Electronics & Embedded Solution

Smart weight lifting machine help an untrained person to get guidance about exercise. In this machine it has a touch screen display which shows user-friendly menu like if the person wants to have a look on instruction it has audio-video option which shows the picture as well as speak out the instruction .The person can also enjoy music by selecting the song from song list. It also has an option to select the weight which user wants to lift e.g. 50kg from the touch keypad and also how many times to lift they can be set by setting a count. If the count are over it show an indication through a led also there is a buzzer.

It four touch switch

1. ENTER: This is usedselect the menu.
2. UP: This is used to scroll screen upside.
3. DOWN: This is used to scroll screen downside.
4. RESET: This is used reset the count if count are over or change the count entered.

This system works in two modes Continuous Mode and Cyclic Mode,it shows on LCD screen which mode is working and there is continuous clock which displays time.If any error occurs while working SMS is sent to a particular mobile number by GSM.

Continuous Mode: In this mode there is continuous flow of water which can be started or stopped by sending ON/OFF signal by a switch. It also notes the duration for which continuous mode is been operated and this duration is displayed on LCD screen. Whenever the water level goes below certain level it gives LED indication, “No Water” is also displayed and SMS is sent to a particular mobile number by GSM.

Cyclic Mode: In this mode there is periodic spray of oil along with water which is done after a fixed time e.g. 5 minutes. It also notes the duration for which cyclic mode is been operated and this duration is displayed on LCD screen. Whencyclic mode is over it resumes back to continuous mode.Whenever the oil level goes below certain level it gives LED indication, “No Oil” is also displayedand SMS is sent to a particular mobile number by GSM.

This system displays amount of CO2 gas as well as Temperature, monitors the data continuously

This Real Time data is displayed and stored according to date and time as a report for analysis.

There is dialog box which indicates the alarm if it exceeds the set limit.

It is easy to add, remove or configure client’s circuit (CO2 & Temperature setup)  from the software.

In one network 250 clients can be handled easily, any parameter of any client can be altered from the software without human involvement.

Microcontroller Based wireless CO2 gas & Temperature monitor system server circuits.

The server can Communicate with PC software & pass all sensor related data to software.

It also Communicate with all client circuits. Collect CO2 & temperature data from all client circuits.

Microcontroller Based wireless CO2 gas & Temperature monitor system client circuits. Every client circuit does CO2 & Temperature Measurement.

Every client circuit generates alarm & send to server circuits.

Every client circuit Communicate with server circuits & pass all sensor related data to server circuits.

Web based software development with below features:

Using web based software remotely monitor & control data of number of centrifuges through GPRS .Admin can add or remove any centrifuges to or from remote mode with in the software. Admin can create individual user account & password for particular centrifuge user. Hence it provides data security. If any event or alarm occurs it is stored in database with date and time. A report is generated to show machine information, customer database, machine maintenance, alarm dashboard and asset management for each user and admin.

Master control Card.

We use Linux operating system with ARM9 (32-bit) based Microcontroller.

A screen of 7inch Graphical Touch LCD  is interfaced for displaying as well as setting  various parameters Time, Temperature, Rotor ID, RPM / RCF. It also measure real time temperature and control it.Master card can communicate with web server and get related data from web server through GPRS.There is facility to recognize rotor automatically, it can also be recognize manually. An imbalance is detected through Gyroscope.1-99 times programs can be set for different user.It has ability to detect Centrifuge failure error, Rotor traceability.Predictive maintenance which will informthe user the no of cycles a specific rotorhas completeddisplays it on LCD.Acceleration and deceleration time andgraph is displayed on LCD.It automatically checks whether lid is not left open until then it willnot start machine.When rotor cycle gets completed it is indicated by buzzer and alarm on LCD TFT screen.Once the cycle is completed sometimes theuser leaves the machine and thecompressor is running, forcingrefrigeration to happen then Eco shut off option occurs.All rotors shall be pre-programmed forspeed, G Force and radius. All information of rotor usage, for how much time, also fault history can be stored in USB Mass Storage Access for user. There is option for temperature option in either Celsius or Fahrenheit

