Manufacturing Process Automation

Andon System

To provide a complete integrated solution for eliminating the major wastage in production shop like stoppage of work through an LED display with a SBC (Single board computer) Kit. The total turnkey solution for the above problem herein will be called as SFVDS (Shop Floor Visual Display System).

System Specification:

  • DIU (Digital Interface Unit) can take Press buttons as an input
  • DIU can control the total LED display
  • DAU (Data acquisition) is capable of 24 hours continuous data logging
  • DIU is communicating with DAU through wireless LAN
  • LED data display modification through DAU
  • The top LED’S is revolving type with red, green and yellow filament
  • The top LED’S have the characteristic nature of revolving and flashing
  • The bottom LED’S have Red filaments
  • Analysis and display software
  • The DIU have the capability of getting the assembly line o/p as one of the inputs for LED data display

Implementation:

Symmetric provides a total Turnkey solution for eliminating the major waste in production shop through an LED display with analysis software which suites the user application. Above block diagram shows the implementation of the Andon display.

Function:

Our Andon system takes press button bars as an input for each work spot namely 12 work lines from the respective DIU’s as shown in the figure. The DAU is a central controller and acquisition system which accepts the data from all twelve DIU’s and will be logged in to the built-in disk with time stamps and data which can be retrieved in excel or flat file and it also available through wireless LAN for redundancy and can be analyzed from remote place.

All twelve DIU’s would be communicating to central DAU through wireless LAN. The DIU will have the facility of 2 lines LCD with button bars, which facilitates the user to give the assembly line output data, which can be viewed in DAU.

Features:

  • DAS unit capable of taking 12 channels inputs from respective DIU’s through wireless LAN
  • Simultaneous all 12 channels 24 hours Data Logging
  • Full-featured user analyzable developed software for logging the data
  • Acquired data viewable in a spreadsheet (Excel) or Flat file
  • Provision for user to give the Assembly line output
  • Analysis software
  • 1. Data controller for LED display

    2. Data entering flexibility for take, plan for center LED display

    3. Formula modification facilities for plan

    4. Data monitoring facilities of 12 different stations with time stamps

    5. Report generation facilities

    6. WLAN connectivity checking

Brief Functionalities of each Subunit with Block Diagram:

    The SYM-ANDON implementation includes following main subunits.

    a) DIU [Data Interface Unit]

    b) DAU [Data Acquisition Unit]

    c) Software

DIU [Data Interface Unit]

DIU is an Industrial [Data interface] Unit which includes Embedded Controller, 5 Press buttons, with an optional LCD display. The Embedded Controller is the core unit of the DIU and 4 press button bars to make the top LED’s glow, 1 press button bar to give the assembly line output as one of the inputs to microcontroller.

Embedded Controller: Embedded Controller will have press button bars for taking inputs and it communicates with central DAU via wireless LAN.

Embedded Controller takes the input from press button bar unit through discrete I/O and sends it to DAU through WLAN. DAU is a main control unit, which controls and communicates with the DIU. DIU has the intelligence that, it provides some minimum controls to user through soft keys. Those are a) DIU Powering On/Off, b) Start new process, c) End Process.

Press Button Bars: There will be a total of 5 button bars. Four button bars will be acting as a indirect controller for top LED’s i.e. for making it ON, flash and revolve.

  • Button 1: For Red LED
  • Button-2: For yellow LED
  • Button-3: For green LED
  • Button-4: For acknowledgement

LCD display is to display the current status.[optional] There would be 12 DIU’s and all would be connected to single DAU as a remote central server

DAU [Data Acquisition Unit]

DAU is a central control and acquisition embedded Industrial Unit. It can handle up to 31 DIU’s connected. DAU consist of Acquisition, Storage and Analysis. All 12 DIU’s would be communicating through WLAN. This controls all DIU operations and collects the acquired data and logs it to local storage. It provides analysis features like real time analysis customized to user application.

Software:

Customized developed software would run on DAU, which is customized to dedicated customer application. The software would have following features.

