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 Utilities & Infrastructure Handhelds Energy, Oil and Gas Telecommunications, fixed and wireless Safety & Security Intelligent Controls Automotive Access Control Systems Time & Attendance terminals Biometric Solutions RFID solution –ISO 14443, ISO 15693 PIR based solutions Automated Toll Payment System Global Positioning systems Variable Message Sign Boards Street Light Controller Diagnostics equipment Infotainment Driver Assistance systems Biometric safety system www.riccooutsourcing.co.uk Case Studies Mass Flow Meters Within the oil and gas Industry, the accuracy and intelligence of each flow meter plays a critical role. To compete with other key players in the Market, this client needed an accurate and cost effective solution for its mass flow meter product line. The client also needed to meet all intrinsic safety requirements. The original flow meter was developed with a custom firmware for which a royalty fee was being charged by the vendor. • 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 on the Coriolis principal. • Iterative field analysis for this 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. Case Studies Control Boards for Plasma Processing System The challenge was to develop a new patented invention created at a 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. 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. Case Studies Time and Attendance Terminal The client wanted to develop a low cost alternative to an expensive time and attendance terminals using RFID Technology. They also required to implement 3G-UMTS technologies and add Ethernet communication for data transfer with the server and future online firmware upgrades for the system. • Hardware designed and developed using ARM 9 Core Processor. • Wireless Technologies used - Low frequency RFID, 3G-UMTS, Wi-Fi, GPS • Implementation of the 3G-UMTS technologies and Ethernet communication for data transfer with the server. • Equipped with various communication options USB/Ethernet/GPRS-EDGE. • Large Graphical LCD Display. • Linux operating system incorporated within the system. • Fingerprint sensor and RFID for identity verification. • VGA Camera with LED Flash for facial recognition • In- terminal Data Base management. • Platform devised for product road map of 10years. 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 visualisation 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) Case Studies Smart metering System – ZigBee case study The ZigBee-based system created a self-forming, self-healing wireless mesh network 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 off Meter 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 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 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 Case Studies Battery Analyser This customer is a leading provider of professional electric power tool equipment markets a broad range of world-class power tools and batteries. A major problems continued to arise when trying to evaluate warranties for equipment in the field. To manage the warranty system of the products there was a need to develop a process where the manufactures could evaluate each product’s warranty period. By providing a simply warranty management system a great deal of time and money would be saved. Development of software , hardware and mechanical design 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 with an initial run of 2000 units including validation of units on assembly line, box packaging and shipment to customer location. Case Studies Data Logger The system is a rugged, user-friendly, low cost data logger 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 (8000 units) including user manual, validation of units on assembly line, box packaging and shipment to customer locations. Mechanical Capabilities Design of Beacon Lamp Product Range Enclosure Design for Energy Meter Unique safety features and tamper proofing Designed for IP54 standards Applying for patents for unique hinge and locking mechanisms Over 35 plastic components of which 8 metering optical standards Interchangeable modular configuration Range of 8 different products Designed for UN 65 regulations Software Design of Sheet Metal Cabinet 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 ProE Wildfire Solid Works Auto Cad Any Customer Specific Software in CAD/CAM 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 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 Additional Projects OEM PRODUCTS Weld Current Analysers Intelligent Pump system Mass Flow Metering System Low Noise Amplifies Battery Charge Analyser I/O CONTROLS 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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