prosys/2

Fie

ld Level

Process L

evel

S

upervisory

Level

Upper Supervis

ory Level

Management Level

THE LINE TAILORED SUPERVISORY SOFTWARE for optimizing production processes (heat, cooling and climate)

Company

Prozessautomatisierung

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In the focus of your processes are heat and cooling treat-ment as well as climate technology. Important for you is to run these processes in a maximum safe way, easy and efficient. This is where we come in.

As a process oriented system house with our own hard-ware and software development we are specialized for many years in the controlling and automatization of such processes. Our advantage: We have grown up with the branch specifications and develop our systems continu-ously according to the needed requirements. Due to our modern systems with many forward-looking features our devices are in operation world-wide.

With our demig process controllers, process supervi-sory systems as well as automatization and adminis-tration-management-solutions we meet exactly your needs. Our technicians and engineers develop in co-operation with you concepts tailored continuously and down to the last detail to your process requirements.

We can do that because we develop our systems in-house. That gives us the opportunity to respond flexibly to developments and to implement at any time new possibilities especially regarding industry 4.0 require-ments.

SPECIALIZED IN TEMPERATURE PROCESSES

Since 1977 More than 40 years of experience in temperature processes

Heat treatment of metals

Environmental simulations

Food industryHeat treatment of glass and ceramic

prosys/2Server

Extendible controllers Extendible clients

You are already working with demig process controllers or with controllers of other manufacturers and want a further process optimization with a supervisory system up to automatization and the connection to an ERP-system? You can do that! In this brochure we present you the many process-optimized features of our process supervi-sory system by which you may run your processes more stringent, saver and more efficient.

An important advantage is the multidimensional scalability: You can use prosys/2 with just one or with any number of installations. The range of applications is from the passive process recording and monitoring to the fully automated production lines, from a single-station system to a net-work multi-station system. Concerning the control system you can use demig as well as various manufacturers (Siemens, etc.). There is compatibility to current and earlier demig sys-tem-generations (even older than 20 years). Moreover, prosys/2 supports proprietary communication protocols

SUPERIOR PROCESS FLOW WITH PROSYS/2

and also open standards. Updates including data migration are possible even after many years.

Integrating further demig controllers the supervisory sys-tem configures automatically for newly connected installa-tions with demig systems (plug and play). That saves costs and time. An exchange of a demig device is simplified by the restoring of its configuration on the controller. The close interaction of demig systems is paying off continu-ously for you.

Our demig technicians are always on your site with advice and support.They are available by phone and support you e.g. by remote. To use the many prosys/2 advantages you do not have to conclude any maintenance contract. You participate from the further demig developments and innovations by upgrades to very favorable conditions.

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Handling program vacuum furnace

Very simple and central creation of process programs by symbolic programming (DSP) using pre-configured program modules. Consequent reduction of incorrect entries at a plausible, consistent program structure:

• Solely usage of pre-defined sequences • Automatic user guidance to necessary, variable data• Footer display of range limit and input control• Defined section depending settings e.g. monitoring and security functions• Export of treatment programs (CSV)

Program administration

Functions

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Save and document quality. All quality relevant system- or charge-related process data with selected time periods may be recorded, displayed, evaluated and archived. The documentation is a necessary part of quality assessment according to DIN ISO 9000ff and is also accepted e.g. by the automobile industry and aerospace technology.

• Configuration of several recorders with different system- or charge-related data• Online recording and archiving• Detailed analysis of archived measuring files – printout in graphical or numerical form• Online-presentation of process documentations and running process• Export of process data (CSV, XML, Excel, ODBC)

Process documentation and evaluation

Measurement diagram graphical print

Measurement data chamber furnace

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Alarms and messages are displayed online. Multilingual help texts or instructions may be related individually to support the user.

• Alarm-statistics and -archiving • Overviews and lists for a later evaluation• Automatic saving of process related alarms in the process documentation

Alarm and message functions

Alarm report

Alarm display

Functions

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Installation overview

Plants and processes may be centrally visualized, monitored and controlled by prosys/2. Animated site views show the installation, parts of the installation or process parameter.

• Full overview of all installations• Monitoring by easily integrable display elements (e.g. indicator lamp, color switch or data display)• Control by configurable buttons with control function

Visualization

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Functions

prosys/2 enables modification of running processes by authorized persons/staff.

