Industrial engineering projects │ IT-Solutions & Applications

Some of completed projects

On our project site you'll find a short overview of applications,

which were developed for our customers within the last months. It should give you an idea, which kind of projects were solved by us and which components were used for. Should you actually have a project to realize - please don't hesitate to contact us. We would be pleased, helping you with the planning!

Mobile Toll Control Units T-Systems / ASFINAG Mobile Toll System
asfinag fahrzeug

The so called „GO-Maut 2.0“ is a central economical factor for ASFINAG, an austrian infrastructure company.
In the course of the expiring of the previous contract and the re-tendering of the toll system, we were contacted by T-Systems, the later contractor of the overall system and charged with the planning of the system for the mobile control units.

Realization:

The planning and delivery included the hardware equipment of 48 vehicles, with which the toll control is carried out throughout Austria.

Special emphasis has been placed on the purchase of equipment that is suitable for both the extended temperature range, as well as for the use in vehicles.

Hardware:

The vehicle computers “VBOX-3610” from our partner Sintrones are used, which are recommended for their variety of interfaces, their high computing power, but also for their suitability for use in motor vehicles under various temperature conditions.

These are suitable for use from -40 ° C to + 70 ° C. The high shock and vibration resistance is also an important feature of the devices.

Furthermore, the devices comply with the MIL-STD-810G

The vehicle equipment around the VehiclePC was supplemented by WIFI LTE routers (including GPS connection), 17 “high-bright display, 24-port managed Ethernet switch, and a rugged tablet for remote operation by the task force.

End of project:

2017
IT Equipment and Maintenance of the Operational Control Center MA 48, Fire Department Vienna Industrial Computer
feuerwehr wien einsatzzentrale

In 2004, Aplica won the tender for the computer equipment of the operations control center of the Vienna Fire Brigade. In addition to the best technical solution, and a functional service, the price-performance ratio was the decisive factor in awarding the contract to Aplica.

Realization:

The task of the MA 68 was anything but trivial and made it difficult to impossible for many competitors to offer suitable equipment:
Server for the operations control center with high performance, industrial Pcs with 2-units limit, multi-monitor graphics cards for video walls, remote operation from more than 50 meters distance plus workstations with maximum speed and operational reliability with an operation as quiet as possible were part of the requirements.

Due to this very special configuration of the systems, it was necessary to subject the hardware to be used in the course of the tendering, intensive tests in its own test field – thus, it was ensured that the technical requirements were met in all points.

Until today, the service contract with the MA 68 is upright and regular system upgrades and maintenance guarantee a smooth process every today.

End of project:

ongoing since 2004
Railway Milage System OEBB - Austrian railways Monitoring System
a train

All the 8000 km (4971 miles) of the railroad in Austria are continuously inspected by special equipped mesasurement coaches. So any abnormalities on the overhead contact wire or on the trackbed can be early identified and repaired to prevent bigger damages. For this process it is at any time necessary to know the exact position of the coach on the track.

The main task of the Milage System is to provide a reliable and exact track position (within a meter) which is recorder synchronously with all other measurement data of the several coach sensor systems and can be automatically linked with detected damages.

But there are some problems to solve: The orientation on the track is historically based on milestones and plates. But after construction work on the rails the distance between two milestones can become longer or shorter than a mile. To handle that, handwritten error profiles were used in the past.

Moreover the error of the incremetal distance measurement based on an odometer increases with time. To correct and synchronize the odometer, magnets of the INDUSI-system (automatic train warning) which are located beside the rail are used, because the are easy to detect and their position is well known.

Realization:

APLICA developed a hardware solution which is a combination of 2 computers (a milage computer and a server) in a 19″-Rack with a DaqBook from IOTech.

The measured analog data are transferred in realtime to the server via LAN and the signals are corrected by a DasyLab application to provide a distance proportional recording. The influence of the coach roll in curves is also being corrected an the output signal is being sent to a digital data recorder. The sampling rate for the INDUSI detection is 1 kHz, so the position accuracy at full speed is in the range a few centimeters. The system works for a coach speed up to 300 km/h, abnormalities and ambiguities will be automatically detected and ignored.

