MQTT-ENABLED HEALTH MONITORING SOLUTION WITH MACHINE LEARNING AND XBEE PAN FOR INDUSTRIAL RUBBER CRUMB GRANULATOR MACHINES

Abstract

A mqtt-enabled health monitoring system with machine learning and xbee pan for industrial rubber crumb granulator machines comprises Granulator Node’s (100) independent energy source, wireless communication module, audio alert system, vibration (103) and current sensors (104), and environmental sensors it allows monitoring of critical parameters in real time, this node records the work process of the equipment in detail, as well as abnormalities, and raises alarms which can assist in operating the equipment safely and can carry out operational maintenance the Collector Node that consists of a central processor, a wireless module, a human-machine interface display, a GSM modem and is self-powered allows data from the different Granulator Nodes to be collected and continually visualized through a user-friendly interface, this allows the personnel always to get the necessary information and contributes to good data transmission for the further analysis on the clouds.

Specification

Description:FIELD OF THE INVENTION
This invention relates to mqtt-enabled health monitoring solution with machine learning and xbee pan for industrial rubber crumb granulator machines.
BACKGROUND OF THE INVENTION
This novelty represents an intelligent healthcare support system for the operable devices of the industrial rubber crumb granulator machines, which is implemented as a multi-node system capable of continuous online monitoring and diagnostics. Major vibration and temperature electrical current coprocessors are used here to establish the primary node, which in turn communicates with a secondary node that consolidates and distributes the information to the tertiary node sitting on the cloud database. In the report, the predictive analytics performed by the system, based on training algorithms, are also presented to the users in an instant so they know what kind of maintenance action they need to take, if any. The objectives of this solution include improving the reliability of the equipment, better management of maintenance events, decreasing the downtimes, and hence increasing the efficiency of complete operation.
The crucial issue of enhancing the operational and performance efficiency of industrial rubber crumb granulators working in complex and aggressive environments, is tackled by this product which allows real time health monitoring and prediction of future maintenance. All elder techniques are slow, cover the process reactively and are manual which leads to unexpected failures, incurred expenses for repair and large time losses. This issue of self-destruction or inability to sufficiently perform is overcome by the introduction of a systematic solution that is able to detect the gradual change in the state of the machine components that would include, but not limited to, the change in temperature and the amount of vibration. Thanks to the advanced analytics, it enables operators to act on problems in advance rather than rectifying the problem post-incident, causing a lot of disruption of process activities, high maintenance costs, and loss of overall productivity within the industrial environment.
CN107790484B: The invention discloses a kitchen waste and fruit and vegetable waste mixing treatment integrated machine and a mixing treatment method, and relates to the technical field of environmental protection. The screening platform is connected to a hopper of the fruit and vegetable garbage crushing dehydrator through a belt conveyor; the fruit and vegetable garbage crushing dehydrator is connected to the organic fertilizer machine through a second belt conveyor; the kitchen garbage crusher is arranged at one side of the upper end of the organic fertilizer machine and is connected with the organic fertilizer machine; a first lifter is arranged on the fruit and vegetable garbage crushing dehydrator; a second lifter is arranged on the kitchen waste crusher; the organic fertilizer machine is connected to the vibration screening machine through the screw conveyor, and the lower end of the vibration screening machine is provided with the granulator. The mixing treatment method comprises the following steps: a fruit and vegetable garbage treatment process flow and a kitchen garbage treatment process flow. The invention has scientific and novel design, compact structure and simple operation, prepares kitchen waste and fruit and vegetable waste into granular feed or fertilizer, realizes the recycling and utilization of the kitchen waste and fruit and vegetable waste, saves resources and protects the environment.
RESEARCH GAP: AI based prediction and recommendations for Rubber Crumb Granulators in Industrial environments is the novelty of the system.
USRE50128E1: A system for the production of ammonium sulfate granules including a pipe cross reactor (PCR) configured to contact concentrated sulfuric acid with anhydrous ammonia to produce a PCR product comprising ammonium sulfate; and a granulator fluidly connected to the PCR, whereby PCR product extracted from the PCR can be introduced into the granulator, an inlet for ammonium sulfate seed material, an ammonia sparger configured to spray liquid anhydrous ammonia onto a bed of ammonium sulfate granules within the granulator, and a granulator product outlet configured for extraction of granulator product comprising ammonium sulfate granules from the granulator. A method of producing ammonium sulfate granules is also provided.
RESEARCH GAP: AI based prediction and recommendations for Rubber Crumb Granulators in Industrial environments 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.
In industrial operations, especially in the processing of rubber crumb granulation, machines have to endure a lot of stress and damage which is part of the rubber processing activity. Maintenance is usually done in two common approaches, one where inspections are done on a scheduled basis or in cases where maintenance is required some damage has occurred. The innovation consists of a system with two nodes that aims at preventing overuse of rubber crumb granulator machines used in industry by offering data collection, communication, and analytics sever that is cloud based. The first node, located on the granulator machine, incorporates a number of sensors that monitor vibration, temperature, and electrical current among other important variables. This data reveals the operational health of the unit and if there is any strain on equipment or impending failure of the unit. The data is securely and efficiently communicated wirelessly to a second node through a communication protocol specifically designed for rough industrial operating conditions. The other node collects the information and sends it to a customized cloud platform that employs machine learning algorithms to analyze trends and detect possible issues. Based on the analysis of their reliability, automated insights and recommendations for proactive maintenance are developed and presented to users in real-time through an easy-to-use interface, enabling them to perform management and maintenance duties of the equipment.
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.
