Industrial Automation Software Development

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DreamSoft's niche technical expertise in terms of Designing to Development to Implementation is in the field of Industrial Automation Software Development. We have a unique combination of understanding the process of development as well as the Device Interface aspect in the Industrial Automation Field. If you are an OEM of Devices which can communicate over specific Protocols like Serial, TCP/IP, ASCII etc. or you have imported Devices for which you want to develop Data Logging, Data Writing, Data Analysis Software then we have that expertise to do that. We study the Protocol over which the Devices can communicate and accordingly we do various functions in our Software. We have in depth understanding in Pharma Industry in developing software which will be Pharma Part 21 CFR Compliant which is the norm of the Pharma Industry. Our Software is often validated by third party for testing an certifications. Device Interface is just one step, from there, we have mastered ourselves in other areas of Industrial Automation Software Development like: PC Based Data Logging Applications, Web Based Data Logging Applications, OPC Interface Applications, Customized Device Interface Applications, Bridging & Reporting Applications, Intelligent Building Management Systems (IBMS), SMS / Email Applications, Dongle Integration, Project Design etc.

We have worked with Equipment Manufacturers, Automation Project Companies, Project Consultants and Corporates in such Application Development. We have not only the development capability of Desktop Based Applications but can make Web Enabled Applications allowing you to have a complete Web Based Interface in Automation Project. We are experts in Reporting and Bridging Applications where there can be multiple types of inputs like PLC, OPC, Database, Serial Port, TCP/IP, xls file system, csv file system, FTP, Device etc. and having our Application as a Bridge, we can compute and work on data and convert/send them to other type of outputs; again like anyone of the names mentioned in inputs. Such complex bridge applications are required in Complex Industrial Processes. Again by using any of the Inputs like PLC, OPC, Database, Serial Port, TCP/IP, xls file system, csv file system, FTP, Device etc we can compute/work out on the data received and save them in our database and generate various types of Analysis Reports on the same.

We have worked on Projects and Complex Applications in countries like USA, Far East (Vietnam, Singapore etc.) and India. In Far East countries we have worked and mastered our understanding of OPC which is a Software Interface Standard that allows Windows Programs to communicate with Industrial Hardware Devices. OPC is implemented in server/client pairs. The OPC server is a software program that converts the hardware communication protocol used by a PLC into the OPC protocol. The OPC client software is any program that needs to connect to the hardware, such as an HMI. The OPC client uses the OPC server to get data from or send commands to the hardware. We have worked extensively on OPC Interfaces in Projects.

With such vast experience in the fields of Industrial Automation Software Development, we are now in a position to design the complete end to end System for the Client including suggesting them which hardware to use for the betterment of the results and output of the Project.

Apart from our own technical expertise, we have dedicated team of Programmers who are well versed with the technologies in these fields and can develop complex software and applications and also can support client on site and understand their issues in dealing with problems.

This section will take you through an interesting modules of Industrial Automation Software Development.

Data Logging Applications

Data Logging Software Applications are required for maintaining the data log from the various parameters of the Devices / Equipments in the Real Time and Offline Mode. Software will be designed to communicate with the Device with a particular protocol which Device supports. Also, with the same protocol, one can configure multiple devices in the Software for Data Logging. Various Modules are there given below along with screen shots of important events. These Applications can be developed with or without Pharma Part 21 Compliances. Desktop Interface as well as Web Interface (With Internet or Intranet) can be used to develop these Applications. We can use OPC Interface (OPC HDA, OPC DA, OPC UA & OPC AE), Modbus TCP/IP, Modbus RTU, PLC Interface, Modbus Ascii, Ethernet Communication,SNMP, UDP,Ascii Communication, Any Customized protocol for Communication with Device / Instrument

