FEATURE ADVANCED MATERIALS & PROCESSES | MARCH 2024 42 of the communication network must happen before utilization can be successful. MANAGING BIG DATA Important information, such as functional data, should be transferred to computational systems for storage, processing, and analysis. The advantage of having this information is the time and cost savings. Processing information used to take days, but now it can be done in seconds. Big data means having high-volume, high-velocity, and high-variety information available to use as a powerful resource. It is not enough to have enormous amounts of data, though; one must have company architectures in place and tools for managing and processing the data for it to be useful. PREDICTIVE MAINTENANCE In the case of heat treaters, the goal of predictive maintenance is to prevent equipment failure and avoid unplanned downtime, but more generally, a predictive system uses stored information to predict future outcomes. It is interconnectivity and Big Data that makes predictive maintenance possible. A company can save a substantial amount of time and money by connecting IIoT-enabled business assets, which process data in milliseconds and use advanced analytics to automate maintenance protocols. A considerable amount of data can be collected at different points of production, and for heat treaters, there are vast amounts of data related to temperature, position, pressure, force, vibration, and more. When used as Big Data, this information provides a realistic view of how the furnace operates and performs. Any anomaly outside of normal functioning will be identified before something goes wrong. IN THE REAL WORLD In heat treatment, it becomes dangerous when power cables overheat. This can occur when the cables are not properly installed. Loose cables can still transfer hundreds of amperes, which can spark and overheat terminal blocks. Cable sheaths can melt and cause fires in the electrical panel. Predictive maintenance will identify these issues before something catastrophic happens. A small electrical problem, like a loose cable, can lead to production losses, equipment damage, and injury. Infrared cameras are often used to check cable temperatures, but only periodically. This activity is preventive, but it is not foolproof. Checks are sometimes carried out when the system is not fully operational, so the problem can be hidden. That’s why ongoing, continuous monitoring is so important (Fig. 1). Continuous monitoring of terminal block temperature is a solution that brings significant advantages. The power controller can use this information to manage a high- temperature alarm threshold. Monitoring is autonomous and will shut off the power supply when a threshold is exceeded (Fig. 2). Damage to the electrical panel is avoided, and the furnace is returned to safe temperature levels. However, normal production is disrupted and can impact the batch. 10 Fig. 1 — Fire in the cabinet. Fig. 2 — The high-temperature alarm turned the power off before the damage became catastrophic.
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