Heat-Treatment Furnace Line Speed Change Time Prediction
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Solution Overview
Problem
In heat-treatment furnaces for metal plates, changing the furnace temperature and line speed to accommodate product demand can be time-consuming, exceeding allowable limits and impacting operator convenience, as existing methods do not provide clear guidance on whether to adjust these parameters.
Innovation Solution
An operation support apparatus that calculates the estimated required time for the heat-treatment furnace to reach a target temperature based on current and target line speeds, allowing operators to decide on necessary adjustments to furnace temperature and line speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the furnace temperature is changed before the line speed change to ensure appropriate heat-treatment temperature, then the strip temperature quality is improved, but the time required to reach target furnace temperature exceeds allowable values
Solution Approach 1:
The system performs preliminary calculation of the required time to reach target furnace temperature before actually changing the line speed. This allows operators to plan ahead and understand the time implications of temperature adjustments, enabling better coordination between temperature changes and production requirements.
Solution Approach 2:
The system provides feedback to operators by displaying the calculated required time for temperature changes. This feedback mechanism allows operators to make informed decisions about whether to proceed with line speed changes based on the time required for temperature adjustment, thus resolving the contradiction between quality assurance and time efficiency.
2Productivity
If the line speed is changed to accommodate product demand, then the productivity is improved, but the furnace temperature may not be appropriate for the new line speed, causing poor product quality
Solution Approach 1:
The system calculates the required furnace temperature for the target line speed before the line speed change is executed. This preliminary determination of target temperature ensures that operators know what temperature adjustment is needed in advance, allowing them to coordinate temperature changes with production requirements to maintain quality while improving productivity.
Solution Approach 2:
The system provides feedback to operators by displaying both the current and target furnace temperatures, enabling informed decision-making about line speed changes. Operators can assess whether the required temperature adjustment is feasible within operational constraints before committing to a productivity increase.
3Ease of operation
If operators are given the option to choose whether to change furnace temperature and line speed, then the ease of operation is improved, but the decision-making process becomes more complex without clear guidance
Solution Approach 1:
The system introduces an intermediary calculation function that automatically determines the required time and target temperature based on current operational parameters and desired line speed changes. This intermediary tool bridges the gap between operator intent and optimal operational settings, providing clear guidance that simplifies decision-making while maintaining operational flexibility.
Solution Approach 2:
The system performs self-service by automatically calculating the required time and target furnace temperature when operators input a desired line speed change. This eliminates the need for operators to manually compute these parameters, reducing operational complexity while preserving the flexibility to make informed decisions about temperature and speed adjustments.
Data Source
AI summary
An operation support apparatus for a heat-treatment furnace for heat-treating a metal plate continuously includes a required time calculation unit configured to calculate, based on a current furnace temperature which is a current temperature of the heat-treatment furnace, a current line speed which is a current conveyance speed of the metal plate, and a target line speed which is a conveyance speed of the metal plate to be changed from the current line speed, an estimated required time until a temperature of the heat-treatment furnace reaches, from the current furnace temperature, a target furnace temperature which is a temperature of the heat-treatment furnace corresponding to the target line speed, and a first output unit configured to output the estimated required time calculated by the required time calculation unit.