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Industrial Automation

Data Loggers Controllers and Monitors Gateways (Wired & wireless) Power Management Systems, Controls and Supplies Utilities Monitoring and Automated Metering Machine Control Signal Conditioners & sensor integrator Motor drives & Power supplies. Industrial Automation. Handhelds

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Industrial Automation

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  1. Data Loggers Controllers and Monitors Gateways (Wired & wireless) Power Management Systems, Controls and Supplies Utilities Monitoring and Automated Metering Machine Control Signal Conditioners & sensor integrator Motor drives & Power supplies Industrial Automation Handhelds Energy, Oil and Gas Telecommunication, fixed and wireless Utilities & Infrastructure Automated Toll Payment System Global Positioning systems Variable Message Sign Boards Street Light Controller Intelligent Controls Access Control Time & Attendance terminals Biometric Solutions RFID solution –ISO 14443, ISO 15693 PIR based solutions Safety & Security Diagnostics equipment Infotainment Driver Assistance systems Biometric safety system Automotive www.riccooutsourcing.co.uk

  2. Case Studies Mass Flow Meters Within the oil and gas Industry, the accuracy and intelligence of each flow meter plays a major role. To compete with other key players in the market, the client needed an accurate and cost effective solution for its mass flow meter products line. The existing flow meter is developed with a custom firmware for which a royalty fee is being charged by the vendor. The other challenge for the client is to meet all intrinsic safety requirements of oil and gas industries they serve, which the existing products lack. • Multi-processor system having MCF5252 and ADSP2141L • Developed highly sophisticated application for critical signal analysis • Royalty free Real-time Linux ported on high frequency 32 – bit microcontroller • User friendly GUI based on QT (Graphical User Interface) for data logging and capturing • Application developed for high speed 16bit digital signal processor for real time signal analysis implemented Coriolis principal. • Iterative field analysis on rugged environment where the product would be used for the next 15 years • The mechanical enclosure designed meets all safety requirements to protect the electronics of the system. • An epoxy protective coating (material which is highly conductive to heat and insulator for electricity) is done for electronics inside the enclosure

  3. Case Studies Control Boards for Plasma Processing System The challenge was to take-up a new patented invention developed at University lab, and convert to an industrial grade product. • Multi-processor architecture, ARM Cortex M3 based microcontroller for the main control logics and a dedicated TMS320F280x series DSP for handling high precision signal generation algorithm. • RTOS based firmware, FreeRTOS running on ARM Cortex M3, and DSPBIOS ported in TMS320F280x. • 40x4 Alphanumeric LCD • 6 Relay outputs and 6 Digital inputs • Rotary switch with Enter, Back keys for user interaction.

  4. Case Studies Scanner System - Image Processing Due to patent expiry of an existing laser based scanning system, the client wanted to Design and develop an advanced system base on photogrammetry which accepts a 2D image with predefined targets and will give an output which is real world 3D coordinates (X, Y, and Z) of the target center points. • Intel based PC104 mother board • Pattern recognition algorithm. • Photogrammetric analysis to get the 3D coordinates from 2D image • Developed a camera calibration algorithm using the Direct Linear Transformation • Robust software developed for critical image capturing and Processing of the image and find 6DOF of targets within 250 ms. • Ethernet, USB 2. 0 and RS232 as the communication interfaces • Wi-Fi communication with server to transfer the identified target pattern. • Provided the Mechanical enclosure with a Rotating plate so the camera can capture images at different angles.

  5. Case Studies ZE09 Time and Attendance Terminal The client wanted to develop low cost alternative to expensive time and attendance terminals using RFID Technology. They also required to implement the 3G-UMTS technologies and Ethernet communication for data transfer with the server and the online firmware upgrade of the system. • Hardware designed and developed using ARM 9 Core Processor. • Wireless Technologies used - Low frequency RFID, 3G-UMTS, WiFi, GPS • Implementation of the 3G-UMTStechnologies and Ethernet communication for data transfer with the server • Equipped with various communication options like USB/Ethernet/GPRS-EDGE • Large Graphical LCD Display • Linux operating system is ported in the system. • Fingerprint sensor and RFID for the identity verification. • VGA Camera with LED Flash for the Picture Input • In terminal Data Base management. • BOM involved low cost component having a road map of next 10years.

  6. Case Studies Wireless based Biomedical & Food Monitoring application Wireless system used in Biomedical monitoring and Food monitoring application. It efficiently monitors and records a range of critical point data, including temperature, humidity, door status, goods receipt conditions and air quality, and provides effective reporting and visualization for ongoing management. • Hardware designed with i.Mx 25 processor from Free scale • Ported with Linux Operating system • Wireless communication at 868,900,902-928 MHz, Spread • Spectrum • Power over Ethernet interface • Data logging with SD card • Battery back up in case of the power failure • EMI/ EMC compliant design • Designed Front end application with • User-defined reports • Access levels and permissions • Flexible reporting intervals • Data export options • Language options • Different critical parameter sensors (with product simulant options) • Customisable alarm notifications (email, SMS, LED message boards, PC pop-up windows, flashing lights)

