Hydrostatic Testing Automation Using Industrial Data Logger & Real-Time Pressure Analytics, Reports & Pump Control!

The pump behaves as an actuated endpoint within a software-defined test cycle, driven entirely by real-time pressure acquisition and deterministic control logic.

Objective

Design and deploy a hydrostatic testing platform capable of:

• Closed-loop pump control based on pressure setpoints

• Continuous pressure acquisition from analog sensors (4–20 mA)

• Real-time visualization of pressure vs time behavior

• Automated logging and report generation

• Repeatable test execution independent of operator experience.

The Embedos goal was to eliminate manual observation and create deterministic testing workflows suitable for industrial QA environments.

System Architecture

The deployed solution consists of an embedded industrial controller running a dedicated HMI application.

Hardware Layer

• Analog Input: Pressure sensor (AI01)

• Digital Output: Pump control (DO01, sinking output)

• Power input: 24V DC or 240V AC compatible

• Local HMI + keyboard/mouse interface

Control Logic Layer

• Parameterized setpoint control

• Automatic pump shutoff at target pressure

• Emergency hard-stop interrupt logic

• Configurable polling intervals

Software Layer

• Real-time UI (local web application)

• Pressure visualization gauge

• Time-series graph plotting

• Data logging service

• Reporting engine with export support

Test Cycle Workflow (Control Logic)

The system executes a structured hydro-test cycle:

1. Operator enters configuration parameters:

   • Gauge range high/low

   • Sensor scaling range

   • Setpoint pressure

   • Hold time

   • Polling interval

2. START command initiates:

   • Pump activation via DO output

   • Pressure sampling

   • Graph plotting engine

   • Data logging process

3. During cycle:

   • Pressure values displayed as live gauge + trend graph

   • Time axis scaled using user-defined polling interval

   • Continuous logging synchronized with RTC

4. Setpoint reached:

   • Pump automatically de-energized

   • Hold-time countdown begins

   • Logging continues until completion

5.  Completion:
   
   

   • Dataset committed to storage

   • Report indexed for export 

     Hard-stop input immediately terminates pump, logging, and plotting for safety override.

Data Acquisition & Visualization

Key implementation characteristics:

• Pressure vs Time plot rendered in real time

• X-axis: 24-hour time format

• Y-axis: pressure in bar units

• Sensor scaling configurable via software mapping

• Live numerical values shown alongside analog-style gauge

This allows operators to detect:

• Pressure instability

• Pump performance anomalies

• Leakage trends during hold phase

Reporting & Data Management

The reporting subsystem supports:

• Individual report downloads

• Batch export as ZIP packages

• Monthly database dumps

• Sortable report indexing by ID or date

Calibration & Configuration

Engineering maintenance includes:

• Two-point or zero/span calibration

• Analog input mapping to process ranges

• RTC synchronization for timestamp integrity

 This reduces drift-related inaccuracies and ensures long-term consistency across test cycles.

Technical Significance

This system effectively shifts hydrostatic testing from a human-observed process to a software-orchestrated control workflow.

Instead of:

Operator watches gauge → manually stops pump → logs readings.

The process becomes:

Sensor feedback → control logic → automatic actuation → timestamped data artifact.

The Embedos Hydro Testing Datalogger demonstrates how a focused embedded system can combine control logic, visualization, and data integrity into a single operator-facing tool.

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