CASE STUDY

Digital twin for heat treatment

To streamline operations and minimize the risk of errors, SECO/WARWICK implemented Siemens' digital twin solutions.

The heat treatment process of metals is exceptionally complex from a technological standpoint. It requires maintaining appropriate operating parameters as well as specific safety conditions. This poses significant challenges for manufacturers of modern industrial furnaces. To minimize the risk of potential errors and to improve the production and on-site assembly processes, the SECO/WARWICK Group uses solutions based on a digital twin provided by Siemens.

SECO/WARWICK is a manufacturer of technologically advanced furnaces for heat treatment of metals, designed and produced in accordance with the individual needs of customers. A key factor in selecting the furnace technology and technical solutions is the customer’s charge (workload), i.e. the metal product to be heat treated. Based on this, the appropriate technology, process, and recipe are selected, which influence the level of complexity of the equipment and control systems. The type of heat treatment technology also determines the selection of safety measures protecting employees from potential hazards.

“For an automation engineer involved in furnace design, a thorough knowledge of the technology and process parameters is crucial, as well as awareness of potential risks. For example, vacuum heat treatment furnaces are programmed quite differently from equipment used for aluminum processing or vacuum metallurgy, despite having a similar hardware structure. Understanding the technology makes it possible to anticipate potential hazards and implement appropriate safeguards,”
emphasizes Sławomir Wachowski, Director of the Automation Division at SECO/WARWICK.

SECO/WARWICK is a manufacturer of technologically advanced furnaces for the heat treatment of metals.

The digital twin supports modeling and testing

To streamline work and minimize the risk of errors, SECO/WARWICK decided to use digital twin solutions provided by Siemens. The company uses, among others, SIMIT software to create digital models of vacuum, atmosphere, and melting furnaces. This tool is also used to test automation systems before the software is handed over for commissioning.The company also uses SIMIT Unit to support the production process and configuration of control cabinets through full simulation of hardware cabinet tests. For more advanced models, such as pumping systems, the Simcenter Amesim simulation platform is used to simulate performance and to assist in selecting the appropriate size of vacuum pumps.

“Currently, in our models we simulate several types of equipment. The main reason we decided to use a digital twin was the complexity of the control software and the variety of challenges we had to face. Many of these issues only became apparent during testing and commissioning — that is, in the final stage, when the equipment had already left our facility,”
explains Radosław Gorowy, Digital Modeling and Simulation Engineer at SECO/WARWICK.

Furnace testing “on the desk”

The digital twin solutions used by SECO/WARWICK make it possible to identify potential errors and issues already at early stages of work on a given device.

The digital twin solutions used by SECO/WARWICK make it possible to identify potential errors and issues already at early stages of work on a given device. Modeling and testing with the use of simulation software significantly improve work efficiency. They also enhance the reliability of the solutions being developed. As a result, industrial furnaces for metal heat treatment can be delivered and commissioned faster, at lower cost, and with reduced labor input.

“Striving for innovation is a very important factor driving the development of our company. In this respect, the digital twin has fully met our expectations. It is used for modeling all the equipment we produce. At present, we have several models prepared. Initially, simulations were created for vacuum furnaces, on which we now fully test our automation systems. Currently, we are developing models for aluminum processing furnaces and vacuum metallurgy. We also have our first experience in modeling atmosphere furnaces, which represent an important segment of the solutions we develop,”
explains Sławomir Wachowski.

SECO/WARWICK uses SIMIT software, among other things, to simulate input and output signals of control systems, to provide detailed simulation of device behavior, and to model processes using dedicated technological libraries.

“In this solution, SIMIT is the key tool; however, to fully leverage its capabilities, the system has been extended with PLCSIM Advanced – a controller emulator – and WinCC for the HMI operator panel. Integration with TIA Portal makes it possible to modify the control program in real time (Software-in-the-Loop). The simulation model can also communicate with a physical controller using SIMIT UNIT (Hardware-in-the-Loop),”
explains Mariusz Waśkowicz, Digitalization Solutions Expert supporting the project on behalf of Siemens.Testing of equipment and automation is carried out literally “on the desk,” where the applied technological solutions are verified before final commissioning.

“The control cabinet is connected to SIMIT Unit and tested using this tool in terms of hardware and measurement performance. This gives us confidence that it will not generate problems, and if any issues do occur on-site, they will stem from other causes related to the physical implementation of the project, rather than from the components we have used,”
explains Wojciech Piasny, Deputy Director of the Automation Department at SECO/WARWICK.

Digital twin software is just one of many elements of the Siemens ecosystem used by the manufacturer. The entire control system is based on Siemens solutions. System control is handled by the S7-1500 controller along with its modules. Siemens also supplies industrial computers and touch panels that serve as the user interface. In addition, the safety systems are built on the manufacturer’s Safety solutions. Siemens components are also used in the control cabinets, including contactors, circuit

Digital twin software is just one of many elements of the Siemens ecosystem used by SECO/WARWICK.

The systems are controlled by the S7-1500 controller and modules.