The whole software for the system is written in Visual C++ and uses the APLBase, APLICA’s Cross-Platform Codebase. All parameters are displayed clearly in a fullscreen dialog and the position and speed data are permanently verified using a GPS receiver. The measured GPS position will be store in a database and could be used for validation of the INDUSI positions.

End of project:

Juni 2004
Development and Construction of the BRIMOS-Recorder VCE Holding GmbH Development
Brimos Recorder

Within the scope of the 5th research framework program a project “IMAC” (Integrated Monitoring and Assessment of Cables) was financed by the European Union. In this project a compact measurement device for monitoring of structural vibration was developed by Aplica in cooperation with VCE Holding GmbH. Major premise during the conception was: simple application, high flexibility, robust system design as well as high quality of the recorded data. The BRIMOS-Recorder was specifically designed for structural health monitoring applications in civil engineering. Moreover a compact design and an autonomic operation without external power supply was demanded.

Hardware: 

In the BRIMOS-Recorder a 3-dimensional acceleration sensor from Kinemetrics (Epi-Sensor) is included. As an option, an extended version is available, which is equipped with an additional external acceleration sensor. The connection of an external temperature sensor is standardized prepared. Data acquisition is done by a data logging unit with internal RAM, flash-memory and a maximum sampling rate of 1 kHz. The data reatment, filtering and A/D conversion of the signals is done with a resolution of 19 bit. External data transmission is perfomed via Ethernet interface. The internal power supply ensures system operation for maximum 8 hours. Aplica was responsible for the design and development, as well as construction and quality control of the recorder.

Software: 

For data transmission as well as fast visualisation of the acquired data the tailored software solution BRIREC was developed, which was specifically adapted to the clients demands. The premise of simple handling from the hardware conception was consequently continued for the software development. The compatibility to usual Windows-operating systems was major task for the implementation. The program enables configuration and set up of the Recorder, data download as well as visualisation of the acquired time signals and related frequency spectra. Modifications of the signals like zoom, offset reduction, fade out of single signals as well as copy to the clipboard for simple reporting are further features of BRIREC. The data are stored at the computer in the Green-Eye format which was developed by Aplica as well. The software is available in German and English and is continuously improved by the strong cooperation between developer and end-user of the technology.

Ende des Forschungsprojektes:

The BRIMOS Recorder has got awarded with the MERCUR 2003 of the Vienna chamber of commerce
Health Monitoring of the Viennese Reichsbrücke Arsenal Research Center Monitoring System
Reichsbrücke Untergrund

Together with the R&D-center Arsenal Research Vienna we developed a new concept for a bridge monitoring system, which is installed on the Viennese Reichsbrücke.
The main challenge in bridge monitoring is to handle many high sensitive sensors (acceleration, strain, temperature, etc.), which are spread over a distance of several hundred meters.

Anyway a synchronized sampling (< 100 µs) of all sensor data must be ensured, so that the data can be analyzed with modern construction analytic tools. Moreover the system has to be resistant to high and low temperature, dust and moisture. A direct internet connection should enable an automatic data transfer to the analyzing and archive systems at Arsenal Research.

Hardware:

The installed monitoring system is controlled by an embedded PC which is built on a reliable PC-104 CPU-board from Digial Logic and acts as a bridge server. The data acquisition hardware has been realized with e.gate and e.bloxx modules from Gantner Instruments.
The fast LocalBus, which connects the modules and sensores to the bridge server, and synchronizes the data aquisition with a maximum jitter of 10 µs makes the monitoring system to a unique synchronized fieldbus system. Thereby it was possible to keep the analog signal wires between sensor and aquisition modules as short as possible, which makes the system to the most accurate one in its area. Currently the system consists of 4 3-dimensional acceleration sensors, 4 strain gage and 6 temperature sensors. On the top of the bridge is a webcam located, which constantly records the traffic situation on the bridge deck. Altogether APLICA laid 2 km cables, mounted the complete subassembly and delivered the system ‘ready to use’ to the customer. Arsenal Research is using the system as a research facility on one hand and monitors the health of the brigde for the bridge owner on the other hand.
The link to the projects website is shown below.

