PROJECT EXECUTED

Load/Distance Real-Time Measurement and Validation System

At Surelogix Solutions, we specialize in crafting innovative, indigenous solutions that address real-world industrial challenges. One of our flagship products is the Load/Distance Real-Time Measurement and Validation System, a state-of-the-art embedded controller designed to deliver unparalleled precision and efficiency in critical applications.

Key Features and Capabilities

1. Dual Analog Input

• Supports real-time analog inputs from both load cells and distance sensors.

• Enables accurate measurement and synchronization of load and distance parameters for high-precision operations.

2. Ultra-Fast Sampling Rate

• Industry-leading shortest sampling rate of 1 ms, adjustable up to 20 ms, providing flexibility to meet application-specific requirements.

• Ensures rapid and accurate data acquisition for dynamic processes.

3. Customizable Scaling

• Designed with user-defined scaling capabilities for load cells and distance sensors, allowing seamless adaptation to varied applications and environments.

4. Real-Time Graph Plotting and Validation

• Provides real-time graphical visualization of load and distance parameters, enabling operators to monitor and validate processes at a glance.

• Integrated pass/fail validation logic with digital output signaling to the PLC, ensuring precise control and immediate feedback for production lines.

5. Seamless Integration with PLCs

• Features a digital input for process initiation from the PLC, ensuring smooth and synchronized operation within automated systems.

• Supports compatibility with various PLCs for easy integration into existing setups.

6. Graphical Region-Based Validation

• Includes a graphical drawing capability with four distinct regions on the real-time graph for load and distance validation.

• Each region can be configured for specific acceptance criteria, enabling detailed analysis and validation.

• Automatic detection and feedback on whether the process lies within acceptable ranges, providing operators with immediate pass/fail results.

7. Inbuilt Recipe Management

• Features an inbuilt recipe management system, allowing users to create, store, and manage multiple process recipes for different applications.

• Provides easy recipe selection and loading directly from the interface, enabling quick setup changes for varied production requirements.

Applications and Benefits

Applications

• Manufacturing and assembly lines requiring precise load and distance measurements.

• Pressing, torquing, or forming operations needing real-time validation and control.

• Quality assurance processes where pass/fail validation is critical.

Benefits

• Enhanced Process Accuracy: Real-time measurement and validation improve precision and reduce errors.

• Improved Productivity: High-speed sampling, automation, and recipe management minimize downtime and manual intervention.

• Ease of Integration: Compact design and PLC compatibility simplify adoption into existing systems.

• Customizable Performance: Adjustable scaling, sampling rates, region-based validation, and recipe features ensure adaptability to various industrial scenarios.

Customized SCADA Software for Parth Industries, Aurangabad

At Surelogix Solutions, we specialize in delivering tailored automation solutions to meet specific customer needs. For Parth Industries, Aurangabad, we designed and developed a customized SCADA software solution to enhance their production monitoring and control capabilities.

Project Scope and Deliverables

1. Design and Development of Customized SCADA Software

• Built a tailored Supervisory Control and Data Acquisition (SCADA) system optimized for the customer’s operational requirements.

• Provided a user-friendly interface for operators and supervisors to monitor and control production processes in real time.

2. Seamless PLC Integration

• Developed an efficient interface between the SCADA software and Programmable Logic Controllers (PLC) for precise machine communication.

• Enabled real-time data exchange for process control and monitoring.

3. Data Logging and Reporting

• Implemented robust data logging functionality to capture critical production parameters and events.

• Designed an automated reporting module, delivering detailed production summaries, trend analysis, and performance insights.

4. Recipe Management

• Integrated an intuitive recipe management system, allowing operators to create, edit, and manage process parameters efficiently.

• Streamlined the selection of predefined recipes for quick production setup.

5. Operator Input for Part Numbers

• Provided a dedicated interface for operators to input part numbers, ensuring accurate traceability and identification of components during production.

6. Production Summary

• Developed a comprehensive production summary dashboard, offering real-time insights into key metrics such as output, efficiency, and downtime.

• Enabled better decision-making with clear visualization of production performance.