In vehicle tracking system it continuously monitors the location of vehicle the position is found with help of longitude, latitude and acceleration by the help of GPRS system it makes easier to find any vehicle at any place this makes vehicle theft impossible. It also counts number of rpm which is used to calculate the speed of vehicle at that particular time. It also indicates fuel level and RFID of the vehicle this information is sent to server. Any device even ignition in vehicle can be controlled made ON or OFF from server. We can monitor up to 12 analog signals. We can monitor 3-pulse input .It can configure 2- user output as per requirement. A report is generated according to date and time along with longitudinal and latitudinal position of vehicle.

In this system a motion sensor connected to refrigerator on sensing the motion, it plays differentshort jingle in sequence as per footsteps as well as varies the intensity, pattern &colourof light connected to display board (i.e. as the person comes near the intensity of light increase, pattern of LED gets changed and the different jingle plays accordingly).
If the person comes near the refrigerator but doesn’t open the door then fan gets start for very short time. When door of refrigerator gets open whole jingle plays completely once, also small fan mounted on refrigerator gets started. A projection logo glowscontinuously on the floor it is OFF when refrigerator gets open.

Output locking system is used to lock particular system or certain task. It has 10-channels which are working individually.Microcontroller is interfaced with HMI’s RS232 port for real time clock & timer vs output setting.This is done by setting fixed time duration from using touchHMI .After lapse of that time task is stopped and locked automatically through relay. Here HMI works as slave when any particular channel is locked it can’t be unlocked until password is entered fromHMI (Connected with microcontroller card).This is applicable to all channel and can work simultaneously. We can take details of last 10 HMI – Microcontroller connection history from microcontroller card using HMI. (Like HMI ID & how many time particular HMIconnected with Microcontroller cardAdmin can change password of Microcontroller card at
any time using HMI.

It takes number of chapattis as input from touch switch. Once the dough is fed as input and make the chapattis as per given number of input also roast on both sides. When the sensor senses the dough of 1 chapatti it flattens into fix round shape which is roasted on both sides by to different plate. The roasted chapatti comes out of flapper. The seven segments here display chapattis prepared as output. It can prepare maximum of 20 chapattis at a time. It prepares chapattis of equal shape and size which help in maintaining quality of chapattis.

It is mainly counting crate in packaging departments of dairy industries. It works in eight parallel lines where status of line is shown in visual basic based desktop software; if it is working it shows running else stop when observed.
It calculates total number of crate, number of pouch; convert it into volume (in liters) &weight (in kilogram), speed of each crate passing through each line.
This calculated output data of all products is stored daily, monthly in the form of report in Microsoft Access which makes analysis much easier for dairies.

It is mainly used in dairy industries to find the Fat percentage in milk. This reads the data from fat machine as fat percentage which is captured and stored in software and report is generated from which an analysis of these collected data is made in the form of graph to check the quality of milk.

This system is used to monitor various parts of machine. When these parts are hold and checked in particular gauge for certain time there is indication through LED .If  the test duration is not over and gauge is placed back it sounds a buzzer. When part is tested by all gauges and found exact match hydraulic punching is done. There is facility to select specific gauges for specific part in machine by selecting the part ID from LCD keypad. Machine’s all parts whose gauge are checked and matched it is indicated by a counter on LCD .e.g. any machine’s 3 parts are matched then counter value displays 3 on LCD .

This system is designed especially for domestic purpose where we can control every appliance in home through just one board. Here the board consistsof 16-switches which control individually any home appliance like tube light, fan, refrigerator, A.C, T.V etc. When the device is made On there is led indication, we can select also select the color combination from R-G-B for indication 5-minutes after the switch is made ON led goes into sleep mode. We can make them ON or OFF The switches on board are metal domed on which an insulated and also the board work on just 5V D.C. which provides protection from shock even if we have wet hands.

