SOLAR-POWERED VISION DEVICE FOR MONITORING AND COUNTING IN PACKAGING MACHINES USING NRF AND LORA RF NETWORK AND GATEWAY

Abstract

A solar-powered vision device for monitoring and counting in packaging machines using nrf and lora rf network and gateway comprises assisted with an image capturing module, wireless communication, integrated power supply, temperature and vibration sensors, the VisionRx Node allows for continuous monitoring and count of items in packaging machines so that information is effectively collected and relayed to the nodes in the middle which strengthens the efficiency of packaging processes this routing node comprises of a control board, two communication modules and a separate power supply and increases the communication distance From the VisionRx Node to SolarGateway Node, this node provides strong data accumulation and dependable transmission of an extended distance for effective packaging machine network observation.

Specification

Description:FIELD OF THE INVENTION
This invention relates to solar-powered vision device for monitoring and counting in packaging machines using nrf and lora rf network and gateway.
BACKGROUND OF THE INVENTION
This development offers an integrated, self-sufficient, and portable technology capable of automatically monitoring and counting objects in the current context of packaging machinery. It consists of a vision module that captures and sends images, a routing module that provides long-distance communication links, and a central gateway that collects the data, presents it to the user in real time, and sends notifications. Because each module gets its energy from renewable sources, it can work anywhere even in a remote or an industrial setting. The system makes use of dual-network connectivity which guarantees effective transmission of data and is aimed at enhancing operational performance of the organization by eliminating the need for on-site presence, allowing preemptive oversight and reducing the need for maintenance.
The product is useful especially when observing and counting the items in a packaging stage where the processes are quite remote and industrial in nature and maintaining human presence continuously isn't a practical situation. A wired solution is rather an expensive option for mounting and maintenance for operational multi purposes and may require continuous individual interference. Other witnesses like unanticipated machine downtimes or the discrepancy in the product's actual count and expectations cause many operational costs, unproductive organizational waste and profits losses. This invention can enable and assist an automatic collection of data which is solar powered with wireless technology, this will assist in real time problem solving hence reducing the operational cost, minimizing errors and enhance monitoring without interruption even in remote areas.
US10543943B2: A horn and an anvil are moved toward and away from each other by axially reciprocating a driving rod and thereby reciprocatingly rotating a forked lever in a predetermined angle range. The horn and the anvil are moved toward and pressed against each other with a predetermined force with a bag mouth b held therebetween. A sensor detects the position of a second mounting block secured to the rear end of a sliding shaft of the anvil, thereby detecting the distance between respective pressing surfaces of the horn and the anvil, i.e. the thickness m of a portion of the bag mouth held between the pressing surfaces. When the thickness m is not less than a predetermined threshold value M, a vibrator is activated to perform sealing. When the thickness m is less than the threshold value M, no sealing is performed.
RESEARCH GAP: Solar-powered, dual-network wireless monitoring and counting for packaging machines using real-time data relay across nRF and LoRa RF networks is the novelty of the system.
US11878829B2: A packaging machine is provided for producing single and multiple compartment film wrapped pouches. Multiple linear motors allow aspects of the forming, filling, cutting and discharging to run at different speeds. The pouches are formed, filled and discharged from platens that are secured to movers that proceed through the packaging process by following magnetic fields created by independently controlled linear motors. Overall, cycle time is decreased as a result of speeding up parts of the process, including the platen return process, possible because there is no mechanical connection and not a single conveyor moving the platens while the other parts of the process may be simultaneously slowed down or even temporarily stopped. Changeover of platens, to accommodate different products, such as single compartment pouch to multiple compartment pouches, is also simplified because platens are simply connected to the movers and are thus easily removed and replaced.
RESEARCH GAP: Solar-powered, dual-network wireless monitoring and counting for packaging machines using real-time data relay across nRF and LoRa RF networks 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.
The invention combines cutting edge wireless technology and solar power to develop a monitoring and counting system aimed at packaging machines. The system consists of three interconnected modules: a vision module, a routing module and a central gateway. Each of these modules have been designed to perform their respective roles. The vision module takes images and collects information regarding the number and movement of the objects on the packaging line, and sends this information through short-range radio frequencies to the routing module. The routing module functions as a link, implementing a different ratio frequency communication technology to achieve a longer communication distance between the vision module and the gateway. This central gateway module retrieves and stores data from various routing modules and shows it on an interactive screen, such that the operational state of the machine is visible in real-time to operators. In addition, remote access through the gateway hardware is possible via a GSM modem, allowing supervisors or maintenance staff to receive messages and data related to equipment operation at large distances. Each module of the system is solar powered and functions on its own and all the time. Thus, this system is appropriate for plants located in remote areas or in regions where energy availability is a challenge.
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 invention combines cutting edge wireless technology and solar power to develop a monitoring and counting system aimed at packaging machines. The system consists of three interconnected modules: a vision module, a routing module and a central gateway. Each of these modules have been designed to perform their respective roles. The vision module takes images and collects information regarding the number and movement of the objects on the packaging line, and sends this information through short-range radio frequencies to the routing module. The routing module functions as a link, implementing a different ratio frequency communication technology to achieve a longer communication distance between the vision module and the gateway. This central gateway module retrieves and stores data from various routing modules and shows it on an interactive screen, such that the operational state of the machine is visible in real-time to operators. In addition, remote access through the gateway hardware is possible via a GSM modem, allowing supervisors or maintenance staff to receive messages and data related to equipment operation at large distances. Each module of the system is solar powered and functions on its own and all the time. Thus, this system is appropriate for plants located in remote areas or in regions where energy availability is a challenge.
