Software
Software
The IntelliSizer software is a comprehensive platform developed specifically for online particle size measurement and process integration. Unlike laboratory software, it is designed for continuous industrial operation and combines measurement, instrument control, data acquisition, PSD calculation, diagnostics, reporting, and automation functions within a single integrated environment. The software serves as the central operating system of the complete Xoptix installation and coordinates all activities required for reliable online analysis.
At the core of the software is the data acquisition and instrument control engine. This continuously communicates with the particle sizer, collects detector signals, controls measurement sequences, monitors instrument status, and manages all online measurement functions. The software is optimized for uninterrupted operation and supports continuous process monitoring 24 hours a day.
The software also controls the auxiliary equipment that forms part of the online system. Sampling devices, conveying systems, pumps, valves, cleaning mechanisms, and other process hardware can be fully automated through configurable control sequences. This allows the entire installation to operate with minimal operator intervention while maintaining reliable sample delivery and measurement performance.
Flexible sequence control enables the software to execute complex operating procedures automatically. Examples include system startup and shutdown routines, automatic cleaning cycles, sampler switching, product changeover procedures, fault recovery actions, and maintenance operations. These functions ensure consistent operation while reducing the possibility of operator error.
A dedicated diagnostics module continuously monitors the health and performance of the analyser. Key operating parameters such as laser power, detector signals, communication status, sample loading, optical attenuation, pneumatic conditions, and hardware functionality are constantly evaluated. Diagnostic information is presented clearly to operators and maintenance personnel, allowing potential issues to be identified before they affect measurement quality.
One of the most important software functions is the conversion of raw detector intensities into particle size distribution data. Sophisticated mathematical algorithms process the scattering information received from the detector array and calculate the PSD in real time. This transformation converts optical measurements into meaningful process information that can be used by operators and automation systems.
The software supports both Fraunhofer and Mie scattering theories, allowing the most appropriate calculation model to be selected for each application. Multiple analysis modes can be configured depending on material properties, particle size range, process requirements, and customer preferences. This flexibility ensures accurate and reliable PSD calculations across a wide variety of industrial applications.
Real-time trend visualisation tools provide operators with a clear understanding of process behaviour. Key PSD parameters, instrument diagnostics, process variables, and calculated results can be displayed as trend graphs over selectable time periods. Historical data analysis allows users to investigate process events, identify correlations, and evaluate the effectiveness of process improvements.
Advanced reporting functions support both operational and quality management requirements. Measurement results can be archived automatically, exported to external systems, incorporated into production reports, or used for long-term process analysis. The software maintains a complete history of measurements and operating events, providing valuable information for troubleshooting and process optimisation.
For integration into modern production environments, IntelliSizer provides a comprehensive automation interface. Standard industrial communication protocols such as OPC allow seamless data exchange with PLC, DCS, SCADA, and APC systems. Measurement data, diagnostic information, alarms, and instrument status can be transmitted to plant control systems, while operating commands and configuration changes can be received from customer automation platforms.
For pharmaceutical and other regulated industries, IntelliSizer software can be supplied with functionality supporting 21 CFR Part 11 compliance requirements. Features such as user management, access control, electronic records, audit trails, and controlled data handling help ensure compliance with regulatory standards while maintaining data integrity and traceability throughout the measurement process.