From Wiring Diagrams to Workflow Wonders: My Journey in Engineering Automation

Introduction

As an electrical engineer, I worked on various projects that involved preparing wiring diagrams—the initial references that spark countless revisions and detailed discussions with clients. Each wiring diagram submitted would return bristling with comments, as meticulous clients scrutinized every comma and endpoint. Responding to these annotations required updating the diagrams and meticulously preparing corresponding responses, known as Change Response Sheets (CRS).

The work got pretty scary. It was such a time-consuming activity: to manually extract every comment from the PDFs into an Excel sheet, arrange, and address them. It was equally much irritating to my productivity and patience. In seeking a solution, I scanned the digital landscape in which tools that may have been put to use for automating this extraction were available, but to no avail. Nothing fit the bill.

While I believe in the saying that necessity is the mother of invention, what actually drives contemporary invention is not necessity but laziness. It is the desire to make tedious tasks easier. With this in mind, I sought to make such a tool—one which could make the process of preparing CRS documents out of extracted comments from a bunch of PDFs so much more straightforward. This was the inception of my project, primarily driven by the urge to be more effective and break free from the monotony of these tasks.

Development Journey

To start off my journey to make comment harvesting easier, I looked up at an unassuming but ever-willing helper; ChatGPT. I shared my needs and from its recommendations, I settled for the Python programming language. While my experience in coding was limited to the development of scripts of different complexity within the VBA language framework for Excel, I realized that now it was quite a different level. With its wide range of libraries and community support, Python should be offering all the flexibility and power that I need to face this challenge.

I rushed to fill the gap in my knowledge and tried to learn Python. I focused on the syntax of Python and their libraries, including PyPDF2 – for pdf manipulation and pandas – data handling. It was so helpful because I could derive ways to start building my application.

PDF Parsing

The first kind of work was creating a function that read and extracted comments made in PDF files. The complexity was based on the fact that the comments can exist in so many formats and nested in any part of the documents.

Data Structuring

I used the results of the analysis mentioned earlier to derive a method of structuring all comments in an ordered, structured Excel. The relationship between each comment and its related section within the wiring diagrams had to be maintained; otherwise, it would not serve the CRS documents properly.

User Interface (UI)

I developed an initial user interface into basic command-line format and continued later on to develop a simple Graphical User Interface (GUI). This made the tool far more accessible—users could simply pick their PDF files and choose where they wanted to save the Excel outputs.

As an example, in the development process, I had to cope with a lot of issues: from supporting a wide range of PDF comment formats to being compatible with many operating systems, every next issue involved getting deeper into the structure details of PDF files and iteratively refining parsing algorithms accordingly to allow one to perform various very specific use cases.

Regular testing and feedback loops with the end users helped to fine-tune the tool to make sure it was, in fact, a practical guide for the poor engineers and project managers trying to battle similar documentation. The sum of this collective effort not only improved the functionality of the tool but also gave insights into the needs and experience of potential users.

Impact and Reflections

Development of the PDF Comment Extractor tool is a big milestone of my engineering career. It not only greatly facilitated the process of updating wiring diagrams and preparation of CRS documents, but also reduced the frequency of mistakes and the workload directly related to manual input. Acceptance of the tool among colleagues has been really good, and much better and smoother working processes have been enabled, leaving our team to focus on more critical engineering tasks.

Not only was this technically very challenging, but personal and professional growth with programming and problem-solving has been a journey because of developing this tool. It took my knowledge about programming and problem solving to another level. Indeed, this has repeatedly underscored the importance of staying abreast and in synchrony with current technologies in the fast-track professional world that exists today.

I vividly recall that during my fourth semester, we were introduced to the wonders of C programming in engineering college. While making simple functions, writing arithmetic operations, or playing with a few mathematical series, the thought in the back of my head had always been, "How do we use this in real life?" I always considered creating the .exe to be the core of software development, something so conceptual and far out.

