CONDITION MONITORING BASED ON IOT TECHNOLOGY FOR CNC TURRET MILLING MACHINES WITHIN AUTOMOBILE INDUSTRY

Abstract

This invention presents the CMCT_MMTMote, an IoT-based condition monitoring system designed for CNC Turret Milling Machines in the automobile industry. Integrated with an ATmega16 MCU Board, GSM Modem, Vibration Sensor, Temperature Sensor, MPU Accelerometer, Pressure Sensor, HMI Display, Piezo Buzzer, and Power Supply, the system captures and analyzes real-time data on critical parameters, including temperature, pressure, acceleration, and vibrations. Data is transmitted to a cloud server, enabling remote monitoring and proactive maintenance. The system provides operators with real-time insights through a local HMI Display, optimizing machine performance and reducing downtime through timely alerts and analytics.

Specification

Description:FIELD OF THE INVENTION
This invention relates to Condition Monitoring based on IoT Technology for CNC Turret Milling Machines within Automobile Industry.
BACKGROUND OF THE INVENTION
This state-of-the-art condition monitoring system leverages a sophisticated integration of sensors, data processing algorithms, and cloud-based technologies specifically built for CNC Turret Milling Machines in the Automobile Industry. It reliably records real-time information on temperature, pressure, acceleration, and vibrations in the equipment, providing a thorough examination of the machinery's operation and environmental factors. This data is then sent to a centralized cloud server, where advanced analytics assess the health of the machine, monitor different metrics, and identify trends. The results are then communicated via user interfaces, which consist of a web dashboard for distant accessibility and a local display for on-site inspection.
In the automotive sector, problems with efficient maintenance and monitoring can lead to unexpected downtime and potential production disruptions for CNC Turret Milling Machines. Poor condition monitoring systems make it difficult to identify problems early on and fix them before they get worse, which drives up maintenance costs and reduces operational dependability. Many of the current monitoring techniques are labor-intensive, manual, and prone to human mistake. Moreover, these challenges are exacerbated by the absence of a centralized system for data processing and reporting.
US8246026B2 - Disclosed are a tool indexer assembly, a computer numerically controlled machine that includes such tool indexer assembly, and associated methods. The assembly in one embodiment includes a turret and an indexer, the indexer including a portion that is movable with respect to the turret and that includes plural tool station configured to receive plural tool structures. The tool indexer is disposed on a facet of the turret, and, in some embodiments includes a table that is rotatable about an axis that is generally orthogonal to the axis of rotation of the turret. In another embodiment, a tool indexer includes a clamping mechanism having a source of pressurized fluid and a piston that is hydraulically actuated by the pressurized fluid and movable to a clamping position. The assembly further includes a conduit for delivery of the pressurized fluid proximal the tool structure as coolant fluid. An integrated solution with IoT And Cloud for Condition Monitoring of CNC Turret Milling within Automobile industry is the novelty of the system.
CN211386916U - The utility model discloses a servo power turret numerical control lathe, which comprises a lathe bed, wherein the end part of the lathe bed is provided with a main shaft mechanism, and the main shaft mechanism comprises a headstock, a rotary oil cylinder and a main shaft motor; the end part of the headstock is provided with a main shaft; the lathe bed corresponds the numerical control slip table that main shaft mechanism is provided with two cross lead screw guide rail and constitutes, numerical control slip table upside is installed power tool turret LT1, and servo tool turret ST1 is installed to numerical control slip table downside, and power tool turret LT1 and servo tool turret ST1 constitute the cutting area, through control system control main shaft and power tool turret LT1 and servo tool turret ST1, the utility model relates to a subvert traditional single cross slip table notion, single cross slip table numerical control can only single-blade smear metal processing, just can tool changing processing lower process after accomplishing the process, and efficiency is the shortcoming of single cross slip table numerical control processing slowly. The utility model discloses constitute the cutting district by two cross sliding tables, can carry out diversified (multitool) combination to different product technological requirements and make this machine compatibility strong, improve product efficiency greatly. An integrated solution with IoT And Cloud for Condition Monitoring of CNC Turret Milling within Automobile industry 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.
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.
A methodical procedure including data collection, transmission, analysis, and user notification is presented by the CMCT_MMTMote invention. Its main goal is to use IoT and cloud-based technologies to monitor and ensure the best possible performance of CNC Turret Milling Machines in the Automotive Industry. The system's integrated sensors, which include the pressure, temperature, vibration, and MPU accelerometer sensors, are what allow the innovation to start working. These sensors collect data on the operation and surroundings of the CNC Turret Milling Machine on a continual basis. For assessing the machine's health and identifying any anomalies suggestive of possible problems, the real-time data is essential. After being gathered, the GSM modem is used to send the data to a specially designed cloud server. This cloud server is made especially to take in, store, and process incoming data. This allows for effective management and analysis of data from various computers and gives an all-encompassing perspective of the system. Predefined algorithms perform data analytics, trend analysis, and parameter monitoring within the cloud server with the goal of identifying trends, abnormalities, and departures from typical operating conditions.
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.
A methodical procedure including data collection, transmission, analysis, and user notification is presented by the CMCT_MMTMote invention. Its main goal is to use IoT and cloud-based technologies to monitor and ensure the best possible performance of CNC Turret Milling Machines in the Automotive Industry. The system's integrated sensors, which include the pressure, temperature, vibration, and MPU accelerometer sensors, are what allow the innovation to start working. These sensors collect data on the operation and surroundings of the CNC Turret Milling Machine on a continual basis. For assessing the machine's health and identifying any anomalies suggestive of possible problems, the real-time data is essential. After being gathered, the GSM modem is used to send the data to a specially designed cloud server. This cloud server is made especially to take in, store, and process incoming data. This allows for effective management and analysis of data from various computers and gives an all-encompassing perspective of the system. Predefined algorithms perform data analytics, trend analysis, and parameter monitoring within the cloud server with the goal of identifying trends, abnormalities, and departures from typical operating conditions.
Two primary interfaces are used to convey the analysis's findings: a personalized web dashboard and the local Human Machine Interface (HMI) Display. The HMI Display provides operators on-site with real-time input on the state of the machine and functions as a local interface. In addition, authorized staff can monitor CNC Turret Milling Machines from any location thanks to the customized web dashboard's remote access capabilities. For maintenance teams and decision-makers who need the most recent data on the condition of the system, this accessibility is very helpful. Alerts are sent when differences or possible maintenance issues are found through analysis. These alerts are transmitted via email to designated operators and other pertinent authorities, as well as through the HMI Display for prompt attention on-site. By taking a proactive approach to maintenance, it is possible to minimize downtime and avoid the emergence of more serious issues by taking necessary actions soon.
BEST METHOD OF WORKING
The CMCT_MMTMote system comprising an ATmega16 MCU Board, GSM Modem, Vibration Sensor, Temperature Sensor, MPU Accelerometer, Pressure Sensor, HMI Display, Piezo Buzzer, and Power Supply for seamless integration of IoT and cloud-based technology, enabling real-time condition monitoring and proactive maintenance of CNC Turret Milling Machines in the automobile industry.
A system where the ATmega16 MCU Board serves as the central control unit, enabling real-time data processing, integration of sensors, and communication with the cloud server for CNC Turret Milling Machines.
A GSM Modem facilitating reliable data transmission and seamless connectivity between the CMCT_MMTMote and the cloud server, allowing remote monitoring and timely updates.
A Vibration Sensor providing real-time vibration data for analyzing the operational status of CNC Turret Milling Machines, supporting preventive maintenance.
A Temperature Sensor continuously monitoring machine temperature to assess thermal stability and detect potential overheating, ensuring safe operation.
An MPU Accelerometer capturing motion data, contributing to precise condition monitoring by detecting unusual movements or imbalances in CNC Turret Milling Machines.
A Pressure Sensor providing environmental pressure data, aiding in comprehensive monitoring and analysis of machine parameters.
An HMI Display providing a user-friendly interface for on-site operators, displaying real-time data, alerts, and analytics, enhancing situational awareness.
A Piezo Buzzer providing audible alerts for immediate response, ensuring prompt attention to maintenance needs and operational deviations.
A Power Supply ensuring continuous operation of all components, supporting reliable condition monitoring of CNC Turret Milling Machines in the automobile industry.


