Heat Treat Furnace Controls-We Speak With the Expert
In our humble opinion “Mr. Bob Fincken”, Sales Manager for controls company “SSi” is one of the most knowledgeable individuals in the entire heat treat industry when it comes to furnace control. We are honored to be able to share his knowledge today in the form of this interview.“Bob Fincken” in our opinion is one of the most knowledgeable and experienced furnace controls individuals in the world- we consider ourselves lucky that he is giving us some of his time today to talk about a number of topics related to furnace controls. Bob lets start off with your background and how you ended up where you are today.
“My first job after college was at a Cincinnati based company assisting with the design of circuit boards for radar detectors. It was a good start but not as challenging as I wanted. I moved on, working for a very talented design engineer, Don Riemenschneider, (who also became an employee of SSi). We were both hired contractors for Cincinnati Steel Treating (CST) and I had the privilege of starting my career working with Dan McCurdy who was employed by CST at the time. I assisted in the design and build of a product called the Multicarb that controlled carbon potential in furnaces used in this industry-I knew nothing about “heat treating” at the time. Dan had a vision of automated process control using a microprocessor and software for data collection. I found this industry to be just the challenge I needed.
Furthering my career, I worked for Marathon Monitors under another pillar of the industry, Bill Thompson, then moved on to Eurotherm which allowed me to expand my skillset but remain focused on heat treating, the industry that I find so rewarding. I am currently working for SSi and have been a part of this organization for 20 years. The team I work with here resolves new challenges every day with a customer focus that is unmatched in the industry that I am proud to be a part of.”
In your long career in the heat treatment industry what would you say is the #1 new technology introduction when it comes to heat treat furnace atmosphere control?
“From my perspective I divide this into two categories, software and hardware.
Without a doubt depending on the process, you are charged with, sensor technology, including the carbon probe, hydrogen sensor, dew point sensor and infrared analyzer changed the industry.
Sensors allowed verification of a process, in general without the sensor technology, instrumentation would not have developed into what it is today. The second category would be software specifically used for data collection.
This could be charts, custom screens any Human/Machine Interface. The interaction with equipment and validation of process allows owners, managers and maintenance personnel to view and organize, plan and react to their specific job functions with a few mouse clicks. The two combined allow for individuals to run a furnace with minimal experience, that experience is so important in this industry, as well as others that are experiencing the loss of talent through retirement.”
What other innovations would you rank as “game changing”?
“Customers looking for information regarding asset utilization has also become more prominent. You can never have too much data in my opinion and this data allows for a different approach to running furnaces. Modern equipment allows for computer calculations based on furnace data that can be used for cost analysis. Systems can now offer the cost per load using metrics like gas usage from flowmeters, electricity usage also. Every electronic flowmeter we sell has the equivalent of a built-in odometer that can be reset through software.”
When you and I entered the industry computers and software were unheard of and remained that way for a number of years. When did software and the power of computers really start to make a difference in the industry and what was the difference?
“Computer based technology didn’t initially present itself as what we use today. The analog controls on a furnace didn’t allow for easy verification of process. Analog devices didn’t have the accuracy or legibility to allow for proof of process without a magnifying glass and a flashlight to determine which notch on a dial you were reading.
The introduction of digital controls allowed for large easy to read display of process variables and the ability to connect to computers for data acquisition. Storage of analog charts had to be in a dimly lit area to reduce fading. Typically, on a mezzanine someplace or a large trailer with rows of file cabinets. Two wire or four wire daisy chain communications were the technology of choice. A bit difficult to troubleshoot but reliable.”
Let’s switch gears from the past and look towards the present and the future. Are you seeing any game changing developments which would rival oxygen probes and computer control of furnaces?
“I am unsure if this is classified as a game changer but the software capabilities of the data acquisition systems have been evolving and providing more process capabilities.
For example, Gap reasons for furnaces, whether in production, down for maintenance or following AMS2750 criteria can be identified and offered in a pie chart for utilization.
