django – matt dale

Masque Sound RFID System

The Masque RFID concept started with George Hahn(the Masque Sound Director of Production) asking me to research various handheld long-range RFID readers to use throughout the Masque Sound warehouse. What this research helped me discover was the world of UHF RFID inventory systems. I designed a system that uses fixed readers rather than mobile readers that interrogate tags and record their locations to a PostgreSQL database and provide real-time alerts to workers for issues that the system finds.

That system description sounds simple enough, but it took a lot of asking “why” to get the results that George was looking for. He was looking for a way to catch items that were not correctly scanned to a given show as a show was being loaded onto a truck. His original plan included a handheld “wand” that would interrogate tags and would respond with their inventory status. By moving this idea to a multiple fixed reader system, I was able to add another, more valuable(in hindsight) feature of asset location logging.

The search for both readers and tags was a long one. Tags needed to be durable, small, versatile and cheap. This requirement set wasn’t able to be satisfied with just one type of tag in the end. Since Masque Sound owns a lot of metal rack mount assets, which are generally at least 1 3/4″ tall, we found a “universal” tag made by Metalcraft that read over 15 feet from a reader, and was small enough to fit on the side of a 1 rack unit asset. It also allowed us to install the tags on other small metal assets, like direct boxes, LCD monitors and mixing consoles.

For our large road cases, we found a very cheap paper tag in the “wet inlay” format, which read from over 15 feet from a reader and had a very large antenna surface area. These tags, from Avery Dennison RFID, are installed underneath the carpet lining of each road case that Masque owns. These tags are very durable due to their hidden installed location, and the large surface area of the antenna. These tags will not read when installed on a metal asset, but they are much cheaper than the “universal” metal-mount tags.

For the smaller niche assets where the larger tags don’t fit, we use a smaller “universal” tag from Metalcraft and a smaller tag from Avery Dennison RFID. These tags read over 10 feet away, but they work well in our environment.

See further posts on how this system integrates with all others in the Masque Sound Warehouse.

Masque Sound Operational Projects

Each of these projects assists in day-to-day operations to improve the efficiency of the sound shop with clean user interfaces and efficient design.

Masque Sound uses the Unibiz R2 rental software, so much of my programming is based around extending this software.

Third Stream Web App

This application provides a more intuitive and more advanced interface for interacting with the Oracle backed, Unibiz inventory software, R2.
Using webservices, stored procedures and direct database queries on multiple databases, this application provides asset tracking, order filling, inventory control, all with a cohesive databse that integrates with all my other applications.

Each tile in the screenshot is a link to a full fledged application, some of which are detailed below.

The Windows 8 design style was adopted to get users used to the “Windows Store” style application before the company wide upgrade to Windows 8. This style guide was created using the PureCSS framework.

While this first iteration of the application is still in use and is the flagship of my development, the new, more streamlined version ThirdstreamV2 has a much more modern look, although it uses Bootstrap to handle its styling.

Mobile Asset Management Apps

This application was designed to give users a mobile way to check asset status throughout the warehouse. We use a Bluetooth barcode scanner that mounts to back of an iPod Touch and incorporated it into the mobile site. By making the app web based, we are able to use this app on many devices including Android devices. This app uses AudioJS to playback sounds corresponding to the statuses of the assets that are scanned. Additionally, “bad scans” are logged to a database table and displayed on a dynamic sign in the manager’s office.

Another application was developed to record asset location information in the warehouse. Using pre-existing shelf location barcodes I created a database that
records the asset’s current shelf. The app simultaneously uses a custom Unibiz stored procedure that writes the shelf location to a field in R2. The R2 field is always the most current location, but asset location history is saved in the Thirdstream database.

Dynamic Signs

The “R2Today Screens” are a set of 5 different signs that are displayed throughout the warehouse on large LCD monitors. These provide a consolidated list of outgoing orders for the various departments. It is updated in realtime with direct queries to the Oracle inventory database.

The design inspiration came from airport/train station arrival/departure screens. It uses color and scrolling statuses to keep warehouse workers up-to-date on what work needs to be done.

Speaker Testing System

The purpose of this system is to automate as much of the speaker testing process as possible to increase warehouse efficiency.

The user interface is programmed using IronPython and connects to the Audio Precision APx API.
The app accepts a barcode scan of the speaker then:

– opens the test procedure,

– checks the status of the asset,

– provides setup prompts for the procedure,

– runs the procedure,

– saves test result data,

– saves asset location data,

– saves test history records

and updates the asset’s information in the R2 inventory system

All with one barcode scan.

RMA System

This system allows clients to enter information about their items that they need to send back to the warehouse. It incorporates an email system to alert the repairs manager and the necessary project managers. There is an admin system for the repairs manager to enter details about a particular RMA. This gives the clients a better idea of the status of their returns and lets them know shipping information. This system is built on Bootstrap V2 and Django 1.10.

Scheduling System

This system is a permissions based calendar with resource/task assignment. It houses the company’s vacation calendar and projects.

The custom interface allows management to see long term workload and day-to-day planning. The front end was designed by Sean Colandrea.

The daily view shows the work to be completed for each day and provides a quick report generator for the manager to run meetings.

“SMURF” scanner interface

Andy Leviss(Duck’s Echo Sound) created a hardware device for scanning the RF spectrum into a CSV file. I created this user interface which takes file and venue information and automatically emails the results to Masque Sound for analysis and frequency coordination.

This uses Tkinter for the UI and pySerial for connection to the hardware device over USB.

