ENERGY CONSUMPTION ANALYSIS OF CHAIN CONVEYOR OVENS FOR CURING COATINGS ON METAL PARTS USING WSN REMOTE NETWORK

Abstract

Energy Consumption Analysis of Chain Conveyor Ovens for Curing Coatings on Metal Parts using WSN Remote Network This invention presents a wireless sensor network (WSN)-based system for real-time energy consumption monitoring and analysis in chain conveyor ovens used for curing coatings on metal parts. The system comprises two primary modules: an ETDC_COCMote (50) for on-site data acquisition and processing, and an ERDC_COCMote (250) for cloud communication and local user interaction. The ETDC_COCMote (50) utilizes an AM62A7 Processor Board (57), sensors (current and voltage), and an XBee RF Module (56) to transmit data wirelessly to a cloud server. The ERDC_COCMote (250) uses an ESP32 Wifi Board (256) for cloud connectivity, providing a user-friendly HMI (251) for real-time monitoring and analysis of energy usage. This system enables efficient energy management and proactive maintenance of chain conveyor ovens.

Specification

Description:FIELD OF THE INVENTION
This invention relates to an Energy Consumption Analysis of Chain Conveyor Ovens for Curing Coatings on Metal Parts using WSN Remote Network
BACKGROUND OF THE INVENTION
The problem of insufficient and in-the-moment energy consumption monitoring systems in chain conveyor ovens used to cure coatings on metal components is the focus of this innovation. Traditional monitoring techniques usually depend on manual measurements and are unable to provide instantaneous information or timely notifications in the event of unusual energy consumption.
CN1968609A - This patent describes an accelerated or speed cooking conveyor oven with at least one discrete cooking zone. It uses two gas-directing members to direct gas streams that collide on the upper or lower surface of the conveyed food, enhancing cooking efficiency. Research Gap: The novelty here is a wireless monitoring solution for energy consumption using XBee and RF technology, specifically designed for chain conveyor ovens.
US10842156B2 - This invention relates to a conveyor oven equipped with a sensor to detect events that may cause internal temperature drops. The oven's controller can proactively increase the heating element's output to compensate for anticipated temperature decreases, optimizing cooking consistency.
Research Gap: The innovation introduced here is wireless energy consumption monitoring using XBee and RF technology, customized for chain conveyor ovens.
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 state-of-the-art technology is designed to give precise energy usage monitoring and analysis in chain conveyor ovens used to cure coatings on metal items. The system enables real-time data collecting from several sensors put on the oven through the use of wireless sensor networks and cloud-based technology, offering a comprehensive understanding of patterns in energy utilization. The gathered data is then processed and shown via an intuitive interface, enabling operators to monitor energy usage from a distance, receive critical alerts, and view trend charts to make educated decisions.
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.
Real-time monitoring, data analysis, and visualization of energy usage in chain conveyor ovens are made possible by the innovation's seamless integration of wireless communication technologies and hardware components. The two main parts of this integration are ERDC_COCMote and ETDC_COCMote. Utilizing a variety of sensors and processing units, such as the AM62A7 Processor Board, XBee RF Module, XBee Base, Current Sensor, Voltage Sensor, RTC Module, and Power Supply, the ETDC_COCMote module is mounted directly on the chain conveyor oven. These sensors gather vital information about energy use, like voltage and current levels, and send it wirelessly to a central cloud server via the XBee-based Wireless Sensor Network (WSN).
The ERDC_COCMote module includes an AM62A7 Processor Board, XBee RF Module, XBee Base, ESP32 Wifi Board, HMI Display, Indicator, and Power Supply to enhance the data gathering process. Using Wi-Fi technology enabled by the ESP32 Wifi Board, this module manages connectivity and local monitoring to guarantee smooth data transfer to the cloud server. For local operators, the HMI Display offers an easy-to-use interface for tracking important metrics and receiving alerts straight from the ERDC_COCMote. The data is processed by pre-established algorithms intended for oil condition monitoring once it reaches the cloud server. Insightful analytics are produced by the cloud server, such as trend charts that show trends of energy consumption over time. Predetermined thresholds are used to highlight critical warnings, guaranteeing prompt notifications in the event of unusual energy consumption. Furthermore, the system has a user-specific web dashboard that can be accessed via secure logins, giving operators the ability to remotely view comprehensive data and keep an eye on the energy usage of the chain conveyor oven.


