure 2, but using a logarithmic scale, illustrating what’s going on near the surface layers more clearly.
In any case, there’s a big difference between the two test locations, and this shows the importance of making sure that all relevant features of the component are adequately characterized!
(Aliya Analytical, Inc.)
AMS2750 Is Golden
This standard is gold and unfortunately has a bad rap today because companies feel it’s just added cost into the process. Today’s technology means you can afford AMS2750E compliant controllers and digital recorders for only a few hundred dollars above a standard offer. This investment will be paid back many times over due to the longer lifetime expected with a quality instrument as well as the quality benefits from better drift performance between calibration intervals, redundant recording (in case of record loss), and overall accurate temperature control, leading to less rejects and reduced rework.
(Eurotherm)
Snagged T/C Wire – Avoid It
Try not to use insulated thermocouple wire if you snag the insulation off the outerjacket along the length of the wire. This may cause the inner insulation to fail andcause low temperature readings.
(WS Thermal)
Order SAT Probes All at Once
Place a yearly blanket order for your SAT probes and ask that they are made from the same coil. This will give you the same correction factors and temperature tolerances.
(GeoCorp)
Out of Control Carburizing? Try This 11-Step Test
When your carburizing atmosphere cannot be controlled, perform this test:
Empty the furnace of all work.
Heat to 1700°F (926°C).
Allow endo gas to continue.
Disable the CP setpoint control loop.
Set generator DP to +35°F (1.7°C).
Run a shim test.
The CP should settle out near 0.4% CP.
If CP settles out substantially lower and the CO2 and DP higher, there’s an oxidation leak, either air, water or CO2 from a leaking radiant tube.
If the leak is small the CP loop will compensate, resulting in more enriching gas usage than normal.
Sometimes but not always a leaking radiant tube can be found by isolating each tube.
To try and find a leaking radiant tube, not only the gas must be shut off but combustion air as well.
(AFC-Holcroft)
3 Tips to Meet Temperature Uniformity Surveys
Adjust the burners with some excess air to improve convection.
Make sure that the low fire adjustment is as small as possible. Since low fire will provide very little energy, it will make the furnace pulse more frequently and this will improve heat transfer by convection and radiation.
Increase internal pressure. This will “push” heat to dead zones allowing you to increase your coldest thermocouples (typically near the floor and in the corners of the furnace).
(Nutec Bickley)
CQI-9 Best Practices
Whether you need to meet rigid CQI-9 standards or not, what are the top 3, nay 4 best practices that nearly every in-house heat treat department ought to follow to make sure their pyrometer stuff is together?
Daily furnace atmosphere checks. Use an alternative method to verify your controls and sensors are operating properly and that there are no issue with your furnace or furnace gases.
Daily endothermic generator checks. Using an alternate method to verify your control parameter (dew point typically) or the gas composition is accurate will alleviate furnace control issues caused by bad endothermic gas.
Verify/validate your heat treat process every 2 hours OR make sure process deviations are automatically alarmed. this is a solid practice to ensure your controls and processes are running properly. This practice can help ensure that parts are being heat treated to the proper specification intended.
Conduct periodic system accuracy tests (SATs) per pre-defined timelines in CQI-9. Good pyrometry practices are an essential part of heat treatment. Because of the importance of temperature in heat treatment, ensure timeliness of all pyrometry practices addressing thermocouple usages, system accuracy tests, calibrations, and temperature uniformity surveys.
(Super Systems, Inc.)
Inspection Mistakes That Cost
Rockwell hardness testing requires adherence to strict procedures for accurate results. Try this exercise to prove the importance of proper test procedures.
A certified Rc 54.3 +/- 1 test block was tested three times and the average of the readings was Rc 54 utilizing a flat anvil. Water was put on the anvil under the test block and the next three readings averaged Rc 52.1.
Why is it so important that samples are clean, dry, and properly prepared?
If your process test samples are actually one point above the high spec limit but you are reading two points lower, you will ship hard parts that your customer can reject.
If your process test samples are one point above the low spec limit but you are reading two points lower, you may reprocess parts that are actually within specification.