Developing this tool in Python has significantly deepened the understanding of how code actually works and the concrete effect of throwing in a user interface. It has lit the whole way from just a piece of code on the screen to a real working application that provides for real-life needs.

I will learn to appreciate the value of allowing the student to extend basic coding exercises to include UI development. Perhaps it would be this motivational bridge for them, whereby their code wouldn't be merely an exercise but a building block of actual tools and applications. For budding developers, creating that user interface might turn the process of software creation into something achievable, changing abstract code into something completely visual and functional—sort of like bringing a skeleton to life.

So far this journey has improved not just my technical skills but also my appreciation for the craft of software development itself. This can come under the name "impressions of key understanding" from hands-on use, and for me, true joy in engineering is turning theory into practical solutions.

Adopting Work-Life Harmony: A Philosophical Perspective

 

Today, my colleague and I were deep into designing an air handling unit—a system made up of fan motors and monitoring devices, all put together for top performance. My colleague, who is great at mechanical design, had just finished creating the unit's structure.

However, we hit a snag when the motor we initially chose was unavailable. The procurement team then found a replacement from another brand. To make sure it would fit perfectly, my colleague carefully checked its dimensions against our design. Everything looked good, but he needed my OK to confirm the electrical specs matched what we needed for the project.

As we sorted this out with suppliers, my mind drifted into a fun analogy. I realized that our process of verifying the motor's compatibility was similar to finding a life partner. Just like we check a motor's dimensions to see if it fits, when searching for a partner, don't we ask about their family background, values, and how they fit into our lives?

Think about it: while we can simulate how a motor will work using software, predicting a person's actions is much harder. Isn't that interesting? How do you handle decisions like these—whether in technical projects or personal relationships? Do you see the similarities in how carefully you choose whether it's for a project or your personal life?

This little analogy added a touch of whimsy to our technical talk and made me reflect on the care needed in both our work and personal lives. Whether it's ensuring a motor runs well or finding someone who fits perfectly, attention to detail and thoughtful consideration are crucial.

Control system design

Best part being an automation engineer in small-scale firm which manufacturing special machine is you could have opportunity to involve in all steps of manufacturing.

• Design and drafting 
• Production 
• Factory testing 
• Commissioning 

Let me explain all steps based on my previous company experience.

Design and drafting

This part is the most important area. Here we discuss the with client and note all the requirements from the client side. Mechanical design engineers check the space constraints and prepare the spacing layouts and complete the dimensions.

In the Electrical design section includes the following steps:

Design of sequence of operation.

Sequence of operation design is based on the clients required. From the client side, they give the process details or machine operation details and final product. According to that one, we design the sequence of operation.

Design of Cause-and-effect matrix.

Cause and effect matrix designs includes operation of machine in the different mode like auto, semi-auto, manual. In this section, we design the response of the machine when the inputs are energized. Emergency response of the machine is designed in this section. From these we will get the exact idea of machine response. According to these causes and effect diagram, we prepare the operating manual and parameter list.

Design of schematic diagram.

Once panel SOP and Cause and effect design completed according to that we prepare the schematic diagram for the machine in this section we select the controller and input and output allocation.

Panel sizing, IO listing and material selection.

After schematic preparation we prepare the general layout of the control panel and according to that we decide the panel size also need to consider the temp effect in panel. VFD panels required additional cooling systems.

Cable routing design

From the 3D models of the machine, we prepare the cable routing and cable tray locations. As per the electrical load, we select the cable size. For instruments required specials cables for the communication systems requires shielded cables. As per the cable's selection, we prepare the cable Termini nation Lay-out. According to the glands and gland plate size is done.

BOM preparation

From the above sections we prepare the bill of materials and in this section, we consider the costing side. We take Quotations from different suppliers and finalize the materials.

Production.

In this section, design is handed over to production department. As per the schematic and BOM, they prepare the control panel wiring and fix it in the machine. Cable routing and terminations are done as per the design.

PLC programming, HMI Design and testing.

As per the sequence of operation and IO listing, we prepare a logic program. Initial stage program output is simulated using software and verify the cause-and-effect diagram. Once simulation is ok then we download the Program to the actual controller.

