Our Projects Showcase

Furnace automation control in year 1998

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This temperature control system was developed to control the temperature of three zones of a 9-tone re-heating furnace installed in Peoples Steel Milles Karachi. This system has a PC based controller and motor driver card to control opining of gas and air valves installed at furnace. Own designed thermocouple amplifiers were used to read the temperature of all three zones of furnace.

DC Motor control and simulation JIG (2000)

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A Siemens PLC S7-300 based torque regulation system for a Pakistan naval ship PNS Moawin. This PLC based system was interfaced with own designed field interface cards for controlling of Thermistor based drive (190kW) for a DC generator. Shunt amplifiers, CT amplifiers, torque sensor bridge amplifier, Resolver amplifier were also designed. A test jig was also designed and developed to test the control performance of winch control system.

Computerized Instrument Tester (2004)

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Computer based instrument tester was developed for testing of a multi output voltages power supply. Tester automatically reads different voltage with and without load to test the voltage regulation of power supply. System is capable of monitoring AC as well as DC power supplies for voltage and frequency reading. Tester can generate printable report for the health of power supply under test.

CNC RETROFITTING PROJECTS (2004-2011)

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Experienced in CNC milling and lath machine retrofitting using MACH3 and EMC2 CNC software’s, using DC, BLDC motor from Rutex and KND motor drives. Spindle control using VFD’s having interface with MACH3 software. Generation of complete wiring diagrams development of control strategy of CNC machine and design and development of PLC control for multi tool control over MODBUS was done for local industry.

Redundant processors-based power control system (2007)

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Redundant processor-based Power Distribution and control System (PDCS) was designed and developed for controlling different power sources required by an industrial processing unit. PDCS is a combination of power electronics and embedded control system. This unit can control and monitor voltages used by industrial control unit and can communicate with a host computer over RS485 link for its command and data transfer to the computer.

Optical and Hall Effect based rotation sensor (2007)

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This sensor system is based on a sensor part using optical (IR) transmitter receiver and hall-based switches to monitor rotation of a wheel in industrial process. Second part of this system is a rotation analyzer which receives the signals from sensor and converts the information in useful data that can be received over a serial link to any computer.

Mechanical concepts of high temperature furnace (2008)

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AutoCAD design concepts for a high temperature (2000⁰C) water cooled furnace for different materials processing. This furnace uses all elements and power delivering electrodes based on carbon slabs and also fitted with carbon nuts and bolts.

Industrial Production and Proto-Typing

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Supervision of industrial production and prototyping is another area of our capabilities

High Current Industrial Power Controllers (2010)

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High current power controllers cab used as Cathodic Protection Plants for protection of underground metallic pipes from corrosion. This unit completely embedded controlled producing firing angle control to a three-phase input supply and controlling a DC voltage at the output. Plant can be configured as constant current as well as constant voltage power supply. This power supply can be operated from three controls selected from front panel push buttons i.e. from analog control using variable pots given at panel, through push buttons and from a remote serial link. Status of the power controller can be monitored from any remote location with two kilo meters over RS485 and can be connected as multiple plants using RS485 link.

Labview GUI development (2010)

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A Tracker Simulator was developed for the training of staff responsible for handling of communication equipments in the field. This simulator can communicate with master computer to get its required information and to generate control for master computer program Tracker Controller. This simulator provides trajectory programming, manual tracking, Auto tracking, Dish position display, target location display, event logging and telemetry feedback display facilities.

3DS Max Modelling

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For modeling of products and for mechanical designing of projects 3Ds MAX software provides a good platform to have a discussion with customers. We can design and develop different models and mechanical casing in 3Ds MAX.

Product Designing

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We are involved in products design and development for local industry. Our designed products are GSM based SCADA system, industrial power meters, power analyzers, voltage monitoring systems, Digital data display systems, Power supplies etc.

Mechanical and electrical design of clean power distribution work benches (2009)

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These power distribution work benches were design and developed for field work stations. These are all foldable units and can be transported to any location using trucks and mobile vans. Distribution work benches are equipped with power sockets and all protection units to protect the instruments from short-circuiting and phase loss. Power analyzer and three phase monitoring are also provided for user information.

Training Systems for PIC and AMTEL microcontrollers

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Many training systems have been developed by us and we have been providing trainings in the field of control and automation, Power electronics and data communication.

Fuzzy based embedded temperature controller (2006)

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A fuzzy based embedded temperature controller was designed to control the temperature of a furnace for process industry. Controller is capable to controlling the temperature of different zones of furnace and has a LCD based GUI. Controller can also communicate with a PC over a serial port using RS232 and RS485 protocols.

Industrial Control Pannel design and development in year 2012

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This project is related to THAR Coal automation for gasifier field. It is Siemens PLC S7-300 based system for controlling air inlet to the wells of gasifier field from a central station over 4-20mA loops. It has two control stations i.e. Auto panel for automatic operation of the field valves and Manual panel for manual operation in case of any failure of automation panel. Manual panel is designed by Delta HMI and own designed embedded controller based on PIC microcontrollers.

HEAD OF MECHATRONICS AT SINA INSTITUTE SINCE 2011 TILL DATE

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We are also supervising mechatronics training in the field of embedded systems design for PIC, AVR and ARM controllers. Other training fields are PLC/SCADA for siemens PLC’s S7-200 and S7-1200 using Step7-Microwin, TIA V13, WinTR SCADA software and WinCC. All the trainers for training are also developed by us.

Elevator Control

S7-1200 Based Furnace Controller

MULTI-VENDOR PLC TRAINERS

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