It is imperative that your personnel are trained in proper sample preparation and hardness testing procedures to maximize your quality results and minimize reprocessing.
(Young Metallurgical Consulting)
Check out these magazines to see where these tips were first featured:
Doug Glenn, publisher of Heat TreatToday, moderates a panel of 5 experts who address questions about the next 5-10 years in the heat treat industry. What are the trends and what should you prepare for. Experts include Peter Sherwin, Eurotherm by Schneider Electric; Janusz Kowaleski, Ipsen Group; Andrew Bassett, Aerospace Testing & Pyrometry; and Dan Herring, the Heat Treat Doctor from The HERRING GROUP, Inc.
You can view this special video edition of Heat Treat Radio by clicking the button below.
A Canadian leader in the coating industry will expand their heat treat capabilities with a floor-standing box furnace used for ceramic coating applications for parts in the aerospace industry.
The L&L Special Furnace Company Inc. model XLE214 is used for curing and bonding ceramic coatings to various steel bodies. This process provides extra strength to aerospace parts that are subject to various heats and stresses under normal operating conditions.
The furnace has an effective work zone of 22" wide by 16" high by 20" deep. A horizontal door with ceramic hearth and support bricks is included to incorporate the customer’s loading system. Nickle chrome elements are used in the furnace that are resistant to any potential contamination the process may cause. Heat shields provide a safe-to-touch case temperature under operating conditions.
Model XLE MDS from L&L Special Furnace Company, Inc.
The model XLE214 is controlled by a Eurotherm program control with overtemperature protection, chart recorder with jack panel, solid-state relays, and zone controls for balance of temperature gradients. Thermocouples, fusing and electrical interconnections are included. The furnace control circuit is completely tested to ensure proper operation prior to shipping.
The furnace case is sealed for use with inert atmosphere to help reduce oxygen impregnation with the parts. The furnace has a manual inert flow panel to control the inert gas flow into the oven.
The model XLE214 also includes a high-convection fan for uniformity of ±10°F/5.5°C above 500°F/260°C to 1,875°F/1,023°C. There is a 4" diameter venturi with a variable frequency drive to evacuate outgassing that occurs during the curing of the ceramics to the steel part. The system is completely automated through the program control logic.
An optical laboratory in northeastern USA will receive a second floor-standing box furnace for heat-treating ceramics and optics used in the medical field.
The L&L Special Furnace Company model XLE 3636 has an effective work zone of 34” wide by 30” high by 32” deep. It features a double pivot horizontal door. The ceramic hearth is supported on lightweight castable piers. A series of heat shields are included to ensure a safe case temperature while at operating temperatures. The furnace is designed for use with inert blanketing gas for atmosphere control to minimize oxidization. A manual flow panel with regulator and flow meter is included.
A Eurotherm program control and high limit safety are standard. The furnace has a stack light mounted to the top of the control panel for an audible and visual indication of current furnace status. Solid-state relays drive the furnace, which is NFPA86 compliant. Startup and training packages are also included to help the customer set up the furnace and process.
State of Industry 4.0 in the North American Heat Treat Market: What’s Being Done and Who’s Using It?
What is “Industry 4.0” and how is this new technology being used in the heat treat industry? Industry experts spoke with Heat Treat Todayabout their involvement with this cutting-edge application of technology. To learn how you can implement Industry 4.0 at your plant, read what experts have to say about the problems, solutions, and the future of Industry 4.0.
In this Heat Treat Today Original Content article, Peter Sherwin at Eurotherm, AymericGoldsteinas at Ipsen, Robert Szadkowski at SECO/WARWICK Group, and Dan Herring at The HERRING GROUP, Inc. bring varied perspectives as they tackle this topic.
“I think IoT should be better applied – period!”
– Peter Sherwin, Global Business Development Heat Treatment Executive, Eurotherm
Industry 4.0 and “the internet of things” (IoT) were hot topics in the crammed online chatrooms of this year’s heat treat events. But exactly what are these technologies in the world of heat treat? What are the current applications that three leaders in Industry 4.0 have applied? What are some problems and solutions that this new tech brings? And lastly, what is the future of Industry 4.0?
