Single Board Computer (SBC-196) based on Intel 80C196KB/KC Microcontroller ·

Windows based Integrated Software development Environment (WISE-96)

Features:

WISE-96 Integrated software development and debugging environment IBM PC with Windows 3.1 or Windows 95/98/Later

Windows based File Editor Assembler/ Compiler

Monitor Program for Debugging

 Specification

• Calicut DSP (CDSP-32) based on Texas Instruments TMS320C32, 32-bit Floating Point DSP
• Windows based Integrated Software development Environment (WISE-32)

CDSP-32

• Double euro size
• Backplane bus based · Modular
• No extra development H/W is required·
• Faster & simpler product development

WISE-32

• Integrated s/w development & debugging environment
• DSP based Integrated Software development & Debugging Environment
• IBM PC with Windows 3.1/95/98/Later

Features:

• Windows based File Editor
• Assembler/ Compiler
• Monitor Program for Debugging

Specification

IMDS-196

• Analog Input/Output Card
• Add-on Card for IMDS-196 and CDSP

Specifications:

Analog Input

• 12-bit ADC (15ms Conversion Time)
• 6 Isolated or 8 non isolated Channels
• Selectable input signal ranges
• 0-10V, 0-20V, ±5V, ±10V, 4-20mA w Linearity: ±1 LSB

• 12-bit resolution
• 1 Isolated Channel
• Selectable Output signal ranges
• 0-5V,0-10V, ±2.5V, ±5V, ±10V, 4-20mA, 0-20mA
• Linearity: ±1 LSB
• Double Euro size, VME Bus Compliant

DIGITAL Input/Output Card

Add-on Card for DSP/SBC-196D

Features:

Digital Input

• 8 Isolated Input Channels
• LED Indicators for all Inputs
• 0-5V DC, or 0-30V DC Inputs
• 7500V Input to Output Isolation

Digital Output

• 16 Isolated Output Channels
• LED Indicators for all outputs
• 0-5V DC or 0- 24V DC Outputs
• Double Euro Size VME Compatible

• Performance of the Mikes used in the telephone hand sets are checked
• Segregated into three different categories
• Telephone handsets are then assembled according to this segregation to meet the DOT standards
• Used by BPL production unit
• SBC-196D is used along with an add-on card for this unit

WinLis is intended for automation of activities of a general Library providing on-line information about the books/journals and also to keep track of details regarding issue of books, return of books, reservation membership details etc.

The system is developed in a client/server model to facilitate searching over the network.

The software also has a web based front end for searching the books/journals available or to find the books issued to a particular person
Features

• Windows based graphical user interface
• All information regarding books, suppliers, publishers, editor, purchase details etc. can be stored.
• All information about members and their category.
• Reservation of books on a priority basis.
• Lost cards and deferred cards are kept track of.
• Supports general query regarding availability of books, issued books, books on a particular topic, by a particular author, location of books in the shelf, members etc.
• Any kind of report based on any information in the database can be taken, and can be configured by the user.
• Stand alone configuration and client server configuration possible.

This software was developed for a Cattle feed plant with around 750 tons of production per day.

The software computerizes all the procedures for Purchase of raw material, and sale of finished goods.

This is a comprehensive software and includes features like automatic weight computation of trucks through weigh-bridge, automated sample code generation for Lab analysis, Computation of material cost based on quality, Supplier Information System, Purchase order processing, Accounts settlement and payments, Purchase and price analysis, Invoice preparation, Sales and price analysis, Routing and scheduling etc.

The software also prepares a Loading schedule for distribution of finished goods, preparation of dispatch schedule etc. A number of reports are created for this which involves a lot of SQL queries.

Features:

• Dynamic Selection of Raw Materials based on quality and cost·
• Automatic entry from Load cell at the Weigh bridge·
• Automatic transportation route generation to minimize the transportation cost·
• Internal generated codes for raw material quality testing.
• Client Server Architecture with Data access Security
• Least Cost Estimation Package

This package was developed for computing an optimal cattle feed formula for production based on the available raw materials.

The software has the features of production planning support, optimization based on production, price etc., It also helps in optimum selection of raw materials based on nutritional value, price and availability etc.

PC based system for monitoring & controlling batch process of any process plant, automatically with minimum operator intervention. The functions of the automatic controller is to run the plant efficiently & effectively and thereby improve the quality and productivity of the plant.

The system consists of three major modules.

IBM compatible PC with windows 3.1 or later version (PC)
Plant Automation Software (PAS)
Intelligent Plant Automation Interface (IPA) 

The PAS runs on IBM Compatible PC and provides a user-friendly environment for configuring and running the plant and gives the MIS.

