The majority of our projects are covered by Non-Disclosure Agreements.

The buttons on the left will take you to more details descriptions of a couple of recent projects.

The following list describes some of our recent unprotected projects.

Key Monitor System

www.keymonitorsystems.com

The Key Monitor System has been a major project over the last 2 years.  The key monitor system is a tracking system for keys.  We have produces the electronic designs, PCB designs, and programming for this project.

The Key Monitor System uses a touch panel computer to allow a user to enter their UserID and password.  The user can then access keys in the key rack.  The keys "slugs" are inserted into the key locks in the panel, and can only be removed when released by the control computer.



User access is controlled by time and date rules which govern key movements.  Each user can have different security levels, and access to different keys.  The system includes its own backup power supply, so it can operate without power for some time.

Alarms monitor key availability are are triggered by keys be out at the wrong times, or in at the wrong times, or out for too long.  The system can be interfaced to an alarm system, and includes its own siren. 

Key security levels are adjustable.  Some keys need a password to be accessed, some keys need two users to authorise their use.  The system can tell a user who currently has a key, and when they got it.  Key slugs are unmarked, nickel plated metal slugs

All activity is logged on the system, and remotely through a network to a logging server. 

The Key Monitor Sytem can control one to four panels of keys.  Each panel can be 18 or 54 keys.





The next development will be to allow a network of Key Monitor Systems to be coordinated, so that keys can be returned to any Key Monitor System, and located accross the network.

Automated Electical Test System

A transformer manufacturer approached us to assist with an upgrade to their test bay processes and record keeping.

We analysed their equipment and requirements and developed a specification for an automated system.  The system uses standard PCs to control electronic measuring instruments, record the measurements, calculate results, and decide on a pass/fail result.

Specification revisions can be handled.  An interface to the MRP system assists with data entry.  Results are centrally stored, and can be queried and analysed for production monitoring.  The system was designed to suit the clients processes.



This project involved:

• process analysis
• testing existing capabilities
• feasibility testing solutions
• database and software design
• PC programming

Plastic Sheet Punch

A plastics manufacturer required a machine to punch sheet plastic as part of a larger production process.

The machine takes a 1200mm x 8000mm sheet of 1.5mm plastic sheet. The sheet is grabbed by pneumatic clamps, and pulled through a hydraulic punch tool. The punch tool punches out 180 small holes in a pattern. Then sheet is then pulled a measured distance through the punch tool and punched again. This process is repeated until the end of the sheet is reached. The sheet is then pulled completely through the punch tool and dropped onto an outfeed table. The punch pattern spacing, punch count and sheet length is adjustable via a control interface.

This project involved:

• Design of system wiring and control interfaces
• Selection of sensors and actuators
• Drive programming to handle movement, pneumatic and hydraulic controls
• HMI programming to handle adjustment requirements
• System testing and commissioning

Automatic Plastic Thermal Welder

An existing automatic weld system had become unreliable and difficult to maintain.

The system “holds” two halves of a plastic assembly, then presses the halves against a heater, then removes the heater, and presses the two halves together until they fuse. The two parts must be held using vacuums in machined grippers. They must then be heated to the correct temperature, while being pressed against the heater with the correct force. They must then be removed from the heater (which now has a vacuum seal to the parts). They must then be pressed together before they cool down, and held together with the correct pressure, until they cool down.

This project involved:

• Analysis of existing pneumatic vacuum systems and positional systems
• Analysis of heating and welding requirements
• Measurement of heating and welding performance
• Modifications to pneumatic circuits and systems
• Reprogramming of control unit to provide status indications and improved operation

Radio Modems

A client had an existing data system using low speed, long range radio modules. He wanted to increase the data link speed, while retaining the existing radio modules.

The existing radio link operated at long range (5km) but low speed (100 bytes per second, simplex communication, point-to-point). We developed an improved data encoding system, and designed an improved communications protocol and radio interface module that allowed the radio link speed to increase significantly (800 bytes per second, duplex communication, star topology).

This project involved:

• Development of data link quality test protocols and systems
• Development and testing of new data encoding system
• Development of new communications protocol
• Design of new radio interface hardware
• Programming of embedded processors in interface hardware
• Programming of embedded processors in network control hardware
• Programming of PC software to connect to network controller
• Programming embedded software in node connection hardware

Automatic Chemical Analysis System

A client had a prototype analysis system that they wanted to put into production. I was asked to review the electrical and process design details of the prototype.

The prototype demonstrated the chemical process, but did not meet the client’s production unit requirements. The design was then fully reviewed and a further development phase commenced in order to achieve the client’s production unit performance requirements.

The system receives a material sample then adds a measured quantity of acid to the sample. The solution is then boiled, and nitrogen gas is used to blow the vapour through a condenser. The remaining gas then passes through a gas analyzer and reagent solution to neutralize the gas.

The user interface and chemistry unit were broken into two separate units, connected by a data link.

An embedded processor is used to monitor acid, gas and water supplies, and monitor hotplate temperatures, gas pressures, and gas compositions, and control acid pumps, gas valves, water pumps, and heaters. The test unit was enlarged to allow two simultaneous tests to be performed.

A Pocket PC was used for the user interface. This provided a rich graphical user interface, with detailed control and monitoring capabilites. System testing, chemical testing, and reporting are all possible from the user interface. The chemistry unit provides all the control and monitoring processing, while the results calculation, recording and reporting is done in the user interface.

This project involved:

• Design Review and Performance Testing
• Process testing and validation
• Design of improved control hardware
• Design of custom heating elements
• Development of a custom communication protocol
• Programming embedded processor to provide automatic control with safety interlocks
• Programming of Pocket PC with system testing and operation software
• Developing user interface and operation philosophy
• Development of graphical results presentation system