VISION-EQUIPPED EDGE DEVICE FOR HEALTH MONITORING OF ELECTRONICS DIE CAST MANUFACTURING MACHINES WITH XBEE AND LORA MULTINETWORK IOT GATEWAY

Abstract

A vision-equipped edge device for health monitoring of electronics die cast manufacturing machines with xbee and lora multinetwork iot gateway comprises Health Monitoring Node which has a Raspberry Pi, an XBee RF Module, a pressure sensor, a temperature sensor, a vibration sensor, a current sensor and a power supply is capable of receiving and transmitting critical machine health data in real time therefore improving the monitoring and the operational reliability of the die cast processes in the die cast manufacturing business the RoutePass Node consisting of STM32 board, XBee RF Module, LoRaWAN Module, HMI Display, buzzer and the power supply on the other hand allows broader functionality by helping provide data for visualization together with instant notification in the case of abnormal machine conditions to the site area operators for immediate feedback.

Specification

Description:FIELD OF THE INVENTION
This invention relates to vision-equipped edge device for health monitoring of electronics die cast manufacturing machines with xbee and lora multinetwork iot gateway.
BACKGROUND OF THE INVENTION
This novel solution presents a fully integrated edge device system aimed at the real-time health monitoring of electronics die cast manufacturing machines. The system consists of several mesh nodes that collect basic information such as pressure, temperature, vibration or current, and distribute it over multi-network gateway that switches between wireless communication types, depending on which network is available. The data gathered is sent to the cloud that has been developed specifically for these tasks and performs analytics based on the deep learning technology to forecast events and determine the best practices with respect to equipment maintenance. Such premises allow authorized personnel to watch over the machines' health through an inbuilt screen and secure online dashboard. Also, if any anomaly is registered, the machine within anpin the system shuts down automatically to avoid any damage or danger and assist in extending the lifespan of the appliances.
This project focuses on an important area - health monitoring and predictive maintenance in die cast manufacturing. In this process, problems like high temperature, high vibration, and high power, if not dealt with, will affect the availability of production capacity, the quality of production, and even safety. It is also quite impossible for conventional visual inspections to find the early tip signs of failure of any component in highly stressed machines. This invention solves that problem by monitoring important machine parameters all the time and analytics is used to find potential problems that are still minor. This is helps to manage and automate shut down if and when required, that in turn leads to reduced downtime, reduced maintenance costs, and improves machine fitness and safety.
CN221473463U: A mold local extrusion device with a casting forming part, a die casting mold and a die casting machine can reduce the porosity of a local thick wall below a molding hole, an oil pipe is arranged in an oil pipe mounting groove of a fixed mold frame, an extrusion core comprises the casting forming part and a rotation stopping shoulder, the rotation stopping shoulder is arranged in a first T-shaped groove of a coupler, a second T-shaped groove of the coupler is connected with an oil cylinder rod, an oil cylinder main body is arranged in an oil cylinder mounting groove of the fixed mold frame, a guide sleeve is fixedly arranged in a guide sleeve mounting groove of the fixed mold frame through a positioning pressing pin in the positioning pressing pin mounting groove, the coupler is provided with a signal rod mounting groove and a rotation stopping boss, the signal rod is arranged in the signal rod mounting groove of the coupler, the rotation stopping boss is aligned with a rotation stopping groove on the guide sleeve, a travel switch is fixed in a travel switch mounting groove of the fixed mold frame, an extrusion sleeve support tube is arranged in an extrusion sleeve support tube mounting groove of the fixed mold frame, the front end of the extrusion sleeve is propped against the rotation stopping shoulder, and a quick-change pressing plate is arranged in the fixed pressing plate mounting groove of the fixed mold frame and is pressed on the extrusion sleeve support tube.