  • Analysis, logger facility (excel or flat file format) identified with INSERT ID
  • Analysis Software
  • 1. Data controller for centre LED display

    2. Data entering flexibility for take, plan for centre LED display

    3. Formula modification facilities for plan

    4. Data monitoring facilities of 12 different stations with time stamps

    5. Report generation facilities

    6. WLAN connectivity checking

  • Absolute and relative time recording facility
  • Channel configuration
  • DIU settings
  • Logger setup

Wireless DAS

We are pleased to provide the brief information on the comprehensive solutions for High end wireless Data Acquisition Systems and provided through our exclusive Technology and authorized System Integrators, Offshore Developers and Custom Engineering Centre. Symmetric has provided solutions for Structural Health Monitoring, Ground Vibration Monitoring, Environmental Monitoring, Radar Antenna Monitoring etc to name a few. We welcome your attention and look forward to talk to you on your specific requirements.

Applications of Industrial Internet of Things (IIoT)

WIFI technology was extremely energy greedy and unreliable. Users working on Structural Health Monitoring (SHM) and condition monitoring were more favourable to deploy proprietary wireless IIOT sensors offering a better reliability and a low power operation. wireless IIOT sensors, our research and development team worked intensively with our customers to bring Wifi Low Power technology, a new generation of WIFI IIOT sensors (vibration, inclination, Strain and shock) which is reliable, ultra-low power, open-standard and adapted to dynamic data acquisition.

Applications Area

Structural Health Monitoring

  • Structural Health Monitoring on Bridge
  • Vibration Monitoring
  • Tilt Monitoring

Ground Vibration Monitoring

Environmental Monitoring

  • Technical Building Management
  • Cold chain traceability
  • Medical lab & white room
  • Transport

Radar Antenna Monitoring

Test and Measurement

  • Automotive
  • Railway
  • Aeronautic
  • Naval equipment

Wireless IIOT Sensors

Structural Health Monitoring

Structural Health Monitoring (SHM) aims to give, at every moment during the life of a structure, a diagnosis of the ―state‖ of the constituent materials, of the different parts, and of the full assembly of these parts constituting the structure as a whole. Structural Health Monitoring combines a variety of sensing technologies with an embedded measurement controller to capture, log, and analyse real-time data. SHM systems are designed to reliably monitor and test the health and performance of structures such as

  • Bridges and dams
  • Buildings and stadiums
  • Vessels and platforms
  • Airframes
  • Wind turbines

Structural Health Monitoring on Bridge

During its long service life, a bridge would be subject to aging processes, harsh environmental conditions and excessive loads, leading to deterioration. Consequences of impaired physical condition can be as severe as the collapse of the structure, causing great financial loss or even casualties, Thus, it is important to have updated information on structural condition and performance of bridges in order to early detect any worrying signs of decline and undertake protective countermeasures. Symmetric provides a Wireless Sensor Network solution suitable for bridge monitoring enabling Engineering practices to monitor assets remotely without the need for costly site visits. It has also the advantage of daily data, whereas traditionally this data was collected weekly or monthly, using physical site visits.

Vibration Monitoring

The Ultra-Low-Power WIFI accelerometer with built-in data logger.

This device comes with two measurement range (±2g and ±10g) and provides a maximum sampling rate of 2 KHz.

It’s very low noise (45 µg/√Hz for the ±2g version), this device is suitable for ground vibration on construction site.

Vibration waveform, frequency spectrum (FFT) and Velocity are displayed in real-time on our monitoring software.

The innovative measurement mode Streaming with event-trigger (S.E.T.) allows to record vibration when a trigger threshold level is reached.

Tilt Monitoring

The Ultra-Low-Power WIFI inclinometer for tilt/inclination measurement.

This device comes with two measurement range (±15° and 30°) and offers a great level of accuracy of ±0.05° (±0.02° on customer request).

This device is suitable for land surveying and bridge monitoring, user can setup alarms by email (from our Wilow®) when a threshold level is reached.

Wireless sensor network on a 3 or 4 spans bridge? No worry, you can easily extend your wireless range by deploying a multi-hop wireless network.