This article will begin by explaining and defining a few prominent technologies before answering each of these questions. Then, read a few thoughts from The Heat Treat Doctor® as you think about application to your heat treat process.
What Is It and Why Does It Matter?
Basically, the term “Industry 4.0” refers to the Fourth Industrial Revolution. See the chart for a breakdown of major topics of the first three industrial revolutions.
Infographic of the four industrial revolutions. Source: Heat Treat Today (images ref. 11)
The idea of new communication is sometimes referred to as cyber-physical connections. This is occurring right now! For example, a sensor (cyber) can monitor a furnace (physical) and send information about the furnace’s conditions to a central data sorting location (connection) for a human to synthesize and respond. The Fourth Industrial Revolution – Industry 4.0 – refers to how the communication between the physical world and the digital world are seamlessly connected.
Click the image to learn more
A key feature of Industry 4.0 is the internet of things (IoT), but other technologies like artificial intelligence (AI), augmented reality (AR), virtual reality (VR), and machine learning also play a part. Let’s define a few of these Industry 4.0 terms that you will see later in the article:
IoT: refers to the physical networking of objects via internet-supported software. Similarly, the “industrial internet of things” (IIoT) refers to these systems supporting industrial purposes, like synthesizing information from furnace sensors on a central app.
artificial intelligence (AI): machines which can process and perform complex directions in a way that mimics natural intelligence.
augmentedreality (AR): digital enhancement of a real-world environment. Think of phone apps which can portray a digital overlay on a video feed, like Snapchat lenses.
virtual reality (VR): digital experience that may be interactive with the real-world environment, or completely simulated.
machine learning: an extension of AI, machine learning describes the result of computer algorithms which modify their performance based on repeated input.
While engineers have been pursuing these new applications for several years, COVID-19 has been a driving factor for businesses to pursue technical options in their daily operations due to limits on travel and physical contact.
[blockquote author=”Robert Szadkowski, VP of Aftermarket Sales, SECO/WARWICK Group” style=”1″]Remote acceptance testing is a highly requested service today. I could say that the financial rationale for such action has always existed, while the epidemiological threat has been the catalyst for change. It is a win-win action.[/blockquote]
According to Aymeric Goldsteinas, project development manager at Ipsen, customers are becoming more willing to implement Ipsen’s Industry 4.0 endeavors, even cloud-based solutions, a willingness that was not present just one decade ago. So how is the heat treat market responding?
Current Applications
We asked suppliers how they implemented Industry 4.0. What follows is how they responded.
Ipsen | PdMetrics
PdMetrics Dashboard Source: Ipsen USA
Ipsen launched a software system in 2016. The company continues to develop and improve its predictive maintenance capabilities to service many of their current customers.
Part of the system’s customer appeal, said Aymeric Goldsteinas, product development manager at Ipsen, is that it can “minimize high-cost events and maximize furnace up-time.”
This is done by using sensor technology and gathering data in their PdMetrics database, which then anticipates future furnace problems. This reduces unplanned downtime and could help heat treaters avoid scrapping loads of high-value parts.
From a consumer perspective, this IoT technology solution leads to improved part quality and part performance.
How it works: PdMetrics assigns a variety of sensors to each system in the heat treat process. For example, a quench system sensor checks vibrations, cooling motor temperature, and water temperature.
Source: Ipsen Harold Click the image to read 5 case studies on PdMetrics.
On Ipsen’s client digital dashboard via PdMetrics, Goldsteinas showed the heat treating systems depicted with a green-yellow-red gauge to portray the working condition of that system. Green indicates that the system is well-maintained, yellow indicates a system needs to be maintained soon, and red means that maintenance is needed immediately. This easy-to-use display is also an example of how Industry 4.0 technologies create user-friendly experiences and cut out excess human input.
This product was used by an aerospace manufacturer to update their systems, integrating this software with their heat treatment process. The results were noticeably increased efficiency of parts and less unplanned downtime. The company was able to schedule maintenance at off-peak hours and plan for future needs by using the platform’s ability to identify maintenance trends, deteriorating conditions, and more.
