Level 2 advanced control with .NET DLL integration for steel slab reheating optimization.
Industry: Steel and Materials

Quick Facts

AttributeValue
Scale200,000+ internal tags
Furnaces5 reheating furnaces
PLCsSiemens controllers
IntegrationSAP, LIMAB Laboratory, TCP/IP Level 1
ArchitectureLevel 2 control with .NET DLL algorithms
Operation24x7 continuous steel processing

The Challenge

Challenge: Implement Level 2 advanced control system for steel slab reheating across 5 furnaces with precise temperature control, fuel optimization, and full integration with SAP and laboratory systems.

Specific pain points:

  • Steel slabs require precise temperature control for different alloy types and applications
  • Manual recipe management inefficient for 24x7 operations
  • Lack of integrated control between charging, tracking, and discharging processes
  • Need for fuel optimization while maintaining product quality
  • Disconnected systems between SAP, laboratory data, and Level 1 control

Impact: Inefficient furnace operation leading to increased fuel consumption, quality variations, and limited production throughput in continuous steel processing operations.

The Solution

Architecture

TierComponentCapabilities
Level 1Siemens PLCs (5 furnaces)Real-time furnace control
Level 2FrameworX EnterpriseAdvanced control algorithms, recipe management
.NET DLL LayerCustom algorithmsTemperature and fuel optimization
IntegrationSAP, LIMAB LabRecipe data, quality feedback
ClientsControl room + field stations24x7 operator interface

Simplified diagram:

Operator Stations Control Room + Field FrameworX Enterprise (Level 2 Control) .NET DLL Layer (Temperature & Fuel Algorithms) Integration Layer 200,000+ Tags SAP Siemens PLCs (5 Furnaces) LIMAB Lab TCP/IP Level 1

Core Functionality

FunctionDescription
Charging ControlWeight validation, measurement, SAP data verification
In-Furnace TrackingReal-time slab position and status monitoring
Discharging ControlCoordinated slab extraction and handoff
Temperature CalculationAdvanced algorithms for optimal heating profiles
Fuel OptimizationMinimized consumption while maintaining quality

Connectivity

SystemProtocol/Interface
Siemens PLCsTCP/IP Level 1 integration
SAPEnterprise integration
LIMAB LaboratoryProprietary laboratory system interface

Key Enablers

FrameworX capabilities that made this solution possible:

CapabilityApplication
.NET DLL IntegrationNative support for custom control algorithms (migrated from C++)
Massive Tag Management200,000+ tags with real-time performance
Multi-Protocol SupportSiemens PLCs, TCP/IP Level 1, laboratory interfaces
Advanced UI ComponentsComplex grids with color-coding for slab status and positioning
24x7 ReliabilityContinuous operation for steel production


The Results

  • Unified Furnace Control — Achieved integrated control across 5 furnaces from single platform
  • Real-time Slab Tracking — Enabled tracking of all slabs through complete furnace cycle
  • Optimized Fuel Consumption — Reduced fuel usage through advanced temperature algorithms
  • 24x7 Reliability — Maintained continuous operation for steel production
  • System Integration — Connected previously disconnected SAP, Laboratory, and Level 1 systems
  • Algorithm Migration — Successfully migrated C++ algorithms to .NET DLLs within FrameworX

This case demonstrates Level 2 advanced control for steel reheating furnaces with .NET DLL algorithm integration and enterprise system connectivity.