The IPA is the hardware interface between PC and the plant. This has a Micro-controller, Output ports for driving the motors, flaps etc. Input ports for reading the load cell value, monitoring the conveyor/mixer status and a serial (RS-232C) interface to PC.

Features:

• Process interruption due to Plant faults ( material flow from storage bin get blocked, bin becomes empty , clogging in conveyers etc.), Operational delays, and Material Wastage has been considerably reduced.
• Plant running information presented to the operator through a simple an effective Mimic diagram on computer screen with user-friendly Graphical User Interface (GUI)
• Provision for process study and modify configuration (such as opening of two bins- of same material – simultaneously to reduce the batch weighing time, trying out different batch weights, modify process timings etc. to enhance the efficiency.

Management Information (MIS) on

• Material consumption and Production details – Shift-wise Daily & Monthly
• Alarm history – Alarm condition, Time, action taken and time to respond.
• Material flow interruption due to blockage or empty bin which has an alternate bin available (the system automatically change over to the alternative bin specified) .
• Bin level below the minimum refill level specified
• Material flow interruption and no further alternative bins available
• Any Plant failure (conveyor, elevator, mixer, flap failure etc.) detected

Installing BAS at the KCMMF cattle feed plant has lead to substantial saving in batching time, resulting in a significant increase in production capacity. It can   be suitably configured for any Batch process

                          Customer : KCMMF (MILMA)

Most of the fork lifts manufactured in India are having conventional rheostat controlled drives. This scheme does not utilise the stored energy in the battery efficiently. Chopper drive provides an alternative scheme for utilising the stored energy efficiently so that the backup time is increased and also this scheme provides a smother drive.

The chopper drive for fork lift truck provides a smooth and efficient control of travel speed from zero to maximum. If the accelerator pedal is depressed fast, the control circuits increase the power to the motor smoothly. The drive circuits can deliver high pulse peak current during starting and has a built in protection to limit the pulse peak current and over current.

The micro controller based supervisory control unit also contains actuation circuits for forward and reverse contactors with interlocking to prevent selection of direction change when the accelerator pedal is depressed. The control unit provides a bar graph indication of the battery charge status and also has audio visual alarm circuits which warns the operator against over load, over temperature and battery low conditions.

Specifications

Customer : TATA STEEL

Metal to Metal Arc welding is one of the most widely used welding technique in industry. The conventional welding units are either transductor type or thyristor types.The high frequency power sources for welding units provide the advantage of better weld quality, small size, low cost and portability.

The unit operates from single phase AC and is basically a switch mode converter providing isolation and a low voltage DC suitable for welding. The electronic feedback control ensures constant welding current in spite of arc length variations. Automatic compensation against input line voltage variations ensure stable output current.

Hot start feature for positive arc striking and anti stick feature to prevent freezing of electrode in the weld pool. Protection against input over and under voltage, over current, over temperature.

Specifications

Customer : TATA STEEL

Presently Alternators and Rectifier cum Regulating Units are having Magnetic amplifier based design. These designs have the inherent limitations of voltage regulation. Also they do not have the feature of charging the batteries with current limit at constant voltage. Since the working of these RRUs is based on magnetic core saturation, the voltage and current ripple in the output vary substantially depending upon the type of load and speed, which may affect the performance/ life of batteries.

Specifications/Features:

Automatic selection of alternator rating 4.5kW/18kW/25kW

Micro controller based design

• GBT based field control circuit
• Selectable Output voltage
• Selectable Output current limiting
• Filed current limiting
• Supports Parallel operation of two alternators
• Data logger support

Indications for

• UVC status
• Alternator/Fuse failure
• Over load
• Battery charging/Discharging Ah
• Output voltage
• Output current
• Battery current
• Field current

This project CROP SHEAR CONTROL SYSTEM  involved the design and development of a shear control system for M/s. Tata Iron and Steel Company, Jamshedpur.

Important Events:

• The prototype of the system was tested successfully using a DC motor.
• Published a paper on “ Design development and implementation of Crop Shear Control System using Digital Signal Processor”, 4th International Seminar on Power Electronics and Automation, INTRONICS-99, IEEMA, January, 1999.