Product line is compatible with WIFI Bridge/Repeater, user can connect up to 7 WIFI Repeater/Bridge with a wireless range up to 2km between each WIFI Repeater/Bridge.

Remote Access

IOT (Internet of things) applications, WiLow® devices integrates MQTT (Message Queuing Telemetry Transport) data frame, a lightweight and open-source Internet of Things protocol. can quickly setup an affordable and scalable IOT application.

Ground Vibration Monitoring

Wireless accelerometer

Construction and industrial dynamic sources can produce environmental vibration problems for adjacent and remote structures. High vibrations and unacceptable dynamic settlements could disturb sensitive devices and people and even be the cause of structural damage. The dynamic sources, the geology at a site, and the condition of structures affect ground and structure vibrations. Each construction or industrial site is unique and requires consideration of specific approaches at the site for decreasing vibration effects of construction activities or industrial dynamic sources on surrounding structures. Monitoring and control of ground and structural vibrations provide the rational to select measures for prevention or mitigation of vibration problems.

Vibration sensor

Available in two versions (measurement range: ±2g or ±10g), the 2.4GHz wireless vibration sensor with built-in data logger. Water proof (IP67/Nema 6) and a lightweight aluminum casing (80x55x21mm, 155g), an ultra-low power,.2.4GHz integrates an innovative antenna diversity design, boosting the radio link quality in environments subject to random and diverse disturbances. Antenna Diversity improves both the quality and reliability of a wireless link by 30.

Features:

  • Wireless tri-axial vibration sensor based on MEMS Technology
  • Real-Time FFT and Velocity display
  • Measurement range: ± 2g or ± 10g
  • Very Low Noise Density: 45 μg/√Hz (± 2g version), 100 μg/√Hz (± 10g version)
  • Maximum sampling rate: 3 KSPS (if 1 channel enabled)
  • Anti-aliasing Butterworth filter (5th order) with a programmable cut-off frequency 1 Hz to 2 KH
  • Integrated Lithium-Polymer rechargeable battery with industrial battery charger (8-28VDC)
  • Waterproof (IP67 | Nema 6) aluminum casing (dimensions Lxlxh: 80x55x21 mm—weight 155g)
  • Tim Sync function: Time-synchronization over the Wireless Sensor Networks with an accuracy of ±2.5 ms

Applications:

  • Ground vibration Monitoring on construction site
  • Dynamic measurement on rolling stock
  • Condition monitoring
  • Structural Health Monitoring (SHM)
  • Vibration analysis

Environmental Monitoring

The awareness regarding the environment is fully integrated within the R&D policy and experience in engineering highly performant and ecological products and offers highly sustainable products.

Ultra-low consumption principles, products will help you lowering your technician intervention cycles and therefore you will spare time and energy by avoiding changing or charging the batteries.

A wireless system entirely dedicated to environmental monitoring

  • Ground humidity measurement sensor: measure the water quality inside the ground and optimize your irrigation system.
  • Hydrologic sensors: These sensors allow the measurement of water level, rate of flow, temperature and oxygen level.
  • Meteorological & agro-meteorological sensors: these sensors are used for climate analysis, meteorology. They can measure variables such as air temperature, atmospheric pressure, humidity, CO2, wind speed, moderate weather sunshine …

Temperature data logger

Wireless temperature data logger providing a storage capacity of 1 million data points. to a small (119x35x35mm) and waterproof (IP67 |Nema 6) casing and a wireless range of 300 meters and ultra-low power wireless technology up to 7-year battery life.