Another major advantage of this system is we can make all of them ON/OFF at once using ALL ON/OFF switch or even we can group them there are 4 group switches for example if we want to make all appliance in main hall ON at one switch we can select the group1 then every time if we have to press just one switch. Also once there are few individual functions going on if we make ALL ON/OFF switch OFF they all become OFF or we can restart only those function by just making ALL ON/OFF switch ON

The speed of fan also can be increased ordecreased by using scroll switches which is displays on 7-segment .We can control 2-fans .On long press of same switches works as timer i.e. we can make the fan ON continuously for hours if segment shows 1-1hour,2-2hours…..9-9hours,0-12hours

We can also control whole system by just sitting at one place, through RF remote which has the same keys as switches on board along with led indication .There no requirement of line of site communication. Here we have same individual as well as group control also dimming and timer option.

There is also a socket which has current capacity of 30-amperes which protects from getting overload. We have the option for backup whenever if power cut occurs it stores the last state of switch or if we don’t want that state again after power comes then we can make it OFF no need to wait.

This is used to control street light vary the intensity of light .when duration of timer selected from switch there are led which scroll to show which timer is selected ,and intensity of light starts dimming. IfTimer1 is selected it consist of three led first for 2-hours ,second for 4-hours,third for 6-hours and among these any led is selected e.g. third, then after six hours the intensity will become 75%.Similarly if Timer2 is selected it also consist of three led first for 2-hours ,second for 4-hours,third for 6-hours and among these any led is selected e.g. second, then after four hours the intensity will become 50%.This is most efficient method to save power because in streets at midnight there is not much requirement of light as there are no people.

RF based switch is used to control four different system ON and OFF. It is having four switch on a remote which works as transmitter to send signal to start the system as feedback the system sends the acknowledgment signal by which led glows .This shows switch can work as trans -receiver .This is applicable to all for system. The system has various advantages like it is wireless due to which there is no chance for noise, it works on 2.4GHz in the free band hence no need for license also it has a good range of 0.5km. The main advantage isevery system has its own unique ID which makes the system more secure.

Battery analyzer is used to check 5-cell at a time to check whether they are yet working or dead. This is also used to test charger is working or not. This is done by checking various parameters like charging time, discharging time, amount of charge and real time voltage .The output of all this parameters are displayed on LCD, PCSoftware & log to Mass Storage Device. This analyzer helps in fault finding of both battery and adaptor.

There are four switches

1. Cycle start: This checks whether the charging cycle or discharging cycle is over or not.
2. Cycle repeat: This again starts the charging cycle and discharging cycle
3. Battery voltage select: This is used to select voltage either 2.4V or 3.6V.
4. Manual Display ON: This is used select from menu by scrolling.

Control card tester is used to test every output of control card .This checks the supply voltage charging voltage and matches it .This checks out analog o/p voltage, digital signal, pulse output at every checkpoint, frequency, pulse-width, also finds the fault and indicates it.This indication is indicated by an led and a buzzer. It displays fault on LCD display.

When appliances are in standby mode, it will automatically switch OFF after certain time.

This time duration for OFF period can be from 1 to 99 minutes. We can start appliances again by using any remote control or by touch switch located on smart switches.These switches can be connected to devices for power saving purpose

Here real time CO2 & O2 gas percentage (%) is measured by sensors in chamber and it is indicated on LCD outside the chamber. The amount of CO2 & O2 is maintained within the chamber between upper and lower limits with the help of cylinder. Similarly Real Time Temperature is also measured by sensors in chamber and indicated on LCD outside the chamber it is also set between upper and lower limit with help of heating coil.If user wishes to calibrate CO2, O2 & Temperature it can be done using touch keypad.This type of controlling is helpful in industries where human being cannot access.

