METAL FORGING PROCESS IN THE 4.0 ERA

The metal forging industry is a highly productive and specialised sector, but very often there happens to be a mixed situation regarding plant automation, as a result of the stratification of technologies and solutions from different periods.

The task consisted in modernising a plant hosting the forging furnaces.

In one part of the plant there were treatment furnaces with obsolete automation on board and equipped with a dated supervision system responsible for the centralized management of recipes, treatment cycles and alarms. In the other, shine new-generation heating and treatment ovens, with a modern level of automation that includes machine interconnection; in this specific area of the plant, the requirements consisted in implementing a customised supervision system that managed both the ovens status and event reporting.

The objective pursued the complete renewal of the entire plant in a way broader than simply revamping of the existing installation.

The company identified THREAD as a qualified strategic partner for carrying out in an efficient manner the digital transformation of the plant, even if a great part of the plant was not aligned with the most widespread and advanced protocols.

THREAD was entrusted with the task of developing a dedicated system to collect data for analytical and process quality certification purposes, making the most of existing technology and opening up new, interesting opportunities to support the company’s growth.

The data collection and analysis system designed by THREAD communicates directly with the factory floor by collecting data from the PLCs installed on the ovens and, unlike traditional systems that store all data centrally, to record them locally on Raspberry devices. These devices act as buffers and send the data in a “store & forward” mode whenever they are synchronised with the central server. The advantage is that, in this way, there is no risk of losing strategically important data in the event of a temporary malfunction of the communication infrastructure.

The tolerances are very tight: in fact, it is not allowed to face a hole in the data collection. This is true both for acquiring a complete picture of the ovens operation and for quality and traceability issues of the forged part.

The most sensitive data are represented by the value of the thermocouples installed in the different areas of the oven, as well as the parameters relative to the temperature of the ovens; these data are essential for the production of process certification reports.

The amount of data collected by the PLCs is conveyed into a central Sql database and, once the furnace cycle is completed, it is possible to produce reports certifying that the heat treatment cycles of the forged parts have taken place in compliance with the highest quality standards. In the past, this data collection activity was carried out with recorders that were moved from forge to forge to download the data related to kilns operation.

In addition to the inconvenience of employing a person specifically dedicated to physically move the recorders between the ovens PLCs, there was also the fact that the recorded data relating to the thermocouple performance was not integrated into a single database, so performing queries and limiting the analysis periods was far from immediate. Moreover, it was necessary to rethink the graphic layout of the data presentation in a more user-friendly way.

The data collection and analysis software developed by THREAD solves this problem. Its streamlined, web-based architecture efficiently supports the store & forward mode implemented on the ovens, interconnecting all PLCs, and allows the extraction of visually attractive pdf reports for certifications.

One of the most appreciated aspects of the software developed by THREAD is that it can connect to all types of PLCs and read the variables directly in the program. The Sql format of the central database allows programs to be loaded from the central server directly onto the PLC, avoiding the problem of having to load programs locally in different versions and formats depending on the kiln’s automation level. Furthermore, the fact that the data is available in a single database and accessible from any machine makes it possible to evaluate the implementation of future business intelligence operations.

The possibility of activating control of the entire system also responds to the need to help operators supervising the forges by entering parameters centrally without the need to load the various recipes locally.

The next step is to analyse the data regarding energy consumption, together with interfacing with the management system for a synergic management of orders, passing from a “passive” use of supervision to an “active” use.

Until now, it had not been possible to make the production and the management level talk to each other because the previous systems had limitations. Today, thanks to the systems developed by THREAD, it is not only possible to collect and analyse the data collected by the furnaces more effectively, but also to address a real network integration of all departments in the plant and pursue a path of intelligent evolution of production.

Last but not least. Thanks to the supervision software, operators can remotely monitor the status of the ovens at any time, connecting to the control system simply by using a computer and launching a web browser. Next step will be granting the access using a mobile device, as to make production control completely flexible and versatile.

Read More

WINEMAKING BETWEEN TRADITION AND INNOVATION

TASK

  • Check the operation of cellar tanks with a stable and flexible supervision system
  • Implementing on existing hardware
  • Remote access to production data

SOLUTION

  • Development of a customer-specific supervision software collecting data from all PLCs installed on tanks and sends alarms in case of critical issues
  • Possibility to expand the architecture according to future needs
  • Design of a secure wireless network
  • App development for remote control

RESULTS

  • Temperature and pressure values of the tanks where the fermentation of the must takes place are displayed also remotely
  • Timely offsite interventions whenever values go out of range allow to preserve the quality of the product
  • Tracking each step of the wine making cycle
  • More efficient working method in the cellar
  • Possibility to schedule preventive maintenance interventions

The best-known Italian exported wine certainly needs no introduction. Prosecco is a high quality product, one of the first to earn the DOC label (DOCG for Prosecco di Conegliano-Valdobbiadene). Its quality and prestige are supported by the work and age-old knowledge of the farmers. Competitiveness is ensured by the introduction in the cellars of technology and innovation to support production..