Importantly, in packing facilities, proper counts and product flow control must be monitored to enhance efficiency and overall cost. Nonetheless, a number of facilities are located in regions where access to uninterrupted supervision and reliable energy or wired connections are available is a challenge. This innovation solves these limitations by providing a stand alone system that runs on solar energy, wireless and able to count packaging materials on the packing line automatically. The system works without the involvement of the human and labor resources are released while the whole system is more reliable. All the photos of the visualized data obtained at the packing area are transmitted to the centralized display where operators are able to see the live data. Due to the remote management possibility, it is easy to monitor the processes and receive notifications in case a problem arises. Such convenience and hassle-free functionality result in shorter periods of inactivity and wastage, which not only conserves resources but also boosts performance as a whole. Additionally, the application addresses renewable energy and therefore it is an environmentally friendly solution allowing industries to fulfil operational and ecological objectives within one solution.
BEST METHOD OF WORKING
Assisted with an image capturing module, wireless communication, integrated power supply, temperature and vibration sensors, the VisionRx Node allows for continuous monitoring and count of items in packaging machines so that information is effectively collected and relayed to the nodes in the middle which strengthens the efficiency of packaging processes.
This routing node comprises of a control board, two communication modules and a separate power supply and increases the communication distance From the VisionRx Node to SolarGateway Node. This node provides strong data accumulation and dependable transmission of an extended distance for effective packaging machine network observation.
The SolarGateway Node includes a control panel, two communication units, a screen, a notification panel and a power supply, it displays all sections of the packaging data and its status. It also displays alerts through the screen which encourages timely workflows for more efficient monitoring in packaging stations.
The solarGateway Node with manufactured modem (GSM) brings off site operator real time packaging information. It also allows for monitoring through greater distance since alerts can be seen and answered anywhere and this makes remote control operations swift and convenient.
The solarGateway Node has the Touch TFT Display for operation purposes which provides bundling processes monitoring in the real time mode. Through this display, operators are able to see the relevant information, check alert systems and interact with the monitoring system seamlessly.
A solar power supply that is attached to each of the nodes gives a solution which allows uninterrupted operation, autonomous from the grid. Doing so allows the system to function optimally in secluded or energy deficient locations, improving efficiency and economies in operational costs.
The nRF wireless communication module integrated in VisionRx Node and Routing Node aids data in short range low power transmission. This module ensures data transfer from nodes is efficient so that the monitoring data is delivered as intended.
Added to the Routing Node and SolarGateway Node, the LoRa RF Communication Module provides long range communication. This module allows data from the VisionRx Node to access remote areas in the network for easy connection of distant nodes and consistent monitoring of large areas.
ADVANTAGES OF THE INVENTION
1. All the processes within the system can be done automatically with little human help which directly reduces labor costs and leaves their workforce to engage in productive activities.
2. Real-Time Monitoring and Alerts Because of the instant sending and receiving of data with alerting features, the operators respond to the problems quickly and reduce the time losses associated with downtimes while enhancing production.
3. Easy implementation and scalability owing to its wireless and modular design, it provides for easy installation into different packaging environments and scalability to various sizes of premises.
4. With the use of solar energy, the system reduces dependence on outside power sources and thus reduces the operational costs while enhancing green technologies.
5. Enhancement of the system by enhancing the accuracy of item counting through high precision and reliable item tracking, the system lessens rejections, increases resource utilization, and enhances efficiency within the process.
, Claims:1. A solar-powered vision device for monitoring and counting in packaging machines using nrf and lora rf network and gateway comprises assisted with an image capturing module, wireless communication, integrated power supply, temperature and vibration sensors, the VisionRx Node allows for continuous monitoring and count of items in packaging machines so that information is effectively collected and relayed to the nodes in the middle which strengthens the efficiency of packaging processes.
2. The device as claimed in claim 1, wherein this routing node comprises of a control board, two communication modules and a separate power supply and increases the communication distance From the VisionRx Node to SolarGateway Node, this node provides strong data accumulation and dependable transmission of an extended distance for effective packaging machine network observation.
3. The device as claimed in claim 1, wherein the SolarGateway Node includes a control panel, two communication units, a screen, a notification panel and a power supply, it displays all sections of the packaging data and its status, it also displays alerts through the screen which encourages timely workflows for more efficient monitoring in packaging stations.
4. The device as claimed in claim 1, wherein the solarGateway Node with manufactured modem (GSM) brings off site operator real time packaging information, it also allows for monitoring through greater distance since alerts can be seen and answered anywhere and this makes remote control operations swift and convenient.
5. The device as claimed in claim 1, wherein the solarGateway Node has the Touch TFT Display for operation purposes which provides bundling processes monitoring in the real time mode, through this display, operators are able to see the relevant information, check alert systems and interact with the monitoring system seamlessly.
6. The device as claimed in claim 1, wherein a solar power supply that is attached to each of the nodes gives a solution which allows uninterrupted operation, autonomous from the grid. Doing so allows the system to function optimally in secluded or energy deficient locations, improving efficiency and economies in operational costs.
7. The device as claimed in claim 1, wherein the nRF wireless communication module integrated in VisionRx Node and Routing Node aids data in short range low power transmission, this module ensures data transfer from nodes is efficient so that the monitoring data is delivered as intended.
8. The device as claimed in claim 1, wherein added to the Routing Node and SolarGateway Node, the LoRa RF Communication Module provides long range communication, this module allows data from the VisionRx Node to access remote areas in the network for easy connection of distant nodes and consistent monitoring of large areas.

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