How does the model talk to the controller?

Modeling takes into account all processes occurring in the furnace: pumping, furnace heating, cooling, and carburizing. In the physical world, such a process takes from several hours to—in the case of certain devices—even several days. By using simulation solutions based on a digital twin of the device, this can be significantly accelerated and the furnace can be comprehensively tested long before its physical counterpart is created. During modeling, both digital and analog parameters, such as temperature and vacuum, are simulated. During testing, the operation of switches, contactors, and other devices connected to the control cabinet, including the entire safety system, is verified.

"The model contains a digital representation of the device's components and the components inside the control cabinet. All of these elements must have a digital equivalent in SIMIT. Using this tool, we build a component library. We examine the individual furnace components, their structure, and then represent them in the model we create. Based on the electrical diagrams, we connect the model to the PLC via inputs/outputs, allowing us to test the operation of individual technological programs. An additional benefit is the ability to use available inputs/outputs," explains Radosław Gorowy.

The modeling takes into account all processes that occur in the furnace: including pumping, furnace heating, cooling and carburizing.

SECO/WARWICK constructs models designed to reflect reality as faithfully as possible. But that's not all, as simulations are also created that generate synthetic data for analysis. Such simulations allow the development team, for example, to test solutions dedicated to the FurnacePlus platform, which extends the functionality of the Group's devices with predictive and energy management systems. Understanding the customer's interface needs is also an important aspect of solution design, as ergonomics are crucial for safety reasons.

"Customers who don't have to worry excessively about dangerous accidents during furnace operation have different needs than those when, due to the material processing technology used, the risk is significant and can have serious consequences. In the latter case, we're dealing with highly skilled operators who also require a specialized interface in the devices they use,"
notes Marek Melnarowicz, Sales Manager at Siemens Polska.

Testing solutions in the digital twin's simulation tools occurs during the handover of the control cabinet and software. Next, the assembly department implements the design and performs the final assembly of the device. Finally, the service department conducts physical testing. The final confirmation that the adopted model has been correctly implemented is its verification on the target facility.

"The models we use for simulation and testing are mature enough and quick enough to create that they practically save us time. Even more importantly, they free up valuable automation resources, as we don't have to engage them in physical testing of the device with service, either at the SECO/WARWICK facility or directly at the customer's premises. The time spent preparing the model also pays off through greater peace of mind when it comes to planning work, especially since each subsequent model costs us less due to the successively built library of our own components. The time savings thanks to the digital twin are therefore enormous,"
explains S. Wachowski.

Faster, safer and more economical

After several months of working with SIMIT and SIMIT Unit, SECO/WARWICK sees significant benefits from using tools that provide comprehensive solutions for automation testing. Among the key benefits of implementing modeling and testing solutions is the reduction in the time required for furnace assembly and commissioning at the customer's facility.

"Before implementing the digital twin, in the case of a vacuum furnace, testing combined with technological trials took 2 to 2.5 weeks for a service technician and 4-5 days for an automation engineer. Testing on the created model shortened their workload several-fold. For systems composed of several or a dozen devices, these times are reduced proportionally from an average of 400-500 hours to 100-150, which translates into significant savings. The workload of electrical installers is also reduced. Lower costs are important, but the feeling of certainty that the device will function correctly on-site is priceless,"
explains Sławomir Wachowski.

By using a digital twin, the furnace can be comprehensively tested long before its physical equivalent is created.

Cloud model

Another significant benefit of using a digital twin is the higher quality of the final product.

Another interesting aspect of using a digital twin is its business implications. A cloud-based vacuum furnace model allows salespeople to demonstrate the device's performance to current and new customers. Another innovative feature is the ability for the development team to test advanced device management solutions. Thanks to the cloud-based model, they no longer need physical data for testing. In the future, Simcenter Amesim will also enable SECO/WARWICK to create advanced mathematical models of learning machines.

"Thanks to working with Amesim, we were able to verify how accurately we are able to model energy consumption, thermal changes, and dynamic gas pressure changes. We see great potential in Amesim for creating even more accurate models, which we can then use as components of SIMIT and more accurately represent reality in the digital world,"
says Wojciech Piasny.

According to Mariusz Waśkowicz from Siemens, a digital twin not only provides tangible organizational and economic benefits but also signals a shift in the direction of automation development and even influences the education of current and future automation specialists.

"The use of a digital twin allows for effective training, for example, for those responsible for machine operation or maintenance. This allows them to thoroughly understand the device or entire production line before they even interact with the physical object, thus learning how to operate it effectively more quickly. They will also pay attention to specific aspects of the work and more quickly identify symptoms of potential failures, and consequently, line downtime," explains Mariusz Waśkowicz.

Marek Melnarowicz also notes the impact of a digital twin on the perception of the automation profession and the development of new directions for the education of industrial automation specialists.

"Thanks to modeling, the world of PLC automation is moving closer to IT. The development of the digital twin means that the physical world no longer binds us, and we can work on machine and device components and the software that controls them before they are implemented in real-world conditions," explains Marek Melnarowicz.