CASE STUDY SNAPSHOT
Customer : An OEM supplying customized equipments for Indian RailwaysSize : >51-200
Project vertical : Industrial
Challenge : Need for low-cost Oscillation Measurement System for deployment in railway application.
Solution : Design and develop it with COTS SBC along with Android App configuration interface.
Services & Products Availed : Product engineering services, Mobile Application Development
Tools and Technologies :
- Key Hardware: Ti Sitara based AM335x EVA SBC
- Software Development: Java, C
- Frameworks: Android
- Frameworks: Accelerometer, Wi-Fi, SMS etc
INTRODUCTION
Our client, a leading equipment supplier for Indian Railways, faced the challenge of modernizing their aging oscillation monitoring systems. They required a highly accurate, portable, and exceptionally cost-effective solution to ensure the safety and quality of railway infrastructure, a critical component of national transport.
CHALLENGE
The primary challenge was economic and technical. The client needed a state-of-the-art Oscillation Measurement System (OMS) for highly specialized, niche applications like railway track quality assessment, bridge structural stability analysis, and machine health monitoring. The demand was for a very small batch—only a few dozen units. This limited production volume made a traditional, large-scale product development cycle with heavy upfront investment financially impractical. The solution had to overcome the limitations of their old, bulky PC-based systems, demanding a portable, field-ready design that delivered high-precision data without the high cost.
SOLUTION
A Smart, Two-Part System
Embien Technologies analyzed the complex requirements and engineered an innovative, affordable solution that bypassed the need for expensive, proprietary hardware and PC software. We strategically split the design into two core components: a rugged Data Acquisition (DAQ) device and a powerful, intuitive Android application, setting a new industry benchmark.
1. The OMS Data Acquisition (DAQ) Device
High-Fidelity Sensing: At its heart, the device integrates a sensitive 2G accelerometer operating at a 10Hz sampling rate, capable of capturing minute vibrations with exceptional accuracy. This is crucial for detecting subtle track imperfections or early signs of structural fatigue.
Pinpoint Location Tracking: We incorporated a high-frequency GPS receiver with an external antenna. This ensures a strong, consistent satellite lock for precise real-time location and time-stamping of all measurement data, even when the device is installed in concealed locations within a train carriage. To counter signal loss in tunnels or dense urban areas, we developed sophisticated dead-reckoning algorithms that accurately estimate the location until GPS connectivity is restored.
Seamless Connectivity & Cloud Integration: The device features dual communication interfaces: Wi-Fi and GSM. It can act as a Wi-Fi access point, allowing a direct, simple socket-based connection to a smartphone for on-the-spot configuration and data retrieval. Simultaneously, the integrated GSM module enables it to automatically push all logged data to a secure Azure IoT cloud platform for centralized storage and analysis. If GSM coverage is lost, the system intelligently buffers all data internally and transmits it once connectivity resumes, guaranteeing zero data loss.
Versatile I/O and Intelligent Alerts: Beyond vibration, the system supports eight analog inputs for acquiring data from other sensors and four digital inputs to map external events. Digital outputs are also available to trigger external alarms or devices. Users can define specific vibration thresholds, and if these are exceeded, the system automatically triggers alerts via LED indicators and sends an SMS with the exact time and geographic coordinates of the event to designated personnel.
Cost-Effective and Durable Design: To meet the strict budgetary constraints without compromising quality, the entire system was built around a proven, Commercial-Off-The-Shelf (COTS) Linux Single Board Computer (SBC) - the Ti Sitara based AM335x EVA SBC. This significantly reduced development time and cost. Housed in a durable enclosure and powered by a high-capacity standalone battery, the device can operate for over a year without maintenance.
2. The Android Application Interface
Replacing the cumbersome PC, we developed a feature-rich Android application that puts complete control in the hands of the field engineer.
Secure and Simple Configuration: The app begins with a secure login screen. From there, users can easily calibrate sensors, configure data acquisition rates, and choose whether to store data locally on the device or upload it directly to the Azure cloud. It also allows for setting the SMS alert thresholds.
Powerful Data Visualization and Reporting: The application provides elaborate data visualization tools, including dynamic charts and graphs that help engineers quickly assess system health and analyze vibration patterns. It can pull data directly from the DAQ device or from the Azure cloud storage. The app generates comprehensive reports that can be instantly viewed, emailed as PDF documents, or printed for official records and compliance.
Over-the-Air (OTA) Firmware Updates: A key innovation is the app's ability to manage device firmware updates remotely. This future-proofs the system, allowing for functional upgrades, security patches, and new features to be deployed wirelessly without the costly and time-consuming process of recalling devices from the field.
This two-pronged approach delivered a powerful, modern, and highly flexible Oscillation Measurement System perfectly tailored to the client's niche requirements and budget.
BENEFITS
Drastic Cost Reduction: Achieved over 70% cost savings compared to traditional development by leveraging a COTS SBC and a smartphone app, eliminating expensive custom hardware and PC software licenses.
Superior Portability & Efficiency: Replaced bulky, legacy equipment with a compact device and a user-friendly Android app, empowering engineers to conduct tests and analysis efficiently in the field.
Uncompromised Data Integrity: Ensured highly accurate, geo-tagged data with high-precision sensors, intelligent algorithms, and a fail-safe mechanism for data buffering and cloud synchronization.
Enhanced Proactive Safety: Enabled immediate response to potential hazards through real-time, automated SMS alerts triggered by excessive vibrations, preventing failures before they occur.
Future-Proof, Low-Maintenance Solution: Provided a scalable system with OTA firmware updates, ensuring long-term viability and easy deployment of new features without physical device recalls.
CONCLUSION
Embien successfully delivered a next-generation Oscillation Measurement System that solved a critical challenge for our client in the Indian Railways sector. By combining intelligent hardware design with a modern mobile interface, we provided a solution that was not only technologically superior but also economically viable for low-volume production. This project underscores our capability to develop highly specialized, cost-effective embedded systems for niche industrial applications.
If your business requires a transition from legacy systems to a modern, efficient, and affordable technology solution, Embien has the expertise to make it happen.