Check out the post to the side to see how a heat treater was able to save thousands to tens of thousands of dollars with PdMetrics system.
While this company has set the pace with their early adoption of IoT in the heat treat industry, it is worth noting that other companies also offer similar products.
In 2013, Eurotherm began their transition to IoT technologies.
“One of our first true cloud-based solutions focused on improving the efficiency of the calibration process,” said Peter Sherwin, global business development heat treatment executive of Eurotherm. He continued, “This system connects third-party calibration providers with their end-customers and provides an enterprise-wide web view of the calibration status (via dashboards) and access to reports. The smart-tablet app provides an easy-to-follow workflow for conducting a compliant calibration and produces an instant report along with the associated QR-code label.”
Referring to their web-based systems and use of cloud platforms, Sherwin said, “along with our parent, Schneider-Electric, we have developed a range of edge-computing solutions to allow simple transfer of data from the plant-floor to cloud-based advisors and visualization software.”
Sherwin says that their systems are being used globally. “Our enterprise calibration platform,” he shared, “is being utilized by several partner companies as well as in Schneider Electric GSC (Global Supply Chain) Manufacturing plants worldwide.”
Sherwin also noted a variety of IoT applications that Eurotherm provides:
A cloud-hosted digital services platform, EcoStruxure™ Manufacturing Compliance Advisor uses asset compliance to “reduce testing costs, increase productivity and be audit-ready with a robust scheduling and testing process.”
A system called EcoStruxure™ Machine Advisor “allows OEMs to track, monitor and fix equipment remotely.” Additionally, operators can predict and execute maintenance schedules, which improves machine availability.
On a mobile device, EcoStruxure™ Augmented Advisor combines “contextual and local information… creating a fusion of the physical, real-life environment with virtual objects.”
Case in point: “An OEM machine manufacturer in the ceramics industry helps customers reduce their energy consumption by 30% by leveraging our IoT software,” Sherwin shared.
SECO/WARWICK | Remote Factory Acceptance and Activation Tools
Remote Control Source: SECO/WARWICK
Recently SECO/WARWICK publicized the fact that they successfully conducted several international and remote factory acceptance tests. Two customers from China, one from South Korea, and one from Mexico all participated. Each customer was able to remotely approve the furnace construction and performance work of their new furnaces while the furnaces were still on the shop floor in SECO/WARWICK’s European manufacturing facility. No customer engineers were involved on-site at the factory.
Recordings from individual cameras, sensors and viewfinders were downloaded to secure servers and made available to customers. The tests were successful, and the adopted procedures guarantee the reliability and completeness of the data, according the company report.
The company has been using these technologies for “internal device supervision for at least ten years,” according to Robert Szadkowski, VP of Aftermarket Sales at SECO/WARWICK. “In our work,” he continued, “we use remote supervision tools and applications, we report overall equipment efficiency (OEE) indicators, and we conduct optimization processes in terms of batch queuing or energy factor consumption.”
Szadkowski at SECO/WARWICK remarked that for most systems, distance furnace commission is very likely. He explained, “It starts at the stage of making arrangements regarding the expected technical and technological parameters, continues throughout the production and commissioning period, and then during the warranty and post-warranty period. The participation of the customer, the end user of the furnace, in the acceptance tests is required, as is training of the operating personnel […]. There are exceptions to this when dealing with high-risk systems, but for many systems this would be perfectly acceptable.”
Still, Szadkowski noted that “this will be primarily a challenge to our ideas and internal acceptance, rather than to technical limitations.”
C3 Data | End-User System Compliance
Finally, the C3 Data application for furnace compliance is an example of an interrelated, stream-lined, digital solution that provides customers with clear, “real-time” data.
Digitizing data ahead of time integrates testing processes. The system scheduler allows compliance tests to be planned ahead of time. Digitizing the calibration data allows for technicians to scan QR codes attached to test instruments and test sensors to access that data as they test for compliance.
