SAPHI

Who was our client?

Farming communities in rural NSW.

What problem did farmers need SAPHI to solve?

SAPHI has always had a soft spot for farmers so when a group of farmers approached us and told our team of the water management problems they were having we decided to act.

The Farmers were frustrated with travelling hours each day to visually check every tank they owned to check the water levels. They also expressed the devastation caused when they realised a tank had sprung a leak overnight and they had lost all of their water.

They needed a more efficient and reliable way to monitor their water in order to protect it.

What was the solution?

In short: SAPHI designed and developed a tank level monitoring system that would enable farmers to track the water level of various tanks from anywhere in the world.

Detailed: SAPHI created an end-to-end solution that farmers could use to monitor the levels of their tanks at any time, from anywhere. The comprehensive system is a great example of SAPHI’s  IoT offering. With our custom software, we can programmed sensors to collect the water data from the tanks, communicated the data to the cloud and made it accessible via an intuitive user interface design, enabling the user to have complete control of the system at all times and locations.

The IoT solution provides a comprehensive data set to a user with an accuracy degree of 1 mm ensuring water health is closely protected. SAPHI implemented a SMART alarm system which included warning emails for water levels falling below configurable volumes, detection of a high rate of change, indicating leakage or open taps, and battery status warnings. Allowing the user to take quick action to protect their arguably most precious resource.

What skills did SAPHI use to implement the solution?

The design and implementation of the system required a broad range of technical skills including:

• Low-level embedded code for reading sonar and temperature sensors that pushed information to a database
• Database design and implementation so the sensor data could be accessed via the web front-end and individual sensors could be assigned to specific user accounts
• API development so the devices could be configured from the web front end
• Front end development of the smart farm user portal
• Design of the solar battery system to ensure the system would run for at least 2 days without sunlight.

Who was our client?

Orica is the world’s largest provider of commercial explosives and innovative blasting systems to the mining, quarrying, oil and gas and construction markets, a leading supplier of sodium cyanide for gold extraction, and a specialist provider of ground support services in mining and tunnelling.

What problem did Orica need SAPHI to solve?

The Orica underground delivery systems are run by LOADPlus Underground software. Orica has hired SAPHI for on-going support to develop, test, commission and support the control system software.

What was the solution?

SAPHI helped develop the underground control system and the user interface that makes up the LOADPlus Underground software. SAPHI also developed a rigorous process for developing, testing, commissioning and supporting the control system software.

What skills is SAPHI using to implement the solution?

The software is based on the IEC 61131-3 standard which runs on a custom-built human-machine interface. SAPHI has leveraged its years of experience working with control systems which includes:

• PLC Programming
• PLC User Interface Implementation
• CAN Bus Communication
• Danfoss Valve Control
• Testing and Debugging of Electrical Control Cabinets

What support is SAPHI offering Orica?

SAPHI has a support contract with Orica and has been providing on-going support and maintenance since 2017.

What problem did SAPHI need to solve?

At the time, search and rescue robots were difficult to control. The necessary movements were counter-intuitive and operators required significant training to be able to reliably deploy these devices in the wild. A newer, more intuitive version was required that would allow for simply adoption by operators.

What was the solution?

In short: Building a robot that could be operated intuitively via a VR headset and controllers.

Detailed: A Telepresence Control System allows for a more natural approach to controlling a complex robotic system. This is made possible by using a Virtual Reality headset and controllers. Virtually Reality technology is used to immerse a user into different worlds such as in games and 360° recorded videos. Telepresence control takes the technology one step further by using the parameters collected from the headset and hand controllers within a 3D space and mathematically modelling the position of each servo motor.

The Search and Rescue Robot SAPHI engineers developed has two manipulator arms and a camera arm. The camera arm gives the pilot a first-person view of the position of the robot via live low latency video feed. The VR headset roll, pitch and yaw sensors are used to determine the angles in which to move the servo motors for positioning the camera.  

The Robots two manipulator arms are controlled via VR hand controllers. The hand controllers are tracked relative to the position of the headset which produces data that can be used in a mathematical model of the manipulators. The model determines the angle in which 16 servo motors need to move to in real-time.

The manipulators have a set of pincers which are used to interact with the environment around the robot. The pincers position can be varied by the amount of pressure placed on triggers that are located on each hand controller. Haptic feedback pressure from the amount of torque being applied to the pincers is also fed back to the hand controllers in the form of vibration. The more pressure being placed on the item being pressed, the more the controller will vibrate.

The benefits of such a control system being used in a rescue situation include;

• Removing rescue personnel from dangerous situations
• Intuitively allow rescue personnel to interact with the environment surrounding the robot with minimal training

What skills did SAPHI use to implement the solution?

SAPHI engineers implemented a complete end-to-end solution by using a broad range of skills within the areas of:

• Control System Design
• Embedded Systems
• Power Systems
• Robot Kinematics
• User Interface Design
• Wireless Communications.

What problem did SAPHI need to solve?

