Project Outline
Automotive sound system installation at this production factory site based nr. Derby. A large industrial facility with a range of manufacturing / production aspects, mostly focused on welded assembly automotive parts and products. The main building facility provides all of the primary business activity operations, including offices, logistics, storage and of course manufacturing production (around 80% of the building footprint).
To help support improve general site communications as well as specific audio integrated operations and manufacturing processes (SCADA). Our brief for this project was to design and install a site wide automotive manufacturer sound system installation to provide the following audio applications and solution design specification.
Audio Applications
- Public Address (PA) / Tannoy
- Multi-zone Microphones
- SIP / VoIP Integration
- iOS/Android Paging App
- Background Music (BGM)
- Mass Notification
- Scheduled Audio Message (break times, process changes)
- Wireless Radio Microphones (management briefing)
Audio Specification & Technologies
- IP 8×8 Audio Matrix Processor
- 100v line, high impedance speaker distribution
- Multiple IP Network players / streamers
- SIP VoIP integration
- Full range, 2-way speakers installed throughout
- True Diversity Radio Microphone system
Installation Details
Many practical installation challenges were identified – particularly throughout the main production and manufacturing areas.
- Manufacturing processes (welding & fabrication)
- High ambient background noise
- Confined & limited access
These challenges are not unique and were somewhat expected. Having previously installed sound systems into many similar factory and production projects these challenges were discussed with the client and supporting project teams, with a number of provisioning and protective measures put in place to assist the installation whilst mitigating possible disruption to the production.
To provide the customer with audio processing and routing control, an IP/network based audio matrix was installed. This unit is accessed, configured and controlled via the LAN/network and provides the primary controls for mixing, pre-amplification, DSP, input-output routing and zone volume controls.
High impedance, 100v line speakers (wide range, 2-way), were installed throughout. As a number of the speaker cabling runs (even when taken in zone isolation) were in excess of 200m, with some approaching 500m, consideration and calculation of cable size/CSA was required. A number of zones were cabled using 4mm and 6mm cable CSA.
Our customer required audio integration with their SCADA (process control) system. The audio matrix was connected to a newly installed SCADA client PC – basic I/O relay controllers, triggered via SCADA process controls initiated playback for numerous audio message files, for playout to specific audio zone areas as routed / required.
A true diversity microphone system, connected via a bespoke pre-amp interface was installed centrally to the main production areas. A local community of speakers were installed to this area (dedicated zone) for playout of staff assembly times & briefings.
We installed a number of network audio players. Browser accessed for control and configuration, these units are used to to provide various lower priority playout (such as break/shift changes and process information tones).
