AI-ENABLED SAFETY ENHANCEMENT WITH RECOMMENDATION AND BEHAVIOR ANALYTICAL SYSTEM FOR ROTATING CUTTER GEAR HOBBING MACHINES USING NRF AND XBEE INTRANET NETWORKS

Abstract

An ai-enabled safety enhancement with recommendation and behavior analytical system for rotating cutter gear hobbing machines using nrf and xbee intranet networks comprises SaftyHob, which contains an Atmega32 Board, an Xbee RF Module, Temperature and Accelerometers, a Weighing scale, a Current sensor and a Power Supply enables the collection and monitoring of machine conditions and as such enables the continuous safety monitoring and risk identification on the operation of rotating cutter gear hob machines in hobbing process this unit lacks builtin incubators and sterilization cabinets. However, it internalizes the atmega32 board, xbee, nRF module, HMI display, indicator LEDs, and a power supply unit, enabling on-site data visualization and seamless communication within the intranet network, allowing operators to get a sense of real-time machine status and get notifications for immediate activation.

Specification

Description:FIELD OF THE INVENTION
This invention relates to ai-enabled safety enhancement with recommendation and behavior analytical system for rotating cutter gear hobbing machines using nrf and xbee intranet networks.
BACKGROUND OF THE INVENTION
This development is the next generation of the secure practical assistive innovation which is helpful in monitoring and assessing the working state of rotating cutter gear hobbing machines. This system includes a large number of connected subunits which measure temperature, acceleration, load and current of the machine parts on a live basis. Data are sent through a private local area network and then to the internet where operational characteristics are interpreted by machine learning models to give the system recommendation on safety improvement measures. With the help of a local display control unit and a web-based dashboard, machine operators and other authorized users can check the operational mode of machines, alarms and perform analytics on the machine's behavior. The use of this system enhances the hobbing machine safety level, aids in the planning of preventive servicing of machines and improves bottom-line productivity in industrial settings.
This project deals with the problem of ensuring a higher degree of safety and operational supervision of hobbing cutter gear machines, where machine failures and accidents during operation time cause economic loss in terms of time, damaged tools, or injury of machine operators. Often such strategies disregard real-time operational performance of machines, or completely ignore the analysis of previous operational experience that is prevented to allow proactively and optimally manage equipment health and safety. Keeping track of and tracking some important machine parameters, and juicy AI, this system allows the identification of possible problems at the early stage and provides recommendations to avoid it, and gives feedback to the operators regarding the current state of the machine. This strategy greatly minimizes the hazards faced in the working environment, increases the level of operational effectiveness in the bloating of industrial maintenance and sustains its methodologies.
CN102689228B: The invention provides an electronic gear controller of gear hobbing machine transmission chain. The electronic gear controller comprises a CP1H-Y programmable controller produced by Japanese OMRON company and a multiple-axle movement controller for M70 lathes produced by Japanese Mitsubishi; an output interface of the programmable controller is connected with a hob spindle and a workpiece servo drive device, an input interface is respectively connected with the hob spindle, a car rack vertical drive shaft and a rotational speed sensor of a hob displacement shaft; an output interface of the multiple-axle movement controller for lathes is respectively connected with a knife rack shaft, a hob displacement shaft, a vertical stand column drive shaft and the knife rack vertical drive shaft of a servo drive device; the programmable controller is provided with a hob spindle-based control device for tracking rotation speed and controlling the rotation speed of a workpiece shaft, and a control device for carrying out the rotation compensating treatment of the workpiece shaft according to the gear workpiece helix angle, hob helix angle, the rotation speed of the car rack vertical drive shaft and the rotation speed of the hob displacement shaft. The electronic gear controller has the advantages of comprehensive and strong functions, simple structure, low price, easiness of promotion in common mechanical gear hobbing machine.
RESEARCH GAP: AI-driven safety monitoring with hybrid nRF and XBee intranet communication for real-time behavioral analysis and recommendations in rotating cutter gear hobbing machines is the uniqueness of this system.
US3859893A: A gear hobbing machine having a gear train interconnecting a hob and a workpiece to be machined by the hob, the gear train being disconnectable to permit of cutting a stationary workpiece by a milling cutter substituted for the hob, a subsidiary motor operable to impart an increment of indexing rotation to the workpiece between successive cutting operations of the milling cutter, an index plate geared to a table supporting the workpiece and arranged when the milling cutter is in operation to perform a predetermined integral number of revolutions for each indexing movement of the workpiece, a bolt which is engageable with the index plate to lock the table against rotation, and a counter for counting the rotations made by the index plate when the bolt is withdrawn and causing arrest of the index plate and re-engagement of the bolt after the predetermined number of revolutions of the index plate have been performed.
