Figure 2 DEWETRON TRIONet3

Figure 3 DEWETRON XR Modules

Figure 4 One of the Completed Test Carts with a Blender on Top

DMC is also a long-standing NI partner, and we leveraged our deep LabVIEW programming experience on this project to deliver a high- quality solution.

The cart measures current, voltage, speed, and temperature, and displays them appropriately on the custom user interface. As a sequence is running, the UI shows the progress in addition to the live data. There’s a separate tab for viewing any alarms, such as application errors, e-stops, or out-of-range values, using DMC’s Alarm Handling toolkit.

There’s also a tab for customized settings, where the customer can specify the units, scaling, and type for each physical channel in the system, depending on what unit they’re testing.

Figure 5 A View of the Test Software with Sequence Monitoring, Data Plots, and a Live Data Table View

Conclusion

DMC’s expertise in a variety of hardware and software platforms made us a great fit for this consumer goods test system, and we’re always looking to do more. Our customer was pleased with how easy it was to switch over to the new test carts,and is excited about adding new features and expanding, already given the system’s flexibility for upgrades. Every product is different, and balancing streamlined features and maintainability with customization and expandability is a challenge DMC is always up for.

Learn more about DMC’s Test & Measurement consumer goods test system expertise and contact us for your next project!

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By integrating a solar panel and employing efficient power management strategies, the robot can maintain extended battery life, reducing the frequency of manual recharging.

A high-performance MCU and IMU established a robust foundation for orientation tracking. In addition to IMU and magnetometer, the robot’s sensors include multiple distance measurement sensors to improve obstacle detection. This comprehensive sensor data, combined with advanced motor control, supports efficient and adaptive navigation in a range of environments.

The inclusion of a wireless module simplifies over-the-air firmware updates and device configuration. The main MCU can be seamlessly placed into bootloader mode by the wireless module, ensuring smooth firmware updates for the main MCU. Additionally, the wireless module features its own firmware update capability, allowing for a comprehensive firmware update system.

DMC also developed a PC-based application that allows users to monitor sensor readings, adjust parameters, visualize the robot’s orientation, and control the robot in real time. This tool streamlined testing and optimization while laying the groundwork for more complex autonomous control algorithms.

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• Conveyor system with automatic buffering/transfers.
• Data tracking using RFID readers and custom PLC logic.
• Vision inspection for pass/fail of parts.
• Automated reject handling based on pass/fail.
• Operator interface station to perform manual intervention.

Automated storage and retrieval system.

• Central buffer for all work in progress parts.
• Storage and retrieval of radios accomplished via integration with robot arm.
• Part data determined via RFID, data stored in custom database.
• Parts delivered to and requested from buffer fully automatically with AMRs – no operator interaction needed.

Packaging station.

• Robotic packaging system to place parts into boxes, place boxes onto pallets, strap pallets, and deliver to warehouse management system.
• Automated conveyor infeed of parts, boxes, and other consumables.
• Flexible assembly sequences based on needs of specific part.
• Integration with WMS and MES systems for fully automated sequences.

DMC programmed each machine using B&R’s PC based PLC platform.  Each machine had its own Industrial PC running both Windows for the HMI and B&R’s Automation Runtime for the PLC. Operator interface was via MappView on a touch-screen panel PC. All PLC and HMI programming was done in Automation Studio, a text based IDE.

Automation Studio files are text based and human readable. Because of this, DMC was able to use a full git based development workflow during both offline and onsite development. This included automated merging features created in parallel by different developers, as well as the ability to resolve merge conflict on a line-by-line basis. This allowed quicker development and higher quality code due to efficient code reviews.

DMC integrated a large variety of communication protocols and devices for the project. This included OPC UA, PROFINET, POWERLINK, X2X, zebra printers, SQL databases, and various systems for MES, AMR, and WMS communication.
 
The communication backbone for the MES, AMR, and WMS systems was OPC UA. B&R’s OPC UA forward platform allowed DMC to effectively communicate with all three systems via OPC server and client methods. Each of the tools automatically requests both work in progress parts from the buffer when needed as well as additional consumable materials when low. Once a part is completed in one tool, requests are automatically sent for AMR pickup at the tool output. These automatic requests for delivery and pickup increased the plant’s efficiency and don’t require operator intervention.

To allow for efficient commissioning, DMC conducted extensive OPC UA method testing against a simulated MES environment before going onsite. This included simulated conveyor data transfers, part tracking, and failure conditions. Once onsite, DMC implemented extensive logging for OPC interactions to assist in debugging unexpected behavior. This logging was available to plant operators via the HMI, allowing DMC to quickly close the loop without having to manually go online with the system.

Overall, our expertise in B&R programming, OPC UA, and MES Integration led us to successfully provide the client with an automated assembly line system that allows the client to respond to changes easily.

Learn more about our PLC Programming expertise and contact us for your next project. 

