A COMPREHENSIVE SOLUTION FOR ROTARY TABLE CONTROL AND REAL-TIME CONDITION MONITORING UTILIZING VIBRATION SENSING TECHNOLOGY

Abstract

This invention introduces a comprehensive solution designed to enhance the operation and safety of rotary tables used in industrial and construction settings. Utilizing advanced vibration sensing technology and an IoT-based cloud infrastructure, it provides real-time monitoring and control capabilities. This system integrates various sensors and communication technologies to detect operational anomalies and facilitate proactive maintenance, significantly increasing operating efficiency and reducing downtime.

Specification

Description:FIELD OF THE INVENTION
This invention relates to A Comprehensive Solution for Rotary Table Control and Real-Time Condition Monitoring Utilizing Vibration Sensing Technology
BACKGROUND OF THE INVENTION
This creative idea addresses the problem of insufficient proactive maintenance options and real-time monitoring for rotating table systems in industrial and construction settings. Traditional surveillance methods usually rely on visual inspections or recurrent evaluations, which provide limited information on the functional state of these critical components.CN110524309B - The invention discloses a geometric error measuring method of a numerical control turntable based on a four-base-station laser tracking system, which comprises the steps of establishing a self-calibration coordinate system and calibrating and tracking the position of an interferometer; respectively placing a target mirror at three non-coplanar points on a rotary table, keeping a certain distance from the rotary table, controlling the rotary table to rotate at certain angle intervals, and solving by using a nonlinear least square method to obtain the coordinates of a measuring point under a self-calibration coordinate system; after the measurement is finished, fitting to obtain a circle center and a radius fitting function of a space circle formed by the three points; establishing a coordinate system of the rotary table; and subtracting the theoretical point coordinates from the coordinates of the actual measurement points in the coordinate system of the turntable to obtain the space position errors of the measurement points, and separating the space position errors of the three points at the same position by establishing a six-item position related geometric error model of the turntable. The invention has the advantages of less detection time, high detection precision and low detection uncertainty, and can be used for the error detection of the rotary table of the precise numerical control machine tool.
Research Gap: A IoT Solution with Cloud technology for condition monitoring of Rotary Table Control with rela time monitoring is the novelty of the system.
CN108921901B - The invention relates to a large-view-field camera calibration method based on a precise two-axis turntable and a laser tracker, which comprises the following steps of: the precise two-axis turntable and the target ball of the laser tracker rotate together, and a conversion matrix from a tracker coordinate system to a turntable coordinate system is calculated; the optical reflection ball is used as an optical reference point for calibrating the camera, is fixed in front of the turntable, and establishes the position of the center of the optical reflection ball under a turntable coordinate system through the precise interchange of the optical reflection ball and a target ball of a tracker and the measurement of the tracker; the camera and the rotary table rotate two-dimensionally together, an optical reference point is shot, the angle value of each station is synchronously recorded, and a virtual calibration control field is established; fitting the elliptical contour of the reflecting ball in the image, and calculating the image position of the center of the calibration target; and establishing a minimum objective function based on the camera imaging model, and calibrating the camera. The method is suitable for completing the internal reference calibration of the high-precision camera in a large-view-field environment; the method is particularly suitable for occasions where the depth change of camera measurement is large and the traditional calibration target is difficult to design and manufacture.
Research Gap: A IoT Solution with Cloud technology for condition monitoring of Rotary Table Control with rela time monitoring is the novelty of the system.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
This innovative development provides a comprehensive method for monitoring and controlling rotary tables in real time. It makes use of state-of-the-art sensor technologies and cloud-based analytics to deliver critical warnings and proactive anomaly identification, enabling preventive maintenance actions. This proactive strategy greatly increases operating efficiency and reduces downtime.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
FIGURE 1: SYSTEM ARCHITECTURE
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a"," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises," "comprising," "includes" and/or "including," when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", "third", and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
With the use of vibration sensing technology, an IoT-based cloud infrastructure, and ESP32 integration, this invention provides a comprehensive solution for controlling and monitoring rotary tables. The innovation offers a dependable means of augmenting operating efficiency, facilitating proactive maintenance, and extending the lifespan of rotating table systems in industrial and construction settings by fusing innovative software features with physical components. The RTCRT_CMNode, a flexible gadget designed to track and evaluate rotary table conditions in real-time, is at the center of this breakthrough. The RTCRT_CMNode is outfitted with multiple sensors, such as vibration, temperature, and humidity sensors, which enable it to continuously collect vital information indicative of the rotary table's working state. The inbuilt GSM modem subsequently sends this data to a bespoke cloud server, where specialist algorithms process the incoming sensor data in real time.