 To be continued......

Wireless thoughts😇

WiTricity!!!!

Have you ever heard this word before???

During the time of my first year of Btech. , I heard this word. In my college all department have their own associations and those are the platform where to interact with seniors.at that year our association was inaugurated by a senior engineer from KSEB.he delivered an inaugural speech and mention about the power transmission. He quoted that communication technology revolution happened after the invention of wireless system and still have the opportunity to find the way to transmit electricity through wireless. Those talks gave me spark in my mind and after that program I googled how can we transmit the electricity wirelessly. That search was ended with word WiTricity.

WiTricity means wireless electricity, this word was firstly used by Massachusetts scientists, and they invented one circuit and transmitted 60 watts energy with 5 meters of distance. Which was based on the theory of eminent scientist tesla. Law of induction, our transformers and electric motors are operating on the basis of the theory of induction. Even in transformer the energy transfer from primary core secondary is by magnetic field, those principle also can be used for the wireless Technology.

From those papers, I got a decent idea about the wireless transmission and at the same time  i realized that it’s not feasible for the long-distance power transmission. But it can be used in the portable device charging. So, I focused my research on the portable device charging.

Wireless charging pad for mobile and laptops, wireless charger for artificial pacemakers, wireless charger for electric cars. From those all applications i have selected wireless charging pad for mobiles for the prototype development.

The wireless charging system consists of a transmitter which includes a power circuit and magnetic oscillator which generates a signal with high frequency. That signal feeds to a coil. Receiver section consists of a Receiver coil and rectifier circuit with voltage regulator. regulator maintains a constant Voltage output.

I discussed these all with my classmates and we formed a team, and our department gives permission to use the lab for testing. we designed an oscillator circuit and transmitter coil. we did some testing in order to check whether the power transfer can be possible through this arrangement. After the testing we realized that that circuit is not enough carry power for the mobile charger.

Around 1-2 months testing we found one circuit which can transfer the power for the mobile charger. at that time my dream was Indian made phone with our wireless charging technology. These all the things happened 2015.

Today we wireless charging is common and premium phone brands are providing wireless charging as optional feature.

All happens for the good reason. When a door is not open towards you, still gives an opportunity to knock other doors. If I quote Paulo Coelho words, it might be a conspiracy of nature.

Inertial quality of sine wave

For an Electrical engineer can’t avoid the sine wave because whatever they are studying which always connected to the sine wave.

For example, when we are studying about power generation, the generated electricity is sinusoidal.When we move to signal processing and analysis, all signals are represented as the sum of sine function (Fourier series).Then we get to communication systems, there sine is considered as fundamental signal!

Have you ever thought about why sine wave is a fundamental wave???

Some might know this reason, sine wave can be produce In lesser cost, but that is not the only reason, to sine wave considered as fundamental.

Sine wave has a unique quality compared to other forms of waves.

Before that, let me explain some basics of electrical circuit. For an electrical circuit, contains components like resistor, capacitor, and inductor. All electric circuits comprise these three major items. In an electric circuit Capacitor means, which will function as an integrator. And the Inductor means which will work as a differentiator.

Coming back to sine wave, when a sine wave passing through the capacitor, which will be integrated. IE a sine wave is passing through capacitor which will be converted as a cosine signal.in other words which will be changed as sine wave with with a 90 degree phase shift.If sine wave is passing through an inductive circuit which will be differentiated and  output is an inverted cosine signal. 

For a square wave when it passes through capacitor which will be converted as triangular wave .when we observe all the waves and behavior in electric circuits its loss its basic nature and changed to different form.but In both cases, sine wave keeps its sinusoidal nature. In my opinion This is the major reason for sine is considered as fundamental wave.

In our way of life, we might pass through up and downs. Sine teach us to never lose our qualities even we are going through the obstructions and struggles! 

Be like sine wave!

Always be like sine wave!

