Live Data Capture Solutions in Bangalore | Real-Time Industrial Data Acquisition

PSA-1341 Data Traceability and Automation System

Fully integrated production platform designed to automate assembly, testing, and data capture across the CSD (Condensate Separator Device) manufacturing process.

System Overview:

It provides real-time visibility, machine-to-server data synchronization, and complete product traceability with automated Poka-Yoke (mistake-proofing) controls at every stage. System Overview

The server logs all inspection data, including test results, thermal profiles, and barcode-based product identifiers, ensuring complete traceability across the entire assembly process.

Each test and assembly station — including Grommet Pressing, Screwing & Labeling, Completeness Checking, and CSD Leak Testing — communicates with the central data server over Modbus TCP or RS-485.

All process results, operator IDs, and barcode data are automatically logged and stored in a secure CSV/SQL database.

The system ensures 100% quality verification of all units produced and eliminates manual recording errors.

Key Features:

• 1. Multi-Station Integration
  • Supports synchronized communication across all PSA-1341 test benches:
  • CSD-1 Grommet Assembly & Leak Test Station
  • CSD-2 Completeness Checking Station
  • CSD-2 Negative Leak Testing with Zebra Label Printing
  • Final EOL Machine with Barcode Validation and Poka-Yoke Interlock
  • All machines are networked to the main data server for centralized monitoring.
• 2. Centralized Data Logging
  • Real-time collection of test results, timestamps, and barcodes.
  • Automated data transfer from PLCs via Modbus TCP.
  • Shift-wise performance reports and auto-backup.
  • Secure storage in structured SQL/CSV databases for audit traceability.
• 3. Functional & Leak Testing
  • Dual-stage leak test validation using ATEQ leak testers.
  • Configurable vacuum/pressure test modes for CSD components.
  • Auto-result classification (PASS/FAIL) and digital signature logging.
  • Integration with Zebra printer for automatic traceability label generation.
• 4. Intelligent Monitoring & Poka-Yoke
  • Real-time dashboards for test status and machine health.
  • Process interlocks prevent operation without barcode scanning or correct part placement.
  • Visual and buzzer alarms for NOK conditions.
  • Operator authentication and shift identification for accountability.

System Benefits:

• 100% digital traceability of all test data.
• Zero operator dependency for data entry.
• Instant OK/NOK decision and data backup.
• Seamless communication with main Modbus data server.
• Compliance with IATF 16949 / ISO 9001 automotive quality standards.

Application Areas:

• Air er and CSD module assembly lines.
• Leak and functional testing for plastic and aluminum housings.
• Barcode-based end-of-line traceability systems.
• Automotive component production with data analytics integration.