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DMC combined the two microchips into a single ESP32 module to lower costs and began by using the built-in capacitive touch on the ESP32 chip. To improve performance, DMC implemented a dedicated capacitive touch controller, which enhanced touch reliability.

Breez Smart Bedroom Fan & White Noise Machine

DMC’s upgrade of the product allows for over-the-air updates and temperature sensing through an added thermistor. It was also designed on a sturdy wood base to prevent rattling noise. The temperature sensing feature automatically turns on and off based on the temperature of the room, can be set to a timer schedule, and can be controlled with a smart plug. The added fan allows consumers to alter the temperature while the product still provides white noise.

DMC’s previous work with the client and our experience with firmware programming and circuit board design allowed us to provide a modern, updated solution and successfully upgrade to dedicated capacitive touch reliability.

Learn more about our Embedded Systems Platform expertise and contact us for your next project.

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DMC delivered a fully open solution which included all source code and hardware schematics. This solution enabled the client’s in-house process and test engineers to maintain, refine, and expand the system over time, supporting any future test requirements.

This solution utilizes NI CompactRIO (cRIO) Single-board controller. This is an embedded system for rapid commercial development and deployment. It is designed for high-volume and OEM embedded control and analysis applications that require high performance and reliability. Featuring an open embedded architecture and compact size, this flexible, customizable, commercial off-the-shelf (COTS) hardware device is part of an accelerated custom design platform that can help you get your custom embedded control system to market quickly. With the CompactRIO platform, you can take advantage of FPGA performance, real-time determinism, and reliability with relatively low nonrecurring engineering compared with custom hardware design.

The complete solution provides out-of-the-box support for peripherals such as USB or Ethernet, the communication interface between the processor and FPGA, and drivers to onboard and modular I/O. The complete integrated software solution reduced the time and risk of a new project and allows engineers to focus on application development.

This solution utilizes CAN Bus Usage on the NI sbRIO. National Instruments (NI) provides a simple toolkit called “NI-Embedded CAN for RIO” for performing CAN operations on sbRIO targets. The toolkit provides access to send and receive CAN bus information at the frame level. The toolkit does not provide automatic processing of CAN frames into engineering data, or support of higher-level protocols such as SAE J1939.

DMC developed a limited feature toolkit to implement the SAE J1939 toolkit on the NI sbRIO platform. The toolkit consists of an example main loop VI with independent write and read loops. The user can initialize both loops with the J1939 PGN and SPNs they are interested in reading and writing, and then they can use the simple functional global VIs to update or read the SPNs they need in the main body of their custom code. Furthermore, DMC validated the sbRIO code for the client on a test bench using standard and well-accepted Vector CAN tools as the benchmark.

Our experience with LabVIEW programming and being a National Instruments Alliance member since 1997 qualified us to provide an updated solution for our client by developing a LabVIEW software toolkit.

The client finished their initial prototype development and evaluation process on time and on-budget, thanks to the DMC J1939 sbRIO toolkit. They were able to provide several prototypes to their customers for preliminary evaluation of their hardware, and, thanks to the flexibility of the DMC toolkit, they were also able to modify their J1939 usage as needed to meet each individual customer’s specific J1939 requirements.

Learn more about DMC’s Test and Measurement Automation expertise and contact us for your next project. 

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This solution utilizes Silicon Labs Bluetooth modules to control the operation of the battery, the main control module, and the remote controller.

We worked to optimize the Bluetooth based remote control reconnection time to eliminate the delay in response after users pushed buttons. DMC came up with our own method of pairing and securing the communication between the remote and the battery that uses the Bluetooth advertising, which does not need to create a full connection. This upgrade allows for significantly improved remote response time and allows the remote to be powered from a small coin cell battery that does not need to be charged or replaced frequently. 

Through the global chip shortage, DMC helped secure the parts for this project and optimize the design to allow for flexibility and multi-source options. Our experience with motor controls, higher power applications, and Bluetooth qualified us to provide a modern upgraded solution and successfully upgrade to Bluetooth based communication.

DMC’s work to upgrade the product allowed the client to expand their product portfolio, add Bluetooth and other new features, and continue selling devices through the chip shortage. 

Learn more about DMC’s Embedded Device Connectivity expertise and contact us for your next project. 

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DMC’s approach was to develop a Python package that wrapped NI’s nidaqmx package and provided a more convenient interface to the rest of their automations. The nidaqmx package contained the official DAQmx bindings but familiarity with DAQmx is required to use it easily.

DMC first trained the client to use NI-MAX to configure DAQmx tasks, which are convenient abstractions that can help set up, use, test, and debug data acquisition hardware. DMC worked with the client to formulate an appropriate test methodology, and we then assisted in the configuration of the DAQmx task to provide the required measurements.

Next, we developed a Python package that gets used as the back-end of both the calibration and data acquisition features. This package was written to provide a convenient API for acquiring calibration data and for applying that data to live measurements.

