Automated Galvanization Pipeline
Flaro Flagav · Process control and monitoring
TL;DR
Nerds designed, developed and deployed the complete automation solution for Flaro Flagav’s galvanization line. It coordinates two cranes across the treatment stations, applies product-specific process profiles and gives operators a view of the line’s progress.
Context & challenge
The existing line had 20 treatment stations and two cranes sharing a rail. The client needed to coordinate crane movements and treatment times for different products, while retaining visibility and manual control when needed.
Our role
We delivered the automation project from design through development and deployment. Our work covered the control software, integration with the existing equipment and sensors, and the PC interface used to configure and monitor the process.
Solution & delivery
The system connects equipment control with a configuration and monitoring application, so operators can manage product profiles and follow the treatment sequence.
- Process profiles. Configurable profiles define the treatment sequence and dwell times for each product type.
- Crane coordination. The control software coordinates movements using sensor inputs and collision-avoidance logic for the shared rail.
- Operator control. The PC panel shows the current state and remaining process time, with automatic and manual operating modes.
Results
The existing line gained automated process control and a shared interface for configuration and monitoring. Operators can run predefined treatment profiles, follow progress and switch to manual control when required.
Client feedback
“I will highly recommend this team for other embedded projects. Based on this collaboration, we implemented an automated control logic for our galvanization process.”
Related services
Our Manufacturing Engineering Solutions cover equipment integration and process monitoring. Through Custom Software Engineering, we develop industrial and embedded software that connects applications to equipment.
For applications supporting a production line, explore our backend systems and integration and web development services.