ONLINE CONDITION MONITORING OF COLD CHAMBER HORIZONTAL DIE-CASTING MACHINE THROUGH LPWAN LONG RANGE TECHNOLOGY FOR INDUSTRIAL MANUFACTURING PROCESS OF CASTING ALLOYS

Abstract

A system of Online Condition Monitoring of Cold Chamber Horizontal Die-Casting Machine through LPWAN Long Range Technology for Industrial Manufacturing Process of casting alloys comprisesOCMCCHDCMote, which is outfitted with an STM32 Processor Board, Lora Module, Vibration Sensor, Temperature Sensor, Pressure Sensor, Accelerometer, RTC Module, and Power Supply; Long-range communication via LPWAN technology enables cloud-based analytics and proactive condition monitoring in the casting alloys manufacturing process. Through the use of an intuitive interface and real-time insights into the operational health of Cold Chamber Horizontal Die-Casting Machines, operators and authorities can make informed decisions and take prompt action in the casting alloy manufacturing process thanks to the OCMCCHDCRMote, which is outfitted with an STM32 Processor Board, Lora Module, ESP01 Wifi Board, HMI Display, and Power Supply.The computational power for data processing, analysis, and communication tasks in both OCMCCHDCMote and OCMCCHDCRMote is provided by the STM32 Processor Board, which is integrated into both nodes; and this helps to ensure the smooth and effective functioning of the online condition monitoring system for Cold Chamber Horizontal Die-Casting Machines in the alloys manufacturing process.