Master
Equipment Master: - This feature will allow user to add n number of Equipment each having a unique Identification number and will have settable option for SV, Alarm LL, Alarm UL and Unit of measurement.
Communication Parameter: - Setting Communication Port, baud rate and other parameter will be fixed and will have an option to change directly from database.
Log Rate Setting: - User can set Log Rate for data logging which will be common for all equipment connected.
Equipment Status: - This option will allow user to update status (Active / Not Active), of each equipment connected so that data logging for that equipment will not be done.
Mobile Master: - This option will allow user to define fixed set of Mobile No to which SMS will be send. SMS will be sent for alarms which are pending for acknowledge and are in high state for a over a specified period of time.
Data Process
Data fetching from the equipment will continuously on once user click on start data fetching on periodic bases w.r.t. to Log rate set. Data will be fetched equipment wise and will be stored in Database for further analysis.
Real Time Display: - Data fetched from equipment can be monitored on Real Time Display Screen. Screen will be designed to display Multiple Equipment at a Time.
Real Time Graph: - Graph of Data fetched from Equipment can be plotted on Real Time Graph Screen w.r.t. equipment.
SMS Triggering: - SMS will be triggered to defined numbers if Alarms is not acknowledge for a specified period and is in high state.
User can save Real Time Graph in BMP format and print later.
Audit Trail will be maintained at each level i.e. change in master setting, change in Alarm Limits, User Logs etc
SMS Audit Trail: - This option will maintain SMS logs for the SMS sent.
Alarm Acknowledgement will be done with user verification and audit trail will be maintained.
Analysis Report
Data Report: - Reports can be viewed w.r.t equipment and date wise. Combined report for multiple equipments will be provided.
Offline Trends: - Offline graph can be viewed w.r.t Equipment and date wise.
Audit Trail Report: - Equipment Wise, User Wise, Alarm Audit Trail and SMS Audit Trial.
History Data Report: - Reports can be viewed w.r.t Equipment and date wise.
History Offline Trends: - History Offline graph can be viewed w.r.t Equipment and date wise.
History Audit Trail Report: - Equipment Wise, User Wise, Alarm Audit Trail and SMS Audit Trial.
MKT Analysis:- MKT Report will be generated w.r.t Equipment
MKT Analysis for History Data:- MKT Report will be generated w.r.t Equipment
Admin Utility
Backup of Database: - Backup utility will be provided to backup database.
Auto Backup: - This option will take auto backup of Database on periodic bases.
Restore of Database: - Restore utility will be provided to restore database.
Deleting Data log (If required): - Data can de truncated w.r.t Date-wise.
Restore History Data: - User can Restore History Database and view analysis report.

OPC Interface Applications

OLE for Process Control. OPC is a software interface standard that allows Windows programs to communicate with industrial hardware devices. OPC is implemented in server/client pairs. The OPC server is a software program that converts the hardware communication protocol used by a PLC into the OPC protocol. We have developed many Interface Applications using OPC Protocols. Below are the Types of OPC's used in Projects:

OPC DA (OPC Data Access) : It is an OPC Foundation specification that defines how real-time data can be transferred between a data source and a data sink (for example: a PLC and an HMI) without either of them having to know each other's native protocol.

OPC UA (OPC Unified Architecture) : It is a machine to machine communication protocol for industrial automation developed by the OPC Foundation.

OPC HDA (OPC Historical Data Access) :It is used to Analyze Historical processed data.

OPC AE (OPC Alarm & Events) : It's the exchange of alarm and event type message information, as well as variable states and state management.

Intelligent Building Management Systems (IBMS)

Building Management System (BMS) is taken one step further by us by developing a complete Softawre / Web Portal where in all the signals and device outputs given by various modules in BMS are tagged in an OPC Server and our portal will take the Signals from the same and compute / display the status of the different devices in real time / offline on screen. Since ours will be a Database Application, outputs taken from OPC Server or any other Interface are stored on Database and relevent Analysis reports are generated. Also, we have few modules for data entries and analysis which are additional part of the Software / Web Portal. Some of the Modules Covered are : OPC Tag Configuration & Monitoring, Asset & Maintenance Management, Help Desk, Facility Booking, Utilities Monitoring, Tanent Billing, Global Directory etc.

Building automation describes the advanced functionality provided by the control system of a building. A building automation system (BAS) is an example of a distributed control system. The control system is a computerized, intelligent network of electronic devices designed to monitor and control the mechanical, electronics, and lighting systems in a building. BAS core functionality keeps the building climate within a specified range, provides lighting based on an occupancy schedule, monitors system performance and device failures, and provides malfunction alarms (via email and/or text notifications) to building engineering/maintenance staff. The BAS functionality reduces building energy and maintenance costs when compared to a non-controlled building. A building controlled by a BAS is often referred to as an intelligent building or a smart home.

