Product Category
Process Control
Product
Temperature Controller 96x96mm Model 151H43B1 with RS485 Communication.
Application
Tempering Hardening & Carbonizing Hardening Chambers.
A Sizzling Solution: GIC’s Recipe for Heat Treatment Excellence
Introduction
A particular client of ours relies on tempering and carbonizing hardening chambers for the heat treatment of critical automobile components. These chambers are tasked with reaching and maintaining temperatures as high as 600/700 degrees Celsius for a soaking period of 90 minutes. To achieve this precision and ensure optimal heat treatment results, we suggested them a solution. Enter the GIC Temperature Controller-PR-69.
Challenges
- Precise Temperature Control: Maintaining accurate and consistent temperatures within the hardening chambers, especially at high temperatures, was crucial to ensure optimal heat treatment results. Fluctuations in temperature could lead to variations in the hardness and mechanical properties of the processed automobile parts.
- Alarm (Hooter) Generation: Generating alarms is used after completion of a soaking period of 90 minutes and ensures prompt corrective action. Timely alerts would minimize scrap production and maintain product quality.
- Data Collection: Collecting temperature data over Modbus RS485 was necessary to monitor the heat treatment process, analyze trends, and optimize process parameters according to industry standards and customer specifications.
Solution
The client implemented the Temperature Controller-PR-69 (96x96mm, Model Number: 151F43B1) to overcome the challenges mentioned above. The controller provided the following features and benefits:
- Precise Temperature Control: The Temperature Controller-PR-69 offered precise and accurate temperature regulation within the hardening chambers. Utilizing a PID control algorithm, it adjusted the output of the heater contactors based on temperature feedback. This ensured stable temperature conditions, minimizing fluctuations and variations in the heat treatment process.
- Alarm (Hooter) Generation and Time Delay: The controller was programmed to generate alarms after a specific time delay of 90 minutes. These alarms promptly notified operators, enabling immediate corrective actions and preventing damage to the chambers. The time delay allowed for appropriate evaluation and minimised false alarms.
- Modbus RS485 Connectivity: With Modbus RS485 communication support, the controller facilitated centralized data collection of temperature readings. This enabled comprehensive monitoring, data analysis, and optimization of the heat treatment process. Trends and patterns could be identified, process parameters adjusted, and compliance with industry standards and customer specifications ensured.By implementing the Temperature Controller-PR-69 (96x96mm, Model Number: 151F43B1) in their tempering and carbonizing hardening chambers, our client achieved precise temperature regulation, timely alarm notifications, and data-driven process optimization. The controller’s features and benefits improved product quality, reduced scrap production, enhanced operational efficiency, and ensured compliance with industry standards and customer specifications. Jyoti Industries successfully enhanced its heat treatment processes, leading to increased customer satisfaction and continued growth in the automotive component manufacturing
The GIC Effect
Imbuing the FCMA Soft Starter Panel with GIC’s innovative arsenal led to a cascade of invaluable advantages:
Enhanced Product Quality: Precise temperature control resulted in reduced inrush current and mechanical shock. This improvement significantly extended the lifespan of motors and equipment, ultimately enhancing product quality.
Operational Efficiency: The controller’s features streamlined operational efficiency by minimizing breakdown times through I/O status displays, providing valuable support to maintenance engineers.
Data-Driven Insights: Comprehensive data collection and analysis offered valuable insights into the heat treatment process, enabling Jyoti Industries to optimize parameters, ensuring compliance with industry standards and customer requirements.
By choosing GIC, the company experienced not only enhanced operational efficiency and product quality but also gained a reliable partner committed to delivering cost-effective, ‘Made in India’ solutions. GIC’s ISO-certified products and prompt after-sales support proved instrumental in Jyoti Industries’ pursuit of excellence in automotive component manufacturing.