Brief Description :

• The crop shear control system is developed for cutting the head and tail ends of a moving hot metal strip to proper shape, required in steel industries. The shear position is controlled optimally with respect to the moving sheet, to achieve the required accuracy. Most effective control is provided by cascading torque, acceleration, speed and position loops along with feedforward control.
• The control system is implemented using the Digital Signal Processor TMS320. The DSP based control unit is connected to a PC through an RS232 communication link. A convenient user interface is provided in the PC for configuring the system and changing parameters . The various algorithms for the operation of the controller are written in ‘C’ and cross-compiled with TMS320 ‘C’ compiler. Broadly the programs are divided into measurement routines, off line routines and online routines. Measurement algorithms are processed as timer interrupt routines. Off line and online programs involve the calculation of feedforward reference trajectories for acceleration, speed and position of shear. Some of the computations that can be done before starting the cut are put in off line routine to save computation time during the online process.
• External interrupt routines are used for initializing the measurements and starting the online calculations. The online programs also calculate the Proportional Integral and Derivative control (PID) law from the predicted error for position control. The algorithms resident in the DSP also check all the preconditions to be met for the satisfactory operation of the shear drive system and thereof positioning of the shear knives to the defined waiting position, if it is already not in waiting position.
• A user-friendly graphical interface is designed to enter the required tuning parameters of the system and establish a two-way communication between PC and DSP system. After entering the required parameters, the user can initiate the process of cutting, by sending these values and handing over the control to DSP system. Once the control is passed to DSP system, the PC get itself switched over to monitoring mode. Now, the status of initialization of the knives, their movements etc., will be communicated to PC and are displayed on the monitor, in the space provided for this purpose. If there is any problem encountered with those operations (e.g. a switch has to be turned off), the same is displayed on the screen, with continuous beep sounds, so that the operator can rectify them. After the cutting process is over, the data required to plot the trends are passed from DSP to PC and are stored in appropriate log files.

Hardware Specifications

Mother Board

Process Interface

MOTOROLA 68HC11A0 MICROCONTROLLER TRAINER SYSTEM SPECIFICATIONS

Scarcity of water is a matter of primary concern. Appropriate measurement of water availability in the form of ground water and surface water are essential for Environmental Planning. Proper management and adoption of water with appropriate technology can solve these problems to some extent. So data of Ground Water and water level changes are of primary importance in planning and management of water resources. Application of electronics/advanced technology for measuring ground water levels, and utilization of this data in the analysis of water levels can lead to better management of water resources.

This developed instrument aims at monitoring, recording and representation of ground water levels from bore wells, dug wells, and other sources. For this purpose an Intelligent Field Instrument (IFI) and Instrument Interface Software (IIS) are developed. The IFI will be located in field, where measurement of ground water level takes place and IIS will be loaded in PC, which will be connected to IFI. The PC loaded with IIS can be connected to IFI only during reading the recorded data of IFI and calibrating the instrument. The IFI measures accurate ground water level readings with the help of inbuilt custom designed transducer as per sample intake time set by user through IIS. The same data can be recorded in non-volatile memory of IFI. The IFI located at different sites can be connected to PC (one unit at a time) serially, which runs IIS. IIS acquires recorded data of these IFIs and stores the same in PC database. This database can be used in preparing ground water tables, which will be useful in analysis of Ground Water movements and proper management of water resources. IIS also interacts with IFI while calibrating the instrument and setting the various user settings like sample time, average in-take time, date, time, etc. The IFI also displays real-time data of ground water level in engineering units. The IFI is designed to compensate all types of disturbances from the measurement and environmental side.

This is a low cost and reliable technology, designed to operate in adverse Indian climatic conditions. Overall, the features of the system are as follows:

• Water level measurement in bore wells, dug wells, canals and rivers
• Full Scale measuring range: 0 to 50 mtrs
• Recording of upto 32,000 samples
• Real time Continuous digital display of water levels
• Manual/Auto calibrating facility
• User friendly software for data acquisition, representation, analysis and calibration
• + 5mm accuracy
• Operability in all climatic conditions
• Data base maintenance in PC
• This instrument consists of three units.
  • Measuring Section
  • Intelligent Processing and Recording Unit (IPRU)
  • Instrument Interface software (IIS) for PC

Measuring Section:

The measuring section reads the depth of water levels along with different disturbances, which affects the actual ground water levels. All these signals will be converted into voltages and amplified to the required levels by the signal conditioning unit attached to this section.

Intelligent Processing and Recording Unit:

This unit calculates actual water level with the help of signals from the measuring unit and same will be recorded. This also displays real-time data. The same data can be passed to PC on request.

Instrument Interface software (IIS) for PC:

This software reads recorded data of IFIs located at different sites through serial port and the same will be stored in PC database. This data will be displayed in the form of graphs and spreadsheets. This software also having the facility of setting user settings like date, time and location in IPRU.

