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Case Studies
 

 

 
WALLRICK SDN BHD with the aim to provide customer with professional and high quality security systems. Here are our projects management details.  
 

IP Cameras

 

Customer and location:

  • Residential home located in Selangor
  • Double storey terrace house, corner house
  • Medium compound with medium height fences

Problems:

  • High gates barred from seeing visitors outside the compound.
  • Medium height fences not high enough to prevent intruders from climbing into the compound
  • Corner houses makes more entry points for intruders to force into the house

Solutions:

  • IP cameras with 1.3 and 2.0 megapixels for best in and outdoor coverage
  • Linked with internet access for remote monitoring at anywhere possible

Workaround:

  • 1.3 megapixels cameras are being installed all over the interior part of the house with focusing entrances and exits in all available areas.
  • Ground floor balcony will be monitored by 2.0 megapixels cameras towards all possible entrances
  • The compound will be also monitored by 2.0 megapixels cameras, watching over the garden and fences with 100% coverage areas.
  • Exterior of the main gate will be also monitored by a camera install in a high place. Visitor area covered.
  • NVR will be linked with an UPS which also will be supplied to the cameras’ power supply for emergency backup when power failure.
  • Internet linked NVR will provide remote view in devices such as smart phones. Real time view achieved whenever needed.

Conclusion:

The house has been totally covered in views of megapixel cameras. All critical points within the compound are well watched and recorded. Customer can now view back to their home in real time as to check the house for abnormalities and be safer when arriving home.
On the other hand, they can now see who’s calling over their gate with a clear picture. Customer never has to open the gate and having a risk to expose them from possible harm.
This also helps customers to get a view on their pets in the compound.

 

Parking Guidance System

 

Customer Location:

Problems:

  • Jams occurred in parking lots as cars unable to search for empty slots
  • Customer frustrates about to pay and unable to park their cars
  • Time wasted searching around for space
  • Hidden empty lots are wasted as some areas are covered nor hard to be seen

Solutions:

  • Installation of parking guidance system with sensors on each parking lots
  • LED panels and light indicators as guides for empty parking lots

Workaround:

  • Each parking lot will be installed a set of sensors above the height of a vehicle. Sensors will trigger when vehicles parked fully in the parking lot.
  • Red and green light indicators will light up depending on the lot’s occupation.
  • The area controllers will be setting up in certain locations to received signals from individual sensors and then relays back to server
  • Server in control center will receive the status from each controller and updates the parking lots availability in the system.
  • The Parking Guidance System will send signal to the LED panels in the entrances of the carpark. It will show how many empty slots in each side of the area.

Conclusion:

               The carpark is being installed with lights and LED as guidance for drivers to find and park in respective empty lots without having to make turns and drive around the whole parking area just only to find out there isn’t any available there. The LED panel will show the quantity available empty slots in each side of the parking level, also the Red and Green light indicators will show about the lot is available or not. Drivers don’t have to drive all the way when they can see all the red lights for the pathway are lit in red lights.
The jams are in minimum due to cars doesn’t ever need to packed and stuck because of lot searching. They can quickly get an empty lot and free the pathway. Drivers can speed up and reduce their adventure when they are guided to availability.

 

Access Control

 

Customer Location:

Problems:

  • Having risk of crimes when letting the entrance door unlock and free of entry
  • Customer needs to keep an eye on the entrance
  • If door locked, customer needs to open the door every time there I people need to walk in and out of the premise

Solutions:

  • Installation of an Access System

Workaround:

  • Door will be bolted with an EM lock for each leaf. Means double leaf doors will have 2 EM locks
  • Card will be issued to each authorized personnel. Scan card to release the door for entry.
  • Password will be hold by the Administrator for the Access System in case of emergency and setup
  • Remote controller will be installed with connection to the door access controllers. Now the door can be opened without going to unlock the door manually
  • A push button will be placed just beside the door so people can release the lock when in need to open the door from inside the premise.

Conclusion:

               Having EM Locks and Access Control installed in the premise, customer won’t have to risk of having an opened door for unauthorized people that may bring unfortunate events. Authorized personnel on the other hand, are required to scan their individual RFID cards on the scanner to release the lock. This may apply to Time Attendance if the system is available.
Administrators now can take control for authorizations for all employees. He or she will be holding a password for the access control system and able to give authorizations to each staff. As staff no longer work for the company, the card they are holding till be invalidated and access will be denied. This can prevent unauthorized entry of previous staff that has not returned their cards from entering.
Staff can remotely open the door by a press of a button to let either customers or visitors in not having to go to the doorway just to release the lock. This saves their time and energy thus making an efficient system.

 

Avery Weighing Bridge System

 

Customer Location:

  • Cement Industries of Malaysia (CIMA) – Bahau Plant

Problems:

  • Manual weighing process takes a long time causing long queues
  • Lorries and trucks not properly positioned on the weighing bridge causes weight miscalculations
  • Drivers unable to tell when the weighing bridge is free for next vehicle
  • Identification and weighing process not able to be monitor 100% and thus unable to provide evidence of process

Solutions:

  • Installation of Avery Weighing Bridge System
  • PLC will be set in control of all devices on the weigh bridge
  • Comes also with sets of barrier gates and sensors for positioning control
  • 2.0 megapixels cameras installed for identification capturing
  • Traffic lights as indicators for queuing drivers
  • Tagging system will be implement with the system for authority checking

Workaround:

  • Lorry drivers will be acknowledged by the traffic lights. Red means the weighing process is undergoing where’s Green shows that the bridge is available and free to load
  • Vehicle will be driven up on the bridge. It should stop just in front of the outgoing barrier gate
  • In the meantime, sensors will detect objects in front and behind of the vehicle. Once the sensors are cleared of any objects, it will trigger the PLC and the system will bring the incoming barrier gate down
  • Avery system installed with connection with the weigh bridge. Automatically calculates in set of 3
  • The system will automatically record the calculations as the driver also need to some of and scan their authority card on the tagging scanner.
  • With the tagging record saved with the weigh calculated, the system saved the data and print out the papers for the driver as a report
  • When the weighing process finished without any errors, the system will notify the PLC and command the outgoing barrier gate to open for the vehicle to proceed and return to the ground
  • In the meantime, the red light will turn to green as if the weigh bridge is available for the next process

Conclusion:

               Manual calculation would serve a very time consuming process for a weighing process. Avery system coupled with all the hardware devices will able to cope with the problems such as time and manpower.
CIMA with hundreds of lorries queuing up for weighing processes, now with full Avery weighing system and devices solution able the prevent miscalculations. It also speeds up dramatically the process of weighing vehicles as it is fully automated.
Manpower in shift working for the weighing control center is left with minimum amount most of the processes are automated by the system itself.
The weigh bridge will not have another miscalculation as both barriers and sensors will keep the vehicle in place. If not, the barrier will not close as sensors still picking up objects in between showing the vehicle is not fully loaded on the bridge.
The tagging system minimizes the entry of data for the administrator and also reduces false entry for into the system.
By now, the whole system able speed up the weighing process by 40% and minimized most errors of both human and machine alike, thus increase of productivity overall.

 

Face Detection and Recognition Time and Access Control

 

Customer and location:


MFE Formwork Technology Sdn. Bhd.

Problems:

  • Mass workers having a great queue for punching in and out of work
  • Scan recognitions works extremely slow causing jams in queue
  • Mistaken identity when in the process of scanning

Solutions:

  • Installation on face and prints detection devices
  • Linked with local network access interconnecting the scanners and server.
  • Scanners are being installed in a several areas which spread apart for employees' convenience.

Workaround:

  • Multibio700 model face and prints detection installed in pairs in each possible entry/exit points around the factory
  • Each scanners connected to the nearest switch which net work are shared with the IP cameras
  • Data in scanners will be sent back to the server via the network backbone which consists of shileded Cat5e cables and fiber optics
  • Admins now controls the timestamps of each employees in front of their desks
  • Download of the data are being set to automation on daily basis

Conclusion:

The factory consists of thousand of eemployees are being manage into one single system no matter they works in the office or at the vast area of the factory. Scans now can be made using their fingers or even their faces as if their hands are not dirty or unavailable. Scans and recognitions are immediate as the data search and match in this new system is excellent. Therefore, the queue has been greatly shorten. Automation of the data collection set in the server downloads and cleared the transaction data to lighten the memory burden in all of the scanners. Daily attendance can be calculated in timely manner without any errors. Reports can be printed in multiple formats following the needs of information to each personnel.




 
 

Industrial Chillers

 

Customer Location:


New Nestlé Manufacturing plant

Problems:

  • In need of new chillers to provide manufacturing products in near freezing point
  • To cut cost of power management in use of chillers
  • Minimize manual work in operation of chillers. Need automation to control temperature and operations

Solutions:

  • Installation of Gea Chillers
  • Linkage with Danfoss inverters
  • Rockwell PLC control for systematic process in operation for

Workaround:

  •  5 units of Gea Chillers (5 degree x 3 units and 2 degree x 2 units). These chillers are for new production lines, freezing processes and new office AHU
  • Chillers are running by ammonia and screw compressor
  • All the pump and motor running by Danfoss inverter for energy saving management
  • PLC by Rockwell, Panel box by Rittal, overall using Lapp cables

Conclusion:               

Gea Chillers provides abundant temperature control for all new production lines in the process in manufacturing chocolate confectioneries.  In the other hand, this provides freezing processes too. The works of the screw compressor pressurize the flow of freezing liquids within the pipe and delivery it to each production lines and freezers.

                Danfoss inverter will greatly help to lower the cost of power consumption as the machines will have to run 24/7. Each power intake and distribution will be installed with ELCB to minimize the risk of power overflow which can damage the machines.
                Lapp cables are used with all the connections of power and data for all the chillers and inverters. All cablings are laid in sequences and with its cable tray for easy maintenance and yet able to tidy up the bundles of wires inter-connecting machineries. All cablings and machinery are installed into respective racks to separate out to each machines and controls. In conjunction, this serve more with the safety code of hardware installation.
                The Rockwell PLC has been set with the system to control and automates the working processes of the chillers, compressors, temperature control and also maintaining the use of power in the most efficient way.
 
Wallrick is a Mechanical and Electrical base company Contact Us
Wallrick is a Mechanical and Electrical base company based is Malaysia with office in Kuala Lumpur and Ipoh.  
   
KL Office :
No3 (ground floor),Jalan ss25/12,
Taman Mayang,47301,
Petaling Jaya,Selangor, Malaysia
Tel : 603-7497 3853 Fax : 603-7880 6853
Ipoh Office :
No183, Jalan Raja Permaisuri Bainum,
30250 Ipoh, Perak, Malaysia
Tel : 605-546 9368 Fax : 605-210 9368
   
 
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