RESEARCH GAP: AI-driven safety monitoring with hybrid nRF and XBee intranet communication for real-time behavioral analysis and recommendations in rotating cutter gear hobbing machines is the uniqueness of this 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.
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.
This development is the first in its kind in the world, a comprehensive monitoring and safety system for rotating cutter gear hobbing machines, which combines use of the data acquisition and machine intellect optimization in real time. The complex includes three dependent parts: the first one is responsible for data transfer, the second one for data acquisition, and the third one for cloud computing and remote interaction. The properties of these units allow acquiring important operation parameters such as temperatures, vibrations, loads and currents of the machine, which make it possible to comprehend the performance of the machine even more. Using hybrid nRf and xBee intranet communication, data originating from the machine environment is sent to a cloud server where machine learning models are employed to capture workflow trends, identify unusual occurrences and facilitate predictive maintenance. One of the advantages of the architecture of the system is that data communication of the system is intact and its operation is not affected when implemented in an extensive industrial domain or dense settings. The technical core of the system consists of the high precision measuring devices, local data processing devices as well as communication units which work harmoniously to ensure real time data is communicated and received from the machines. The first unit that is of this kind, which specializes in collecting various machine parameters, communicates with the on-site monitoring unit through a short-range intranet connection that can design a data architecture with sufficient speed. This second unit comprises HMI display so that the operator can have direct video feedback regarding the machine and distressing models are implemented on the shop floor itself. The third unit, on the other hand, transmits information to the cloud through GSM, granting access to the analytical system for deep learning and pattern recognition, which can provide behaviorial predictions based on AI algorithms. Their behavior is built both on the HMI screen itself and on a personalized web page of the dashboard, which allows registered users to remotely manage machine condition, health, and operating parameters in real time.
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.
This development is the first in its kind in the world, a comprehensive monitoring and safety system for rotating cutter gear hobbing machines, which combines use of the data acquisition and machine intellect optimization in real time. The complex includes three dependent parts: the first one is responsible for data transfer, the second one for data acquisition, and the third one for cloud computing and remote interaction. The properties of these units allow acquiring important operation parameters such as temperatures, vibrations, loads and currents of the machine, which make it possible to comprehend the performance of the machine even more. Using hybrid nRf and xBee intranet communication, data originating from the machine environment is sent to a cloud server where machine learning models are employed to capture workflow trends, identify unusual occurrences and facilitate predictive maintenance. One of the advantages of the architecture of the system is that data communication of the system is intact and its operation is not affected when implemented in an extensive industrial domain or dense settings. The technical core of the system consists of the high precision measuring devices, local data processing devices as well as communication units which work harmoniously to ensure real time data is communicated and received from the machines. The first unit that is of this kind, which specializes in collecting various machine parameters, communicates with the on-site monitoring unit through a short-range intranet connection that can design a data architecture with sufficient speed. This second unit comprises HMI display so that the operator can have direct video feedback regarding the machine and distressing models are implemented on the shop floor itself. The third unit, on the other hand, transmits information to the cloud through GSM, granting access to the analytical system for deep learning and pattern recognition, which can provide behaviorial predictions based on AI algorithms. Their behavior is built both on the HMI screen itself and on a personalized web page of the dashboard, which allows registered users to remotely manage machine condition, health, and operating parameters in real time.
