We are able to supply turn-key customized atypical solutions for the industry. We are focused on using modern technologies; e.g. 3D, augmented, virtual reality and image recognition. These are suitable wherever a standard controlling system is not applicable. For our solutions we have capacities for design and realization of IT infrastructure used by projects.

case studies:

Remote control of a gantry crane in a low visibility environment

Situation

  • Anthracite warehouse
  • Two gantry cranes
  • The gantry crane is also used for unloading railway wagons.
  • Operator sitting in the cabin on the crane in the hall.
  • Partial automation, but not for unloading wagons.

Issues

  • Extremely high concentration of anthracite dust particles in the air causes:
    • very low visibility (1-3m),
    • serious health risk for the crane operator,
    • prevents usage of cameras for a typical remote control.
  • Impossibility of reconstruction of the space into a new, modern, dust-free warehouse.

Solution

  • A set of ultrasonic sensors for spot position measurement of anthracite surfaces.
  • 3D virtual space dynamically updated with the real sensor data.
  • Remote control using 3D display outside the warehouse.
  • Accuracy allows unloading of railway wagons
  • Full automation a later possibility.

Measurement of molten metal level in the furnace using image recognition

Situation

  • A hall with a number of metallurgical furnaces, where it is necessary to measure the height of the molten metal.
  • Daily level measurements using:
    • metal rod submerged into the molten metal in the furnace,
    • optical difference between two heated parts distinguished by the designated worker,
    • using a classical metal meter.

Issues

  • Measurement inaccuracy due to a human error.
  • Measurement differences caused by the different workers and a subjective evaluation.
  • Increased safety risk for the worker
  • Strong electromagnetic fields cause malfunctioning of complex electronical devices.

Solution

  • Automated optical measurement of the measuring rod.
  • Two stages:
    • Handheld optical meter
      • measures the level with a manually inserted measuring rod,
      • the meter utilizes image recognition techniques to distinguished between levels of molten metal,
      • results are sent through wifi to a central information system.
    • Half-autonomous trolley:
      • the measuring rod is inserted automatically by the robotic arm,
      • evaluation runs in the same way as in the previous example.

Load swing damping for a gantry crane

Situation

  • A hall with manually operated specialized gantry cranes.
  • Staff working in the hall.
  • Forklifts and other small vehicles moving in the hall.

Issues

  • Moving the load in narrow spaces leads to a damage to both the load and/or to the environment.
  • A crane with a load poses a safety risk to the working personnel and vehicles .

Solution

  • Installation of multiple video cameras controlling the crane and working area.
  • The cameras also control the load swinging.
  • The image from the cameras is analyzed and based on that:
    • adjusts the movement speed to reduce vibration,
    • warns the operator in case of potential obstacles and threats,
    • automatically stops in case of an imminent danger.
    • Possibility to take full automatic control in confined spaces.

Augmented reality maintenance support

Situation

  • Multiple industrial devices which need a periodic maintenance.
  • A technical support staff with various levels of skill.
  • Non-trivial maintenance and repair procedures.

Issues

  • Maintenance and repair manuals are scarce and non-centralized.
  • Number of experienced, senior staff significantly lower than junior staff.

Solution

  • Centralization and categorization of all manuals into a singular software system.
  • New video and text manuals created by the experienced stuff accessible on mobile devices (i.e. cellphones and tablets).
  • Augmented reality manuals created by the expert technicians.
  • Remote support using augmented reality:
    • A technician in site shares the video feed from his mobile device
    • Remote support can help by anotating the video with a set of markings (arrows, circles, text…) which are anchored to the real objects in the video and keep their relative positions even when the camera moves.
    • The technician in site sees the anotatations in real time on his mobile device together with the image from the camera.
    • A set of interactive step-by-step guides can be prepared with immediate recording of the process.