Project Benefits

• Enhanced Operational Control: Real-time monitoring and control improved process precision and reliability.

• Improved Traceability: Operator input for part numbers and data logging ensured complete production traceability.

• Streamlined Workflows: Recipe management reduced setup times and minimized operator errors.

• Data-Driven Decisions: Comprehensive reporting and summaries provided actionable insights for process optimization.

• Ease of Use: The user-friendly SCADA interface simplified system operation for all levels of personnel.

Con Rod Bush Press Machine for Parth Industries

At Surelogix Solutions, we take pride in delivering cutting-edge automation solutions tailored to meet complex industrial challenges. One of our accomplished projects is the Con Rod Bush Press Machine, where we developed and implemented advanced software for seamless operation and integration.

Project Highlights

1. PLC and HMI Software Development
We engineered robust software for the machine’s Programmable Logic Controller (PLC) and Human Machine Interface (HMI), ensuring intuitive control, precision, and operator ease. Our solution allowed smooth interaction and adaptability for varying production requirements.

2. Vision System Integration with Cognex Cameras
To ensure high-quality standards and accuracy, we integrated Cognex cameras for advanced vision-based inspections. The system enabled real-time validation, improving the overall reliability of the manufacturing process.

3. Barcode Scanning for Traceability
The incorporation of barcode scanners facilitated efficient tracking and traceability of components, streamlining workflow and minimizing errors in the production process.

4. Burster Load Cell Controller Integration
Precision and quality control were further enhanced by integrating the Burster load cell controller, providing real-time force measurement during the pressing operation. This ensured that the con rod bush was pressed within specified tolerances.

5. Interfacing with Torquing Machine
To deliver a cohesive production line, our solution included seamless interfacing with a torquing machine, ensuring synchronized operations and process efficiency.

Outcomes and Benefits

• Enhanced Process Accuracy: The combination of vision systems and load cell technology ensured precision at every step.

• Improved Productivity: Automation reduced manual interventions, leading to faster cycle times and consistent quality.

• Real-Time Monitoring: The intuitive HMI allowed operators to monitor and control the process efficiently.

• Seamless Integration: Compatibility with existing machinery and systems ensured minimal disruption during implementation.

Currently executing:

Technical Consultation: Development of Automated Guided Vehicle (AGV) for Megabotic

At Surelogix Solutions, we pride ourselves on being a trusted partner in driving innovation for advanced automation technologies. We provided technical consultation to Megabotic for the development of a state-of-the-art Automated Guided Vehicle (AGV), delivering valuable expertise and solutions to streamline their project.

Scope of Consultation

1. Conceptual Design and System Architecture

• Assisted in defining the functional requirements and conceptual framework for the AGV.

• Developed the system architecture, outlining mechanical, electrical, and software integration strategies for seamless operation.

2. Navigation and Control Systems

• Provided guidance on navigation technologies, including laser-based, vision-based, and magnetic guidance systems, tailored to their application needs.

• Designed robust control algorithms for precise movement, obstacle avoidance, and optimized path planning.

3. Payload and Material Handling Optimization

• Advised on the AGV’s payload capacity and material handling mechanism to ensure compatibility with diverse operational scenarios.

• Recommended efficient solutions for lifting, transferring, and docking processes.

4. Power Management

• Supported the design of an optimized battery management system (BMS) for extended operational autonomy.

• Suggested charging infrastructure and strategies, including opportunity charging for uninterrupted workflow.

5. Communication and Data Handling

• Recommended implementation of IoT-enabled communication systems for real-time data exchange with central control units.

• Enabled integration with warehouse management systems (WMS) and enterprise resource planning (ERP) platforms.

6. Safety and Compliance

• Provided insights on implementing safety standards such as emergency stop mechanisms, collision detection, and compliance with relevant industrial regulations.

Key Outcomes for Megabotic

• Accelerated the development timeline for their AGV project.

• Delivered a scalable and efficient design ready for deployment in industrial environments.

• Equipped Megabotic with advanced knowledge of automation technologies and practical implementation strategies.

• Ensured their AGV meets industry standards and provides seamless integration with existing operational systems.

OUR ESTEEMED CUSTOMERS