Finally, DMC developed a simple graphical application for operators to conduct regular calibrations. For this, we used QtQuick, a graphical framework provided by the Qt library. Qt provides Python bindings via the PySide6 package, allowing QtQuick to integrate well with Python, and making it easy to produce professional, customizable, highly-dynamic user interfaces. All of the system’s software and hardware components can be visualized as follows:

Our approach and the technologies we employed had several benefits to our client. The NI hardware provided high-quality, high-precision measurements of the values of interest. The NI-MAX utility and the DAQmx drivers improved the debugging experience and allowed DMC to use simulated devices to keep costs low by eliminating travel and/or shipping costs.

Furthermore, Python enabled the client to easily integrate these measurements into their existing (Python-based) automations. NI’s nidaqmx package provided a convenient Python interface for DAQmx so the hardware could be integrated quickly and easily. QtQuick as a graphical framework allowed DMC to quickly create a simple, portable GUI application in Python.

Overall, we met the client’s goals and provided their deliverables using our expertise with NI’s DAQ hardware, the Python interface to that hardware, and a simple but powerful GUI framework.

Read more about DMC’s Python Development Services, and contact us today for your next project!

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With the client’s functional proof of concept and goal of wide deployment, DMC engineered an optimized application that is robust and capable when utilized and efficient while awaiting use or confirming reliability and availability. As each single use of the device or test of the system had an outsized impact on battery life, DMC calculated the amount of power that would remain over time – with the battery capacity decaying naturally, regular check ins with the phone, and then the trigger events (if they occur) needing to be accounted for and taking energy.

With our multidisciplinary background, DMC ensured the client used the best choice for controls with the hardware selected. Our responsiveness and locality to the client allowed for effective communication and led DMC to ultimately deliver technology with two years of battery life and extremely low power modes.

In addition to developing the embedded firmware, DMC supported a request the client passed on from the factory for an easy-to-use test process for use on the factory floor for manufacturing quality control.  DMC came up with an extremely simplified test system that pairs, simulate an alarm, and checks for communications with a freshly-built system before returning it to an un-paired system ready for the end user to set up for themselves.

Stay tuned from new developments in personal safety from the invisaWear team!

Learn more about DMC’s Embedded Development and Embedded Programming expertise and contact us today for your next project.

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Next, DMC began work on the production electronics. Engineers made improvements to the device’s fan speed control and battery management to maximize runtime. A custom PCB was designed to fit seamlessly into the design envelope.

The Airsafe Face Shield can run for several hours using a custom lithium battery pack with quick charge capabilities. The resulting product is safer and allows the user to breathe naturally while maintaining better protection than traditional masks.

Learn more about the Seguro Airsafe Face Shield here.

Learn more about DMC’s product development expertise and contact us to get started on your next project.

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To do so, DMC replaced their existing stand alone panel HMIs with a network of Ignition Edge panels running on Siemens IPCs that will function as a centralized system or independently in the case of a network outage.

Architecture

DMC replaced the client’s existing production line HMIs with Siemens Panel IPCs that run Ignition Edge. Each panel runs both the Ignition Edge server and the Ignition client that operators use to view and control the machine. Each panel is an independent unit, but also interfaces with a central server and data storage to receive software updates, load recipes, or log process data. This DMC developed architecture allows the panels to operate independently in the event of a plant to plant network failure.

Ignition

With our expertise in Ignition, DMC was able to directly integrate all of client’s Siemens SIMOTION controllers with the Ignition Edge IPC with data then being transmitted up to the central Ignition server. We tested different communications strategies and opted to use the SIMOTION controller’s built-in OPC-UA server to transmit data.

We used Ignition’s Hub and Spoke Architecture, which allows the client to have one central Ignition server and multiple Ignition Edge servers for the different lines. To link the central and Edge servers, we use the Enterprise Administration Module (EAM) and Edge Sync Services. EAM is used to synchronize data such as updates and program versions across the Edge panels so we can edit once and deploy changes to all lines across the country. Edge Sync is used to send data from the individual Edge panels back to the central server.

Conclusion

DMC’s combined experience in Siemens automation & motion control and Ignition SCADA allowed us to successfully standardized the client’s panels, recipes, and the automation programs themselves. The client can now centrally monitor and manage all of their lines without the need to maintain code and data for each facility and machine.

The system DMC developed allows the client to store, maintain, and compare their recipes without having to go to every individual line. The client can modify those recipes from any where in their plants, and can now maintain a higher level of consistency and quality for all of their products. And with the architecture DMC deployed, the panels can work together with the central server, or, in the instance of a network failure, may fail over to the local Ignition Edge HMI.

The client is continuing to gain extra benefits from this centralized system. After project completion, they were able to replace an additional datalogging system with Ignition’s built-in solution: the SQL Bridge Module. They are also working to integrate Active Directory authentication to standardize operator login credentials across all panels in the plant. These additional advantages of Ignition were only realized after the system was already deployed.

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