Specifications:

Transducer:

• Full Scale measuring range: 0 to 50 mtrs
• Measuring accuracy: + 1cm
• Resolution: 0.25 mV/cm
• Input resistance(sensor) range: 0-10Kohms
• Output range: 0 to 5V
• Accuracy: + 0.5cm

Processing Card:

• Processor: Intel 87C51 microcontroller
• Frequency: 12 MHz
• Inputs:
  • Analog: Range 0-5V
  • Resolution: 8bit
  • No of channels: 6
  • Digital: 2 no inputs for Contact sensing
• Outputs: 2 no of digital outputs to motor driver
• 8 no of TTL digital outputs for fault indication
• 64 K flash memory
• 256 bytes RAM
• 4 digit digital display
• One RS232C serial port to interface PC

Power Supply Board:

• Output : +5V, + 12V DC
• VA rating: 150VA(approx)
• Input: 230 V + 10%, 50Hz
• Battery backup: 7 AMPH

Environmental Specifications:

• Temperature range: 0 to 50oC
• Project outlay: Rs. 4.0 Lakh
• Funding Agency: DST, Govt. of India

Status:Completed

At NIELIT Calicut we have designed and being developed the Process Automation Training Plant with following objectives

• Develop a platform for conducting practical oriented M. Tech course in Process Control and Industrial Automation
• Develop a platform for Application Research &Development of new process control and instrumentation strategies
• Develop a platform for studying advanced control strategies required for automation of process industries before applying on the real process
• Develop a state of the art training setup that can be eventually supplied to educational institutions ( through various funding agencies)
• To expose fresh engineers to real process and industrial automation
• Training of in house manpower in project engineering for plant automation

To impart training in:

•  engineering standards and methods
• hardware and software features for industrial automation to engineers, plant supervisors & plant operators

In recent years the performance requirement of process plants has become increasingly difficult to satisfy. Stronger competition, tougher environmental and safety regulations, and globalization of economy have been key factors for tightening product quality specifications. This has lead to, not only improvement of process but also the development of new methods for measurement, instrumentation and implementation of advanced control for process automation. Elementary teaching equipment for demonstrating the principles of process control are widely available from a number of sources.

Process control simulators in which the plant is represented by a computer are also widely available. However, these equipment will not provide the trainees, hands on experience with required complexities as demanded by a real process plant. Also it is not economical to study and analyse the advance process control techniques on the actual plant, which may lead to unexpected hazards and production loss. Hence for studying, analysing, troubleshooting and experimenting with various process control instruments and advanced control system needed for process automation, the development of a plant using real sized instruments is essential. The effectiveness of modern process control algorithms, like adaptive control and predictive control aspects can be better studied in a training plant that uses real sized instruments rather than laboratory sized equipment. This has led to the design and development of a process automation training plant.

This plant is an ideal set up to train engineers, in real life problems of industrial process automation. The plant has fundamental control loops such as level, pressure, temperature, flow, and interactive control loops of temperature & level, pressure & level. It has real sized equipment like that of a process plant such as open tank, pressure tank, heat exchanger, various types of level transmitters, control valves, orifice plates, centrifugal pumps, solenoid valves and an oil free compressor.

The monitoring and control of the plant is selectable either through an industrial PC with associated hardware and software or through a PLC. Hence it can be easily tailored for teaching PC /PLC based process automation & control and experimenting the various advanced control strategies required for process automation

 Specification

1) FEEDBACK CONTROL

i) TEMPERATURE

a) WITH DISTANCE VELOCITY LAG
b) WITH CAPACITY LAG

ii) FLOW
iii) LEVEL
iv) PRESSURE

2) CASCADE CONTROL

i) LEVEL AND FLOW

3) THREE ELEMENT CONTROL

i) TEMPERATURE
ii) FLOW
iii) LEVEL
iv) PRESSURE

4) FEED FORWARD CONTROL

i) TEMPERATURE

5) HEAT EXCHANGER CONTROL

i) CONVENTIONAL AND FEED FORWARD

6) RATIO CONTROL

i)FLOW

7) INTERACTIVE CONTROL

i) LEVEL AND TEMPERATURE
ii) PRESSURE AND LEVEL

8) BATCH CONTROL SIMULATION, MODELING AND MANY MORE !!!

POWER CONSUMPTION
INSTRUMENTATION 2.7 KW HEATER 12 KW
WATER SUPPLY    HOT 5 lit/min AT 1 BAR COLD 8.3 lit./min AT 1BAR
AIR SUPPLY 8.19 M3/hr AT 10 BAR
DIMENSION 5.0 X 3.4 X 0.88 M