When compliance is tested, the results are immediate for the technician and the quality assurance manager (QAM). The technician uses a portable device to complete these tests, scanning the test instrument and the test sensor, and then inputting the stabilized temperatures from the test instrument and the furnace instrument. In twelve seconds, a technician can complete a system accuracy test (SAT); watch the video above to see the SAT Additionally, the system automatically populates paperless reports to be signed and sent to the QAM. This allows the quality assurance manager to check the reports in real time.
Similar to earlier products, a digital dashboard depicts furnace compliance data. The graphic visualizations allow users to quickly evaluate which furnaces are in compliance, and, if not, why.
Problems // Solutions
Businesses have experienced a few problems with integrating the technology. But there are solutions.
Aymeric Goldensteinas Product Development Manager Ipsen Source: padtronics.com
The first problem is data storage. Like all storage, data storage is finite, and therefore costly. The use of interrelated systems that require high volumes of data to flow between sensors and central systems necessitates investment on the front end for storing data. Additionally, having limited bandwidth to keep digital communication lines open can cause blackouts and connectivity issues. But after acquiring storage, there are practices to use that storage as efficiently as possible.
A solution that Ipsen implements to alleviate this active/working storage stress is “the frequency rule.” This rule establishes a rate of data movement to allow data to move across system memory.
A second issue is privacy/security. It is necessary that the heat treater’s product or process data is properly secured, and while the supplier has certain responsibilities to mitigate this issue, heat treaters should be aware of ways to safeguard their intellectual property. One option, which Ipsen suggests, would be to purchase a unique VPN to ensure better data security. Some companies, including Ipsen, use a stand-alone system that works independent of the PLC, which ensures proprietary data is kept private while following secure industry software standards.
A third issue is user acceptance or, simply put, how comfortable you are with 4.0 technologies. If a heat treater is not comfortable with the technology itself, then Industry 4.0-related tech can be more difficult to implement. On the flip side, suppliers — regarding all processes — must be ready and able to meet the customer’s demands for new products, as Dan Herring, The Heat Treat Doctor®, has indicated. (Ref. 5) An example of digital demands is the AMS2750F requirement that paper chart recorders be replaced with digital data acquisition systems by June 29, 2022.
User acceptance relates to the final problem: relationship with the supplier. While not a bad thing in and of itself, if your relationship with your supplier is not good, then it will be a challenge to develop an effective Industry 4.0 solution process. Be sure you develop an open, communicative relationship with your supplier so that they can offer you unique solutions for your plant’s operation.
The Future of Heat Treat
Here are some interesting applications that people in the industry are looking to with the progression of Industry 4.0:
1. Increased Servitization
Robert Szadkowski Director, Vice President of the Aftermarket Sales Segment SECO/WARWICK Source: Robert Szadkowski
Szadkowski at SECO/WARWICK emphasized that these rapid changes to heat treat systems makes it likely that the servitization — the selling of services rather than products — of the heat treat industry is likely to develop in the near future.
“I am strongly convinced,” Szadkowski wrote, “that sooner or later the servitization will cover the heat treatment industry. When looking at the potential benefits, it’s basically inevitable. The customer, user of the furnace, will be able to focus on their core business instead of worrying about the operation of the furnaces. The manufacturer of the device will be keenly interested in ensuring that its furnace works flawlessly (so that the availability is as high as possible) and brings business benefits to the user. What’s more, with a correctly prepared PaaS (Product as a Service) contract, the OEM will also be interested in improving the operating parameters of such a device after delivery.”
He continues that “Such solutions have existed in the industry for years, e.g. the Rolls-Royce model of selling aircraft engines known as Power-by-the-Hour. The benefits are on both sides; both parties can focus on what they are best at and what is their core business, reducing costs and increasing efficiency. Both parties are interested in long-term cooperation, not a one-off transaction. In light of global problems with access to service engineers, including maintenance staff, the shift of responsibility for the operation of devices from the user to the manufacturer is a natural direction of change.”
There are a few hypotheses revolving around the use of AR service glasses. SECO/LENS augmented reality is currently being explored. This would help in providing remote field service support to the heat treater.