Jio dairies📄

After my Btech. degree I did Specialization in automation technology and joined in automation company, from there I got exposure in certain process control projects like water treatment plant automation, crusher automation medium level substation automation, machine automation which were all for to reduce the Human efforts in the manufacturing process and improves the quality of the product. Those were all really excited project, and I had got a opportunity to involve in the gyro sensor manufacturing machine automation for t one of the ISRO lab...

ഓട്ടോമേഷൻ ഒരു അത്ഭുതമായി തോന്നിയത് ജിയോil വർക്ക്

ചെയ്യുമ്പോഴാണ്....

Which has enterally different from systems that I had worked before. instead of controlling the machines here only accumulating the data's and give instructions to maintenance teams. I got surprised, even with a minimum number of technicians, they are effectively maintaining the system uptime as high (for communication network output is rated on terms of up times i.e. for tower needs to be functioned 24hrs).

Before talking about that system, I would like to brief about the mobile communication system, simply in mobile communication system consists of mobile towers and Fiber networks. For tower-to-tower communication the fiber network and microwave bands are using, nowadays towers are mostly connected with fiber network. Other connectivity is from tower to mobile phones, for that   radio bands are using. For this, system have different equipment's like RF antenna microwave antenna, EnodeB which is the heart of mobile communication system, routers, and utility system like gen-set, rectifiers and batteries. in order maintain the system at 100% uptime each Equipment having one dedicated engineer for the maintenance coordination Utility engineer for the power,Enodeb engineer for the Enodeb, Backhaul and IP engineer for the routers for one engineer for fiber maintenance. With these 5 engineers and 20 technicians along with the automated maintenance system they are controls operation of 900 mobile towers in the 2 districts.
From my point of view that automated system is the vein of of the operation team which were connects the field level technicians' engineers and higher-level managers.

The scope of the automated system is,

•Fault monitoring 

•Alarm generation  

 •Information about the fault module passes to corresponding technician and engineer

•Help to find the Root cause of fault 

•Spare Material movement Tracking 

•Spare management 

•Effective tracking of fault rectification.

In detail, once any of the equipment got faulty in the system then automated system will generate a trouble ticket (TT) and give an automated call and message to corresponding technician and engineer. That TT has to clear within four hours. After getting the message Technician needs to go to the tower location, which is also tracked using the software. after reaching the site technician check the fault and he has to inform the engineer whether any spare required for the fault rectification and engineer will book the material against that trouble ticket and mobilize the material from the local warehouse to fault occurred location. This has to complete within the time of four hour span otherwise first level escalation will go to the managerial level and if there is reason manager will extend the time to 8 hours.

Perception!

Mathematics is a must-study subject for our students in classes 1 to 10 in our system of education. The standard form of the dimensional equation we are studying during this period,

(a+b)^2=a2+b2+2*a*b,

Sinx !

Cosx !

Tanx !

Do we usually use them in our daily lives???

Yet, have you ever wondered why we are learning what? 

The need for the study of mathematics is very high in modern times when unscientific information, fake news, and truth travel faster.

Mathematics organizes our lives and prevents chaos.  Some of the qualities that maths nurtures are the power of reasoning, creativity, spatial understanding, critical thinking, problem-solving ability, and effective communication skills.

Maths is the cradle of all creation, without which the world cannot move an inch. Whether it's a cook or farmer, a carpenter or a mechanic, a shopkeeper, a doctor, an engineer, a scientist, a musician, or a magician, everyone requires mathematics in their everyday lives.  Even insects use maths for survival in their regular lives.

Snails create their shells, spiders design their nets, and bees prepare hexagonal combs. There are countless examples of mathematical patterns in the fabrics of nature. Math puzzles and riddles encourage and appeal to a cautious and open-minded attitude among young people, and help them develop clarity in their thinking. The emphasis should be on developing a simple concept in a child's maths from elementary classes itself.

Modern times are all about skill development and innovation. The more mathematically we are in our approach, the more successful we will be. Mathematics gives rationality to our thoughts. It's a tool to make our lives simpler and simpler.