CPT International 3/2019

MELTING SHOP
Figure 6: OCP system visualization screen.
Figure 7: Indication of yoke temperatures.
Processing and visualization of OCP
temperature data
Unlike prior OCP software versions, the
present one has data management and
processing features designed fully in
line with the Industry 4.0 concept as
based on the OPC UA standard. This will
permit future cross-system communication
and a standardized data exchange
with higher-level systems.
Figure 5:
Software
architecture
(schematic).
Moreover, in redesigning the visualization
and control interfaces, web-based
solutions were developed so that
the full functionality is also available
with mobile terminal devices (Figure 4).
In a further step, a feature was
implemented whereby OCP temperature
data, together with other furnace
information such as actual furnace
power, charge weight and furnace operating
status, can be stored in a cloud
system in coordination with the plant
owner. This enables Otto Junker, e.g.,
on the one hand, to view and analyze
data so as to assist with the user‘s interpretation
thereof in a given case. On
the other hand, it lays the foundation
for the use of tools such as, e.g., artificial
intelligence to improve the system‘s
predictive capabilities.
Figure 5 illustrates the current software
architecture in simplified form.
Finally, the opportunity was used to
fully redesign the individual input and
visualization screens, with clarity, simplicity
and intuitive control being accorded
high priority. It goes without saying
that alternative (i.e., mouse, keyboard
or touch screen) control methods are
supported.
Let us now look at the relevant
visualization windows by way of
example: The main OCP visualization
screen is depicted in Figure 6. This
window shows a schematic top view of
the furnace, with four meandering
optical fibre layers in this case. On principle,
the temperatures in each of the
four meander layers are initially displayed
in polar form, with the option
to suppress individual layers for the
sake of clarity. The temperature axis
can be scaled at will. As an alternative
to the polar temperature diagram
shown, a corresponding linear rendering
of the temperature profiles in
the meander layers is available. When
an alarm threshold is exceeded, this
will be indicated by appropriate symbols
next to the temperature graphs.
At the same time, the border colour of
the symbolic furnace will change traffic
light style, i.e., from green through yellow
(warning) to red (shutdown), in
the relevant segments. Depending on
the number of furnaces in place, these
can be visualized simultaneously in
separate windows.
By selecting a playback function
and entering a date and time, historic
temperature profiles can be viewed. It
is also possible to show temperature
profile images in a video-like animated
mode, at an adjustable playback speed,
between a previously entered start and
end time. These latter features are particularly
helpful in tracking the
development of a crucible defect in
time and hence, to understand its evolution.
Figure 7 shows the yoke temperature
monitoring screen. Again, the furnace
is shown in a schematic top view
and comprises eight yokes in this case.
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