Features:

  • Wireless temperature sensor with built-in data logger
  • Ultra-Power and license-free 2.4 GHz radio technology (IEEE 802.15.4E)
  • Maximum wireless range: 300 m (L.O.S)
  • High accuracy temperature sensor:
  • - 50°C to +150°C (standard accuracy)
  • - 10°c to +60°C (high accuracy)
  • Embedded data logger: up to 1 million data points
  • Waterproof IP67 polycarbonate enclosure
  • Weight: 120g, Size (Lxlxh): 119x35x35mm

Applications:

  • Technical Building Management
  • Cold chain traceability
  • Medical lab & white room
  • Environmental Monitoring
  • Transport

Test and Measurement

Solutions for rolling stock, naval and aeronautic manufacture in terms of test and measurement,

  • Automotive: Tests on raceway and dirt track, wind tunnel testing, laboratory test benching
  • Railway: Vibration monitoring on train wheels, automatic fault detection on sensitive device and systems
  • Aeronautic: Comfort measurement, flight test measurement, Health and usage monitoring system
  • Naval equipment: Tracking, monitoring, surveillance, underwater test benching, engine room monitoring
  • Dynamic measurement with our wireless technology:
  • Shock Measurement (SSD– Smart Shock Detection—Technology)
  • Tilt measurement
  • Vibration Measurement

Smart Sensor Range Main Applications

1. Wireless accelerometer sensor | shock and impact monitoring | built-in datalogger

Features:

  • Wireless Triaxial accelerometer dedicated to shock measurement
  • Ultra-Power and license-free 2.4 GHz radio technology (IEEE 802.15.4E)
  • Maximum Radio Range: 500 m (L.O.S)
  • Excellent radio link budget thanks to our antenna diversity innovative design
  • Scalable measurement range: ±6g/±12g/±24g or ±2g/±4g/±8g
  • SSD (Smart Shock Detection), the device wakes up on shock detection
  • Maximum sampling rate: 3 KSPS (if 1 channel enabled)
  • Non-contact actuation for faster and safer installation
  • Current consumption in sleep mode: < 15 uA @3.3V
  • Embedded Data Logger: up to 1 million data points (with events dating)
  • Integrated Lithium-Polymer rechargeable battery with industrial battery charger (8-28VDC)
  • Waterproof (IP67 | Nema 6) aluminum casing (dimensions Lxlxh: 80x55x21 mm—weight 155g)

2. Wireless inclinometer sensor | tilt/inclination/slope monitoring

Features:

  • Wireless inclinometer based on MEMS technology with a high accuracy
  • Ultra-Power and license-free 2.4 GHz radio technology (IEEE 802.15.4E)
  • Maximum Radio Range: 500 m (L.O.S)
  • Excellent radio link budget thanks to our antenna diversity innovative design
  • Measurement range: ±15° or ±30° mono-axial and bi-axial
  • MEMS Inclinometer with a high resolution 0.001° and a very high accuracy (±0.057° for the version ±15°)
  • Maximum sampling rate: 60 samples per second
  • Non-contact actuation for faster and safer installation
  • Current consumption in sleep mode: < 35 uA @3.3V
  • Embedded Data Logger: up to 1 million data points (with events dating)
  • Integrated Lithium-Polymer rechargeable battery with industrial battery charger (8-28VDC)
  • Waterproof (IP67|Nema 6) aluminum casing (dimensions Lxlxh: 100x60x31 mm—weight 217 g) with a rugged base plate and three-point-mounting
  • TimSync function: Time-synchronization over the Wireless Sensor Networks with an accuracy of ±2.5 ms

Real time Case Studys

1. Flight Test Measurement & Vehicle Test Bench

The (wireless tiltmeter) for pitch and roll measurement on a commercial airplane during flight testing. This device is very easy to deploy (no cable), lightweight (145g) and comes with a high accuracy (±0.05°) . The wireless range inside a plane is between 35 to 50 meters. Our wireless sensor network is based on IEEE 802.15.4 standard, ensuring a reliable co-existence with other wireless networks at 2.4 GHz.

Wireless sensors proved to be a great alternative to wired sensors when flexible and lightweight sensors are required. Our wireless sensors provide a high long-term stability and a low temperature-drift. The customer decided to use other devices for vibration monitoring and shock detection.

2. Vehicle brake system testing

The AN-420 is specialised in vehicle test benching (automobile, heavy trucks, industrial vehicles, agricultural vehicles), have joined their knowledge in an effort to offer an innovative solution which will change the way vehicles will undergo testing in the future.

The concept of «Plug & Drive» laboratory vehicle pushs backs the limits in terms of testbed vehicle instrumentation by integrating wireless technology.