The server quickly identifies anomalies such excessive vibration, unusual temperature swings, or low humidity levels using advanced data processing techniques. These anomalies serve as early warning indicators of possible rotary table system malfunctions or inefficiencies in operation. Notably, this invention empowers users to fix recognized issues prior to their escalation, hence enabling proactive maintenance. The system sends out important notifications when it finds anomalies, directing operators to take the appropriate corrective action. This preventive strategy reduces the likelihood of expensive downtime or equipment failures while also increasing operational efficiency. Furthermore, the innovation facilitates remote monitoring and management by means of an intuitive interface that can be accessed through a local online dashboard. Operators with internet access can obtain trend charts, vital warnings, and real-time data from any place. This accessibility maximizes rotary table performance and ensures operational safety by enabling operators to make well-informed decisions quickly.
BEST METHOD OF WORKING
1. To enable proactive condition monitoring and facilitate remote management of rotary table systems, the RTCRT_CMNode, which is outfitted with an ESP32 Board, GSM Modem, Vibration Sensor, Temperature Sensor, Humidity Sensor, RTC Module, SD Card Module, Indicator, and Power Supply, is utilized for real-time data collection.
2. The main microcontroller unit in this invention, the ESP32 Board, allows for smooth integration of sensor data for real-time monitoring and control of rotary table systems. It also facilitates communication between various hardware components.
3. To facilitate wireless connectivity with the cloud server and real-time transmission of sensor data and important warnings for remote monitoring and preventive maintenance of rotary table systems, the integrated GSM modem in RTCRT_CMNode is utilized.
4. The temperature, humidity, and vibration sensors are all connected to the RTCRT_CMNode and work together to provide vital information about machine conditions. By identifying anomalies like excessive vibration, unusual temperature fluctuations, and unfavorable humidity levels, these sensors allow for proactive maintenance and rotary table performance optimization.
5. To ensure continuous operation of its integrated components, the Power Supply plugin in RTCRT_CMNode provides the necessary electrical power to enable continuous monitoring and control of rotary table systems.
ADVANTAGES OF THE INVENTION
1. To enable proactive condition monitoring and remote control of rotary table systems, the RTCRT_CMNode serves as the hub for real-time data collection from various sensors.
2. The ESP32 Board, which acts as the main microcontroller unit, enables communication between different hardware components and guarantees the seamless integration of sensor data for rotary table system monitoring and control in real time.
3. Wireless communication with the cloud server is made possible by the GSM modem, which enables the quick transfer of sensor data and important alerts for remote monitoring and preventative maintenance of rotary table systems.
4. Working together, the temperature, humidity, and vibration sensors provide critical information about the state of the machine by identifying anomalies such as excessive vibration, unusual temperature fluctuations, and low humidity. The rotary table systems' performance is improved and preventative maintenance is enabled by this data.
5. The Power Supply provides the necessary electrical power to ensure continuous monitoring and control of rotary table systems, ensuring the RTCRT_CMNode and its associated components operate without interruption.
, Claims:We Claim:
1. A comprehensive solution for rotary table control and real-time condition monitoring, comprising: an RTCRT_CMNode (100) configured with an ESP32 Board (109), GSM Modem (108), Vibration Sensor (107), Temperature Sensor (105), Humidity Sensor (106), RTC Module (101), SD Card Module (102), Power Supply (104), and an Indicator (103), to facilitate proactive condition monitoring and remote management of rotary table systems.
2. The system, as claimed in Claim 1, wherein the ESP32 Board (109) serves as the main microcontroller unit, enabling the integration of data from multiple sensors and facilitating real-time communication between various hardware components for effective monitoring and control of rotary table systems.
3. The system, as claimed in Claim 1, wherein the integrated GSM Modem (108) provides wireless communication capabilities, enabling the quick transmission of sensor data and crucial alerts to a cloud server for remote monitoring and preventive maintenance of rotary table systems.
4. The system, as claimed in Claim 1, wherein the Vibration Sensor (107), Temperature Sensor (105), and Humidity Sensor (106) work collaboratively to detect anomalies like excessive vibration, unusual temperature fluctuations, and adverse humidity levels, allowing for proactive maintenance and optimization of rotary table performance.
5. The system, as claimed in Claim 1, wherein the Power Supply (104) ensures continuous operation of the RTCRT_CMNode and its associated sensors, supporting uninterrupted monitoring and control of rotary table systems.

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