Specification

Description:FIELD OF THE INVENTION
This invention relates to the Online Condition Monitoring of Cold Chamber Horizontal Die-Casting Machine through LPWAN Long Range Technology for Industrial Manufacturing Process of casting alloys.
BACKGROUND OF THE INVENTION
A lack of real-time capabilities and advanced analytics is a common shortcoming of the current state of condition monitoring systems for Cold Chamber Horizontal Die-Casting Machines in industrial manufacturing processes. This leads to subpar operating efficiency and increased downtime. Traditional monitoring systems may not provide thorough insights into critical characteristics such as vibration, temperature, and pressure, which limits the ability to detect possible problems in advance.
CN109306413B - The present invention relates to a kind of die-cast aluminum alloy materials and its preparation method and application of high-intensitive high thermal conductivity.Its main component and its mass percentage content are as follows: Si 8.0 ~ 10.0%, Mg 1.5 ~ 3.5%, Fe 0.06 ~ 0.5%, Sr 0.005 ~ 0.05%;Surplus is Al and other inevitable impurity elements.By the way that suitable magnesium elements are added in the excellent Al-Si alloy of casting character, the content of the impurity elements such as Fe, Cu, Mn, Cr, V, Ti is controlled simultaneously, under the premise of guaranteeing good casting forming performance, realize that the conventional pack alloy such as mechanical property and heating conduction ratio ADC12, YL102, A380 increases substantially. Suitable for producing communication machine box, radiator, plate etc. is complex-shaped mobile phone and needs die casting that is high-intensitive and improving heating conduction.
Research Gap: LPWAN Long Range and Cloud integrated technology for machine condition monitoring Technology is the novelty of the system.
CN105414515B - The invention discloses a kind of die casting mechanism of horizontal cold room vacuum die casting machine, including pressure chamber, compression mod, vacuum valve, drift, penetrate bar, the first stop valve, the first vacuum system, the second stop valve, the second vacuum system, control device and displacement transducer, compression mod includes fixed half and moving half, and the dynamic model cooperatively forms die cavity, ingate, exhaust duct with the cover half;Vacuum valve is arranged at the valve pocket in cover half; Drift is fixedly connected with the bar of penetrating; Sprue gate and tube connection ports are provided with pressure chamber, the second vacuum tube is connected with the tube connection ports, the other end of second vacuum tube is connected with the second stop valve, and second stop valve connects second vacuum system;Control device is used for the operating for controlling first vacuum system and the second vacuum system, and the opening and closing of the first stop valve and the second stop valve;The present invention has the advantages of good vacuumizing effect, setting easy maintenance, fault rate is low, service life is long.
Research Gap: LPWAN Long Range and Cloud integrated technology for machine condition monitoring Technology 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 innovative method completely changes how Cold Chamber Horizontal Die-Casting Machines are monitored and maintained in industrial alloy casting manufacturing operations. The technology makes it possible to collect data in real-time on vital characteristics like vibration, temperature, and pressure by integrating sensors and communication technologies seamlessly. In order to do advanced analytics and processing on this data, algorithms for trend analysis, data analytics, and anomaly identification are sent to a cloud server. The results are then accessible via an intuitive web dashboard, giving authorities and operators direct visibility into the machine's operational condition.
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.
A complex interplay of hardware and software components powers this creation. The OCMCCHDCMote and OCMCCHDCRMote, two essential components of the system, are each outfitted with unique sensors and communication modules. The Cold Chamber Horizontal Die-Casting Machine's direct installed sensing device is the OCMCCHDCMote. The STM32 Processor Board, LoRa Module, Accelerometer, Temperature, Pressure, Vibration, RTC, and Power Supply are all included. Together, these parts work to continuously monitor the machine's critical parameters, including vibration, temperature, and pressure. The RTC Module makes sure that the data is accurately timestamping the data that is collected. By enabling long-range connection, the LoRa Module effectively sends real-time data to the cloud server.The OCMCCHDCRMote, on the other hand, is equipped with an STM32 Processor Board, LoRa Module, ESP01 WiFi Board, HMI Display, and Power Supply and functions as a remote monitoring and display device. The LoRa Module establishes communication with the OCMCCHDCMote, while the ESP01 WiFi Board expands the range of available connectivity. Serving as a localized user interface, the HMI Display provides operators and nearby staff with access to real-time data and alarms.
The OCMCCHDCMote and the specially created cloud server can communicate seamlessly, low-power, and over long distances because to the innovation's use of LPWAN (Low-Power Wide-Area Network) Long Range Technology. The processing and analysis of data is centrally located on the cloud server. The server uses pre-programmed algorithms for Data Analytics, Trending, and Fast Fourier Transform (FFT) after receiving machine data. The OCMCCHDCRMote's HMI Display then shows the analysis results for local monitoring, along with trend patterns and anomalies found. Concurrently, the results are incorporated into a customized web dashboard that can be accessed online. Authorized staff can monitor and evaluate the Cold Chamber Horizontal Die-Casting Machine's operational health remotely thanks to this web dashboard, which provides a thorough picture of the machine's state.In addition, the cloud-based solution includes an alarm system. The system uses the studied data to create alerts for particular machine conditions or possible problems. These alerts are then instantly shown on the local HMI Display as well as the remote web dashboard, guaranteeing operators and the appropriate authorities receive real-time notifications.
BEST METHOD OF WORKING
1. Real-time vibration, temperature, and pressure data from Cold Chamber Horizontal Die-Casting Machines are collected by the OCMCCHDCMote, which is outfitted with an STM32 Processor Board, Lora Module, Vibration Sensor, Temperature Sensor, Pressure Sensor, Accelerometer, RTC Module, and Power Supply. Long-range communication via LPWAN technology enables cloud-based analytics and proactive condition monitoring in the casting alloys manufacturing process.
2. Through the use of an intuitive interface and real-time insights into the operational health of Cold Chamber Horizontal Die-Casting Machines, operators and authorities can make informed decisions and take prompt action in the casting alloy manufacturing process thanks to the OCMCCHDCRMote, which is outfitted with an STM32 Processor Board, Lora Module, ESP01 Wifi Board, HMI Display, and Power Supply.
3. The computational power for data processing, analysis, and communication tasks in both OCMCCHDCMote and OCMCCHDCRMote is provided by the STM32 Processor Board, which is integrated into both nodes. This helps to ensure the smooth and effective functioning of the online condition monitoring system for Cold Chamber Horizontal Die-Casting Machines in the alloys manufacturing process.
4. The LoRa Module, which is also included in both motes, is utilized to enable effective long-range wireless communication between the cloud server and the OCMCCHDCMote. This allows real-time vibration, temperature, and pressure data from Cold Chamber Horizontal Die-Casting Machines to be transmitted efficiently, improving the online condition monitoring system for the alloy casting manufacturing process.
5. The temperature, pressure, accelerometer, and vibration sensors are all integrated into the OCMCCHDCMote and are used in concert to provide extensive real-time data on the operational parameters of Cold Chamber Horizontal Die-Casting Machines. This allows for accurate condition monitoring for prompt alerts and sophisticated analytics during the alloy casting manufacturing process.
6. The ESP01 WiFi Board, which is built into the OCMCCHDCRMote, improves connectivity options by enabling WiFi communication, making remote monitoring easier, and offering a second channel for real-time information about the operational health of the Cold Chamber Horizontal Die-Casting Machines used in the alloy casting manufacturing process.
7. The HMI Display, which is integrated into the OCMCCHDCRMote, serves as the user interface and locally presents real-time data and alerts, giving operators and authorities prompt knowledge about the state of the Cold Chamber Horizontal Die-Casting Machines used in the alloy casting manufacturing process.
8. To guarantee that there is enough electrical energy for the nodes to operate continuously, the Power Supply, which is plugged into both the OCMCCHDCMote and the OCMCCHDCRMote, is utilized.