ADVANTAGES OF THE INVENTION
1. The CMCT_MMTMote is a comprehensive IoT-enabled solution that combines cloud-based analytics and sensors in a seamless manner. For CNC Turret Milling Machines used in the Automotive Industry, this integration provides real-time condition monitoring, data analysis, and preventive maintenance, which eventually improves operating efficiency and reduces downtime.
2. By enabling dependable communication and data transfer between the customized cloud server and the Condition Monitoring system for CNC Turret Milling Machines, the GSM Modem plays a critical role. This feature guarantees uninterrupted communication and timely updates, which helps the automotive industry maintain its machinery efficiently.
3. Together, the temperature sensor, pressure sensor, MPU accelerometer, and vibration sensor provide an extensive collection of real-time data. With the use of this data, the Condition Monitoring system is better equipped to evaluate and keep an eye on important CNC Turret Milling Machine characteristics in the automotive sector. With the use of timely notifications and analytics, this proactive strategy helps to minimize future disruptions.
4. The HMI Display serves as an easy-to-use user interface that gives on-site operators real-time insights into the state of CNC Turret Milling Machines used in the automotive industry. This feature makes it possible to make decisions quickly and to keep an eye on the machine's performance locally.
, Claims:We Claim:
1. A Condition Monitoring based on IoT System for CNC Turret Milling Machines within Automobile Industrycomprises TheCMCT_MMTMote system, also having an ATmega16 MCU Board, GSM Modem, Vibration Sensor, Temperature Sensor, MPU Accelerometer, Pressure Sensor, HMI Display, Piezo Buzzer, and Power Supply, integrates IoT and cloud-based technology for real-time condition monitoring and proactive maintenance of CNC Turret Milling Machines in the automobile industry.
2. The system as claimed in Claim 1, wherein the ATmega16 MCU Board serves as the central control unit, enabling real-time data processing, integration of sensors, and communication with the cloud server for CNC Turret Milling Machines.
3. The system as claimed in Claim 1, facilitating reliable data transmission and seamless connectivity between the CMCT_MMTMote and the cloud server, allowing remote monitoring and timely updates.
4. The systemas claimed in Claim 1, providing real-time vibration data for analyzing the operational status of CNC Turret Milling Machines, supporting preventive maintenance.
5. The systemas claimed in Claim 1, continuously monitoring machine temperature to assess thermal stability and detect potential overheating, ensuring safe operation.
6. The systemas claimed in Claim 1, capturing motion data, contributing to precise condition monitoring by detecting unusual movements or imbalances in CNC Turret Milling Machines.
7. The systemas claimed in Claim 1, providing environmental pressure data, aiding in comprehensive monitoring and analysis of machine parameters.
8. The systemin Claim 1, providing a user-friendly interface for on-site operators, displaying real-time data, alerts, and analytics, enhancing situational awareness.
9. The systemas claimed in Claim 1, providing audible alerts for immediate response, ensuring prompt attention to maintenance needs and operational deviations.
10. The systemas claimed in Claim 1, ensuring continuous operation of all components, supporting reliable condition monitoring of CNC Turret Milling Machines in the automobile industry.

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