The “Basys4Brenner” project, funded by the German Federal Ministry of Education and Research under grant 01IS21016, ran from 1 April 2021 to 31 July 2023 and was carried out by the Institute of Information and Automation Systems for Process and Materials Technology (IAT) and the Institute of Industrial Furnace Construction and Heat Technology (IOB) at RWTH Aachen University together with Hermann Zander GmbH & Co. KG and Hans Hennig GmbH. The aim was to develop a certifiable, Industry 4.0‑ready furnace control system based on the BaSys concepts of Asset Administration Shells (VWS) and Process Control Components (PFK). The project was structured into seven work packages: analysis of requirements and norms, creation of a Minimum Working Example (MWE), concept design and specification, hardware development, software development, prototype development, and evaluation and generalisation. In the MWE phase a 100 kW natural‑gas cold‑air burner was instrumented with a safety‑rated ignition electrode and flame monitoring. The system was tested on a Revolution Pi development board and at the IOB technical training facility, with safety scenarios executed in accordance with DIN EN 746‑2 and DIN EN 298. The MWE demonstrated that the BaSys VWS could be used to model the entire control architecture, providing a higher abstraction level and standardised self‑description of variables and functions. The final prototype incorporated redundant control logic, requiring two controllers to capture all inputs and agree on the same decision, thereby meeting safety‑critical requirements. Live data exchange was implemented via the open‑source open62541 OPC‑UA library, enabling real‑time monitoring and diagnostics. The prototype was validated on an industrial burner at Hans Hennig and at the IOB facility, confirming compliance with all relevant safety standards and demonstrating readiness for certification. The project also highlighted the integration of BaSys VWS and PFK for safety‑critical components, showing that the system can serve as a foundation for future services such as monitoring, diagnostics, availability analysis, predictive maintenance, and advanced optimisation tools using AI or machine learning. Supply‑chain disruptions caused by the COVID‑19 pandemic and the Ukraine war delayed hardware procurement, leading to a four‑month extension of the project timeline. Despite these challenges, the final device—comprising hardware, software, and BaSys‑relevant interfaces—offers a versatile platform for industrial furnace operators to achieve digitalisation, service‑orientation, and compliance with Industry 4.0 standards. The authors of the report—Ramy Hana, Shagufta, Dr.-Ing. Torben Miny, Lukas Sankowski, Benedikt Schmetz, and Thorsten Günther—present the technical outcomes and the collaborative framework that enabled the successful development of this innovative, certifiable furnace control system.
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