United Process Controls (UPC) upgraded the system controls of two Surface Combustion batch IQ furnaces used by precision gear manufacturer United Gear & Assembly. The modernized HMI platform based on Protherm 600 controllers from UPC offers a new level of speed, accuracy and flexibility in creating and modifying carburizing recipes. Menu screens and programming are more user-friendly when it comes to finding data and making changes, and new recipe entries are easier to create, thus reducing setup time. Furnace I/Os and all process data coming back to the Protherm 600 are trended automatically, which helps pinpoint problems quickly and efficiently, saving operator hours and downtime.          

The enhanced controls also provide the United Gear & Assembly plant with the option to integrate UPC instrumentation with SCADA at a future expansion. Furthermore, with quenching functions embedded into the Protherm 600, the system achieves effective utilization of the quench cycle and eliminates standby power consumption, conserving energy and reducing utility costs. Hudson, Wis.-based United Gear & Assembly is an ISO/TS 16949-registered contract manufacturer of precision gears and shafts and is a strategic/core supplier to several global OEMs.