  7. Case Studies Smart metering System – Zigbee case study The Zigbee-based system created a self-forming, self-healing wireless mesh networks across neighborhoods and apartment complexes that link meters with utilities’ corporate offices. They can remotely monitor a residence’s electric, gas and water usage more efficiently with fewer errors and at lower costs, while improving customer service. • Hardware designed with MSP430F2274 from Texas Instruments • Meter Reading: Automatic Meter Reading and appointed meter reading  • Real time Clock (RTC) Working Minimum 2 years after power offMeter carrier capacity • Daily Frozen data storage • Save the succeed/failed meter reading time • Save data when power off • Digital Outputs • Password protection • PC based Front application for Collection Of Readings and Controls

  8. Case Studies Building Automation - Management System Energy monitoring and Management System. The system is based on wireless self healing networked topology and is capable for using existing power line as means of communication only in rare cases of wireless communication path failure. As a standalone solution (with out power line back-up) the wireless only Network system shall be ensured for at least distance coverage of 200 meters with 150 nodes. • Hardware designed with Power PC • Remote and touch screen based User interface. • Intercommunication with the different devices implemented • System Had following Interfaces • RF based Remote Interface • Burger Alarm • Motion Sensor • Dimmer unit Interface • Skirting Light • IR Interface • User-friendly GUI Interface

  9. Case Studies Data Logger Front end application The system represents the latest in low cost data-logging technology. It can be used as an independent monitor to log the conditions second by second in any controlled or uncontrolled environment. • Set the real time clock • Define the engineering units of each input and calibrate them. • Set alarm set-points, hysteresis (dead-band) and time delay for the two alarm points of each input. • Link any of the inputs to act as the set-point of another input so you can adjust a set-point from other equipment • Tabulate the results of the monitoring. This reporting feature allows you to select a time and date range for the report and select how many points you wish to report in that time period. The data is then averaged out but the maximum and minimum are still retained. • The software also allows you to export the data to Excel in CSV format so you can utilise the full power of Excel to display the data

  10. Case Study Battery Analyzer Customer is a leading provider of professional electric power tool equipments., markets a broad range of world-class power tools and batteries. Any product based entity has major concerns on the product warranty system. The warranty is one of the key criteria for the company profitability and product success in the current market scenario. To manage the warranty system of the products there was a need to come out with a requirement where the manufactures can evaluate their product’s warranty period; this warranty management system enhances the company’s profitability and better service to their customer. • Complete design and development of software , hardware and mechanical • Hardware Designed with MSP430F149 from Texas Instruments. • Robust firmware to read the data from the batteries to calculate the warranty terms • Key challenge of designing a system to with stand 2 meter drop test and the rugged product usage environment • Complete production of the system (2K quantity) with activities including user manual, manufacture, assembly, validation of units on assembly line, box packaging and shipment to customer location.

  11. Case Study Data Logger The system is a rugged, user-friendly, low cost data logger Use it to precisely monitor, alarm and permanently log up to 6 different inputs second by second onto an SD memory card. • Complete design and development of software and Hardware • Hardware Designed with PIC 18ZF47J53 from Microchip. • SD card Interface for data Storage • USB interface For external Interface • LED indicators • 6 analogue inputs each catering for:- • Current: 0-20mA, 4-20mA, 0-10mA • Voltage: 0-10V, 0-5V, 1-5V, 0-1V and • 10K NTC thermistors over the range of –50oC to +100oC • PC Based application for data retrieval and settings Update • EMI / EMC Compliance • Complete production of the system (8K quantity) with activities including user manual, manufacture, assembly, validation of units on assembly line, box packaging and shipment to customer location.

  12. Mechanical Capabilities Design ofBeacon Lamp Product Range • Over 35 plastic components of which 8 metering optical standards • Interchangeable modular configuration • Range of 8 different products • Designed for UN 65 regulations Enclosure Design for Energy Meter • Unique safety features and tamper proofing • Designed for IP54 standards • Applying for patents for unique hinge and locking mechanisms

  13. Software • ProE Wildfire • Solid Works • Auto Cad • Any Customer Specific Software in CAD/CAM Capabilities • Complete Solution in Product Design from Voice of Customer to Prototyping and Mass Production • Legacy/Data Conversion – 2D to 3D and Vice Versa • Stress – Strain Analysis/Thermal Analysis/Value Engineering • Manufacturing, Prototyping and Tooling Design Solutions Engineering Services • 2D to 3D Conversion of 5000 Sheet Metal Components • Completed in a Record Span of 3 Months • Quality Output with Less Than 0.05% Rejection Design of Sheet Metal Cabinet for Process Industries Design of Switches, Contactors, Relays, Fan, Heat Sink and other Components Cabinet Design Front Panel Design with Ventilation Placement of Components based on the Analysis of Airflow / Ventilation Wire Harnessing

  14. Additional Projects OEMPRODUCTS Weld Current Analyzers Intelligent P u m p s y s t e m Mass Flow Metering System Low Noise Amplifies Battery Charge Analyzer I/OCONTROLS PCI CARD WITH 32 OPTICALLY ISOLATED DIGITAL I/OS Wireless gateway Quad Channel CAN ProPMC Board PC/104 MULTIFUNCTIONAL I/O BOARD

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