Ipsen’s Goldsteinas has also noted several benefits. He explains the application working by connecting a customer or field service engineer who is at the site with an expert from Ipsen or another service provider. This remote assistance wherein an informant is able to see a problem and give first-hand direction is a common example used to describe the benefits of AR. This application could, for example, decrease the down-time if a furnace were to unexpectedly fail.
Additionally, Goldsteinas envisions training sessions that are conducted in mixed reality. Using virtual reality with an oculus — a type of goggle that digitally enhance or recreate a digitally interactive, environment — companies could reduce training time by recreating experiences, like meetings or practical training sessions, that could be collaborative or solitary. Mixed reality devices like the HoloLens may also be integrated for similar purposes. (Watch video to the right to see examples of Microsoft’s HoloLens and other enhanced reality examples.)
The future could also involve virtual collaboration in the form of an augmented reality meeting room to allow employees from across different Ipsen facilities to discuss and interact with the same content in real-time
3. Efficient Cloud Capabilities
Peter Sherwin personally foresees that attention to the Cloud’s abilities and security will be leveraged in new ways: “An example of this is looking at some of the cost-effective modern-day instrument SCADA [supervisory control and data acquisition] offerings that can provide an on-premise hub for certain applications while managing security policies for linking to cloud based IoT offers.”
4. Increased Systemwide Application
Specifically looking at IoT technologies, Sherwin shared, “I think an expanded view of IoT that encompasses automation across the enterprise (termed as Intelligent Automation or Hyperautomation) is more useful if you really want to achieve significant returns on investment [of IoT technologies]. IoT solutions can improve speed and reduce costs across sales, operations, maintenance, quality, service and administration.”
Advice: To Use or Not To Use
Dan Herring The Heat Treat Doctor®
Dan Herring, The Heat Treat Doctor®, has written about Industry 4.0 and how thinking about seven considerations in any continuation of or change to one’s heat treating process is essential. Ask yourself:
Do I understand what I want to accomplish metallurgically?
Can I predict the outcome of the heat treatment operation?
Can I build repeatability into the process?
Am I using state of the art heat treating equipment?
Am I aware of changes to manufacturing operations?
Am I compromising on quality?
Do I know the costs?
At the end of the day, noted The Heat Treat Doctor®, heat treaters need to know that what they are doing is being done the right way, the first time with the best procedures and processes for their particular operation.
Reflections on The Heat Treat Doctor®
Peter Sherwin of Eurotherm commented on the seven-part advice of The Heat Treat Doctor®, noting, “I think it is very appropriate to look at the value of IoT through the seven considerations that [he] outlines. Building these solutions requires heat treat know-how and an understanding of the data to be captured in order to provide valuable solutions. Value is unlocked in the following categories:
“Right first-time quality improvements. A good heat treater will have quality costs <1% of turnover. The MTI suggests that the cost of quality (all activities) can hit $750k for a decent-size heat treat operation. The knock-on [effects] of poor quality impacts customer satisfaction through delayed deliveries and costs in rework/rejects.”
“Maintenance. These costs can fluctuate – but lets assume a well run plant with fairly modern equipment has costs around 5% of turnover. Significant purchase/cost savings can be made via remote support as well as an understanding of remaining useful life of key components (and avoiding panic purchases).”
“Energy. Again this can fluctuate, but let’s say 10% of turnover. Modern efficient solutions (gas or electric) can significantly reduce the cost of energy and this can be further optimized via IoT solutions.”
“Labor Costs. Say an average of 20% of turnover. Some of the modern XR offers (Extended reality – covers AR, MR, VR etc.) can definitely speed up training, help retention of knowledge, and reduce the time and costs in troubleshooting as well as aiding remote support.”
“It won’t be too long before IoT offers enhanced decision support to heat treaters to aid making profitable decisions,” Sherwin concludes.
Concluding Thoughts
Peter Sherwin Global Business Development Heat Treatment Executive Eurotherm
Whether we like it or not, Industry 4.0 related digital integration is becoming essential rather than simply a better option. Again, the recently published AMS2750F revision highlights this shift for heat treaters.