• Remote control and data exchange• Transfer of created programs between supervisory system and process control systems (both ways)• Active data manipulation (handling program, parameter)• Process time shift

System operation

Time shift

Remote control

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User management / Event log

The prosys/2 user management enables an individually assignment of functions and menus to single users. Assignment basis can be the particular function, the knowledge level or security relevant reasons.

• Comprehensive role- and permission-management for users• Recording of system-/user-activities in the supervisory system and the installations• „Logbook“-protocol of all security-relevant events (incidents) as well as of all events triggered by the system or the user

User management

Logbook protocol

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Functions

prosys/2 supports different languages.

• Switch to a different display language even in running process• Creating and assigning multilingual alarm- and help-texts • Direct language import for process parameter from the controller configuration – the languages are switchable

Multilingual capability

The automated data exchange between prosys/2 and demig process control systems saves time, effort and thus costs. The exchange works in both directions.

• Auto-configuration for demig process controller• Automatic backup of demig controller configuration• Automatic import of demig controller visualization• Automatic import of demig controller configuration language

Configuration

Data-Interfaces

prosys/2 provides various data interfaces for the easy data exchange with other process integrated systems.

• Various export mechanism to meet the industry 4.0 requirements (big data analysis)• High level of integration for AMS (ERP system)

Service

• Worldwide support by remote access• Exchanging demig control system in case of repair or modernization the configuration restore is made simple and easy via prosys/2 (plug and play)

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Administration of signaling system

prosydiff

Module for calculation and simulation of carburizing pro-cesses as well as for creation and optimization of treatment programs without expensive test charges. Central process parameters are considered: carburizing-temperature and -duration, atmosphere parameter (C-level), alloy components ...

• Creation of a process graphic of the carburizing profile via computer simulation• The treatment program may be optimized by parameter modifications up to the required result• With the online diffusion calculation module of the demig controller the program is adopted to the running process

Additional modules

Diffusion simulation

prosytel

In a pre-defined alarm case the message system informs the responsible staff members by SMS or e-mail.

• Alarms can be assigned individually to staff members or groups• Definition of responsibility-periods by calendar function

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prover/2prover/2

Order-related charge protocol

The automatization solution

In the basic version, the material flow is recorded at the charge level. With this charge tracking, basically two kinds of charges are differentiated: real and virtual charges. They result from the kind of installation charg-ing or from the material flow through the installation. In the expanded version, the size of the trading units can be changed during the treatment. Finally it is possible to track individual parts on their way through the installation. Using installations with more than one zone (usually continuous band or continuous flow installations), an optional zone-oriented presetting of setpoint can be carried out.

Real Charges Concrete charge packets (mostly on charge transport-ers or plates) at defined positions.

Virtual Charges Abstract charges, which are spread over several con-crete or virtual positions, e.g. by distributing the heat treatment parts on a belt.

Module 1

Charge / Product tracking (with single part tracking)

In the program prover/2 our engineers develop project specific solutions for all automatization tasks. Standard modules are used as a basis and then customized specifically for each customer. By doing so, low-priced solutions for all degrees of automation can be offered.

In the expansion of the process control system prosys/2 with an SQL- data base, production data are available online at any time, so that all divisions of the company can receive necessary information, transfer data or even directly influence the process.

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This module is closely associated with the charge tracking. Because of this charge relation, there are also two differ-ent principles.

Real charges in periodically working installations Depending on the installation where the charge is current-ly treated, a measurement file is created and assigned to the charge. If the charge goes through several installations successively, then such a file will be created and assigned each time. This process can be repeated as many times as needed.

Real and virtual charges in continuously working installations All process variables are recorded first in a central pool. Because of the charge tracking, the system knows the time when the charge was treated in the different installa-tion sectors.

From this information, a measurement file will be created to which the charge will be assigned when leaving the installation.

Charge-related process data recording

Module 2

prover/2 is the user interface for expanded automation tasks, based on an SQL Database Management System:

• Creation and management of heat treatment cycles • Charge tracking and charge-related process data • Generation of transport commands for an automatic operation mode

Order-related charge protocol

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prover/2prover/2

The logistic is based on the information from the charge tracking. For a fully automation line, the process supervisory system has the ability to generate transport commands for the transport unit (loader, manipulator, shuttle etc.) based on the disposition of the load and unload facilities.

