Previous projects
We have been engaged in various projects related to analytical and technological equipment. For example, binding different laboratory instruments into a central feed of analytical results for aluminum plant servers, developing utilities for efficient operation of large alloys assets for OE spectrometers, creating communication protocols and control logic for robotic systems, etc.
Please find below several other interesting projects of our team.
Please find below several other interesting projects of our team.
Software for GNR Explorer XRD/XRF Bath Ratio
Customer:
GNR Nord (Russia) / GNR s.r.l. (Italy)
Objectives:
To develop software to control combined XRD/XRF GNR Explorer instruments and elaborate new analytical approach to perform automated measurement of Bath Ratio in Aluminum industry.
Platform:
Windows x64
Technology stack:
C#/WPF, Matlab
Languages:
English, Italian, Russian, other on request
Links:
GNR Explorer
GNR Nord (Russia) / GNR s.r.l. (Italy)
Objectives:
To develop software to control combined XRD/XRF GNR Explorer instruments and elaborate new analytical approach to perform automated measurement of Bath Ratio in Aluminum industry.
Platform:
Windows x64
Technology stack:
C#/WPF, Matlab
Languages:
English, Italian, Russian, other on request
Links:
GNR Explorer
Advantages and results
Aluminum plants of Rusal, the biggest Russian aluminum producer, use our software to measure Bath Ratio in electrolyte with combined XRF/XRD GNR Explorer instruments. The results are used to optimize the production process in real-time and reduce costs. Therefore, both performance and precision of analysis are of great importance.
After performing extensive R&D on Rusal samples we have developed a new approach to calculate bath ratio from both X-Ray diffraction and X-Ray fluorescence data. Despite the quite high number of calibration parameters obtained (more than 10) the instrument can be successfully calibrated with a limited number of regular working samples without the need to produce complicated calibration standards. Due to the complexity of calculations the analytical module was implemented in the form of compiled Matlab library used directly from C# application.
This new approach allowed us to nearly double measurement accuracy in comparison to other instruments on the market in less acquisition time. Additional work was done to increase performance even more. The final performance significantly increased (~55 sec/sample) after all hardware control routines were rewritten from scratch and clever mechanics synchronization was applied.
We have built a complex engineering UI for calibration which is quite rarely used in the field because of exciting instrument stability. In contrast, UI for laboratory personnel was minimized to just several buttons and tables. The instrument measures a set of 22 samples completely automatically and sends the results to a plant server without requiring any operator interaction. We have also developed background recalibration procedures to assure correct results during the whole instrument lifetime without regular time loss for adjustment procedures.
The instruments analyze up to 800 samples on a daily basis with minimal operator attention. No software bugs and troubles were reported for years after the initial integration process.
Aluminum plants of Rusal, the biggest Russian aluminum producer, use our software to measure Bath Ratio in electrolyte with combined XRF/XRD GNR Explorer instruments. The results are used to optimize the production process in real-time and reduce costs. Therefore, both performance and precision of analysis are of great importance.
After performing extensive R&D on Rusal samples we have developed a new approach to calculate bath ratio from both X-Ray diffraction and X-Ray fluorescence data. Despite the quite high number of calibration parameters obtained (more than 10) the instrument can be successfully calibrated with a limited number of regular working samples without the need to produce complicated calibration standards. Due to the complexity of calculations the analytical module was implemented in the form of compiled Matlab library used directly from C# application.
This new approach allowed us to nearly double measurement accuracy in comparison to other instruments on the market in less acquisition time. Additional work was done to increase performance even more. The final performance significantly increased (~55 sec/sample) after all hardware control routines were rewritten from scratch and clever mechanics synchronization was applied.
We have built a complex engineering UI for calibration which is quite rarely used in the field because of exciting instrument stability. In contrast, UI for laboratory personnel was minimized to just several buttons and tables. The instrument measures a set of 22 samples completely automatically and sends the results to a plant server without requiring any operator interaction. We have also developed background recalibration procedures to assure correct results during the whole instrument lifetime without regular time loss for adjustment procedures.
The instruments analyze up to 800 samples on a daily basis with minimal operator attention. No software bugs and troubles were reported for years after the initial integration process.
Control software for automated sampling system of a fertilizer plant
Customer:
Phosagro (Russia)
Objectives:
To develop control software for the robotic sampling system of the fertilizer plant, including quality control and transmission of results to the central plant server.
Platforms:
Windows x86, Siemens microcontrollers
Technology stack:
C, Java/Spring
Phosagro (Russia)
Objectives:
To develop control software for the robotic sampling system of the fertilizer plant, including quality control and transmission of results to the central plant server.
Platforms:
Windows x86, Siemens microcontrollers
Technology stack:
C, Java/Spring
Description
The software for control of an automated robotic sampling system for one of the biggest Phosagro plants was developed in 2010 together with ASG Engineering company.
It is responsible for fully automated control of an enormous robotic sampling system, performing quality checking of sampled materials, running analytical measurements, transmitting results to the central plant server, and regulating production parameters.
Pure C modules were used to control numerous Siemens microcontrollers. Several kinds of UIs were implemented to manage the system and monitor the results. Central control station in Java is used to operate the whole system. Backend server generates a number of various reports that can be accessed from any place through a web browser by responsible personnel.
The integration of the developed solution has reduced the production costs, increased performance and quality of sampling, made it much more convenient and effective for engineering personnel. The system outperformed competitive solutions by that time and works to this day.
The software for control of an automated robotic sampling system for one of the biggest Phosagro plants was developed in 2010 together with ASG Engineering company.
It is responsible for fully automated control of an enormous robotic sampling system, performing quality checking of sampled materials, running analytical measurements, transmitting results to the central plant server, and regulating production parameters.
Pure C modules were used to control numerous Siemens microcontrollers. Several kinds of UIs were implemented to manage the system and monitor the results. Central control station in Java is used to operate the whole system. Backend server generates a number of various reports that can be accessed from any place through a web browser by responsible personnel.
The integration of the developed solution has reduced the production costs, increased performance and quality of sampling, made it much more convenient and effective for engineering personnel. The system outperformed competitive solutions by that time and works to this day.
