Skilled in the design of complete systems, Winter and Smith will uniquely tailored to a any of your system requirements, whatever the industry.
It is often the case that a system will consist of custom electronic equipment designed to perform a function that is impossible to achieve using off-the-shelf parts. In many cases embedded software and PC software is required, and even machinery or mechanical equipment. But not to worry, as Winter and Smith have a comprehensive machine shop ready to go for any of your requirements.
One system we made was for M&I Materials, manufacturers of Metrosil silicon carbide varistors used as surge protection devices for such applications as the railway network, and power lines. Their larger varistors are capable of absorbing energies up to 50,000 joules per disk.
We were contracted to design a system to test and grade the various types of varistor as they left production. This would QA check the manufacturing process, and calculate the characteristics of the varistors.
The system however – needed to apply variable voltages of up to 3000Vdc, and measure the current through the Varistors…
Protecting workers’ hearing is essential in any modern factory. In environments filled with heavy machinery, wearing hearing protection at all times can seem like the simplest answer, but in large facilities, it isn’t always practical.
Often, only one machine is running, positioned in a distant corner of the building. Workers elsewhere may not hear it, and may not realise protection is required. That was the challenge faced by Winter & Smith Electronics.
The solution was a networked noise-detection system, made up of intelligent sensors, each paired with a highly visible illuminated warning sign.
…the system required however, needed more than just electronics.
The first stage was the design and creation of a test chamber to test the Varistors in. We also needed to design and machine up custom brass test probes on a mechanical lever arrangement, that could be lowered onto the disk prior to testing; all this whilst ensuring that the system was completely safe to use.
Using a combination of Mechanical Design, 3d Printing, 3d Cad and 2d Cad – and using the expertise of a local plastic sign maker – the test chamber was designed and built.
Our client decided to add a new feature to the system. As well as making large varistors of several inches in diameter, they also make smaller varistors with legs – suitable for fitting onto circuit boards. The decision was made that the system looked so good, that they would also like to use it to test these devices – so they requested that we design a smaller chamber, to test these devices as well, and add the ability to switch between chambers.
We designed the smaller test chamber with a hinged lid, so that it could be opened to access the probes – we then fitted interlocking safety switches on the unit, so that when the lid was opened – the system could not operate.
Once the system was fully designed, this test chamber worked perfectly.
After seeing how well the system was working, the client requested that we do another design for the system – as a “halfway house” to allow them to also test slightly larger modules, that are the size of coins.
We then designed another test chamber, this one based on the design and mechanics of an old school Morse Key (drawing on Mikes knowledge from Amateur Radio), with a lever based test chamber – where the probe was attached to the lid.
A key part of the system, was the requirement for it to be capable of generating between 0 and 3000V in programmed increments of 1V, with a very fast response time. Using a bespoke Power supply from Spellman High Voltage, we could fully programme remotely.
The decision was made to fit all the electronics into a double height electronics rack, and make all of the control cards plug in (This would also mean that should any issues occur with any cards, a replacement could simply be plugged in – a problem that has not yet arisen, over 10 years since the system was designed).
The control system incorporated many different control cards, safety interlock systems, means of displaying data.
In order to obtain the key figures, the operator would specify two currents (in mA) that the disk should reach. The system would ramp up the DC voltage until it reached current 1, it would then log the voltage at which this occurred. It would then continue the ramp up to the second current test point. The voltage would also be recorded here. These figures could then be used in a number of calculations – in order to obtain the operating characteristics of each varistor.
The system even incorporated a smoke alarm, so should a varistor catch fire – the testing would be aborted.
It was requested that a piece of bespoke PC software was written, to allow the system log and serial number each disk – and output to a printing system, so each disk could be identified. A serial interface was added to the control rack to facilitate
We have worked on many complex Systems over the years including:
We are currently working on the design of a train radiator cleaning system for Rolls Royce.
If you have a complex system you require – that doesn’t just require electronics design, but a lot more in addition – consider Winter & Smith. We have a comprehensive network of other suppliers we work with to create almost anything.
