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Our company's specialists have experience solving problems across various industries.
And while technological processes in different industries vary greatly, the needs and principles for meeting them are similar.
For example, both a potato chip factory and a mining company need to measure the weight of raw materials and products. For the factory, we created an automated system that receives data from truck scales (an electronic weighing processor); for the mining company, the weight of iron ore was determined using a load table for mining dump trucks (Caterpillar®, Komatsu®) based on a ready signal from a time-tested Krupp® crusher equipped with an early Siemens® Simatic® S5 controller. We successfully solved both tasks.
Below, we provide several interesting examples of projects we have implemented.
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We handle a wide range of tasks:
From guest tracking in the HoReCa sector to data collection for traceability systems in the metallurgy industry; from climate control panels in DIY workshops to performance monitoring of large-scale crushers at mining and processing plants. From a warehouse management system for a small trading company to a distributed monitoring system for control centers of main pipelines.
In addition to the industrial automation tasks listed above, we have also solved applied business tasks: warehouse management with up-to-date information in real time; production tracking; accounting and reporting (financial/tax); tracking of working hours and monitoring of employee task completion; conversion of paper-based document flow to electronic.
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Comprehensive Enterprise Resource Planning (ERP) System for a Distribution Company
The program implements functions for multi-stage customer management (Sales/CRM), supplier relationship management (SRM), order fulfillment management, warehouse management (WMS), accounting and tax accounting (Accounting), human resources and payroll management (HR), and electronic document management. For management accounting purposes, the system provides forecasts of financial status and tax burden, as well as current and projected inventory levels, taking into account logistics flows (SCM).
Data exchange with external programs and integration with barcode scanners have been implemented.
Products & Tools: Microsoft® SQL Server®, Delphi®.
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Data gateway between the automated process control system and the quality control system
To provide data for the new quality control (traceability) system being implemented for the production of high-quality steel, maintenance-free hardware-software gateways (black-box principle) were developed to facilitate data exchange between process automation systems and enterprise management systems. They are based on embedded PCs with a watchdog device that receives process information from the local process automation system of a specific metallurgical shop. Several gateways in each shop at all stages of metal processing provide actual data to the new system at the ArcelorMittal® steel mill.
Products & Tools: Delphi® (console app), Wonderware® Device I/O Servers, TCP/IP networking. Data sources: Siemens® Simatic® S7-400/S7-300, Schneider Electric® Modicon® Quantum/Premium, Wonderware® InTouch® HMI v.7, Microsoft® Access®. Data destination: Oracle® Database, TCP/IP UDP listener.
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Automated system for tracking and controlling the movement of raw materials and products for a food processing plant
An automated tracking system was developed and implemented to monitor and track the movement of raw materials, products, and waste into and out of the Kraft® Foods plant. This system eliminated manual data entry by employees, significantly increasing accounting accuracy and reducing specific losses. The system automatically receives data on the empty and loaded weights of vehicles from various types of truck scales installed at all factory gates. The data is verified and signed off by an authorized operator using a personal electronic pass. Subroutines implementing the corresponding serial and network protocols were developed to interface with the scales and electronic pass readers.
Products & Tools: Microsoft® SQL Server®, Delphi®.
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Compressor Station Control Room
The control system for a gas transmission company’s distributed compressor shops was designed to integrate data from two dozen different control subsystems in each multi-turbine gas compressor shop. It has been implemented in fifteen unique facilities, plus a consolidated information system in the central control room. The flowcharts of various subsystems were standardized and replicated in a single project based on HMI/SCADA software, while distributed storage of all process information was organized. Secure data acquisition methods were implemented for standalone systems and non-standard devices.
Products & Tools: AVEVA™ InTouch HMI (formerly Wonderware® InTouch), Delphi®.
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Software for Quality Control Laboratories
To improve product quality, an automated workstation for laboratory staff has been developed to verify the quality of manufactured products. It allows users to define testing algorithms for each product type and generate both individual reports on test results and summary reports for implementing organizational and technical measures.
Products & Tools: InterBase® SQL Database, Delphi®.
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SCADA Driver
When implementing a pilot cathodic protection system for main gas pipelines, the developers utilized innovative, specialized UPS/rectifiers. The gas transmission company operates a dispatch control system, and a requirement arose to transfer data from the new cathodic protection system to the dispatch control system. The UPS/rectifiers were retrofitted with communication modules featuring proprietary application-layer protocols based on the TCP/IP protocol suite. Our specialists developed a driver program to connect the special-purpose UPS/rectifier with a custom network API/protocol to the Wonderware InTouch SCADA system for real-time bidirectional data exchange. The data exchange driver included additional functions for self-diagnostics and remote device configuration. Products & Tools: Delphi®