Apart from the advancement of technologies, this system responds to the demand to improve safety and preventative maintenance in industrial settings. By providing operators and managers with information which can be acted upon in as short a time as possible, the system facilitates active safety measures which in turn lowers the probability of accidents or expensive breakdowns drastically. Furthermore, the cloud-based dashboard of the system and simple HMI display do not require advanced technical operators, which allows for the prospect of broad usage in various industrial environments. With such an interface, operators are ensured of prompt and guided feedback and response to safety concerns, which improves the speed and efficiency of addressing critical safety matters. The project not only improves the safety of workers at the worksite but also promotes ethical practices of maintenance as it helps managers in the avoidance of breakdown of machines by notifying on impending danger which increases the lifespan of the machines and reduces the cost of operation.
BEST METHOD OF WORKING
This unit SaftyHob, which contains an Atmega32 Board, an Xbee RF Module, Temperature and Accelerometers, a Weighing scale, a Current sensor and a Power Supply enables the collection and monitoring of machine conditions and as such enables the continuous safety monitoring and risk identification on the operation of rotating cutter gear hob machines in hobbing process.
This unit lacks builtin incubators and sterilization cabinets. However, it internalizes the atmega32 board, xbee, nRF module, HMI display, indicator LEDs, and a power supply unit, enabling on-site data visualization and seamless communication within the intranet network, allowing operators to get a sense of real-time machine status and get notifications for immediate activation.
The unit is made up of a Raspberry Pi board, nRF module, GSM modem and a Buzzer and a power supply. It focuses on enabling the remote availability of real time machine data through the internet allowing authorized operators to view and control the machine safety from any place.
The operation of both the SaftyHob and CentralCom units involved deploying a Xbee RF module which enabled the provision of short-range intranet network communication, allowing for the data relay of the machines conditions such to enable effective local supervision and rapid operator reaction.
The already discussed unit CentralCom also possesses the homonymous modules which enable interface interaction with HMI display on site, This unit features a simple modular structure.
ADVANTAGES OF THE INVENTION
1. To guarantee the safety of the machine and the operators, the Temperature Sensor and the Accelerometer located in the SaftyHob Unit help eliminate the chances of overheating or extreme vibrations. These advanced systems provide real-time information on the state in which the machine is functioning thus minimizing the chances of accidents occurring.
2. Monitors in large industries stay functional through the use of the Xbee RF Module and nRF Module. These units can transmit data across the intranet thus enhancing reliability in monitoring machine conditions even if in a vast working space or large industries.
3. The machine learning algorithms can be integrated in the cloud and when the data sent by Raspberry Pi in the IoTGateway Unit is fed into the cloud server, the algorithms then analyze this data, create a pattern and generate recommendations making maintenance of the machines more efficient for the operators.
4. These devices delivers messages in an immediate manner to the operators. Whenever an alert is detected, the HMI Display shows it and this enables the operators to introduce appropriate action according to the level of the faulty machine component.
5. A custom web dashboard is used to view this information. Task force members with the help of GSM Modem within IoTGateway Unit are able to login into the system and get the real time data and suggestions and this increases efficiency within industrial managers.
, Claims:1. An ai-enabled safety enhancement with recommendation and behavior analytical system for rotating cutter gear hobbing machines using nrf and xbee intranet networks comprises SaftyHob, which contains an Atmega32 Board, an Xbee RF Module, Temperature and Accelerometers, a Weighing scale, a Current sensor and a Power Supply enables the collection and monitoring of machine conditions and as such enables the continuous safety monitoring and risk identification on the operation of rotating cutter gear hob machines in hobbing process.
2. The system as claimed in claim 1, wherein this unit lacks builtin incubators and sterilization cabinets. However, it internalizes the atmega32 board, xbee, nRF module, HMI display, indicator LEDs, and a power supply unit, enabling on-site data visualization and seamless communication within the intranet network, allowing operators to get a sense of real-time machine status and get notifications for immediate activation.
3. The system as claimed in claim 1, wherein the unit is made up of a Raspberry Pi board, nRF module, GSM modem and a Buzzer and a power supply, it focuses on enabling the remote availability of real time machine data through the internet allowing authorized operators to view and control the machine safety from any place.
4. The system as claimed in claim 1, wherein the operation of both the SaftyHob and CentralCom units involved deploying a Xbee RF module which enabled the provision of short-range intranet network communication, allowing for the data relay of the machines conditions such to enable effective local supervision and rapid operator reaction.
5. The system as claimed in claim 1, wherein the already discussed unit CentralCom also possesses the homonymous modules which enable interface interaction with HMI display on site, This unit features a simple modular structure.

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