Our Projects – Mage Control Systems

Ice Drill Controller and Data Logging System

Mage Control — Fri, 06 Dec 2019 15:06:19 +0000

Powering climate change research

As part of the Antarctic Survey, an American university research programme sought technical support from Mage Control Systems for a high-powered motor drive to power the drill responsible for cutting ice cores.

The embedded electronics powering the motor and the motor itself, had to be rated to -50^oC and be capable of reaching depths of up to 3km. This was deeper than their current equipment could achieve.

The new system was designed to provide a new drill motor, motor controller and communication systems using a custom LabVIEW HMI.

New features of the system were as follows:

9 axis attitude sensing – capable of sensing anti-torque, and other vibrational modes
Borehole pressure monitoring
High power density electronics
High precision adaptive control
BLDC in place of a brushed motor

A new high voltage, high-speed communication system was implemented to work with the accompanying LabVIEW HMI.

The final design for the motor drive has since been upgraded with expanded functionality by our engineers, attracting interest from others working on similar projects across the globe.

We welcome further enquiries about this product and look forward to working with others to achieve their goals.

HV/LV Cable Analyser

Mage Control — Fri, 06 Dec 2019 14:18:20 +0000

Non-Invasive Analysis for High Voltage Armoured Cables

Mage Control Systems has developed a non-invasive cable analyser – a completely new and unique tool – as part of an OFGEM funded Open Innovation call for Scottish Power Energy Networks (SPEN). Initially, SPEN sought a new solution that could:

Detect the live status of buried armoured cables such as P.I.L.C, Waveform, PICAS, CORAL, CNE, XLPE
Determine the voltage level – whether high or low – within a live cable (0V – 33kV)

Mage Control Systems was responsible for designing and assembling a set of handheld sensor clamps, designed to fit numerous cable diameters as well as a processor box to determine the results.

Using bespoke, innovative magnetometers coupled with inertial technology, the device does measure non-invasively cable statuses: i.e. Non-Energised, Voltage-Energised or Current-Energised.

The cable analyser will also allow detection of voltage levels within the cable and the number of conductors and cores present. This device will enable the defective section of cable to be pinpointed within a distance of 1cm.

Our team is now exploring further design opportunities for its HV/LV cable analyser in both gas and marine environments.

FADEC for Gas Turbines

Mage Control — Fri, 06 Dec 2019 13:00:13 +0000

Engine and turbine control for groundbreaking UAVs

The future of flight is with electric propulsion and we’re proud to be making huge leaps in innovative design for this sector. Mage Control Systems is currently designing a bespoke solution that does not currently exist, requested by a company seeking to revolutionise the future of UAV flight.

As UAV development continues to soar within industrial and consumer markets, the demand for increased capability will follow. Mage Control Systems stands at the forefront in this growing sector with our range of in-house technologies, expertise and unique design services.

Mage Control Systems was chosen as a design partner by our aerospace client to work alongside our senior engineers with their extensive experience in aerospace and defence sectors. Our engineering expertise is also drawn from safety-critical firmware development, advanced algorithm creation and mathematical modelling, setting the company apart from most other design SMEs.

We are responsible for the design of both the Full Authority Digital Engine Control (FADEC) and Power Management Unit (PMU). The FADEC essentially serves as the engine control unit for the UAV and monitors various parameters in order to achieve optimal performance. The PMU serves to control the electrical power BUS system.

The design team at Mage Control Systems has consolidated a number of separate PCBs onto only two units by means of a stacked PCB assembly. The tightly coupled FADEC and PMU allow for the fast, dynamic rate of change of engine control and power balancing functions under variable load conditions. Our unrivalled high-power density designs are perfectly suited to meet the project requirements for a complex battery/generator solution.

Our key expertise is both in high-power electronics and motion control for hardware design; essentially, this is achieved via the development of complex control laws and algorithms using state of the art tools such as MATLAB, Simulink and associated toolchains. Development using these tools allows for fault-free automatic code generation to meet DO-178C standard.

The PMU and the FADEC systems utilise a very fast processor loop cycle period for efficient space-vector modulated sinusoidal commutation – the electronics are rated up to 200,000RPM. The system is also fully dual-redundant (from processor to bridge to motor feedback) and the electronics have been designed to meet the required DO-254 standard. The hardware is also designed to meet DO-160G standard.

