ABB Foundry Group Customer Success Story
Company Size
1,000+
Region
- America
Country
- United States
Product
- ICONICS GENESIS32
- GraphWorX™32
- AlarmWorX™32
- TrendWorX™32
- eMelt
Tech Stack
- OPC
- Microsoft Access
- Visual Basic
- Microsoft Visual Studio
- Windows 2000
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Cost Savings
- Productivity Improvements
Technology Category
- Application Infrastructure & Middleware - API Integration & Management
- Application Infrastructure & Middleware - Data Exchange & Integration
- Application Infrastructure & Middleware - Middleware, SDKs & Libraries
Applicable Industries
- Metals
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Use Cases
- Machine Condition Monitoring
- Predictive Maintenance
- Process Control & Optimization
Services
- Software Design & Engineering Services
- System Integration
About The Customer
The ABB Foundry Group in New Berlin, WI is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs around 115,000 people worldwide. The ABB Foundry Group has designed their eMelt product around ICONICS GENESIS32 software. This product is an MMI, SCADA, and MES global solution for ABB’s Foundry segment. It provides the monitoring and controlling of foundry processes for as many as four furnaces.
The Challenge
ABB Foundry Group needed a solution to monitor and control the melting process in their foundries. They required a system that could handle connectivity to multiple devices from a single Windows-based server. The system needed to connect to temperature measurement devices, analyzers, and spectrometers, and offer a variety of operational reports. The system also needed to be quick-to-learn, easy-to-use, controller (PLC) independent, support multiple languages, and work with different unit systems. The system was to be configured to individual foundry requirements and operations.
The Solution
ABB Foundry Group implemented the eMelt foundry system, based on GENESIS32, which was designed by the ABB Foundry Group. Thermocouples, a type of spectrometer, are connected to the ABB Digital Inter Control Unit (DICO). This DICO then interfaces to GENESIS32 for operators to monitor and control the melting process. The GENESIS32 application is also communicating via OPC to a Modicon PLC as well as PLC5 and ControlLogix hardware from Allen Bradley. All data is logged to Microsoft Access via ADO and Visual Basic. Microsoft Visual Studio and Office is also used in conjunction with this system running on the Windows 2000 operating system.
Operational Impact
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