[blockquote author=”Peter Sherwin, global business development heat treatment of Eurotherm” style=”1″]I think it is important that we use IoT where it can truly bring value and don’t view it as a silver-bullet for everything.[/blockquote]
That does not mean you need to scramble to jump on the bandwagon, but strategically assess your position, your operations, and your options to identify what option is best. Look to other examples in the industry and heat treating tech insiders to inform these new, powerful realities.
Read/Watch More:
Pascal Bornet, Ian Barkin, Jochen Wirtz, Intelligent Automation. Suggested by Peter Sherwin at Eurotherm.
Lindsay Glider, “Rockwell Automation’s 4-Step Guide to Starting Your Digital Transformation Journey,” com (13 October 2020). https://tinyurl.com/yynfoufs.
A commercial heat treating company located in the heart of the aerospace industry on the West Coast of the United States recently commissioned a custom built batch tempering furnace. With a working load size of 168” wide, 48” deep, and 48” tall, coupled with a max load weight of 10,000 pounds, the furnace from Gasbarre Thermal Processing Systems can accommodate a number of differently sized parts within its market.
The gas fired air furnace passes survey at +/- 10℉ over a temperature range of 850℉ to 1350℉ per AMS2750E. At the customer’s request, the electrical controls are UL approved and include the latest in Eurotherm brand temperature controlling instrumentation.
Heat Treat 2019 is coming, and one of the great benefits of gathering with a community of heat treaters is the opportunity to challenge old habits and look at new ways of doing things. Heat Treat Today’s101 Heat TreatTips is another opportunity to learn the tips, tricks, and hacks shared by some of the industry’s foremost experts.
Today’s Technical Tuesday features 10 Tips from a variety of categories, including SCR Power Controls (56), Cooling Systems (64), Combustion (66, 101), Induction Heat Treating (71), Thermocouples (79), AMS2750 (86), Vacuum Furnaces (92), and Miscellaneous (41, 87). These tips come from the 2018 list of 101 Heat TreatTips published in the FNA 2018 Special Print Edition. This special edition is available in a digital format here.
If you have a heat treat-related tip that would benefit your industry colleagues, you can submit your tip(s) to doug@heattreattoday.com or editor@heattreattoday.com—or stop by to see us at Booth #2123 in Detroit!
Heat TreatTip #41
Discolored Part—Who’s to Blame?
If your parts are coming out of the quench oil with discoloration and you are unsure if it is from the prewash, furnace, or oil quench, you can rule out the quench if the discoloration cannot be rubbed off. Check this before the part is post-washed and tempered.
Other possible causes:
Can be burnt oils as parts go through the quench door flame screen
Poor prewash
Furnace atmosphere inlet (particularly if it is drip methanol)
When we buy a pint of beer we don’t expect the head (or foam) to be ½ the glass. We can get this situation when we pay for our plant’s electricity; we pay for both the working power that drives the process (analogy: beer) and reactive power that doesn’t directly drive the process (analogy: foam/head). The lower the Power Factor the worse this situation. The latest SCR devices can help combat this while maintaining precise control and reducing overall peak load demands (using flexible firing methods).
Plan for future growth. It is more cost-effective to provide additional capacity while equipment is being installed. Simple planning for the addition of future pumps (e.g. providing extra valved ports on tanks) and space for heat transfer equipment (e.g. pouring a larger pad or adding extra piers) can save considerable money down the road with little upfront expenditure. Consider installing one size larger piping for the main distribution supply and return. If this is not possible make sure you can add an additional piping run on the hangers you will install now.
Above all, be sure to include all necessary drains, vents, isolation valves, and plenty of instrumentation. These items are critical aids in maintenance and troubleshooting and future system expansion.
Don’t neglect burner tuning—a 1% reduction in excess O2 in the flue products can save you $1,000.00/year on your IQ batch or $2,000.00/year on a 2000-pound/hour continuous furnace—not to mention consistent temp uniformity, better heat-up rates. Pretty good payback for a couple of hours’ work.
