FFT ANALYSIS BASED ON VIBRATION AND ACCELEROMETER OF CNC TURRET MILLING MACHINES WITHIN AUTOMOBILE INDUSTRY

Abstract

A system of FFT Analysis based on Vibration and Accelerometer of CNC Turret Milling Machines within Automobile Industry comprises a FAVAC_TMote (100) that is equipped with STM32 Processor Board (101), GSM Modem (102), Vibration Sensor (103), 3 Axis Accelerometer Board (104), RTC Module (105), SD Card Module (106), HMI Display (107) and Power Supply (108), is employed for integrating sensor data, real-time FFT analysis, and cloud connectivity, enabling precise monitoring, early detection of irregularities, and remote access to insights for optimizing the achievement and maintenance of CNC Turret Milling Machines in the Automobile Manufacturing. This innovation's central processing unit, the STM32 Processor Board, analyzes vibration and accelerometer data using a predefined algorithm for Fast Fourier Transform analysis. This allows for the real-time identification of anomalies and provides vital information for the effective monitoring and maintenance of CNC Turret Milling Machines in the automotive industry.

Specification

Description:FIELD OF THE INVENTION
This invention relates to a system of FFT Analysis based on Vibration and Accelerometer of CNC Turret Milling Machines within Automobile Industry.
BACKGROUND OF THE INVENTION
The problem of monitoring and maintaining CNC Turret Milling Machines in the automobile industry is effectively addressed by this novel solution. The problem stems from the historical lack of a comprehensive real-time analysis system for vibration and acceleration data, which makes it challenging to identify potential problems in a timely manner. Unexpected malfunctions can lead to downtime, increased maintenance costs, and a decrease in operational efficiency.
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.
Research Gap: FFT analysis based on Vibration and Acceleration with Cloud integration or this innovation is the novelty of the system.
WO2009049200A1 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.
Research Gap: FFT analysis based on Vibration and Acceleration with Cloud integration or this innovation 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 state-of-the-art system is designed especially for precise monitoring and analysis of CNC Turret Milling Machines in the Automobile Industry. With the help of modern sensors, real-time data analysis, and cloud-based connectivity, it is possible to identify potential issues related to acceleration and vibration during machine operations. The system's algorithmic analysis provides a comprehensive understanding of the machinery's performance, presenting results in an intuitive interface. Operators are promptly alerted to any abnormalities, allowing prompt intervention to prevent malfunctions and improve maintenance optimization.
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.
The FAVAC_TMote utilizes a painstakingly crafted procedure that combines cutting edge hardware elements and sophisticated data analysis methods to provide detailed insights into the functioning of CNC Turret Milling Machines in the Automobile Industry. The operational sequence begins with the acquisition of vital data from the machinery via the integration of a 3 Axis Accelerometer Board and a Vibration Sensor, both of which record real-time data regarding the accelerations and vibration patterns that the milling machines encounter while in operation. The collected data is then processed by the STM32 Processor Board, which serves as the central component of the system. Here, the incoming data is subjected to a preset algorithm that performs FFT analysis. This algorithm is highly effective in transforming accelerometer and vibration data in the time domain into frequency domain information, revealing particular frequency components that are inherent in the machine's operation. Ultimately, this analysis is used to identify any irregularities or anomalies in the functioning of the CNC Turret Milling Machines.
The results of the FFT analysis are shown on the HMI (Human-Machine Interface) Display. This visual aid makes it possible for operators to quickly analyze the results and gain insights into the condition and functionality of the milling machines. In the event that the analysis uncovers any problems or irregularities, the system triggers an alert system that notifies operators via the Alert Section of the HMI Display. This prompt notification enables operators to take appropriate action and prevent machinery failures. At the same time, the processed data is sent to a customized cloud server via the integrated GSM Modem. This cloud server is specifically made to handle and store the data produced by the FFT analysis. Operators and other authorized personnel can view this data via a customized cloud-based web dashboard. This remote accessibility facilitates real-time monitoring and gives stakeholders the power to decide how best to maintain and operate the CNC Turret Milling Machines.
BEST METHOD OF WORKING
1. A system of FFT Analysis based on Vibration and Accelerometer of CNC Turret Milling Machines within Automobile Industry comprises a FAVAC_TMote (100) that is equipped with STM32 Processor Board (101), GSM Modem (102), Vibration Sensor (103), 3 Axis Accelerometer Board (104), RTC Module (105), SD Card Module (106), HMI Display (107) and Power Supply (108), is employed for integrating sensor data, real-time FFT analysis, and cloud connectivity, enabling precise monitoring, early detection of irregularities, and remote access to insights for optimizing the achievement and maintenance of CNC Turret Milling Machines in the Automobile Manufacturing.
2. This innovation's central processing unit, the STM32 Processor Board, analyzes vibration and accelerometer data using a predefined algorithm for Fast Fourier Transform analysis. This allows for the real-time identification of anomalies and provides vital information for the effective monitoring and maintenance of CNC Turret Milling Machines in the automotive industry.