We are keen to grow our network in this evolving sector and would welcome any enquiries from those looking to develop similar products. Please get in touch at enquiries@magecontrol.com.

Precision Instrumentation

@rycramweb — Sun, 19 May 2019 09:33:48 +0000

In hospitals worldwide

Mage Control Systems redesigned the electronics for the legacy HemaTechnologies ESR STAT™ PLUS sedimentation rate analyser, designing for improved accuracy and performance, lower unit production cost and higher reliability. New, modern and advanced features include:

Advanced algorithmic control – increased speed, accuracy and sample rate testing per cycle
Modern interface options – USB and Ethernet while maintaining legacy adapters
Improved power performance
Reduced unit production cost

This work is a prime example of Mage Control System’s capability to understand the requirements around trends and technological advances that require the upgrade of already highly successful legacy products, helping our customers to remain clear market leaders.

Inertial Navigation

@rycramweb — Sun, 19 May 2019 09:25:59 +0000

Stable control in an unpredictable environment

Working with Thistle Design, this project required the expert development of a north seeking gyro-compass as a functional demonstrator for testing MEMs internal sensors for Thales Optronics, Glasgow as the end customer.

Work produced a test bed, delivered to bespoke specifications that gave the customer the technology required to test inertial sensing technologies being developed.

Expertise in precision, high accuracy embedded motion control technology led the design that integrated:

Low noise analogue design
High scan rate
A to D conversion
Provision of all hardware, software and electronics elements
HMI development using Labview
Integrated logging system

This work was completed utilising detailed knowledge of internal processing algorithms and the know-how to couple the Labview HMI with an integrated logging system.

Robotic Control and Actuation

@rycramweb — Sun, 19 May 2019 09:23:12 +0000

Electronics for groundbreaking medical robots

We are working with Thistle Design and a group of industry and academic partners to develop Morow Ltd’s prototype robot that will enable people to learn to walk again after experiencing a stroke. The project’s main aim is to produce a working model that can be used for clinical trials.

The Motorised Rehabilitation of Walking (MoRoW3) robot’s motion control system actuates machinery by utilising proprietary control algorithms and advanced adaptive control techniques.

Phase 1 of the development is now complete and Mage Control System’s work included:

Precision servo control and all electronics
Algorithms for walking motion
HMI development for use with medical tablet
High power density hardware design
Safety critical coding to DO178C standard

Mage Control Systems are delighted to have taken part in Phase 1 of the project and are pleased to note that we continue to be involved in Phase 2. The focus now is to add further functionality to the robot that will enable the already proven motion control system to respond more specifically to the nuances of individual patient biometric profiles.

Harsh Environment Electronics

@rycramweb — Sun, 19 May 2019 09:14:50 +0000

High temperature electronics for downhole tools and communication

We are listening to the demands from oil, gas and well intervention markets for downhole tools that can operate reliably and accurately in increasingly harsh, high temperature environments. The requirement to make tools and resources more robust and higher performing has inspired us to design the electronics that will drive these tools beyond current capabilities.

Currently, we already have electronic designs for a motor drive controller and an intelligent sensing and communication data logger for downhole use that will comfortably operate at 210°C.

We are now developing the next generation of our technology for downhole tools that will operate at 230°C. Using unique design and production methodologies, we can leverage the knowledge and expertise gained by the team at Mage from both the oil & gas and aerospace & security sectors, benefitting from the best technologies of both worlds.

Our current data logger PCB uses CAN BUS and RS 485 to intelligently sense and monitor function, performance and status. It can capture data over extended periods, analysing and storing it by clever utilisation of unique capture algorithms.

If you want to discuss how the developments of our new technology could boost your performance and productivity, we’d like to hear from you – please contact us. We are currently gathering expressions of interest and looking for partners who may wish to test our newly developed prototypes with a view to early adoption.

Wind Turbine Motion Control

@rycramweb — Fri, 17 May 2019 07:36:05 +0000

Driving renewable energy technology

The requirement was for a wind turbine pitch blade controller unit for SWIFT as the end customer. What was specifically needed and challenging was the provision of a scaled vertical axis wind turbine motor drive.

Complex motor control is one of the things we do very well and in this case we:

Designed and developed holistic electronics, software and the HMI
Designed complex motion control profiles for aerofoils
Implemented a smart communications network between 5 aerofoils
Developed algorithm processing electronics

With this project completed, it allowed the customer to trial and validate aeronautical models being tested for continued wind turbine development.