For the transport command generation exits also an additional option for the time optimized usage of pre-heating furnaces. Likewise, an empty plate management can be integrated, where the empty plates will be taken back to the magazine store and then be managed by the system. Users can request an empty plate for loading at any time.

for the automatic loading and unloading of installations

Transport command generation

Module 3

Charge correction

The automatization solution

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In many management levels, an administrative system such as the AdministrationManagement-System (AMS) is installed in addition to the technical control system. With this system, the pro-duction planning tasks as well as the order tracking and the calculation are realized. Therefore the process control system provides the necessary logistical data (charge position, installation’s occupancy time etc.), as well as the process documentation for quality verification.

Data created during the production planning may be received from the process control system in order to treat the material with the determined programs/recipes.

for ERP-systems

Data preparation and provision

Module 4

Heat treatment cycle

Terminal BT1000

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InterfaceInterface

The TAM interface module extends the ERP interface by the connection with the Administra-tionManagementSystem AMS. The system is (specially) tailored to the requirements of heat treatment shops and displays the full process from the calculation and quotations, hardness- and metallographic-test up to auto-mated invoice creation in an optimal way.

Data exchange AMS –> prosys/2• Automatic transfer of process program-name to controller at charge registration• Dispatch of customer data and assignment to the treatment charges• Live access to supervisory system viewer

Data exchange prosys/2 –> AMS• Supply of treatment programs for charge planning prior to the charging• Transfer of all alarms during process• Transfer of furnace status including remaining time for planning plant utilization and information to customer• Supply of order-related process documentation including relevant alarms• Transfer of installation- and charge-related energy- and gas-quantity for supply- and profitability-analysis

TAM-interface

The prosys/2-ERP-interface-modul connects the functional area of the supervisory system with the ERP system of the management level. This provides a higher consistency in the full business process.

• Exchange of process data in different formats for further processing in superordinate systems• Project-specific adaptions

ERP-interface

ERPTAM

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AMS administration of equipment

AMS schedule charging

Energy consumption per batch

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ProjectsProjectsProject examplesfrom a variety of implemented automations

Project: Automatic chamber furnace line (with time-optimized loading of tempering furnaces for preheating) with a connection to AMS (AdministrationManagementSystem).

The following modules were used: • Logistical tracking of charges and materials (real charges)• Charge-related recording of process data (real charges in periodically working installations)• Transport command generation for automatic loading and unloading of the installations (fully automatic transport unit for loading and unloading the furnaces and the magazine store)• Data preparation and provision for the superordinate ERP-system (AMS)

Project: Continuous belt furnace with charge tracking and automatic zone-related presetting of set point.

The following modules were used:• Logistical charge / material tracking (virtual charges)• Charge-related process data recording (virtual charges in continuous working installations)• Automatic zone-related presetting of set point

Project: Material tracking down to individual parts in a fully automatic installation consisting of a high temperature furnace, a following low-temperature furnace, several robotics and automatic test stations for the treatment of aluminum parts.

The following modules were used:• Logistical charge / product tracking (Real charges with tracking of individual parts) • Charge-related process data recording (real charges in continuous working installations)• Individual part-related allocation of test results, data preparation and provision for superordinate ERP system

Project: Two automatic chamber furnace lines, one pusher furnace installation and two high-rack storage, operated by an external transport unit. Furthermore a connection to the ERP-system (VAX mainframe) is realized.

The following modules were used:• Logistical tracking of charges and products (real charges)• Charge-related recording of process data (real charges in periodically working installations) • Transport command generation for automatic loading and unloading of the installations (fully automatic transport unit for loading and unloading of the installations and the magazine store)• Empty plate management• Data preparation and provision for the superordinate ERP- system

An important and interesting aspect here is that each line is independently (self-sufficiently) operational.

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Chamber furnace line

Continuous belt furnace

Automatic line for aluminium parts

Process documentation and evaluation

Program administration

System operation Multilingual capability

Charge / Product tracking

Charge-related process data recording

Transport command generation

Data preparation and provision

User management / Event log

Additional modules:prosydiff & prosytel

Data-Interfaces Service

prover/2

prosys/2

Configuration

Alarm and message functions

Visualization

Functional Overview

Haardtstraße 40 • D-57076 Siegen • GermanyPhone: +49 (0) 271 - 7 72 02-0 • Fax: +49 (0) 271 - 7 47 04

info@demig.de • www.demig.de