Proactive Modernization of Control Technology at SEW-EURODRIVE Germany
For many years, the AICHELIN continuous double-chamber furnace has been operating continuously at SEW-EURODRIVE in Bruchsal, Germany. Regular maintenance and modernization work carried out by Aichelin Service play a key role in ensuring that the plant remains state-of-the-art and can be operated reliably and without interruption. As part of the scheduled annual maintenance, the KS98 temperature controller was successfully upgraded to an integrated SIEMENS S7-1200 PLC control system.
Initial Situation: Control System Requires Modernization
Thermocouples and O₂ probes in both chambers of the heat treatment system, as well as thermocouples in the oil bath, send signals to the KS98 temperature controller. Until now, the hardware-based controller handled key tasks related to temperature and carbon potential control.
Since the KS98 has meanwhile been discontinued and spare parts are becoming increasingly difficult to source, action was required. In addition, its limited integration capabilities with modern control systems, increased maintenance requirements, and growing risk of failure made long-term reliable plant operation more challenging. These factors clearly supported the decision to modernize the controller.
The Solution: Upgrade to a SIEMENS PLC with Integrated Software Controllers
For our customers, we have developed a future-proof and high-performance solution that replaces the existing KS98 controllers with modern SIEMENS PLC controllers featuring AICHELIN software branding. These advanced temperature controllers are based on standard components with integrated software control and communicate via Profinet. The controller is directly integrated into a standalone PLC, eliminating the need for additional hardware controllers. At the same time, the solution can be fully integrated into the existing system.
This provides several clear advantages:
High operational reliability through modern technology
Improved connectivity with modern systems
Intuitive operation through a standardized user interface
Easy and long-term availability of spare parts
Convenient foil offset adjustment via touch panel
With this modernization step, SEW Bruchsal is investing in safe and efficient control technology at the cutting edge of technology, thereby ensuring the long-term future viability of its heat treatment system.
We would also like to take this opportunity to thank SEW Bruchsal for their trust and many years of collaborative partnership.
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