CANTINE RUGGERI

Founded in 1949 by Giustino Bisol in Santo Stefano di Valdobbiadene, Cantine Ruggeri is one of the most renowned and ancient wineries in the prosecco production area. Every year, the winery produces approximately three million bottles of prosecco and sparkling wine, 60% of which is destined for the Italian market and the rest goes abroad, in over 50 countries. Cantine Ruggeri’s wines have been awarded several times by The Wine Advocate and Gambero Rosso, proof that the search for the highest quality is a mandatory principle for the Italian winery.

Quality pairs with a constant aspiration to innovation and to implementing the latest technologies, aiming to always produce the best wine.

FACTORY AUTOMATION IN A CELLAR

“Assuming that certain operations are still carried out in person, such as the management of the cuvées and quality controls by the winemaker, industrial automation ensures valuable support in process control, as well as in the bottling and packaging phases,” says Gianluca Tognon, agrotechnician at Cantine Ruggeri.

In particular, one of the most delicate and important steps is the management of the temperatures in the tanks where the fermentation of the must takes place. The constant maintenance of controlled medium-low temperatures in the tanks allows the release of aromas and flavours that enhance the fragrance and freshness of the wine, representing its unique features.

“In the past we used a system that allowed us to control the temperature of the tanks. Unfortunately it was not sufficiently stable or flexible, and required a person to go to the cellar and stand in front of the panel mounted on the tank”. The process of monitoring the temperature of the tanks required a decisive technological step forward.

A PROFESSIONAL SUPERVISION SYSTEM MADE EASY

Cantine Ruggeri relied on THREAD to solve this strategic critical issue.

THREAD developed a customer-specific supervision system that collects data from the PLCs installed on fermentation tanks and autoclaves, monitoring their operation and allowing for remote control of the temperature and pressure of all phases of must fermentation. The system provides Cantine Ruggeri with the stability it missed, for a total of 130 tanks and 45 autoclaves.

The immediate advantage of relying on a software development company such as THREAD is the total customisation of the system, which is developed according to the specific needs of the customer, and the possibility of implementing the software on existing hardware, without necessarily having to purchase a standalone package from a single supplier with all the integration and updating problems that this entails.  Of strategic importance was also the collaboration with Nicon Srl by Luca Nicola, a company with consolidated experience in the wine sector.

The supervision system is managed both locally – on the HMI terminal installed in the cellar – and remotely, with app access on mobile devices; in this way, the parameters are controlled on-the-go both by the operators in the cellar, according to different levels of access, and remotely, where the agronomist and oenologist keep under observation the wine production cycles.

CUSTMOER-SPECIFIC SOLUTION

Alarm notifications signal any departure from the preset temperature and pressure ranges, to prompt corrective action.

“If the temperature values are exceeded, or if there are difficulties in topping the entered value, or, again, when unwanted trends occur, we receive an SMS notification,” adds Tognon. “In this way, we can connect immediately to the tank, and, if necessary, we can intervene to bring the parameter back into its pre-set range”. All of this occurs remotely, no need of sending personnel to the cellar anymore.

THREAD also designed a custom graphic interface that meets the requirements of intuitiveness and usability and that makes the supervision system easy to use for all the operators. Red, yellow and green colors immediately identify the state of the tank, so that at a glance you can see where the tank in need of intervention is located.

MAKING WINE IN A BRAND NEW WAY

The implementation of a secure wireless network in the cellar also made it possible to improve the stability of the connection and to evolve the way of working towards “on-the-go” data control, i.e. from tablets moving around the cellar and not from a static panel mounted on the tank.

The data collection makes it possible to analyze the operation of the tanks over time, and to check that the refrigeration efficiency is always optimal.

“The control of the cellar is now complete,” concludes Ruggeri. “Access to data is possible from the display on-site, from tablets and remotely on smartphones. At any time we are able to know the state of the fermentation and discipline it in the desired direction”.

