QA Maturity Assessment

Case Studies

IoT Solution Bottling Line Capper Head Calibration and Monitoring System

IoT Solution Bottling Line Capper Head Calibration and Monitoring System

 

 

North American leader in integrated packaging solutions wanted to develop a solution for calibration of production line capper set up. 

Results / Outcomes

The Solution

 The Solution - System Overview

System Description

Gadgeon developed the complete system based on Delpheon platform. 

Robobottle DAQ system

Robobottle is a dummy bottle with electronics to measure the various forces applied on a bottle during the capping process. Measuring the forces provide valuable insights to calibrating the production line and also enables analysis of the quality of the capping operation. Robobottle is designed to start the data acquisition automatically, once the top load force crosses a pre-set threshold.

Gadgeon designed the Robobottle electronics and firmware. The system is based on WIFI microcontroller and integrates various sensors, WIFI module, battery level using fuel gauge and RFID reader for capper head identification. It communicates wirelessly to Gateway.

Edge Gateway 

Embedded Linux based Gateway application, which communicates with bottle and collects the data in real time. For the calibration process, the data is displayed in real time on the HMI of the Gateway. Mechanic can calibrate the various forces in order, one at a time, by tuning the capper head. He can see the changes on local HMI in real time. Once the sensor is within range, the mechanic presses a ‘DONE’ button on the local HMI, and the sensor data is sent to the Cloud to be recorded. After a sensor is done, the next sensor in specified order is fine tuned, and this procedure is continued till all sensors are within range.

Minimal customization was done in DelEdge implementation of Delpheon  to achieve the functionality. The customizations included adding a docker for MQTT communication with the wireless module, modifications in Event Generator to handle 9 sensors simultaneously. Changes to local HMI included adding a bullet chart for monitoring purposes which is viewed by mechanic while adjusting the sensors, and addition of product catalogue for grouping sensors in a Robobottle. 

The rest of the functionality from DelEdge implementation was reused, including the RabbitMQ based intra docker communication, MongoDB for storage of configuration  and Signal R for live updates to local HMI.

Cloud Application

The Cloud UI is used by Admin user to create users and assign roles to each user. Also the RoboBottle product provisioning with the configuration of sensor thresholds is done at the Cloud UI. The Production Manager can provision the RoboBottle and alter the pre-configured thresholds if necessary.

The Cloud application receives the sensor data from the Gateway during the ‘Bottling Line Run’ procedure and displays at the Cloud UI.The same is also stored in Cloud storage. Once the sensor data is available at the Cloud UI, the same is applied to predictive mathematical models. Provision to add python scripts to Cloud which can be run to get predictive mathematical models was added. Also dashboards to display the results of ‘Run’ procedure was added. Authentication specific to customer requirements was added.
Existing SignalR .net library used for live updates to Cloud GUI, abstracted as a docker in DelCloud. Flexible data model which can be tailored to suit customer needs, MongoDB used as database to cater to varying customer requirements.

Summary

Reusable components


The table below represents the components customized vs reused from the Delpheon platform. 

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