Case Study: Visualization of Operations in the New Factory through Furnace Monitoring System
The operation of the new factory, located about 35 km away, is visualized through the furnace monitoring system. The maintenance department is now able to carry out maintenance work at both factories flexibly.
■Remote monitoring system using IoT technology By grasping operational data of key points and aggregating it through a network, analysis can be conducted on-site or in the office. It not only "visualizes" operational conditions but can also be utilized for anomaly monitoring, preventive maintenance, and analysis of optimal operating patterns.
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basic information
Case study of the introduction of a high-frequency induction furnace and a furnace operation monitoring system. The challenge faced by our customer, a foundry (cast iron), was the need to double production capacity in response to the increasing demand for collision safety devices for automobiles, while also dealing with the aging equipment at the headquarters factory. By implementing our furnace operation monitoring system, we achieved visibility of operations from the headquarters factory, which is approximately 35 km away. The maintenance department was able to conduct maintenance work at both factories more flexibly.
Applications/Examples of results
■Overview of Implementation Case Industry: Foundry (Cast Iron Casting) Implemented Products: High-Frequency Induction Furnace, Furnace Operation Monitoring System <Customer Feedback> The crucible capacity is twice that of the melting furnace at our headquarters, and we were worried about whether the pouring speed to the automatic molding line would be sufficient. However, after actually using it, we found that the IGBT power supply operates at full power from the beginning of melting, resulting in a fast melting speed, and we are able to pour as planned. We hope to further increase production efficiency through the accumulation and analysis of furnace operation data in the future. <Issues Before Implementation> Due to the rising demand for collision safety devices for automobiles, we planned to double our production capacity. As we celebrated our 50th anniversary, the aging equipment at our headquarters became a challenge, leading to the decision to construct a new factory. <Implementation Effects> By implementing the furnace operation monitoring system, we achieved visibility of operations from our headquarters, which is about 35 km away. The maintenance department can now conduct maintenance work at both factories more flexibly.
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Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools
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