RAUCH focuses on process optimization through remote maintenance and visualization in the cloud

RAUCH Furnace Technology paves the way towards digitalization with remote maintenance

The export company RAUCH Furnace Technology paves the way towards digitalization with the data acquisition and visualization of important sensor data from melting furnaces. They were supported by the automation specialist and Secomea Distributor Routeco, which offers a new and secure IoT solution with Secomea and A1 Digital, which not only identifies risks early on but also reduces Co2 emissions and extends the service life of the equipment.

The challenge:

A need to eliminate and trace possible eventualities

The high-quality melting technology solutions for the processing of magnesium, zinc, and other non-ferrous metals from RAUCH stand for sustainability, quality, and reliability over several production cycles. The continuous optimization of the plants in different areas is essential to be able to eliminate and trace possible eventualities, which could negatively influence the process as well as the safety, in time. With an export rate of around 99%, fast, simple, and secure remote access to the customer’s plant plays an important role. The company was looking for an uncomplicated remote maintenance solution that simplifies processes and can compare and analyze internal company experience with real data collected directly from the customer’s plant.

The Solution:

Automation specialist enables real-time access to equipment

For more than 20 years Routeco GesmbH in Upper Austria has been active as a specialist in sales and consulting of automation technology. In conjunction with its special offer, which ranges from sensors to clouds, Routeco thus covers almost all areas of automation. With the industrial router and edge device “SiteManager” from Secomea, Routeco enables its customers to have secure remote access to their industrial plants and equipment in real-time. Remote maintenance can be started easily and anywhere from any device, be it a laptop or cell phone, via a web browser without any extra tool or as a VPN tunnel. The SiteManager transmits the collected data such as temperature, speed, and running time of the machine equipment at fixed intervals to the IoT platform of A1 Digital International GmbH. The cloud-based IoT toolkit Cumulocity, developed in cooperation with Software AG, enables the configuration of industry-specific applications for the management and monitoring of devices and services in real-time.

The result

Melting furnaces worldwide at a glance with just one click

With the new data acquisition and visualization option, various sensor data via Secomea’s SiteManager and the A1 Digital Cumulocity Cloud, RAUCH can now identify and track problems and risks at an early stage and thus prevent a breakdown. The acquisition of process data helps to increase machine and production efficiency and extend the service life of the equipment.

“The introduction of Secomea remote maintenance and analysis with A1 Digital has greatly simplified customer support and the further development of our products and laid the foundation for future digitalization projects. Especially the situation with Covid-19 showed us how important this step was for us and our customers. We are now in the fortunate position of being able to maintain our service level and, if necessary, to perform virtual commissioning.„

– Robert Loidl, Team Coordinator Software Engineering at RAUCH Furnace Technology GmbH.

Optimal temperature control saves costs and protects the environment

For example, remote analysis of temperature data can be used to optimize the heating controller, thereby reducing energy consumption, minimizing CO2, and saving costs. Predictive maintenance can be ensured by evaluating recorded data. In the future, it would also be conceivable with sensors attached to machines to simulate the service life or wear of the melting furnace when critical materials are used (e.g. temperature curves of the melting material). With the use of “what if analyses” risk failures could be avoided and the lifetime of the whole plant could be extended significantly.

The security certified remote maintenance solution from Secomea

Data security always plays a major role when implementing a remote maintenance solution, for customers and especially their IT department. Secomea offers simple, convenient and above all secure remote maintenance of the systems with the tested end-to-end security certificate according to the IEC 62443-3 standard. In addition, there are regular updates of the equipment to ensure the necessary security standards are maintained at the customer’s premises.

Remote maintenance as an optimal tool in times of Corona

“The introduction of Secomea remote maintenance and analysis with A1 Digital has greatly simplified customer support and the further development of our products and laid the foundation for future digitalization projects. Especially the situation with Covid-19 showed us how important this step was for us and our customers. We are now in the fortunate position of being able to maintain our service level and, if necessary, to perform virtual commissioning. We already have a long-standing partnership with Routeco, not least because Routeco thinks future-oriented and convinces us with fast, competent and personal support around the clock,„ explains Robert Loidl, Team Coordinator Software Engineering at RAUCH Furnace Technology GmbH.