Industrial furnace
An industrial furnace can be monitored continuously with IoT: temperatures, fill levels, energy consumption and the condition of drives flow into one platform. Operators and furnace builders detect problems earlier, save energy and extend the service life of the plant.
Industrial furnace at a glance
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Verified projects featuring Industrial furnace
IoT energy monitoring: transparent consumption data for measurable savings
Evaluating energy data live in the plant – creating visibility without coding
Smart factory solution creates efficiency and quality improvement in the production process
Maximum availability of drive systems in cement production
Optimising the melting process in the foundry with machine data
With a SIM card for plants to new sales and business models
Industrial furnace monitoring: temperature, fill level and energy
In the solution examples, an industrial router with edge functionality collects temperature, speed and running time and sends them via an A1 Digital M2M SIM card, which always logs into the best network, to a platform based on Cumulocity. For holding furnaces in foundries, the data comes partly from the PLC and partly from retrofitted sensors and reaches the azeti cloud via an IoT gateway. On the drives of a cement plant, sensors measure electrical power, temperature and vibration, and Siemens' SIDRIVE IQ platform analyses them and raises an alarm for unusual values. For energy consumption, platforms such as Schaeffler's autinityE3 or Itanta Analytics bring together meter data from furnaces and other large consumers.
The examples come from chemicals and raw materials, construction, mechanical engineering, and metal and electronics, as condition monitoring, energy monitoring and remote analysis. Furnace builder RAUCH Furnace Technology works with Routeco and A1 Digital to analyse temperature data from its plants at customer sites remotely and builds new services on this basis. Norican's Refill-Monitor shows the fill levels of all holding furnaces in real time. When comparing identical paternoster furnaces, autinityE3 traced higher consumption to the design of the furnace door, which was then modified.
Podcast episodes featuring Industrial furnace
Industrial furnace monitoring: frequently asked questions
How can an industrial furnace be monitored remotely?
An industrial furnace can be monitored remotely via an industrial router with a cellular connection. At RAUCH Furnace Technology, the SiteManager collects temperature, speed and running time and sends them at fixed intervals to the A1 Digital IoT platform. The M2M SIM card withstands the high temperatures of furnace construction and always logs into the best available network. Both the manufacturer and the customer can view the data in a dashboard around the clock.
How does energy monitoring help reduce the consumption of industrial furnaces?
Energy monitoring shows how much each furnace consumes and reveals outliers between identical units. With Schaeffler Digital Solutions' autinityE3, the consumption of identical paternoster furnaces was compared in a dashboard, and the cause of the deviation was found in the design of the furnace door. A rolling bearing manufacturer in Bangalore uses Itanta Analytics to monitor more than 80 energy meters, including those for furnaces, and compares consumption by shift.
How does IoT help with holding furnaces in a foundry?
IoT shows in real time how much molten metal each holding furnace contains. Norican developed the Refill-Monitor on the azeti IoT platform for this purpose, which analyses data from the PLC and from retrofitted sensors. Operators know when to top up which furnace with exactly the amount required. Running dry, overfilling and waiting for melt are avoided, and there is less scrap from refilling at too low a level.
How do the drives of a cement plant's rotary kiln stay available?
The drives stay available when motors and converters are monitored continuously and anomalies trigger an early alarm. At Rohrdorfer Zement, the rotary kiln is at the heart of production, and its waste heat covers around 30 percent of the plant's electricity demand. Innomotics records electrical power, temperature and vibration on the drive systems and transmits the data via an IoT gateway to SIDRIVE IQ. The rolling bearings are analysed with algorithms from Schaeffler.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
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