Tube & Pipe Heat Treatment Is Different Than Solid Cylinder Heat Treating
Induction heating of tubes and pipes is somewhat different from the heating of solid cylinders. There is a difference in the frequency selection that would maximize energy efficiency for heating tubular products as compared to solid cylinders. In tube and pipe heating, the frequency, which corresponds to maximum coil efficiency, is typically shifted toward lower frequencies providing larger current penetration depth than the tube wall thickness (except for heating of tubes with electromagnetically small diameters). This condition can produce an improvement in electrical efficiency of 10–16 % and even higher. One simplified formula that is used in industry for rough estimate of the electrically efficient frequency is shown in the image, where:
ρ – electrical resistivity of heated metal (Ω*m)
Am = average diameter; Am = (Tube O.D. – h) (m)
h = wall thickness (m)
In cases when induction heaters cannot be considered to be electromagnetically long coils, the values of the optimum frequency will be higher than the values suggested according to formula, and computer modeling can help determining its exact value.
Place a yearly blanket order for your SAT probes and ask that they are made from the same coil. This will give you the same correction factors and temperature tolerances.
This standard is gold and unfortunately has a bad rap today because companies feel it’s just added cost into the process. Today’s technology means you can afford AMS2750E compliant controllers and digital recorders for only a few hundred dollars above a standard offer. This investment will be paid back many times over due to the longer lifetime expected with a quality instrument as well as the quality benefits from better drift performance between calibration intervals, redundant recording (in case of record loss), and overall accurate temperature control, leading to less rejects and reduced rework.
When trying to determine a materials response to heat treatment, it is important to understand its form (e.g., bar, plate, wire, forging, etc.), prior treatments (e.g. mill anneal, mill normalize), chemical composition, grain size, hardenability, and perhaps even the mechanical properties of the heat of steel from which production parts will be manufactured. The material certification sheet supplies this basic information, and it is important to know what these documents are and how to interpret them.
Certain alloying elements have a strong influence on both the response to heat treatment and the ability of the product to perform its intended function. For example, boron in a composition range of 0.0005% to 0.003% is a common addition to fastener steels. It is extremely effective as a hardening agent and impacts hardenability. It does not adversely affect the formability or machinability. Boron permits the use of lower carbon content steels with improved formability and machinability.
During the steelmaking process, failure to tie up the free nitrogen results in the formation of boron nitrides that will prevent the boron from being available for hardening. Titanium and/or aluminum are added for this purpose. It is important, therefore, that the mill carefully controls the titanium/nitrogen ratio. Both titanium and aluminum tend to reduce machinability of the steel, however, the formability typically improves. Boron content in excess of 0.003% has a detrimental effect on impact strength due to grain boundary precipitation.
Since the material certification sheets are based on the entire heat of steel, it is always useful to have an outside laboratory do a full material chemistry (including trace elements) on your incoming raw material. For example, certain trace elements (e.g. titanium, niobium, and aluminum) may retard carburization. In addition, mount and look at the microstructure of the incoming raw material as an indicator of potential heat treat problems.
When loading parts, carefully place the workload on the center of the hearth (front-to-back and side-to-side). Make sure it is stable and no part of the load is close to or touching the heating elements. This can create arcing and damage your parts. Tip: Once the load is in place, mark the hearth posts with a hacksaw to quickly find the front and back measurements each time.
Perfect combustion is based upon the concept of neither excess oxygen or a deficiency of oxygen in the combustion process. This is known as stoichiometric or theoretical combustion. Why is this considered as theoretical and not possible under normal field conditions? Consider the factors that can affect your combustion process: temperature of air or gas, pressure fluctuations, gas composition or supply changes, operating conditions, etc. Therefore theoretical combustion is just that: perfect combustion is only possible in a lab setting. Burner adjustment and calibration normally maintains a minimum of 10% excess air to compensate for these variables and avoid operating gas-rich with high levels of CO in the combustion process.
Out of Control Carburizing? Try This 11-Step Test
Discolored Part—Who’s to Blame?
AMS2750 Is Golden