Trucking System

Masque was using a paper and bulletin board method for trucking dispatch requests. There were too many human errors with this system, so I built a simple dispatching system that requires users to enter the correct information. The system continues to print dispatches on paper for the drivers to carry, but creates a traceable, searchable history for auditing.

Reporting System

Tracking the shows that have Masque equipment on Broadway became a fun way of testing how healthy the business is. I developed a simple database reporting app that creates a nice metrics application.

Purchasing System

Masque previously used paper/pencil and spreadsheets to keep track of purchase requests and statuses. This was handled by one employee who was overworked and needed help. I built this application directly with this employee to make his job simpler and easier to track the millions of dollars of equipment that he purchases for the company. The system sends notification emails and texts when requested items are ordered, delivered or received, and connects to APIs on FedEx, UPS and DHL to get delivery status updates.

Physical Inventory System

This system was built to accommodate more frequent inventory counts. The previous method was to use an outside vendor to capture the data, then spend days importing the data back into R2. By creating a custom solution that works on smart phones, we are able to conduct cycle counts, and format the data correctly prior to importing into R2. The flexibility that this system offers gives more validity to the availability feature in R2.

RFID Inventory System

I designed and deployed an RFID inventory system at Masque Sound that uses Alien ALR-9680 readers and an assortment of RFID tags to track high value equipment through the warehouse.

The system was created to aid in asset tracking and inventory control and supplements the current barcode system in use. The various readers around the warehouse connect to a PostgreSQL database and through the Twilio API provides text message updates to alert of asset issues.

An alarm system is setup in two locations to provide immediate feedback to a shop employee in the area.
Using the GPO of the readers, a strobe light is turned on and a sound is played until the offending condition is addressed.

Loading Dock RFID System

This system is integrated with the Third Stream web application and the R2 inventory system. The user interface is a touch screen mounted on the wall near the loading docks. When a truck driver is loading a truck, they press the “Use Dock” button and the system goes into inventory control mode. As items pass through the loading dock, the CAEN Ion RFID reader verifies that each item has been properly documented in the R2 inventory system. It also updates a location history record in Third Stream. If the system finds a “bad” asset, a flashing light is set off, the item is displayed on the user interface and a warning message is texted to the shop foreman, the inventory control manager and me. This allows one of us to fix the bad item without stopping the truck loading.

When the system is not using the loading docks, it goes into “watch” mode. Every item that is seen on any one of its 16 antennas gets an asset history location record in Third Stream for asset tracking.

The user interface is programmed using IronPython to create a C# Winforms application. It connects over TCP to the CAEN RFID reader.

OSC Controller Button Box

By combining my knowledge and experience of Python programming, web site construction, and basic electronics, I was able to construct a hardware device that sends OSC commands. I used a Raspberry Pi running a simple web server and listens for button presses. When a button is pressed, it sends the OSC command.

The concept is simple, a 4 button box that sends OSC commands when a button is pressed. These OSC commands are configurable with a web page that the device hosts. The first iteration of this box was used on a Broadway show to trigger a global system mute. When the button was pressed, it sent an OSC message to mute the eight Meyer Sound Galileos and change the Meyer Sound D’Mitri scene to the MUTED scene. After completing this device, I realized that it could be developed into something much more versatile.

The second revision includes programmable LCD buttons, multiple scenes, OSC subscriptions and an opto-isolated General Purpose Input. Using the Q5 switch from http://www.ledswitches.co.uk/lcd-oled-products/lcd-switches/q5-lcd-switch.html was the first challenge. These amazing switches are similar to what is used on the DiGiCo sound consoles. Their specs are quite good, and they are fairly easy to use. Although it is probably not the best choice due to speed, I chose to use Python to program the switches, and through much trial and error, came up with this library. This experimental library functions well enough, but has been significantly improved in the production code.

The Q5 does not have a chip select pin, so in order to address each switch individually I multiplexed the clock signal from the Raspberry Pi. The following picture shows this in action.

Q5 Breadboard — Q5 Switches on a breadboard

Once the switches were working on a breadboard, I attempted to design a PCB for the box. I learned just enough KiCAD to design a board, and used OshPark to produce it.

This PCB worked reasonably well, but like all first attempts, it can use some improvement. After populating this board, I designed a front panel using Front Panel Express. This allowed me to make a very professional looking front panel for this device.

Finally, Felix Kutlik helped make an enclosure to hold the PCB and the Raspberry Pi. In its current state, the OSC controller functions, but I am adding more features to it. Using the web configuration console allows changing button colors, text, OSC messages, confirmation messages, etc.

designdb.online

Masque Sound occasionally provides for a show or event that requires us to build a sound design and act as the “production engineer”, making cable decisions etc. We also occasionally design, build, prep and install systems for “one-off” events or shows. In these situations, I have used FileMaker Pro database solutions, Microsoft Excel or the gaff tape/Sharpie method of labeling. These methods were never quite good enough for my liking and I set out to build a free simple solution for this task.

Using the Django web framework and current HTML5 technologies, I was able to build a system that functions as a fast and elegant solution to sound system documentation and labeling. While it doesn’t currently include equipment management, or fancy features, it prints directly to Avery 5167 and 5160 address labels right from the web browser (Google Chrome) without having to save to PDF and print from another program, or in browser reader.

Next time you need to build a show, don’t use gaff tape and Sharpie, use designdb.online!

Currently in the Beta phase with a limited number of user accounts available, I am working on issues daily. Sign up at designdb.online.