Our client required a bespoke control system to manage the filling of construction equipment at Key HS2 sites. A Human Machine Interface (HMI) was also required to allow on-site operators to adjust setpoints, configure settings, and view system status, with multiple security levels for different users. Additionally, the client requested a remote access functionality to monitor and control the system off-site.
Gemini Control Systems Ltd implemented a tailored approach to meet the client’s objectives efficiently and effectively, managing the project’s design, manufacturing, and testing phases to deliver a bespoke control system.
It was proposed that key system functions would be controlled through a Programmable Logic Controller (PLC). To ensure efficient operation, bespoke software had to be developed, supported by research into how the control panel would interface with the proposed equipment. The PLC also needed to operate fuel dispensers and card readers - functionality not standard to typical systems - which required additional custom software development.
The control system that Gemini Control Systems proposed was specifically tailored to meet the customer needs – there is not anything similar on the market. The complete project was designed to suit, from the control circuits to the parts being selected and the PLC software.
Gemini Control Systems also implemented a HMI that enabled on-site operators to adjust setpoints and configure system settings. This required additional software development and the creation of custom HMI graphics to meet the client’s specific requirements. Furthermore, multiple security levels were integrated within the HMI to provide separate access for operators and engineers.
By incorporating a PLC controller and HMI, the fuel pumping system achieved significant improvement over a standard system. The HMI provided operators with greater control, enabling easy adjustment of setpoints and parameters. In addition, the system’s enhanced intelligence allowed for quicker fault detection and diagnostics, delivering a more efficient, reliable, and user-friendly operation.
System Integration: Uncertainty around integrating the PLC with customer-selected equipment required extensive research and testing to identify suitable components and ensure seamless communication.
Remote Access and Control: Initial uncertainty about the method of remote access and required software prompted extensive research and development to ensure reliable and secure system operation.