Software:

The bridge server embedded PC is operated by a Linux-OS which is customized by APLICA for measurement applications. It needs only 20 MB of RAM and occupies only 20 MB on the harddisk. For data aquisition and data preprocessing we used the powerful and relieable Green Node Kernel software, which has already proved its abilities in other customer projects. This software manages the whole data stream, splits it in segement files and creates an hirarchically organized data archive (months/days). The local archive on the bridge uses a 20 GB harddrive which can hold the complete measurement data of 2 months. By an upcoming data volume of about 500 million samples / day, the storage of the data archive on such a small harddrive is only possible by using the Green Eye data format. This binary data format, a development of APLICA, compresses the data by a factor 10 in realtime and stores it to disk.
Moreover, features like an ftp server and a secure shell deamon on the bridge server, make this system to an easy remote accessable data server, which is also comfortable and secure to maintain.

End of project:

Mai 2005
Project Teststand for brush grades Hoffmann Elektrokohle GmbH Teststand

The realised test stands are used for testing the service life of starter engines for conventional motor vehicles. A starting cycle as well as a power output measurement should be performed. Moreover it was required to fix 2 starter engines at the same time, which are tested alternating. The test procedure should be performed according to a free adjustable parameter file. In doing so a maximum number of 20.000 check cycles should be performed. For each cycle it is required to graphically display the sensor data online and store them for further assessment.

Realisierung:

An exceptionally tricky problem was the realisation of the so-called compression simulation. As a result, the realistic behaviour (resistance) of the combustion engine during the start procedure should be modelled.

Hardware:

Data acquisition is done by a DaqBoard2000 from IOtech with a 5B – signal conditioning unit in combination with a 19” industrial computer system.

Software:

The software consists of two major parts: on the one hand there is the algorithm which is controlling the electrical starter drive as well as the brake mechanism. These tasks have been realised on a TwinCat-system from Beckhoff. On the other hand there is the user interface including the control of the global test procedure. This was performed by a VisualBasic application with embedded Green-Eye technology (curve window, data storage and algorithms).

End of project:

 

Prüfstand 1: Juni 2002 Prüfstand 2: Juli 2003 Prüfstand 3: Jänner 2006 Prüfstand 4: November 2007
Vibration Monitoring System on the Tai Chung Cable Stayed Bridge VCE Holding GmbH Monitoring System
Tai Chung Projekt

The Tai-Chung cable stayed bridge in Taiwan should have been equipped with a permanent monitoring system, which is acquiring the vibration behaviour of the global construction as well as the vibration response of the stay cables in particular. Based upon these data, the cable forces can be calculated and the health condition of the global structure for safety evaluation can be assessed. A special challenge of this project was the acquisition of 24 channels in total with a sampling rate of 100 Hz continuously, 365 days a year. The pre-evaluation and temporary storage of the data is done on a server installed to the bridge, which is directly connected to the internet.

Hardware: 

To fulfil these monitoring requirements an extensive measurement equipment according to the current state of the art was installed together with our partner VCE Holding GmbH. On selected cables 1-dimensional acceleration sensors Kistler 8305 have been fixed and are connected to the base station by special data cables. The vibration response of the stiffening girder is monitored by 3-dimensional Epi-sensors from Kinemetrics which are installed to characteristic points of the structure. In addition a seismic sensor is installed to the basement of the pylon in order to determine ground induced movements. The combination with temperature measurements and sensors for wind velocity and direction enable extensive diversion of the global vibration response of the bridge. All data are centrally acquired by use of a IO-tech DaqBook 2000E data logger with a sampling rate of 100 Hz. These data are directly transmitted to the server software for evaluation and storage.