Building Automation System is taken one step further by us by developing a complete Softawre / Web Portal where in all the signals and device outputs given by various modules in BMS are tagged in an OPC Server and our portal will take the Signals from the same and compute / display the status of the different devices in real time / offline on screen. Since ours will be a Database Application, outputs taken from OPC Server or any other Interface are stored on Database and relevent Analysis reports are generated. Also, we have few modules for data entries and analysis which are additional part of the Software / Web Portal.

Salient Features
Application will be installed on a central server which can be accessed from any client node through a browser using a specific URL.
Data fetching application will run as service on Server hence Application need not be opened all the time.
Application will support multiple protocol interfaces (OPC Interface and any other client protocol.)
Auto Emailing Facility.
Real Time OPC Tag Monitoring & Setting Value.
Alpha Numeric Password with min 8 char.
Password ageing.
User Name and Password Encryption.
Wrong Password attempt account locking.
User login with same user name from different location will not be allowed
Auto Log out of no activity done.
User Access level.
Audit trail at each event.
Digitally acknowledgement of Alarms with audit trails.
Application will be protected with a Soft Key license.
Modules in IBMS

Browser Application Feature

Administration:

User Access Group: - This option will allow administrator to create different Application group like admin, Department Head, Department Operator etc.
Application User: - This option will allow administrator to create a new user w.r.t Department. Application will also have a flexibility to define access to multiple departments for any managerial level person.
Application Setting: - This option will allow user to set different application as below

Local and Remote data Backup Path. 3 Version of file will be maintained for Day before yesterday, Yesterday, Today
Backup Date and Time
Header Footer details
SMTP Settings
Backup Database: - This option will allow Admin to manual take backup of Database if required.
Restore Database: - This option will allow Administrator to restore Database.
Email Account Definition: - This option will user to define email accounts who will receive email of defined modules like BMS Security, Help Desk etc.
OPC Server Configuration: - This option will allow user configure OPC Server information.

OPC Tag Configuration & Monitoring:

OPC Tag Master: - This option will allow user to configure OPC Tag w.r.t OPC Group i.e. PA, VAV etc.
OPC Tag Monitoring: - This option will allow user to monitor and control OPC Tags real time value.
Lift Monitoring: - This option will allow user to monitor Lift status and position in an animated format.
OPC Alarm Monitoring: - This option will allow user to monitor OPC Alarms generated w.r.t OPC Group.
OPC Alarm Acknowledgement: - This option will allow user to acknowledge OPC Alarm. Audit Trial will be maintained for each alarm.

Asset & Maintenance Management:

Asset Type Master: - This option allows user to create different Assert Type e.g. Data Logger, Servers, AHU etc.
Asset Parameters Template: - This option will allow user to create asset parameter based on asset type in order to classify asset.
Vendor Master: - This option allows user to define vendor list who have supplied asset.
Asset Master: - This option will allow user to create different asset in the system along with parameters and vendors.
Asset Maintenance Parameters: -This option allows user to define multiple maintenance parameters along with default value w.r.t each asset.
Asset Maintenance Schedule: - This option allows user to define Maintenance Schedule for each asset along with a frequency of repetition. System will generate an auto Maintenance Schedule task based on frequency. Also an email will be generated incase external vendor is to be intimated.

Help Desk:

Fault Type: - This option allows user to create different Fault Type e.g. BMS System, Electric System etc.
Service Type: - This option will allow user to create different Service Type w.r.t Fault Type e.g. Access Switch, Computer, DDC Controller, Flow meter etc.
Work Order Check List: - This option allows user to define Check List for each Service Type.
Staff Master: - This option allows user to define Staff who are responsible to executing the work order.
Fault Request: - This option allows user to generate a Fault request which a tenant will raise.
Work Order Generation: - This option will allow user to generate work order on the bases of Fault. Work Order will be allocated to staff.
Work order Execution: - This option will allow user to enter work order task execution details i.e. user will update check list based on the fault.
Work order Status: - This option will allow user to update work order status based on the feedback from tenant.
Analysis Reports: - This option will have user to have various analysis report for Help Desk.

