Steel slabs required precise temperature control across multiple furnaces for different alloy types and applications
Manual recipe management and tracking was inefficient for 24x7 operations
Lack of integrated control between charging, tracking, and discharging processes
Need for fuel optimization while maintaining product quality across 5 furnaces
Disconnected systems between SAP, laboratory data, and Level 1 control systems
Business impact: Inefficient furnace operation leading to increased fuel consumption, quality variations, and limited production throughput in continuous steel processing operations.
Architecture Details:
FrameworX Enterprise managing Level 2 advanced control system
Multi-tier architecture supporting control room and distributed operator stations
Integration layer connecting multiple data sources and control systems
24x7 continuous operation environment
[Operator Stations]
Control Room + Field
|
FrameworX Enterprise
(Level 2 Control)
|
[.NET DLL Layer]
(Temperature & Fuel Algorithms)
|
[Integration Layer]
200,000+ Tags
|
???????????????????????????????????????
| | |
[SAP] [Siemens PLCs] [LIMAB Lab]
| (5 Furnaces) |
| | |
???????????????????????????????????????
|
[TCP/IP Level 1] |
Technical Specifications:
PLCs: Siemens controllers
Communication protocols: TCP/IP for Level 1 integration, proprietary protocols for laboratory systems
External systems: SAP integration, LIMAB laboratory data system
.NET DLL components for specialized control algorithms
Scale: 200,000+ internal tags
Coverage: 5 reheating furnaces
Deployment: Central control room plus distributed operator stations
Core Functionality:
Originally C++ algorithms migrated to .NET DLLs for:
Charging control (weight validation, measurement, SAP data verification)
In-furnace tracking
Discharging control
Advanced temperature calculation and fuel optimization
Essential capabilities that made this solution possible:
.NET DLL Integration: Native support for loading and executing custom .NET assemblies containing proprietary control algorithms
Massive Tag Management: Ability to handle 200,000+ tags with real-time performance
Multi-Protocol Support: Simultaneous communication with Siemens PLCs, TCP/IP Level 1 systems, and laboratory interfaces
Advanced UI Components: Complex grid controls with color-coding for slab status and positioning visualization
Measurable improvements:
Achieved unified control across 5 furnaces from single platform
Enabled real-time tracking of all slabs through complete furnace cycle
Optimized fuel consumption through advanced temperature algorithms
Maintained 24x7 operation reliability for continuous production
Integrated previously disconnected systems (SAP, Laboratory, Level 1)