Nitrex process control systems are products of extensive research and development in process automation. (find the list of systems with links below)

Our engineers can integrate control systems with any accessory or other system to make it a part of an intelligent management center, which oversees the operation of all production equipment in the shop, along with supporting infrastructure, e.g. closed loop cooling water system. The operation of any motor, pump, valve, recording device, or virtually any other piece of equipment may be overseen by the control system.

Nitrex’s engineers will be happy to work with any combination of equipment, accessories, installation features and requirements.

Refurbishing old or used systems
If you have a control system that needs to be refurbished our experts will gladly transform it according to your needs.

List of Control Systems

Gas Nitriding Process Control

The gas nitriding process control systems are designed to provide a fully automatic operation. The entire nitriding process is executed in an automatic, self-adjusting and operator independent manner.

Process Control Hardware

A typical system is configured in three distinct sections, which facilitate operation and maintenance of the system. They consist of:

1. An electronic process control panel with I/O boards, an industrial computer and a color monitor.
   
2. A gas control panel with: gas analyzing, flow and pressure measuring transducers, calibration and safety features.
   
3. An electric control panel with: one SCR controller for each heating zone, transformers, contactors, fuses, and switches.
   
    

   

This type of set-up provides a high degree of accuracy in process execution, contributing to consistency in nitriding results.

The Nitrex Process Control System monitors and controls automatically the following parameters and operating functions:

• Furnace heating functions such as process temperature, and overheat control with automatic emergency procedures.
• Atmosphere composition and flow for a particular cycle.
• Nitriding atmosphere ratios.
• Nitriding Potential Kn (dissociation rate, for customer defined cycles).
• Temperature for each process stage.
• Gas pressure inside the retort.
• Gas recirculation.
• Execution of the cooling stage and shutdown.
• Cooling water.
• Process safety features.

Operation

The operator follows simple steps to execute a process. Once the parts are cleaned, the furnace is loaded and sealed.

The desired process is selected and started from the process control panel. Thereafter, all stages of the nitriding cycle (e.g., purge, heat, process control, and cool) are automatically carried out sequentially in one uninterrupted cycle, without further operator intervention.

The nitriding process control is carried out in a closed loop circuit. This, coupled with advanced features, enables the process control system to automatically respond to the changes in nitriding conditions, which occur during the process.

To adjust the process parameters, the furnace atmosphere is continuously sampled and analyzed. Based on the data extracted, the process computer adjusts the incoming atmosphere, thus maintaining the preset value of the nitriding potential as accurately as possible.

System Software

Nitrex Gas nitriding process control systems are supplied with several independent software packages. The software has been developed to adapt to the rigorous process control requirements for enhancing nitriding. Troubleshooting, emergency and calibration software packages aid the operator in maintaining and operating the installation.

Visual displays allow the operator to access information on the status of important control points, while the process is being executed.

The process control system monitors all essential process variables (e.g. temperatures, flows, power output, nitriding potential, pressure, elapsed time, etc.) and displays them continuously on the process screen, in a clear and precise manner.

A simple menu allows the operator to select the desired nitriding procedure from a library of pre-established cycles. The library contains researched and tested recipes designed to produce a specific nitrided case on a chosen material.

Each process is developed to meet specific nitriding requirements defined by the customer. This complex procedure requires considerable expertise in the field of nitriding. It involves taking the nitrided case requirements into consideration, and relating these to all other parameters which influence the end result.

Once established and stored in the integrated library, it can be used repeatedly to produce consistent results.

Traceability and Self Diagnosis

Each nitriding cycle’s log file provides a timed account of the actual process execution, and contains all alarms, process interruptions or operator interventions which may have occurred.

The data contained in the log file can be presented in the form of diagrams, thus facilitating preparation of Statistical Process Control (SPC).

back to the list 

return to the top 

Intelligent Vacuum Control Systems

The Nitrex Vacuum Furnace Automatic Control System offers a technologically advanced solution to automatic process control in vacuum heat treatment. The uniqueness of this system lies in its ability to control the process in automatic mode.