When it comes to Surf Life Saving a set of binoculars is a crucial piece of equipment used to identify distressed swimmers. Once identified current methods of rescue not only place the rescuer in varying levels of danger but consume a considerable amount of precious time available to the distressed. The use of drones has started being trialled in rescue situations but still rely on trained pilots to pilot the drone to the distressed location for delivery of a flotation device.

What was the solution?

In Short: Augmented reality control system that determines GPS coordinates of the distressed for drone navigation using visuals alone.

Detailed: SAPHI Engineers designed a new control system for Surf Life Saver Drones by switching out the surf lifesavers binoculars for a virtual reality headset that controls a camera. This creates an Augmented Reality Control System which works by applying a digital overlay to the world we see with our eyes. In this application, a crosshair is used to line up the distressed for the GPS coordinate calculation. From the height, angle and orientation of the camera, it is possible to determine the GPS coordinate of the distressed based on visuals alone.

The VR headset has a first-person view from the camera’s location on top of the lifeguard tower. When the surf lifesaver moves their head the roll, pitch and yaw sensor data are used to change the angle of the camera. Once the GPS coordinate is calculated, the drone is deployed to fly to the location of the distressed and give aid in the form of a flotation device and verbal commands.

Benefits of such a control system being used in surf lifesaving situations include;

• Reduced response time between identifying the distressed and getting to their location.
• Minimum training required to use a VR
• Audio link between the shoreline and the distressed.

What skills did SAPHI use to implement the solution?

The tech stack and experience required for this job included a broad range of skills from our team of computer, electrical and software engineers, including:

• NodeJS
• C++
• Angular
• PWA
• No SQL Database Design Implementation

Who was our client?

Ampcontrol delivers integrated electrical, electronic and control solutions to improve safety and efficiency in mining, renewable, infrastructure and industrial applications.

What problem did Amcontrol need SAPHI to solve?

Ampcontrol has a production line for manufacturing its products and was having efficiency problems when it came to testing through the assembly line. SAPHI was hired to make this process more efficient.

What was the solution?

SAPHI’s engineers and developers recognised that the best possible solution for maximising client outcomes was automation. SAPHI and Ampcontrol agreed that constructing an automated test system would be the best way for Ampcontrol to reliably and efficiently test its products.

What skills did SAPHI use to implement the solution?

SAPHI leveraged its expertise in a broad range of areas to construct the system, including:

• Test Jig PCB Design
• Hardware Specification
• Test System Control Software
• Test Sequencing Software for Unit Tests
• PCB construction
• Jig wiring and installation
• Test system commissioning and documentation

What support did SAPHI offer after completion?

SAPHI continues to support the automated test system on an on-going basis as required by Ampcontrol. This includes working with production test engineers to help increase the capability of the system and provide basic training on the software development.

Who was our client?

Virtual Simulation Systems develops industry-leading simulators for the defence industry, creating replica cockpit training systems that are combined with Titan Vanguard simulation software to create realistic flight training systems.

What problem did they need SAPHI to solve?

VSS was contracted by a defence agency to construct an advanced helicopter simulation system that could accurately replicate scenarios for training purposes. VSS required SAPHI’s expertise to construct a suitable system that would meet the requirements of VSS’s client.

What was our solution?

SAPHI and VSS decided that building a haptic feedback system for a helicopter cockpit that would simulate real-world conditions would meet the requirements of VSS’s client.

The control system provided variable force on the operator based on the delta of the control sticks centre position. It also fed the position of each axis back into the TITAN software to control the virtual helicopters roll pitch and thrust. SAPHI also developed a cross-platform user interface for calibrating and tuning the system on commissioning at the customer’s site.

What skills did SAPHI use to implement the solution?

SAPHI was involved in the complete development of the feedback system which required a broad range of skills including:

• Hardware Specification
• Electrical Design
• Control Systems Software
• User Interface Design
• Titan Vanguard Software Integration
• Wiring
• Installation and Commissioning

Who is Orica?

Orica is the world’s largest provider of commercial explosives and innovative blasting systems to the mining, quarrying, oil and gas and construction markets, a leading supplier of sodium cyanide for gold extraction, and a specialist provider of ground support services in mining and tunnelling.

Why did Orica hire SAPHI?

Orica hired SAPHI to write LOADPlus control system software and develop the user interface for the Bulkmaster 7.

What is the Bulkmaster 7?

The Bulkmaster™ 7 is the latest addition to our industry-leading bulk explosive delivery systems. This state of the art technology creates a step-change in efficiency on bench for customers in the open cut mining sector.
The Bulkmaster™ 7 minimises the number of assets, people and time it takes to load a blast. 

What is the solution?

SAPHI works with the Orica team to develop the low-level control code and implement the user interface based on feedback from the Orica UX design team. SAPHI has also assisted in the development of the automated test system architecture and in the writing of automated tests for the LOADPlus software.

What skills is SAPHI using to implement the solution?

Saphi implemented its solutions for this project using a broad range of skills including:

• LabVIEW Real-Time
• FPGA Code
• TestStand
• API Development
• Adobe XD Mockup Translation 
• PWA
• No SQL Database Design Implementation

What support has SAPHI offered Orica?

SAPHI has a support contract with Orica and has been providing on-going support and maintenance since 2017.