In industrial operations, especially in the processing of rubber crumb granulation, machines have to endure a lot of stress and damage which is part of the rubber processing activity. Maintenance is usually done in two common approaches, one where inspections are done on a scheduled basis or in cases where maintenance is required some damage has occurred. The innovation consists of a system with two nodes that aims at preventing overuse of rubber crumb granulator machines used in industry by offering data collection, communication, and analytics sever that is cloud based. The first node, located on the granulator machine, incorporates a number of sensors that monitor vibration, temperature, and electrical current among other important variables. This data reveals the operational health of the unit and if there is any strain on equipment or impending failure of the unit. The data is securely and efficiently communicated wirelessly to a second node through a communication protocol specifically designed for rough industrial operating conditions. The other node collects the information and sends it to a customized cloud platform that employs machine learning algorithms to analyze trends and detect possible issues. Based on the analysis of their reliability, automated insights and recommendations for proactive maintenance are developed and presented to users in real-time through an easy-to-use interface, enabling them to perform management and maintenance duties of the equipment.
Apart from providing a live feed of activities within its system, this system also exists in a hermetically sealed network allowing high security of data and low chances of cross communication by other devices despite the crowded industrial environments. The solution employs the use of the MQTT (Message Queuing Telemetry Transport) protocol which enables efficient data transmission and optimizes bandwidth use whilst improving connectivity in weak power settings. This technical configuration, in turn, makes sure that the solution is guaranteed to be scalable, flexible, and able to merge with different machine health monitoring systems, leading to a decentralized model of industrial health monitoring. The cloud storage and computation of the data allows for trend analysis over long durations, which helps in enhancing the reliability of the machines and the durability of the equipment through effective operational tactics.
BEST METHOD OF WORKING
Thanks to the Granulator Node's independent energy source, wireless communication module, audio alert system, vibration and current sensors, and environmental sensors it allows monitoring of critical parameters in real time. This node records the work process of the equipment in detail, as well as abnormalities, and raises alarms which can assist in operating the equipment safely and can carry out operational maintenance.
The Collector Node that consists of a central processor, a wireless module, a human-machine interface display, a GSM modem and is self-powered allows data from the different Granulator Nodes to be collected and continually visualized through a user-friendly interface. This allows the personnel always to get the necessary information and contributes to good data transmission for the further analysis on the clouds.
The XBee RF Module is a data transmission module used in the Granulator Node and the Collector Node. It helps the seamless transmission of data within the network. This module is particularly important in the transmission owing reliability, robustness and low latency communication to perform its adequate and expected duties in realtime monitoring and data transmission in an industrial setup.
The HMI Touch Display embedded in the Collector Node allows users to actively monitor the state of the machine, view its alerts, and get maintenance suggestions. This particular interface helps operators see trends in data and indeed quickly react/respond to alerts which improves interaction with the monitoring system.
The Collector Node also houses a GSM Modem that facilitates remote communication by sending data in real time to the analytics that is hosted on the cloud. Such features allow the operators to control the system from different locations effectively so as to maintain control of the operations at all times and in multiple locations.
ADVANTAGES OF THE INVENTION
1. Through the use of predictive AI which tracks machine health manually or automatically, this innovation can notify you of problems in advance so they may be fixed before it fails completely allowing for any maintenance. This ensures unplanned downtimes are minimal and operations are running smoothly.
2. Instruments trained to integrate and interpret real-time data from machine tools help prevent machinery from being severely damaged and drastically cut down the associated repair costs while also improving the service life of parts. Scheduled maintenance intervals can be avoided because maintenance can be performed where it is absolutely needed, consequently improving the usage of resources and lowering operational costs.
3. The supervisor has a role of ensuring the operators do not work under conditions that are dangerous to machinery and people. Such conditions can include regardless of the dominant one that prevails high level of vibrations or temperatures. This has the effect of improving the working conditions of persons engaged in the operations.
4. The technology provides a competitive advantage by enabling actionable analyses of the operational data allowing performance to be maximized for operational reliability of machines ensuring machines work on optimal parameters and maximization efficiency.
5. The benefit of cloud connectivity allows the stakeholders to monitor the machine parameters and take appropriate actions although they may not be present physically. This is a scalable system which can be configured in many ways, coupled to many machines or to different sites, suitable for a range of industrial applications.
, Claims:1. A mqtt-enabled health monitoring system with machine learning and xbee pan for industrial rubber crumb granulator machines comprises Granulator Node's independent energy source, wireless communication module, audio alert system, vibration and current sensors, and environmental sensors it allows monitoring of critical parameters in real time, this node records the work process of the equipment in detail, as well as abnormalities, and raises alarms which can assist in operating the equipment safely and can carry out operational maintenance.
2. The system as claimed in claim 1, wherein the Collector Node that consists of a central processor, a wireless module, a human-machine interface display, a GSM modem and is self-powered allows data from the different Granulator Nodes to be collected and continually visualized through a user-friendly interface, this allows the personnel always to get the necessary information and contributes to good data transmission for the further analysis on the clouds.
3. The system as claimed in claim 1, wherein the XBee RF Module is a data transmission module used in the Granulator Node and the Collector Node, it helps the seamless transmission of data within the network, this module is particularly important in the transmission owing reliability, robustness and low latency communication to perform its adequate and expected duties in realtime monitoring and data transmission in an industrial setup.
4. The system as claimed in claim 1, wherein the HMI Touch Display embedded in the Collector Node allows users to actively monitor the state of the machine, view its alerts, and get maintenance suggestions, this particular interface helps operators see trends in data and indeed quickly react/respond to alerts which improves interaction with the monitoring system.
5. The system as claimed in claim 1, wherein the Collector Node also houses a GSM Modem that facilitates remote communication by sending data in real time to the analytics that is hosted on the cloud, such features allow the operators to control the system from different locations effectively so as to maintain control of the operations at all times and in multiple locations.

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