Industrial furnace manufacturers needed an integrated control system for high-temperature furnaces (up to 1652°F) used in metal treatment processes. Major automotive manufacturers required complete traceability for recall management, extending accountability throughout the supply chain. Manual data entry created risks for human error in critical process parameters, while the lack of integrated monitoring systems limited visibility into temperature, timing, and atmospheric conditions essential for chemical surface treatment processes.
An integrated HMI (Human Machine Interface) solution was embedded directly into industrial furnaces at the point of manufacture. The system provides comprehensive monitoring and control for high-temperature metal treatment processes, including gas infiltration for chemical surface modification. The solution features automatic data capture via barcode scanning, eliminating manual entry errors, and provides complete database management for traceability requirements.
Simple Architecture Diagram:
Temperature/Atmosphere Sensors → PLCs/Controllers → HMI Software → Database System
↓
Barcode Scanners
↓
Operator Interface
↓
Traceability Reports
Technical Specifications:
Process Control: Temperature monitoring up to 1652°F, atmospheric gas control
Data Points: 1,500 to 4,000 configurable points
Data Capture: Automated barcode scanning system
Database: Integrated database management system with full traceability
Architecture: Redundant configuration available for critical applications
Integration: Direct sensor integration with automated controllers
Embedded HMI Solution: Pre-installed software ships with each furnace unit, ensuring consistent implementation
Automated Data Capture: Barcode-only data entry eliminates human error in critical process documentation
Full Traceability: Complete audit trail meets automotive industry recall requirements
Redundancy Capability: System supports redundant configurations for high-availability requirements
Real-time Process Control: Continuous monitoring of temperature, time, and atmospheric conditions
Delivered complete traceability for automotive supply chain compliance and recall management
Eliminated manual data entry errors through automated barcode scanning
Enabled precise control of chemical surface treatment processes (hardening, wear resistance, oxidation prevention)
Improved product quality through real-time monitoring of critical parameters
Scaled to support operations ranging from 1,500 to 4,000 monitoring points
Reduced liability risks for manufacturers through comprehensive process documentation