Milling machine is used to engrave the lens this gives an accurate shape and size of lens and also reduced contamination of the workpiece itself. CAD-CAM software allows multiple profile shapes in one program only.Here the users have just to import dxf file in software where the G-code (x-y co-ordinates) are generated automaticallyfrom which convergence of lens its curvature and dimensions are set. There is 3-axis stepper motor interpolation which gets its position of co-ordinates from software .With the help of M-code we can control air, vacuum and chilling plate. This reduces manual involvement also is accurate.

Mini CNC is used to where quality testing is difficult for human beings i.e. parts with in the machine of very small size. These parts are checked with reference to (x, y) co-ordinates generated from auto-CAD drawing which is converted into text file  and stored in SD-card .CAD-CAM technology allows the user to draw 2D wireframe geometry or import it as a DXF type file. The CAM side of the software provides simple 2 Axis profile milling capabilities that can be created as tool path for posting to a CNC vision system.It can trace multiple points through this file. We can get zoomed images of that segment along with their position(x, y) co-ordinates. These images are stored in SD-card which can be seen in computer.

It can be used as an event timer i.e. we can set alarm at particular time, it triggers other device connected with it. Timer is used to display number of hour and minutes on 4-seven segments. It also calculates total number of hours which is stored in EPROM of controller. It has three working mode .These mode be selected by using scroll key.
1. Temporary timer:Display number of hour and minutes gets reset on power ON.
2. Permanent timer:Display number of hour from start which is stored in EPROM of controller on Power ONit resumes back .It can be reset using reset switch.
3. Permanent timer with password: Display number of hour from start which is stored in EPROM of controller on power ON it resume back, but it cannot be reset without entering 4-digit password.

The battery charger hasfollowing features:

• The input Voltage Range is 12VDC to 24V DC
• Cooling by free Air Convection
• Input Reverse Voltage Protection
• 100% Full Load Burn in test
• High Reliability
• Output 1.4A Constant Current Limit
• Output Short circuit Protection
• Output Adjustment Range from  11 to 15V DC(14V Normal)
• Line Regulation ±1 %
• Load Regulation ±1 %
• Output Ripple Voltage : less than 100mV
• Output Current Limit :1.4A for 7AH Lead Acid Battery(This Function is very useful when Battery is in Dip Discharge and it Draws more current than Battery Charger is Damaged but due to 1.4A Current limiting Feature Battery does not draw more than 1.4A Current and it will save life of Battery Charger.
• True Full Charge and Charging Indication: In most of Battery Charger gives indication  Battery Charging and Battery Full Charge by monitoring BatteryVoltage in which Battery Full Charge indication comes early than actualBattery Full Charge so due to not proper Charging of Battery its lifegets affected in our charger give indication of Battery Chargingand Full Charging by monitoring Battery Charging Current so it will give indication of Battery Full Charge when Actually Batteryis full charge which increase Battery Life.

This system is senses the motion on the basis of which it controls it varies the intensity of light, or to make the system ON or OFF. This principle is mostly applicable where intensity needs to be changed as per necessity e.g. street light. When it is evening around 7-10 p.m.  the motion is sensed intensity gets increased up to 100% .At  night in complete darkness whenever the motion is sensed the intensity  from 10 to 11 p.m. becomes 90 %,from  11 p.m. to 12 a.m. becomes 85%, from 12 a.m. to 1 a.m. becomes 80% ,from 1a.m. to 2 a.m. becomes 75%,from  2a.m. to 3 a.m. becomes 70% , 3 a.m. to 4 a.m. becomes 60% and 4 a.m. to 5 a.m. becomes 50% 70% but if the motion does not continue after 5-minutes it  again automatically becomes  30%. And during day time there is no need of light it makes light OFF .This helps to save the power.