Software: 

The server software for acquisition, pre-evaluation, visualisation and storage of data on the bridge server was developed by Aplica based upon an in-house created extensive measurement software. Data time segments of 5 minutes length are joined to a total file and stored in the Green-Eye data format which was developed by Aplica as well. The data compression realised in the Green-Eye data format enables a considerable increase of temporary stored data, at the same time reducing transmission time of the data via the internet.
A further evaluation and application software was developed by our client VCE in order to determine acting cable forces and natural frequencies of the structure based upon measurements of ambient time history. All data are centrally transmitted to a control centre, which enables continuous monitoring of the structural condition at any time.

End of project:

 Februar 2004
Production test stand for electrical drives Traktionssysteme Austria GmbH Test stand

Die Traktionssysteme Austria als einer der führenden Hersteller von Antrieben für Straßenbahn und Bahn führt für alle produzierten Maschinen eine Qualitätskontrolle vor Auslieferung durch. Da es sich sowohl um Typen- wie auch Serienprüfungen handelt, müssen jährlich bis zu 3000 Antriebe dieser Testprozedur unterzogen werden.

Aufgabenstellung:

Bis zu 2 Antriebe sollen je an einem der drei vorhandenen Prüfplätze getestet werden. Geprüft werden die Wicklungswiderstände, das Leerlauf- und Kurzschlussverhalten sowie mechanische und elektrische Verluste und die Isolation. Im Anschluss daran soll noch ein Getriebelauf nach vorgegebenen Lastspielen zur Ermittlung der Erwärmung durchgeführt werden. Als Ergebnis der Messung wird ein Prüfzertifikat erstellt, welches der Maschine zur Lieferung beigelegt wird.
Die aufgenommenen Messdaten sollen in einer Datenbank archiviert werden um Statistiken über Prüfserien hinsichtlich Toleranzabweichungen durchführen zu können. Einmal aufgenommene Daten dürfen nicht verändert werden können.

Realisierung:

Die Datenerfassung erfolgt mit Ausnahme der elektrischen Kenngrößen durch ebloxx Module von Gantner. Das gesamte System ist in einem von uns konzipierten 19“ Schaltschrank untergebracht in dem sich auch der Steuerrechner mit GPIB- und Profibus Schnittstelle befindet. Elektrische Größen werden über GPIB von einem Yokogawa Poweranalyzer gemessen und an die Prüfsoftware übertragen. Die Ansteuerung der Antriebe geschieht ebenfalls über das Prüfprogramm mittels ABB Umformer der per Profibus angesteuert wird.

Software:

Aufgrund der umfangreichen Maschinendaten von denen die Prüfparameter abgeleitet und in Form von Prüfergebnissen pro getesteter Maschine abgelegt werden müssen, fiel die Entscheidung, das Prüfprogramm in einer MS Access Datenbankumgebung zu entwickeln. Diese wurde um die APLICA eigenen APLBASE Funktionen wie Kurvendarstellung, Datenmanagement und Dateifunktionen sowie GPIB- und Profibus Schnittstellen erweitert.

End of project:

 

THree test stands between 2007 to 2009
Teststand for cooling compressors Frigopol - RHL Kälteanlagen GmbH Teststand
Frigopol

In order to fulfil the increasing quality demands, our client Frigopol decided to purchase an automated test bed for testing their compressors of refrigerating machines. Besides the measurement of electric data like voltage, current, real power, idle power, apparent power, cosPhi and frequency it is possible to acquire up to 30 temperature measurements. The temperature sensors type PT1000 are designed for an application in chlorinated liquid atmosphere.

A complete test procedure consists of reaching specified temperatures and the following control of flow and pressure. The data are presented online and are further modified for presentation in the resulting record.

Hardware:

A Delphin Topmessage was selected as data acquisition unit. The basic equipment already provides extensive control mechanisms, thus the main part of the control was shifted to the hardware. Moreover Delphin units support data transmission via Ethernet besides highest accuracy (0,2°C at 24 Bit). This feature enables, to follow up the test procedure on site as well as from decentralised control spots.