3. The GSM modem attached to the FAVAC_TMote is utilized to enable smooth communication by sending processed data to a customized cloud server, guaranteeing prompt notifications and giving operators and authorities remote access. This improves the efficiency of maintenance and monitoring plans for CNC turret milling machines in the automotive sector.
4. The 3 Axis Accelerometer Board and Vibration Sensor, which are both connected in FAVAC_TMote, work together to collect real-time data that allows for the accurate tracking of accelerations and vibration patterns in CNC Turret Milling Machines. This data is essential for the analysis of the Fast Fourier Transform and the early identification of possible problems in the automotive industry.
5. The SD Card Module offers local storage capability, improving data integrity and facilitating thorough analysis and record-keeping for CNC Turret Milling Machines in the Automobile Industry. The RTC Module is used to ensure accurate timekeeping for timestamping data. Both modules are connected in the FAVAC_TMote.
6. The Fast Fourier Transform analysis results in real-time, along with timely alerts and insightful information, are presented by the HMI Display interfaced in the FAVAC_TMote. This user-friendly interface empowers operators to make well-informed decisions regarding the best upkeep and functionality of CNC Turret Milling Machines in the Automobile Industry.
7. The Power Supply, which plugs into the FAVAC_TMote, is used to support the alert, analytic, and monitoring mechanisms for CNC Turret Milling Machines in the Automobile Industry. It also guarantees the continuous and dependable functioning of the complete system.
ADVANTAGES OF THE INVENTION
1. Through the seamless integration of sensor data, real-time FFT analysis, and cloud connectivity, the FAVAC_TMote is a key component of this innovative technology that ultimately optimizes the performance and maintenance of CNC Turret Milling Machines in the automobile industry. This integration allows for precise monitoring, early detection of irregularities, and remote access to insights.
2. The GSM Modem makes communication easier by sending processed data to a personalized cloud server. This guarantees alerts in a timely manner and gives operators and authorities remote access, which improves the efficiency of maintenance and monitoring plans for CNC Turret Milling Machines in the Automobile Industry.
3. The RTC Module assures accurate timekeeping for timestamping data, while the SD Card Module provides local storage capability. This promotes data integrity and supports extensive analysis and record-keeping for CNC Turret Milling Machines in the Automobile Industry.
4. By providing real-time Fast Fourier Transform analysis results, instant alerts, and insightful information, the HMI Display acts as an intuitive interface that enables operators to make well-informed decisions regarding the best maintenance and performance of CNC Turret Milling Machines in the Automobile Industry.
, Claims:1. A system of FFT Analysis based on Vibration and Accelerometer of CNC Turret Milling Machines within Automobile Industry comprises a FAVAC_TMote (100) that is equipped with STM32 Processor Board (101), GSM Modem (102), Vibration Sensor (103), 3 Axis Accelerometer Board (104), RTC Module (105), SD Card Module (106), HMI Display (107) and Power Supply (108), is employed for integrating sensor data, real-time FFT analysis, and cloud connectivity, enabling precise monitoring, early detection of irregularities, and remote access to insights for optimizing the achievement and maintenance of CNC Turret Milling Machines in the Automobile Manufacturing.
2. The system as claimed in claim 1, wherein central processing unit, the STM32 Processor Board, analyzes vibration and accelerometer data using a predefined algorithm for Fast Fourier Transform analysis; which allows for the real-time identification of anomalies and provides vital information for the effective monitoring and maintenance of CNC Turret Milling Machines in the automotive industry.
3. The system as claimed in claim 1, wherein the GSM modem attached to the FAVAC_TMote is utilized to enable smooth communication by sending processed data to a customized cloud server, guaranteeing prompt notifications and giving operators and authorities remote access; and this improves the efficiency of maintenance and monitoring plans for CNC turret milling machines in the automotive sector.
4. The system as claimed in claim 1, wherein the 3 Axis Accelerometer Board and Vibration Sensor, which are both connected in FAVAC_TMote, work together to collect real-time data that allows for the accurate tracking of accelerations and vibration patterns in CNC Turret Milling Machines; and this data is essential for the analysis of the Fast Fourier Transform and the early identification of possible problems in the automotive industry.
5. The system as claimed in claim 1, wherein the SD Card Module offers local storage capability, improving data integrity and facilitating thorough analysis and record-keeping for CNC Turret Milling Machines in the Automobile Industry. The RTC Module is used to ensure accurate timekeeping for timestamping data; and Both modules are connected in the FAVAC_TMote.
6. The system as claimed in claim 1, wherein the Fast Fourier Transform analysis results in real-time, along with timely alerts and insightful information, are presented by the HMI Display interfaced in the FAVAC_TMote; and This user-friendly interface empowers operators to make well-informed decisions regarding the best upkeep and functionality of CNC Turret Milling Machines in the Automobile Industry.
7. The system as claimed in claim 1, wherein The Power Supply, which plugs into the FAVAC_TMote, is used to support the alert, analytic, and monitoring mechanisms for CNC Turret Milling Machines in the Automobile Industry, which also guarantees the continuous and dependable functioning of the complete system.

Documents