ADVANTAGES OF THE INVENTION
1. Cold Chamber Horizontal Die-Casting Machines provide real-time vibration, temperature, and pressure data to the OCMCCHDCMote, which serves as the main sensor unit. It makes use of long-range wireless local area network (LPWAN) technologies to enable proactive condition monitoring and cloud-based analytics in the casting alloy manufacturing process.
2. With WiFi connectivity and an HMI display, the OCMCCHDCRMote functions as a remote monitoring and display device. Through an intuitive interface, this configuration provides operators and authorities with up-to-date information about the operational health of Cold Chamber Horizontal Die-Casting Machines, facilitating prompt and effective decision-making in the casting alloy manufacturing process.
3. The OCMCCHDCMote and the cloud server can communicate wirelessly over great distances thanks to the LoRa Module. This feature improves the online condition monitoring system for the casting alloy manufacturing process by ensuring the effective transfer of real-time vibration, temperature, and pressure data from Cold Chamber Horizontal Die-Casting Machines.
4. Together, the OCMCCHDCMote's Accelerometer, Temperature, Pressure, and Vibration Sensors provide full real-time data on the operating parameters of Cold Chamber Horizontal Die-Casting Machines. This feature makes it possible to precisely monitor conditions, which in turn produces timely alarms and sophisticated analytics during the casting alloy manufacturing process.
5. By enabling WiFi communication, the ESP01 WiFi Board inside the OCMCCHDCRMote expands connectivity choices. This feature makes remote monitoring easier and offers a second way to get up-to-date information about the operational health of Cold Chamber Horizontal Die-Casting Machines used in the alloy casting manufacturing process.
6. The OCMCCHDCRMote's integrated HMI Display presents data and warnings in real time locally, serving as a user interface. This function provides operators and authorities with real-time information about the state of Cold Chamber Horizontal Die-Casting Machines used in the alloy casting manufacturing process.

, Claims:1. A system of Online Condition Monitoring of Cold Chamber Horizontal Die-Casting Machine through LPWAN Long Range Technology for Industrial Manufacturing Process of casting alloys comprisesOCMCCHDCMote, which is outfitted with an STM32 Processor Board, Lora Module, Vibration Sensor, Temperature Sensor, Pressure Sensor, Accelerometer, RTC Module, and Power Supply; Long-range communication via LPWAN technology enables cloud-based analytics and proactive condition monitoring in the casting alloys manufacturing process.
2. The system as claimed in claim, wherein through the use of an intuitive interface and real-time insights into the operational health of Cold Chamber Horizontal Die-Casting Machines, operators and authorities can make informed decisions and take prompt action in the casting alloy manufacturing process thanks to the OCMCCHDCRMote, which is outfitted with an STM32 Processor Board, Lora Module, ESP01 Wifi Board, HMI Display, and Power Supply.
3.The system as claimed in claim, wherein the computational power for data processing, analysis, and communication tasks in both OCMCCHDCMote and OCMCCHDCRMote is provided by the STM32 Processor Board, which is integrated into both nodes; and this helps to ensure the smooth and effective functioning of the online condition monitoring system for Cold Chamber Horizontal Die-Casting Machines in the alloys manufacturing process.
4.The system as claimed in claim, wherein the LoRa Module, which is also included in both motes, is utilized to enable effective long-range wireless communication between the cloud server and the OCMCCHDCMote; and this allows real-time vibration, temperature, and pressure data from Cold Chamber Horizontal Die-Casting Machines to be transmitted efficiently, improving the online condition monitoring system for the alloy casting manufacturing process.
5.The system as claimed in claim, wherein the temperature, pressure, accelerometer, and vibration sensors are all integrated into the OCMCCHDCMote and are used in concert to provide extensive real-time data on the operational parameters of Cold Chamber Horizontal Die-Casting Machines; and this allows for accurate condition monitoring for prompt alerts and sophisticated analytics during the alloy casting manufacturing process.
6.The system as claimed in claim, wherein the ESP01 WiFi Board, which is built into the OCMCCHDCRMote, improves connectivity options by enabling WiFi communication, making remote monitoring easier, and offering a second channel for real-time information about the operational health of the Cold Chamber Horizontal Die-Casting Machines used in the alloy casting manufacturing process.
7.The system as claimed in claim, wherein the HMI Display, which is integrated into the OCMCCHDCRMote, serves as the user interface and locally presents real-time data and alerts, giving operators and authorities prompt knowledge about the state of the Cold Chamber Horizontal Die-Casting Machines used in the alloy casting manufacturing process.
8.The system as claimed in claim, wherein to guarantee that there is enough electrical energy for the nodes to operate continuously, the Power Supply, which is plugged into both the OCMCCHDCMote and the OCMCCHDCRMote, is utilized.

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