RESEARCH GAP: The novelty of this system is its multi-network IoT gateway integrating XBee, LoRa, GSM, and WiFi for adaptive, real-time health monitoring and predictive maintenance in die cast manufacturing.
US10081054B2: A die-casting process method for die-cast molding of a metal in a semi-solid state, wherein a semi-solid state die-casting machine is used as a processing device and a pulper is used as a device for preparing and delivering a slurry in a semi-solid state; the method comprises the steps: spraying a mold release agent and mold clamping; melting the raw material and keeping the temperature; adding a metal modificator into the molten raw material to prepare the slurry in a semi-solid state; transferring the slurry in a semi-solid state into a mold by the pulper; die-casting, opening the mold and exporting a die-cast; removing the sprue to obtain the final die-cast. In the process method, a metal modificator is added to the liquid metal raw material during the preparation of the slurry in a semi-solid state so as to generate more crystal nuclei, so that die-cast products have better mechanical properties; by way of die-casting the slurry in a semi-solid state, during mold stripping the die-cast is low in temperature and small in deformation quantity, and the best shapes and surface smoothness of the product can be guaranteed; and the die-cast is compact interiorly with producing air holes, and the best interior structure and mechanical properties of the die-cast product are guaranteed.
RESEARCH GAP: The novelty of this system is its multi-network IoT gateway integrating XBee, LoRa, GSM, and WiFi for adaptive, real-time health monitoring and predictive maintenance in die cast manufacturing.
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.
This innovation operates through a unique network of dedicated nodes that are capable of monitoring, analyzing and transmitting real-time relevant information from the die cast machines. It commences with several nodes embedded with sensors that obtain critical operational data such as temperature, pressure, vibrations or the machine's electrical current. This information is conveyed wirelessly over a reliable communication infrastructure through a range of protocols for data transmission resiliency as well as diversity. Each node is built for the purpose of collecting data in such a way that machine functioning is not affected and hence unobtrusive monitoring is possible throughout the production cycle.
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.
This innovation operates through a unique network of dedicated nodes that are capable of monitoring, analyzing and transmitting real-time relevant information from the die cast machines. It commences with several nodes embedded with sensors that obtain critical operational data such as temperature, pressure, vibrations or the machine's electrical current. This information is conveyed wirelessly over a reliable communication infrastructure through a range of protocols for data transmission resiliency as well as diversity. Each node is built for the purpose of collecting data in such a way that machine functioning is not affected and hence unobtrusive monitoring is possible throughout the production cycle.
The communication system uses a multinetwork gateway that switches between protocols depending on the availability of the signal and the network such that data is sent to the cloud using the strongest relay. The main media for this transmission are RF modules plus long-range networks, with cellular or WiFi connections as a backup. This type of network and communication structure should withstand the constraints of data transmission, which is especially important in the context of offshore or industrial regions that may have intermittent connectivity. Each machine's data is therefore securely transmitted to a dedicated cloud server which is then analyzed by machine learning features to detect trends, outliers and failures in the future.
When data goes into the cloud, it has to be evaluated and transformed into operational insights. A recommendation system based on machine learning analyzes the information by detecting any types of deviance or trends that could suggest developing complications. These insights are encased in an HMI and Die Seite die nur für berechtigte Benutzer zugänglich ist und auch per Web Interface angezeigt has been moved here. This system saves time for the operators as it provides real time access to current machine status and other relevant information and even allow them to go back in history for better understanding which machine is working in what condition thus allowing for future interventions.

