Automated system for setup, calibration, and verification of gas sensors
Project requirements
Project overview.
Control Software Solutions collaborated with a manufacturer of gas detection sensors to design a robust system for the setup, calibration, and verification of their CO2 and hydrocarbon sensor range. The primary objectives were to streamline the manufacturing process, reduce costs, and enhance quality assurance.
By implementing this solution, the manufacturer improved production throughout and achieved cost savings of over £50,000 annually in gas usage alone.
Results
Our solution.
The solution cantered around a Windows-based desktop application integrated with multiple jigs housed in environmental chambers. Each chamber supported up to 16 jigs, with each jig capable of holding 24 sensors.
Key features
Sensor communication:
The software used a custom protocol over RS232 to communicate with the sensors, setting calibration parameters and verifying performance at various temperatures.
Environmental control
Temperature and humidity within the chambers were regulated via MODBUS TCP-controlled environmental systems, ensuring optimal calibration conditions.
Automated reporting
Real-time production reports were generated and emailed to the production manager, providing continuous oversight of the process.
Alert mechanisms
Automatic alerts were sent to technicians for critical issues, such as low gas levels or rig malfunctions, minimising operational disruptions.
Impact.
The deployment of this system revolutionised the sensor calibration and verification process:
Increased efficiency
Automation significantly reduced manual intervention, enhancing manufacturing throughput.
Cost savings
Optimised gas usage resulted in annual savings exceeding £50,000.
Improved reliability
Automated alerts and real-time reporting bolstered system reliability, reducing downtime caused by unexpected issues.
Verdict
Conclusion.
This project highlights how Control Software Solutions’ expertise in tailored system development can deliver significant operational improvements. The solution not only addressed the client’s immediate challenges but also helped them achieve long-term production and cost-efficiency goals.
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01457 740025
info@controlsoftwaresolutions.com
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01457 740025
info@controlsoftwaresolutions.com
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Saddleworth Business Centre,
Huddersfield Road,
Delph, Saddleworth,
Greater Manchester,
OL3 5DF