Defining maintenance schedules, offering detail on gas or electric usage and cost per load can really be helpful to commercial heat treaters. Sharing database information on parts and load routing between two different systems eliminating double entry is also a vast improvement. Automated approval for every load meeting specific requirement in the recipe is also a feature that will help quality control and delivery of product.”
This question is really a follow up to the previous one about new technologies in the industry. SSi has come up with some new products for 2025 such as Load Entry 3, “SuperGen”, and Mass Flow meters-care to elaborate on what these new products will do for heat treaters?
“Load Entry assists with recipe management and tracking by providing a single, PC-based interface to control all activities for a heat treat facility.
Load Entry allows you to enter various operations, furnaces, recipes, parts, and users, but also enables you to “apply” these items to one another as required by your facility. This allows for easy tracking, management, and information retrieval, saving you time and money. We have videos on our website which will offer a quick description on the new software. Load Entry 3 https://youtu.be/_pgfB-ynGxQ
We have recently enhanced this software module adding Maintenance and Scheduling. These two modules allow scheduling of loads and maintenance including any pyrometry activities. What makes this software unique is the ability to remove a furnace from production. The system uses SuperDATAPro to communicate thus allowing for a software lockout of the furnace. https://youtu.be/MHzz8790XxE”
The “SuperGen” uses our VMix technology for endothermic generator demand control.
The product has been improved in both software and hardware from our previous model called AutoGen. https://supersystems.com/systems/generator/
The number one issue which all captive and commercial heat treaters bring up these days is the lack of good experienced people in the industry. I (and I am sure you also) hear this from heat treaters in Mexico, California, New York, Ontario pretty much everywhere that finding people is the biggest challenge there is these days. Do you feel that technology can solve this problem?
“Technology has the opportunity to reduce the burden. Sure, robots can load the furnace. Controls can guarantee the cycle runs correctly and data acquisition can provide proof of process. At the end of the day though the people in any organization are what makes the whole process effective.”
Bob you must have seen hundreds if not thousands of heat treats over the years and been involved in untold numbers of furnace projects. Which ones really stick out in your mind either for being extremely ambitious, a complete disaster or perfectly executed from beginning to end? If you can share names great, if not just an overview would work.
“I would like to stay positive here. There have been far too many projects where the controls have been outdated for years. Think about how often you change your PC for a newer model. Similar rules should apply to process controls. I can say that some of the projects have been very challenging due to some unknown factors that weren’t shared between the customer and our team until the project was started. We know now that specific questions need to be asked. For example, with a vacuum furnace, we will ask when was the last time this furnace passed a survey. Or for an atmosphere furnace, do you have any issues maintaining carbon potential.”
Is the furnace controls market a crowded one-in other words are there many capable firms competing for this business? Do you run across competition from non North American suppliers very often?
“The furnace controls market is competitive. Local suppliers, engineering firms, furnace OEM’s and the controls manufacturers themselves all compete for projects. Travel costs can be an integral part of the final price. I believe we have a reputation for customer service and the use of the latest proven technology. As with any company SSI is results driven and we have provided controls for simple and complex applications where a strong engineering and support staff makes the job flow through to completion without too many problems to overcome.
For our projects in the United States there have been very few foreign competitors. Sometimes if a furnace was manufactured overseas, they are invited into the bidding process for a retrofit. Across North America yes, we do sometimes run across foreign competitors due to the fact that each country has their own infrastructure in place and we are competing in their regions sometimes.”
You have often said that one of the biggest barometers of how busy the heat treat industry is, is by the number of oxygen probes being sold. What does this barometer or others tell you about the health of the industry as we come close to closing out 2025?
“As a manufacturer of oxygen probes we do have a unique way of estimating how many furnaces are in operation. Historically when the economy is struggling, we have the ability to evaluate the quantity of probes that are being rebuilt or purchased new.”
Bob I really appreciate your time, honesty and candor today-thank you, Gord.
“Gord thank you for the opportunity, I have worked with you for over 35 years in this industry and I continue to learn something new all the time. Our customers and my coworkers are what keep me involved in this industry. It is a pleasure to come to work everyday to provide solutions and interact with so many good people.”