Software:

The Software is primary based upon DASYLab, the application program tailored to the specific tasks of this project was designed and developed by Aplica. Since a driver is recently available for Delphin units, the development time was very short and hence the application was very cost efficient. Moreover the client has the possibility to modify the existing program according to the current requirements.

End of project:

September 2003
Cantilever Arm Lift Measurement OEBB - Austrian railways Monitoring System
ÖBB Kilometrierungssystem

In the course of testing the new highspeed railway track at Pöchlarn (Lower Austria) in summer 2004, some test runs were made with the german ICE. The Austrian Railway Authority wanted to know, if the track infrastructure would be capable for train speeds up to 300 km/h (186 mph). This was the first time that a train reached this speed in Austria.

A major part of these tests was to study the reaction of the overhead contact wire to the 186 mph pass of a pantograph.

The crucial points are the pole locations where the contact wire is connected to a flexible cantilever arm. To idea behind the test was to measure the vertical liftup of the contact wire at the cantilever position during a train pass and to record the following decaying vibration. The recorded data of a total of 10 measuring points at 10 different poles, which were located in a range of a couple of miles, had to be transmitted immediately to the test team to help them to decide if they could proceed the tests or if they had to abort them.

Realization:

The whole measurement system was designed and developed by APLICA. It was the first time, that our new Green-Node datalogger has been used in a customer project. This remote data node uses a GPRS modem to transmit the recorded data immediately after completion to a specified ftp server. By the use of the special developed visualization software “SAM”, all the data can be viewed online via the internet.

Hardware:

For the first time our Green-Node Datalogger has been successfully tested in a practical, outdoor environment. It is based on an embedded PC104-system from our partner Diamond Systems with 16 analog channels, 100 kHz total sample rate and 256 MB memory. For the access to the internet a GPRS/FTP modem connection is used, where the size of the transmitted data packets is minimized by using APLICA’s highly compressing Green-Eye Data Format.

Software:

The user interface of the visualization software “SAM” was developed in Visual Basic and the curve window and data handling was created with our Green-Eye component library.

End of project:

 August 2004
Dust proof printer Semmelrock GmbH Development
Drucker staubgeschützt

Die Produktionsleitung der Fa. Semmelrock trat mit der Aufgabenstellung an uns heran, einen staubgeschützten Laserdrucker, der unter verschiedensten Umgebungstemperaturen verläßlich eine hohe Zahl an Seiten drucken kann, zu liefern. Die Fa. Semmelrock produziert im Mehrschichtbetrieb u.a Pflastersteine und Industriepflaster,

in der Fertigungshalle können je nach Jahreszeit Temperaturen zwischen -5°C bis +40°C herrschen, wobei herstellungs-bedingt eine hohe Staubbelastung auftritt.

Realisierung:

Nach eingehenden Recherchen über die am Markt erhältlichen Systeme, entschlossen wir uns das benötigte Gerät selbst zu konstruieren und zu bauen. Im Wesentlichen handelt es sich hierbei um ein mit Überdruck belüftetes Mehrkammernsystem, das zusätzlich mit regelbaren Heizplatten ausgestattet wurde. Um eine möglichst staubfreie Umluft im Inneren gewährleisten zu können wurden zusätzlich mehrstufige Filter eingebaut. Großes Augenmerk wurde auf eine problemfreie Handhabbarkeit bei der Beladung der 2 Papierladen, sowie auf den Papierauswurf gelegt.

Hardware:

Neben dem netzwerksfähigen Laserdrucker KYOCERA FS-3830N kam ein, von uns entwickeltes, passgenaues Spezialgehäuse, zum Einsatz. Die aktive Teperatur- und Lüftersteuerung, sowie die Einschaltverzögerung bei Niedertemperatur übernehmen 2 mehrkanalige Regler. Komplettiert wurde das System durch 2 Heizplatten sowie die Lüftungs, Filter- und Überdruckeinheit.

End of project:

Mai 2004


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