When the one of the system identifies a dangerous defect that can affect the efficiency and security of the machine, it automatically activates the essential cut off feature that conforms to the designated operator safety standards. It stops the operations of the machine using a mechanical device to avoid any further problems. The key advantage of this automatic shutting down feature is that it can protect the system against its own self-damage and at the same time mitigate production interruptions and operator accidents.
BEST METHOD OF WORKING
The Health Monitoring Node which has a Raspberry Pi, an XBee RF Module, a pressure sensor, a temperature sensor, a vibration sensor, a current sensor and a power supply is capable of receiving and transmitting critical machine health data in real time therefore improving the monitoring and the operational reliability of the die cast processes in the die cast manufacturing business.
The RoutePass Node consisting of STM32 board, XBee RF Module, LoRaWAN Module, HMI Display, buzzer and the power supply on the other hand allows broader functionality by helping provide data for visualization together with instant notification in the case of abnormal machine conditions to the site area operators for immediate feedback.
The GatewayPass Node constructed by combining Raspberry Pi, LoRaWAN Module, GSM Modem, LED indicator light and power supply facilitates the transmission of data to a custom cloud server through GSM or Wifi and in so doing enhances the availability of real time machine analysis and remote operations in order to improve management oversight.
The HMI Display placed at the RoutePass Node is located specifically to allow users to easily understand machine health data in real time and thus enable the on-site operators to monitor critical parameters and respond, if need be, to alerts in real time.
The GatewayPass Node use of a GSM Modem manages efficient long distance data transfer to the Cloud Server effectively enabling the monitoring and analysis of machine conditions in network restricted areas and for efficient proactive management of the health of machines.
The XBee RF Module built into HealthMonitoring Node as well as the RoutePass Node provides means for peer-to-peer wireless data exchange between the nodes and thus facilitate proper data transfer between the nodes and all the nodes working together.
ADVANTAGES OF THE INVENTION
1. A Network HealthMonitoring Node (Raspeberry Pi powered with an embedded XBee RF Module) contributes to precise real-time information from critical machine parts and allows timely analysis of goods with the help of sensors monitoring pressure, temperature, vibration and current activity.
2. The RoutePass Node with STM32 based device with LoRaWAN Module and Xbee RF Module provides flexibility and long-range data communication for circuitry placed in restrictive environments. It does not lose its operational capabilities because it automatically triggers the switch between XBee and LoRaWAN depending on the environment.
3. The Gateway Pass Node interacts with a Raspberry Pi and a LoRaWAN Module, pushes data gathered with a GSM Modem to a customized cloud server through GPRS or Wifi which can be analyzed for machine learning based insights and also offer an AI recommendation engine. The arrangement helps provide predictive maintenance recommendations that will help avoid unscheduled downtimes and extend the life of machines.
4. Remote control of machine status by operators and other authorized persons is made possible by HMI Display and buzzer at the RoutePass Node and via a web-based dashboard. Because of visual and audio alerts generated by the system, responding to prevent machine malfunction is fast.
5. These Systems Shut Down Automatically for Safety Features: If the abnormal situation is severe, then the apparatus switches an actuator which stops the actions of the machine so that it is safe and there is no damage incurred. As a protective measure against machinery and personnel abuse, this automatic shutdown provides a turn down Mendoza feature that minimizes the chances of any operational risk.
, Claims:1. A vision-equipped edge device for health monitoring of electronics die cast manufacturing machines with xbee and lora multinetwork iot gateway comprises Health Monitoring Node which has a Raspberry Pi, an XBee RF Module, a pressure sensor, a temperature sensor, a vibration sensor, a current sensor and a power supply is capable of receiving and transmitting critical machine health data in real time therefore improving the monitoring and the operational reliability of the die cast processes in the die cast manufacturing business.
2. The device as claimed in claim 1, wherein the RoutePass Node consisting of STM32 board, XBee RF Module, LoRaWAN Module, HMI Display, buzzer and the power supply on the other hand allows broader functionality by helping provide data for visualization together with instant notification in the case of abnormal machine conditions to the site area operators for immediate feedback.
3. The device as claimed in claim 1, wherein the GatewayPass Node constructed by combining Raspberry Pi, LoRaWAN Module, GSM Modem, LED indicator light and power supply facilitates the transmission of data to a custom cloud server through GSM or Wifi and in so doing enhances the availability of real time machine analysis and remote operations in order to improve management oversight.
4. The device as claimed in claim 1, wherein the HMI Display placed at the RoutePass Node is located specifically to allow users to easily understand machine health data in real time and thus enable the on-site operators to monitor critical parameters and respond, if need be, to alerts in real time.
5. The device as claimed in claim 1, wherein the GatewayPass Node use of a GSM Modem manages efficient long distance data transfer to the Cloud Server effectively enabling the monitoring and analysis of machine conditions in network restricted areas and for efficient proactive management of the health of machines.
6. The device as claimed in claim 1, wherein the XBee RF Module built into HealthMonitoring Node as well as the RoutePass Node provides means for peer-to-peer wireless data exchange between the nodes and thus facilitate proper data transfer between the nodes and all the nodes working together.

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