Industrial-grade embedded firmware and display software for line-mounted differential pressure and flow indicators, delivering high-visibility plant-floor telemetry, real-time linearization, and process alarm interlocks.
The Challenge
Monitoring differential pressure DP and volumetric flow across plant-floor piping, filter banks, and orifice runs demands rugged, split-second readability in harsh industrial environments. Analog gauges vibrate out of calibration and offer no digital telemetry, while complex field transmitters often feature cramped LCDs that operators cannot read from a distance or through protective gear. In high-stakes manufacturing and utility lines, unflagged pressure drops or clogged filter elements lead to sudden pump cavitation, process contamination, and costly unplanned downtime.
What We Built
We engineered the dedicated embedded control firmware and local display interface for line of industrial differential pressure and flow indicators. The software continuously samples high-accuracy piezoresistive and differential pressure sensor bridges, executing edge square-root extraction, thermal compensation, and digital filtering to compute instantaneous flow and pressure drop. Designed for maximum visibility in active plant environments, the software drives high-luminance, wide-angle displays paired with configurable 4–20 mA, Modbus RS-485, and relay alarm outputs for direct integration into plant SCADA systems.
Key Capabilities
- Dynamic Flow: Real-time embedded algorithms executing square-root extraction, moving-average smoothing, and temperature compensation for gases, liquids, and steam lines.
- High-Luminance Plant-Floor UI: High-contrast, bold numeric readouts and visual trend/bar indicators engineered for clear legibility from across the shop floor and under dim factory lighting.
- Direct Field Transmitter & PLC Interfacing: Simultaneous output scaling across 4–20 mA current loops and Modbus RS-485 registers for seamless SCADA, PLC, and DCS integration.
- Configurable Trip & Filter Interlocks: Programmable high/low limit triggers and relay outputs that instantly flag filter saturation, burst lines, or pump flow anomalies.
- On-Machine Push-Button Calibration: Straightforward field zeroing, span calibration, and engineering unit conversion (bar, mbar, psi, m^3/h, LPM) directly from ruggedized front-panel keys.
Outcome
Delivered an ultra-reliable, ruggedized digital window into process line dynamics. Operators gain immediate, glanceable situational awareness on the plant floor, while maintenance teams prevent equipment failure through automated threshold alarms and rock-solid SCADA telemetry.