Facility Booking:

Facility Type: - This option allows user to create different Facility Type e.g. Conference Room, Meeting Room, Projector Room, Video Conferencing Room etc.
Facility Amenities: - This option will allow user to create different amenities like Chairs, Projector, Snacks and Coffee etc.
Facility Details: - This option will allow user to define different facility available w.r.t Type of Facility and amenities available along with Operating Timing w.r.t each day.
Facility Booking: - This option allows user to book facility w.r.t Date and time and availability, user will have an option of defining amenities required while booking the facility.
Email Reminder: - System will send an email reminder to user who has booked facility 2 days prior and also to the facility in charge.
Booking Cancelation: - This option will allow user to cancel his booking incase he does not require facility.
Booking analysis: - This option will have various booking analysis w.r.t. facility, user and date.

Global Directory:

Tenant Master: - This option allows user to create tenants along with tenant details.
Division Master: - This information allows user to create different division which are applicable w.r.t tenant.
Department Master: - This option allows user to create different Department under each division w.r.t tenant.
Designation Master: - This option allows user to create different designation application in an organization.
Tenant Employee: - This information allows user to define employee information of tenants and location where they are seated, it will also have an option whether to display contact details to public for global directory.
Global Directory: - This option will have an option for user to search employee with various search parameters.

Data Fetching Application Feature

This Application installed on the server. This application will perform read write operation for OPC Tag monitoring and auto functionality.

Salient Features
Application will be continuously polling OPC Tags for real time monitoring.
Application will execute auto functionality like sending emails, auto backup etc.

Development Includes:

Detailed Analysis and Complete Development of the System
Testing at DreamSoft Office
Functional Documentation under Client guidelines.
Factory Acceptance Test (FAT) at Client Office / Site
User Acceptance Test (UAT) at Site
Documentation of the System (Help)

Customized Device Interface Applications

DreamSoft has developed Specific Customized Device Interface Applications for many esteemed clients as per their requirements. DreamSoft acts as an OEM Application Development Company for them and we provide complete support for Installation of the Application at their Client's Units. Thus as OEM, we have successfully installed more then 500 Applications in many large scale multinationals. We will provide Analysis to Implementation Solution for Customized Software Solution.

Part 21 CFR Highlights

21 CFR is the part of Title 21 of the Code of Federal Regulations that establishes the United States Food and Drug Administration (FDA) regulations on electronic records and electronic signatures (ERES). Compulsorily used in Pharma Industry, DreamSoft has achieved full compliance in Industrial Software Application with 21 CFR.

Alpha Numeric Password with min 8 char.
Password ageing.
User Name and Password Encryption.
Wrong Password attempt account locking.
User login with same user name from different location will not be allowed
Auto Log out of no activity done.
User Access level.
Audit trail at each event with comments from user.
Digitally acknowledgement of Alarms with audit trails.
Digital Approval of Data with 2 level facilities along with Batch Approval facility.
a) Review Data Log.
b) Approved Data Log.
Electronic Signature : Printing of User Name at the bottom of Report with date and time of User who is generating the report, user who is authorizing data

Bridging & Reporting Applications

Bridging & Reporting Applications are very customized Applications development in which the requirements are like there is a Source of Data Available in form of: Device / Equipment / PLC / XLS Format Files / CSV Format Files / OPC Interface / Serial Communication / FTP / SAP File / XML File etc. Client may want these data to be computed / worked up on and transfer them to other Output Systems like: PLC / OPC / Database etc. In such requirements, we have to understand the nature of Data Computations and develop a Bridge Application which will take the data from Source: Compute / Work on the same ;Supply the changed format data to Destination depending on the system requirements. In large scale installations and plants where Automation is present, such many Bridging Applications are required to be built. We have expertise on the same. We can understand the format of each type of data available and have successfully bridge them to various other formats as shown in the pictures below. In case of Reporting Applications, we have to study the Source of Data ; take those data generated in a Database and then generate various types of Analysis Reports from the database. Some times, its not only interface application, after the data is picked up from Source, there are some data entries being done and then Reports are generated so it can be a mix project of Bridging and Reporting Application as well, we study the requirement and then give the proper solution. Technologies used for development will be either VB.NET or ASP.NET with MS SQL Server as Database or MS ACCESS as Database depending on the requirements.

