WP 6 - Integration of sensors and industrial control 

Lead beneficiary: FT SYSTEM S.R.L. - Italy 

Period: month 8-18

Obiectives

- Design an integrated system of inspection
- Design of the entire machine
- The entire system architecture from mechanical, hardware and software point of view will be defined
- Definition of the platform real time control architecture. Complexity is related to control of the performances of
several simultaneous processes

Description of work and role of partners

Produce design concepts in CAD based on the two discrete approaches. Simulations will be used to predict the
performance of the different approaches for the demonstration parts in the process.

Task 6.1: Design an integrated system of inspection 
An overall architecture of the system of inspection will be defined according to the in-line and off-line inspection
mode.

Task 6.2: Machine Conceptual design 
Block diagrams with functionalities, inputs and outputs, interaction with other modules. Framework and housing,
electrical, etc., and life cycle analysis. The entire system architecture from mechanical, hardware and software
point of views will be defined.
The machine concept will be defined by means of 3D CAD tools. All geometrical data will be simulated inside
CAD program to optimise the setting and interaction with the different components. There will be different
CAD design being created to find out the most suitable machine concept. Provision for human safety e.g.
optimised ergonomically properties for usage and service will be taken into account. Based on the different
CAD design concepts, the most suitable one will be finally selected and completely designed. Robustness and
stability calculations will be performed. Next to the integration of the hardware tools the circuit diagram has to
be worked out. Different electrical standards in Europe and other countries will be taken into account during the
development. Highest safety standards will be reached. Transformation systems for the ability to use different
voltages and frequencies will be considered. All the activities related to the design, development of the machine
and of the future production will be done in accordance to ISO9000 standards.

Task 6.3: Control System design 
The Machine architecture will be defined in detail in order to identify all the components to be interfaced. The
Operating systems and the system reaction times will be defined, in order to achieve the real time performances
requested to achieve the expected performances and final resolution. In order to get the maximum efficiency,
to keep centralized all the commands / feedback / signals needed to manage the inspection process in real
time and to control the working area positioning, a centralized system based on a real time control system
(so-called Process Control Software). The definition of the PCS architecture is a fundamental step to achieve the
performances requested by SAFETYPACK project. The PCS architecture will be based on a industrial control of
last generation based on real time parallel processor architecture build by a work stations

Task 6.4: Master Control Software design and programming 
A Supervisor software will be designed and implemented to manage the entire platform, safety and human
interface, as well as controlling and communicating with other pieces of software in charge of specific modules'tasks.
The machine control software will perform real time inspection integrated in food and beverage production
line using the SAFETYPACK inspection system. All the machine components will be controlled and special
attention will be dedicated to the real time process control and the parallel distribute computing.
In particular the user interface must have the following modules:
- Statistic: access to statistical data of the measures taken. Processing in real time of the statistical information
in order to produce warning in case of detecting drifts during the packaging process that may cause safety
problems on the product itself.
- Configuration and management of the different formats that can be produced on a specific line.
- Management of the validation procedures for the measuring system.
- Diagnostic: the system performs a self-diagnostic of its component by displaying any faults and guiding the
user in the rapid recover of its functionality.
- Data logging: The system can store the statistics of production in order to ensure the traceability of the product
lots.