This system measures the usage of energy and displays all parameters such as instantaneous voltage, current, and power, IRMS and VRMS, apparent, reactive, and active (real) power, active fundamental and harmonic power, reactive fundamental, power factor, and line frequency, energy-to-pulse conversion and temperature output on LCD display. Hence the output becomes digital rather than analog. This also helps by alarm which rings when over voltage or under voltage or over current occurs. This helps to protect many appliances from getting damaged.

This system measures the usage of energy and displays all parameters such as instantaneous voltage, current, and power, IRMS and VRMS, apparent, reactive, and active (real) power, active fundamental and harmonic power, reactive fundamental, power factor, and line frequency, energy-to-pulse conversion and temperature output on software. This data is sent to server through GPRS Hence the output becomes easy to monitor. This also helps by alarm which displays as warning pop-up when over voltage or under voltage or over current occurs. This helps to protect many appliances from getting damaged. These energy monitoring can be done not only for one machine but it can be done for number of  machines through RS-485 Protocol to main control card  which communicate this  informationto the main server.Thus the data stored by date, can be downloaded ,all machine data can be analyzed ,total power consumption can be determined.

Semi-automatic three piece ball valve assembly system is the labor-saving component to meet the demands of high production of three piece ball valve. It is designed to provide a helping solution for valve proper clamping and tighten the stud and nut with same torque every time with the help of pneumatic gun.  Only one employee required to manually load valve and tighten the nuts with adequate force – an otherwise tedious and time consuming task which was only possible with fully skilled worker. Changeovers from one size valve to another are as easy as rotating the hand wheel and changing the flanges with only two bolts only. Machine improves the quality with proper fitting of all valves every time with approximate 50% of time reduction.

• Easy clamping and unclamping of valve.
• Easy changeover parts at valve size changing which provides minimum time for valve change
• Machine improves the quality of valves with proper fitting of all valves every time.
• Contact parts becomeresistant to flaking, chipping, scuffing so will not cause any cosmetic damage to valves.
• Increases efficiency of working because of systematic work. Saves money through efficient use of personnel
• Minimal operator training
• Fast adjustment reduce downtime and maximize uptime

Built to be reliable, trouble-free and dependable for years of operation

Automatic Ball Valve Rotator is the perfect labor-saving component to meet the demands of rotate the ball inside the over molded valve. Single machine can rotate wide range of ball valve from 1/2″ to 3″size. Only one labor required to manually pick the ball valve from Injection Molding machine and put it on rotators die. Now Hot PVC Ball valve will be smooth with one touch.  Changeovers from one size Valve to another are as easy as pushing a single button on the control panel. Machine provides Valve with Improved Quality, Increased efficiency, Cost savings and High productivity by achieving speeds up to 8 valves-per-minute.

It can work out for any shape like round, oval, Hexagon, etc.

• It is critical to handle and rotate manually Hot Valve directly coming from Injection Mold.
• This system ensures that you will get same fit for all ball valve
• High Speed and Automated rotation of ball in clockwise and anti-clock wise.
• Only 2 changeover parts and total 4 bolts to open at valve size changing which provides minimum time for valve change which is approximate 10 sec.
• Increases efficiency and productivity for production lines.
• Contact parts are resistant to flaking, chipping, scuffing so will not cause any cosmetic damage to valve surface.
• Saves money through efficient use of personnel.
• Minimal operator training
• Designed to accommodate various valve shapes and sizes.
• ACVFD for Rotator motor.
• User friendly & maintenance less
• Low noise level at higher speed.
• Fast adjustment reduces downtime and maximizesuptime.

Built to be reliable, trouble-free and dependable for years of operation

RF and GPRS based data logging system mainly works when number of machine are working together and their output is monitored continuously. Here a network of machine is connected through RF in which each machine having its unique ID to computerwhere the complete data is monitored it checks the amount of parts produced, if any error while production then it is detected. The data is stored in computer as well as it is sent on server through GPRS. This DATA on server can be analyzed as report, individual machine data can be obtained as well as machine can be controlled from the server.