SMS / Email / Voice Alarm Applications

DreamSoft specializes into Device Interface based SMS and Email Applications where our application will be connected via device followed protocol to the device or equipments and as per the defined Alarm or Interrupt configurations, application at desired point can send SMS / Email to a group of users. SMS / Email is sent from application in Manual and Auto Modes. Voice Alarm can also get generated and we have designed Application to convert Text into Voice. There is a Alarm acknowledge module as well where users will be able to do the acknowledgement. Also features like acceleration are provided for multiple level of users. This is a very intelligent system for any critical or non critical industrial processes or devices / equipments.

Salient Features

Configuration Utility

Mobile User Config: - This will allow user to define Mobile Numbers along with Mobile User Name.
Group Master: - Admin can create different groups and map mobile user into this group to which SMS has to be sent.
Alarm Configuration: - This will allow user to define different alarm message which is to be transmitted when an alarm event occurs. User can also define type of Alarm i.e Critical or Non Critical even it can define Group for Level 1 / Level 2 / Level 3 to which SMS has to be accelerated.
Configuration Setting: - This option will allow user to define communication port at which GPRS modem is to be communicated. User can also define SMS String how it is to be sent to User.
Manual SMS:- This option will have an option of Sending Manual SMS incase Admin want to update all user incase of any maintenance work on so that SMS Generated has to be ignored or even test system by sending manual SMS.
Manual Acknowledge: - This option will allow user to Manual acknowledge any SMS which was triggered falsely so that it is not accelerated further to next level.
SMS Log: - This option will allow user to check SMS log sent by the System. Printable option for the same is also available.
Application User: - This option allows Administrator to create multiple Application user who can access configuration utility. There will be 2 groups defined i.e. Administrator having access to all menus, Operator who can send Manual SMS, view SMS Log, Acknowledge SMS but will not have an access to configuration utility.

Admin Utility

Backup of Database: - Backup utility will be provided to backup database.
Restore of Database: - Restore utility will be provided to restore database.
Pending SMS Deletion: - This option will allow Admin to Delete any False SMS Generate by the system.

SMS Application

Application will continuously poll all defined Sensors and monitor status of each sensor. On Change of alarm condition application will generate an SMS for system.

Project Design

DreamSoft's Core competency is and will be in Analysis, Development Cycle & Implementation for various Web Based and Desktop Based Software Solutions in various fields. But after mastering the art of the Software Project Cycle, we have been able to guide the clients with the complete design of the Automation Process. After understanding the clients requirement, we can guide them which Automation Devices like PLC's, OPC Servers etc. will be or won't be required and what should be the flow of the logic for the same, integration of protocols with Devices and Equipments is one thing but getting specialized into which PLC or Logic Controller should be used is something which requires overall System Design Expertise.We have guided many clients with right advice and with practicality for their Device / Equipment / Automation Projects implementation. We have taken up many projects in which design consultants have used wrong methodology / concept and we have entered in that situation and changed the logic and have given successful implementation. Now with our experience, we can even help client in outsourcing right hardware vendor for Automation Devices and Equipments. Many times, as a Software Developer, its not our role to get into the consultancy of Hardware Design or suggesting some Hardware to client, but if we feel that better solution can be derived after changing the system, we do suggest our ideas to client. This is the reason, our clients don't want to leave us and want to use our expertise in various domains. We work as third party vendor too in many project implementations. We work seamlessly with the other teams working on the same project and integrate our solutions with them. Please do let us know if you need any consultation for End to End Project requirements too.

Protocols

Database & Scripts
SQL
.Net
Protocols
OPC Interface (OPC HDA, OPC DA, OPC UA & OPC AE)
Modbus TCP/IP
Modbus RTU
PLC Interface
Modbus Ascii
Ethernet Communication
SNMP
UDP
Ascii Communication
Any Customized protocol
Platforms
Windows
Core Expertise Areas
PLC and SCADA based application development
SCADA with OPC server
Developing Reports Application for SCADA / DCS PLC Projects
Developing bridge Application for SCADA / DCS Projects / PLC Projects
Web based Intelligent Building Management System

Contact Us

DreamSoft IT Solutions Pvt. Ltd.

105/106, Hinal,
Datta Mandir Road,
Dahanukarwadi Junction,
Kandivali (West),
Mumbai-400067.
India

Nirav Buch : +91 9870310606
Hiren Thakkar : +91 9821174015

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