It is a fully computerized, automatic control system for vacuum furnaces utilizing state-of-the-art industrial computers to control all furnace functions and those of any accessory that the user may wish to integrate with the furnace. It is fully compatible with all new installations, and can be retrofitted to any existing ones. Highly sophisticated, yet user friendly, this system guarantees not only process uniformity and repeatability, but also safe and flawless operation.

1. A process control panel with I/O boards, a computer and a color monitor.
2. An electrical panel.

• Furnace temperature control functions with ramping (heating and cooling).
• Pressure or vacuum for each process stage.
• Controlled quench process.
• Cooling water circulation.

The control system has the following features and characteristics:

• Graphic status indications of signal sampling points.
• On-line graphic presentation of temperature and vacuum/pressure.
• Continuous vacuum / pressure regulation inside the furnace
• Temperature control and overheat protection control configuration which provides a double protection against unexpected system failures.
• On-screen and control panel alarm indications with troubleshooting instructions for major process malfunction.
• Data logging in separate files with the possibility of storage of the log file in database, on floppy disks, or generating a printout on a printer.
• Graphic and/or numerical process documentation.

Ease of Operation (hands-off)

The control system is designed to monitor and control all process parameters in an automatic and continuous fashion. It also provides an automatic operations sequence during processing in which the separate process stages such as purge, heating, cooling, quenching and isothermal quenching are all carried out one after another without the operator's intervention. The operator has only to select the desired process from a library of preset cycles. These cycles are designed and tested for your specific application and requirements, so you know that process after process, you are guaranteed consistent results.

Operating the system is truly as simple as 1-2-3: (1) operator loads the furnace, (2) selects the appropriate cycle from a user-friendly menu, and (3) goes ahead with the run. From that moment on, no operator involvement is needed until the load is ready to be taken out of the furnace.

While the process is running the computer monitor displays all pertinent information. The operator does not have to do anything. If there is a problem the system will take care of itself. And if you have remote control installed it will call you at home, or on your cell-phone, anywhere you choose.

The control system works in a closed loop, which means that the process variables are continuously analyzed, and the information is sent to the process computer. The computer compares the received information with a set of stored data (heat treatment cycle reference parameters) describing ideal process conditions for the processed material.

The vacuum process control systems are supplied with several independent software packages. The software has been developed to adapt to the rigorous process control requirements for enhancing vacuum treatments. Troubleshooting, emergency and calibration software packages aid the operator in maintaining and operating the installation.

The system operates via user friendly, menu driven software, which assists and helps the operator in the selection of heat treating cycles and in troubleshooting. The desired cycle is selected from a library of process cycles. Once the cycle has been selected the computer takes over further operations until parts are ready for discharge.

Click here to see a photo of a typical screen showing the furnace and individual key elements of the control system. A time-temperature graph may be displayed in a separate window.

Traceability and Self Diagnosis

Each cycle’s log file provides a timed account of the actual process execution, and contains all alarms, process interruptions or operator interventions which may have occurred.

The data contained in the log file can be presented in the form of diagrams, thus facilitating preparation of Statistical Process Control (SPC).

 under construction

Die Preheat Control Systems

The Nitrex Die Preheating System system incorporates features like on-screen alarms, overheat protection control, automatic oven purge, troubleshooting and diagnostic help menus, process logging and archiving capabilities, automatic process restart in case of a power failure, and networking with the main production system.

Click here to view a modular front-loading oven with an automatic control system that monitors and controls all preheating stages and parameters such as temperature and gas flow, as well as elapsed / remaining time, in an automatic and continuous manner.

Expertise

Since we operate our equipment in our own commercial facilities, our customers get the most thoroughly manufacturer/user-tested equipment available anywhere in the world. Few control systems are as thoroughly tested by their manufacturers as ours. When you have a question, a concern, or a problem to solve, the odds are that we have most likely already dealt with it in our commercial shops.

Even if your problem is extremely complex, Nitrex engineering and technological departments, along with our wide network of consultants will be at your service, working with you to find an optimum solution.