Read More

WINEMAKING BETWEEN TRADITION AND INNOVATION

TASK

  • Check the operation of cellar tanks with a stable and flexible supervision system
  • Implementing on existing hardware
  • Remote access to production data

SOLUTION

  • Development of a customer-specific supervision software collecting data from all PLCs installed on tanks and sends alarms in case of critical issues
  • Possibility to expand the architecture according to future needs
  • Design of a secure wireless network
  • App development for remote control

RESULTS

  • Temperature and pressure values of the tanks where the fermentation of the must takes place are displayed also remotely
  • Timely offsite interventions whenever values go out of range allow to preserve the quality of the product
  • Tracking each step of the wine making cycle
  • More efficient working method in the cellar
  • Possibility to schedule preventive maintenance interventions

The best-known Italian exported wine certainly needs no introduction. Prosecco is a high quality product, one of the first to earn the DOC label (DOCG for Prosecco di Conegliano-Valdobbiadene). Its quality and prestige are supported by the work and age-old knowledge of the farmers. Competitiveness is ensured by the introduction in the cellars of technology and innovation to support production.

CANTINE RUGGERI

Founded in 1949 by Giustino Bisol in Santo Stefano di Valdobbiadene, Cantine Ruggeri is one of the most renowned and ancient wineries in the prosecco production area. Every year, the winery produces approximately three million bottles of prosecco and sparkling wine, 60% of which is destined for the Italian market and the rest goes abroad, in over 50 countries. Cantine Ruggeri’s wines have been awarded several times by The Wine Advocate and Gambero Rosso, proof that the search for the highest quality is a mandatory principle for the Italian winery.

Quality pairs with a constant aspiration to innovation and to implementing the latest technologies, aiming to always produce the best wine.

FACTORY AUTOMATION… IN A CELLAR

“Assuming that certain operations are still carried out in person, such as the management of the cuvées and quality controls by the winemaker, industrial automation ensures valuable support in process control, as well as in the bottling and packaging phases,” says Gianluca Tognon, agrotechnician at Cantine Ruggeri.

In particular, one of the most delicate and important steps is the management of the temperatures in the tanks where the fermentation of the must takes place. The constant maintenance of controlled medium-low temperatures in the tanks allows the release of aromas and flavours that enhance the fragrance and freshness of the wine, representing its unique features.

“In the past we used a system that allowed us to control the temperature of the tanks. Unfortunately it was not sufficiently stable or flexible, and required a person to go to the cellar and stand in front of the panel mounted on the tank”. The process of monitoring the temperature of the tanks required a decisive technological step forward.

A PROFESSIONAL SUPERVISION SYSTEM MADE EASY

Cantine Ruggeri relied on THREAD to solve this strategic critical issue.

THREAD developed a customer-specific supervision system that collects data from the PLCs installed on fermentation tanks and autoclaves, monitoring their operation and allowing for remote control of the temperature and pressure of all phases of must fermentation. The system provides Cantine Ruggeri with the stability it missed, for a total of 130 tanks and 45 autoclaves.

The immediate advantage of relying on a software development company such as THREAD is the total customisation of the system, which is developed according to the specific needs of the customer, and the possibility of implementing the software on existing hardware, without necessarily having to purchase a standalone package from a single supplier with all the integration and updating problems that this entails.  Of strategic importance was also the collaboration with Nicon Srl by Luca Nicola, a company with consolidated experience in the wine sector.

The supervision system is managed both locally – on the HMI terminal installed in the cellar – and remotely, with app access on mobile devices; in this way, the parameters are controlled on-the-go both by the operators in the cellar, according to different levels of access, and remotely, where the agronomist and oenologist keep under observation the wine production cycles.

CUSTOMER-SPECIFIC SOLUTION

Alarm notifications signal any departure from the preset temperature and pressure ranges, to prompt corrective action.

“If the temperature values are exceeded, or if there are difficulties in topping the entered value, or, again, when unwanted trends occur, we receive an SMS notification,” adds Tognon. “In this way, we can connect immediately to the tank, and, if necessary, we can intervene to bring the parameter back into its pre-set range”. All of this occurs remotely, no need of sending personnel to the cellar anymore.

THREAD also designed a custom graphic interface that meets the requirements of intuitiveness and usability and that makes the supervision system easy to use for all the operators. Red, yellow and green colors immediately identify the state of the tank, so that at a glance you can see where the tank in need of intervention is located.

MAKING WINE IN A BRAND NEW WAY

The implementation of a secure wireless network in the cellar also made it possible to improve the stability of the connection and to evolve the way of working towards “on-the-go” data control, i.e. from tablets moving around the cellar and not from a static panel mounted on the tank.

The data collection makes it possible to analyze the operation of the tanks over time, and to check that the refrigeration efficiency is always optimal.

“The control of the cellar is now complete,” concludes Ruggeri. “Access to data is possible from the display on-site, from tablets and remotely on smartphones. At any time we are able to know the state of the fermentation and discipline it in the desired direction”.

Read More