BEST METHOD OF WORKING
1. The ETDC_COCMote is an on-site data acquisition and processing unit that combines a variety of sensors and processing components to gather real-time energy consumption data from chain conveyor ovens and wirelessly transmit it to the central cloud server. It is equipped with an AM62A7 Processor Board, an XBee RF Module, an XBee Base, a current sensor, a voltage sensor, an RTC Module, and a power supply.
2. The ERDC_COCMote is utilized to enable smooth communication via Wi-Fi technology with the cloud server. It also provides a local Human-Machine Interface (HMI) for operators to monitor important parameters, receive alerts, and participate in real-time decision-making in the energy consumption analysis of chain conveyor ovens for curing coatings on metal parts. The ERDC_COCMote is equipped with the AM62A7 Processor Board, XBee RF Module, XBee Base, ESP32 Wifi Board, HMI Display, Indicator, and Power Supply.
3. The central processing unit of both motes, the AM62A7 Processor Board, facilitates effective data handling and computation for the analysis of energy consumption in chain conveyor ovens, hence augmenting the overall efficacy of the monitoring and control system.
4. The innovation's wireless communication is made possible by the XBee RF Module, which is also integrated into both of the motes. This module allows for smooth data transmission between the ETDC_COCMote and ERDC_COCMote modules and ensures effective connectivity when analyzing the energy consumption of chain conveyor ovens used to cure coatings on metal parts.
5. Accurately measuring and gathering real-time data on current and voltage levels in chain conveyor ovens is made possible by the Current Sensor and Voltage Sensor, both of which are connected to ETDC_COCMote. This allows for precise energy consumption analysis for coatings curing on metal parts.
6. The ESP32 Wifi Board, which is linked to ERDC_COCMote, is utilized to improve connectivity and enable remote monitoring in the energy consumption analysis of chain conveyor ovens for curing coatings on metal parts. It also makes wireless communication and data transmission to the cloud server easier.
7. The ERDC_COCMote's interfaced HMI Display provides a user-friendly interface for local operators to keep an eye on important parameters, get alerts in real time, and help make informed decisions when it comes to the energy consumption analysis of chain conveyor ovens used to cure coatings on metal parts.
ADVANTAGES OF THE INVENTION
1. As the on-site data acquisition and processing device, the ETDC_COCMote plays a crucial part in this creative solution. It wirelessly transfers real-time energy consumption data from chain conveyor ovens to the central cloud server by combining a number of sensors and processing components.
2. A key element of this innovation is the ERDC_COCMote, which uses Wi-Fi technology to provide smooth communication with the cloud server. It gives operators a local Human-Machine Interface (HMI) through which they can keep an eye on important metrics, get alerts, and participate in real-time decision-making when it comes to the analysis of energy usage in chain conveyor ovens used to cure coatings on metal parts.
3. An essential component of the innovation that makes wireless communication possible is the XBee RF Module. The ETDC_COCMote and ERDC_COCMote modules are able to transmit data with ease, which guarantees effective connectivity while analyzing the energy consumption of chain conveyor ovens used to cure coatings on metal components.
4. The ETDC_COCMote's integrated Current Sensor and Voltage Sensor are crucial parts. They are essential to the precise measurement and gathering of current and voltage levels in chain conveyor ovens in real time, which permits the investigation of energy usage for the curing of coatings on metal parts.
5. The ERDC_COCMote relies heavily on the ESP32 Wifi Board to provide wireless connectivity and data transmission to the cloud server. In the examination of chain conveyor ovens' energy consumption for curing coatings on metal items, it improves connection and permits remote monitoring.
, Claims:1. A system for Energy Consumption Analysis of Chain Conveyor Ovens for Curing Coatings on Metal Parts using a WSN Remote Network, comprising an ETDC_COCMote (50) unit, which includes an AM62A7 Processor Board (57), XBee RF Module (56), XBee Base (55), Current Sensor (54), Voltage Sensor (53), RTC Module (52), and Power Supply (51); said unit collecting and transmitting real-time energy consumption data from a chain conveyor oven to a central cloud server.
2. The system, as claimed in Claim 1, further comprising an ERDC_COCMote (250) unit, which includes an AM62A7 Processor Board (257), XBee RF Module (252), XBee Base (253), ESP32 Wifi Board (256), HMI Display (251), Indicator (255), and Power Supply (254); said unit enabling smooth communication with the cloud server, providing a local Human-Machine Interface (HMI) for operators to monitor parameters, receive alerts, and participate in real-time decision-making.
3. The system, as claimed in Claim 1, wherein the AM62A7 Processor Board (57 and 257), integrated into both the ETDC_COCMote (50) and ERDC_COCMote (250) units, facilitates effective data handling and computation for analyzing energy consumption in chain conveyor ovens.
4. The system, as claimed in Claim 1, wherein the XBee RF Module (56 and 252), integrated into both the ETDC_COCMote (50) and ERDC_COCMote (250) units, enables wireless communication for smooth data transmission between the units and the cloud server.
5. The system, as claimed in Claim 1, wherein the Current Sensor (54) and Voltage Sensor (53), connected to the ETDC_COCMote (50) unit, accurately measure and gather real-time data on current and voltage levels in chain conveyor ovens, allowing for precise energy consumption analysis.
6. The system, as claimed in Claim 2, wherein the ESP32 Wifi Board (256), integrated into the ERDC_COCMote (250) unit, improves connectivity and enables remote monitoring in the energy consumption analysis of chain conveyor ovens.
7. The system, as claimed in Claim 2, wherein the ERDC_COCMote's (250) HMI Display (251) provides a user-friendly interface for local operators to monitor parameters, receive alerts, and make informed decisions regarding energy consumption.

Documents