Wireless data logger, the AN-420 were coupled with a pressure sensor, allowing validate the ABS (Anti-lock braking system) & ESP (Electronic Stability Program) on a vehicle.

All measurements are recorded and stored on the AN-420. Each measurement is time stamped and Geotagged in real time within a 1Hz bandwidth. It is therefore possible to efficiently analyse the behaviour of a vehicle and geolocate it when an alarm is being issued.

Software and Accessories

Real time measurement monitoring

All measurements are recorded and stored. Each measurement is time stamped and Geotagged in real time within a 1Hz bandwidth. It is therefore possible to efficiently analyse the behaviour of a vehicle and geolocate it when an alarm is being issued.

The real time WSN supervision and control monitor. to monitor and operate in real time WSN.

Features:

  • Supervision software fully dedicated to Wireless Sensor Networks
  • Fully integrated Wireless Sensor Networks maintenance tool
  • Easy integration to a third-party supervision software thanks to our OPC server
  • User friendly and highly adaptable to user’s environment
  • Highly intuitive and easy to use GUI (Graphical User Interface)
  • Real time integrated database
  • For user working on building and ground vibration provides advanced vibration analysis tools:
  • Real-Time vibration and Velocity display
  • Advanced vibration analysis tool: FFT, PPV (Peak Particle Velocity), Velocity
  • Automatic FFT (with PPV values) and Velocity reports (meeting the DIN4150-3 standard)
  • Alarm and reports notifications by email when a trigger is reached
  • Simultaneous Multi-WSN handling (can be connected to several Gateways)
  • Customizable data panel board

DIN4150-3 specifies a method of measuring and evaluating the effects of vibration on structures designed primarily for static loading. It applies to structures which do not need to be designed to specific standards or codes of practice as regards dynamic loading.

The report is generated with the following information:

  • Building Type
  • Pipeline Material
  • Velocity Average
  • Sampling Rate
  • Analyze Duration
  • LTVEE: Long Term Vibration Evaluation Effect
  • LTEBP: Long Term Effect on Buried Pipework
  • STEBP: Short Term Effect on Buried Pipework
  • STVEE: Short Term Effect Evaluation

Features:

The Multiview offers a multi-user access to Wireless Sensor Networks:

  • A server version of the can be hosted on a PC with administrator rights to configure remotely WSN
  • Several clients can be deployed on different PC without administrators’ rights, user can only visualize & backup all the measurements data transmitted by wireless sensors

Accessories

1. Wall mounting kit

2. Mechanical Mounting

1. Adhesive mounting

  • Advance Tapes
  • Thickness 0,09mm
  • Breaking load: 35 N/cm
  • Adhesion: 4 N/cm
  • Water resistant

2. Screw Mounting

  • Screw mounting Three M5 drilled flanges
  • Flatness 38,1 μm
  • Surface Roughness RA 1.6 (μm)
  • Surface treatment Black anodized (Corrosion-proof)
  • Material AL 7075 (twice harder than AL6061)

3. AC/DC Power Adapter for Wilow Sensors

  • Waterproof aluminum casing (IP67)
  • Input voltage: 85-264 VAC
  • Output voltage: 5VDC
  • Can power supply up to 4

4. WIFI AP / Repeater / Bridge/Antenna

  • Wireless AP/Repeater with an integrated N-Type RF connector + High Gain Antenna
  • WIFI Access Point/Bridge/Repeater
  • Integrated N-Type RF connector + High Gain Antenna with 9 dBdi of Gain.
  • Casing: Outdoor UV Stabilized Plastic, Dimensions (w/o antenna): 190 x 46 mm,
  • Weight: 196 g
  • Antenna Connector: N-Type Connector (male), Power over Ethernet power supply (24VDC)
  • Max. Power Consumption: 6 Watts
  • Operating Temperature: -40 to 80° C
  • Shock and Vibration: ETSI300-019-1.4
  • Included:
  • 1x AC to 24VDC POE Power supply
  • 1x High Gain Antenna 9dBi