Software solutions

In the process industry, a huge amount of information is usually available in various IT and OT systems. The availability of favourable storage solutions leads to an extensive range of data that must be interpreted by plant operators and process experts. New measuring systems are also available, the information from which must be processed and visualised for the user.

Using the latest development tools, BFI develops customised software solutions that integrate harmoniously into the IT and OT environment of the plants. Depending on customer specifications, individual requirements are implemented as a stand-alone solution or as a web service in the plant's network.

The BFI also offers some turnkey solutions that only need to be adapted to the existing data interfaces of the plants. Some examples are listed in the following sections.

BFI HR server

The use of modern measuring systems in the production of flat steel products means that high-resolution (HR) data is increasingly being generated along the entire process chain. This data is stored in plant-wide quality databases that are optimised for strip-by-strip access.

However, it is not enough to look at individual belts to uncover systematic problems in production. A superimposed analysis of many coils enables a much faster and more precise search for possible causes of errors.

If there are also several process steps between the actual measurement of the quality variable (e.g. surface defects) and the system causing the defect, the quality data must first be ‘rewound’ virtually through production in order to be able to compare it with the system data. This step cannot be implemented efficiently with existing data models.

BFI HR server: Simultaneous storage across all process stages

Our solution:

The BFI has developed a new concept for processing large volumes of data based on a multi-scale data model across all process stages. It provides easy and fast access to HR data and enables the in-situ aggregation of millions of quality and process data within seconds. While detailed analyses of HR data previously often took weeks, the new concept is able to generate precise results across thousands of coils within seconds.

This refinement of the database opens up a new dimension for quality data assessment, as it enables immediate and interactive HR data analysis as soon as a quality issue arises.

Please find below detailed information about the BFI HR server:

Introduction BFI HR server

BFI SEP-1670

In addition to DIN EN 10045-1, the “Stahl-Eisen-Prüfblatt” SEP 1670 describes the determination of the FATT (Fracture Appearance Transition Temperature) and explains the evaluation of the results. The SEP-1670 applies to forged steels in particular in accordance with SEW 555 and is intended to contribute to the standardisation of test evaluation. Application to other product groups is permitted. The methodology for FATT calculation developed at the VDEh Steel Institute allows a significant reduction in the scatter of FATT values compared to previous methods.

BFI SEP-1670: Illustration of the equalisation curve

Our solution:

In order to ensure a globally comparable evaluation of the notched bar impact energy values, the VDEh-Betriebsforschungsinstitut (BFI) has developed the BFI SEP-1670 software, which reproducibly determines the relevant characteristic values FATT and additionally ETT and MET from the results of the notched bar impact tests and the determination of the brittle fracture fraction in accordance with the specifications of SEP 1670. The BFI SEP 1670 software is implemented as a multi-user version that can be used on up to five computers with one licence. The user interface is bilingual (German/English) and the metric and US unit systems are supported.

Please find below detailed informationen about the software:

user manual

BFI DataProSIS

Optical surface inspection systems (OIS) are used at various points in the process chain to ensure that surface quality meets customer requirements. These systems offered by various manufacturers inspect the products seamlessly and, in addition to images of detected defects, provide a list of the detected and classified defects with their coordinates. This presents the following challenges:

  • OIS can produce enormous amounts of data.
  • The reliability of OIS results is not automatically verifiable.
  • An OIS is not a measuring system.
  • The OIS results are not comparable as they are usually trained individually.
DataProSIS: Plausibility check of OIS data

Our solution:

The BFI DataProSIS software supports those responsible in interpreting the numerous OIS by applying standardised rules to the original OIS data and transferring it to a standardised, manufacturer-independent database. DataProSIS improves the usability of the OIS data by incorporating expert knowledge, integrating plausibility rules, aggregating individual defects, and concentrating relevant information. This significantly increases the quality of the classification decision.

BFI-SMO

A significant contribution to the circular economy in steel production is the use of steel scrap as a feedstock. Targeted use of the various types of scrap requires knowledge of their properties, which vary greatly, and determination of the cost-optimised scrap mix for the steel grades to be produced.     

BFI-CMO: Scrap mix characterisation

Our solution:

To characterise the variable properties of steel scrap, the BFI has developed the web-based software BFI-SMO, which uses statistical calculations to determine the metallic yield, composition and melting energy requirements of the various scrap types based on the process data generally available and to track their development over time. A cost and quality-based optimisation of the scrap mix then always uses the current results of the scrap characterisation.  The software tool also supports the evaluation and quality monitoring of the scrap delivered to the steelworks.

BFI-SMO is a web-based software that can be used both for scrap characterisation studies and for on-line scrap mix optimisation. The process and quality data as well as restrictions for scrap mix optimisation can be read in via database interfaces.