WIRELESS HYDRAULIC OIL CONDITION MONITORING IN DIE MAKING INDUSTRY USING ZIGBEE TECHNOLOGY FOR HYDRAULIC RAM EXTRUSION

Abstract

A system of wireless hydraulic oil condition monitoring in die making industry using zigbee technology for hydraulic ram extrusion comprises TZHREH_OMNode (10), which is outfitted with an ATmega2560 Board (10F), a ZigBee RF Module (10A), a NAS Sensor (10E), a Velocity Sensor (10C), and a Power Supply (10B), this allows for the seamless transmission of vital data to the cloud-based IoT platform for thorough analytics and monitoring to receive and process data transmitted by the TZHREH_OMNode, operators can utilize the RZHREH_OMNode, which is outfitted with an ATmega2560 Board, a ZigBee RF Module, an ESP8266 WiFi Module, a display, and a power supply, this allows for seamless integration with the cloud-based IoT platform, which enables comprehensive hydraulic system monitoring in the die-making industry, operators can access real-time insights and critical alerts displayed on a local screen.

Specification

Description:FIELD OF THE INVENTION
This invention relates to wireless hydraulic oil condition monitoring in die making industry using zigbee technology for hydraulic ram extrusion.
BACKGROUND OF THE INVENTION
This innovative hydraulic oil condition monitoring device revolutionizes the die-making industry by giving real-time information about the health and effectiveness of hydraulic systems during ram extrusion operations. Through the use of wireless sensors and advanced communication technologies, the system reliably gathers critical data, including velocity, temperature, and pressure parameters. The collected data is easily sent to an IoT platform hosted in the cloud, where machine learning algorithms examine the information, create trend graphs, and identify possible problems. Operators have access to an intuitive web interface with extensive analytics, enabling them to monitor the state of the hydraulic system, spot anomalies, and get fast notifications for corrective action.
The die-making industry is currently facing challenges in effectively monitoring and maintaining the hydraulic systems used in ram extrusion operations. Traditional methods of hydraulic oil condition monitoring are often labor-intensive, manual, and prone to human mistake; this leads to inefficiencies, unplanned downtime, and increased maintenance costs. The lack of real-time data analysis also makes it more difficult for the sector to proactively address possible issues, which results in less than ideal performance and decreased production overall.
US9114447B2: An extrusion press includes an end platen, a fixed platen arranged at the rear thereof, a tie rod configured to link the end platen and the fixed platen, a die, a container loaded with a billet, an extrusion stem configured to press the billet, a crosshead attached with the extrusion stem, and an extrusion drive configured to reciprocate the extrusion stem. The extrusion drive includes a rotatable wire drum driven by an electric extrusion main motor and drives the extrusion stem to perform extrusion molding by winding the wire by rotating the wire drum.
RESEARCH GAP: ZigBEe based Wireless Hydraulic Oil Monitoring for Hydraulic Ram Extrusion is the novelty of the system.
WO2012003540A2: Disclosed herein is an extruding machine. The extruding machine comprises a frame defined by upper and lower pairs of tie rods, between which extend a main cylinder platen, a front platen, and a crosshead container fixture, all of which are axially adjustably mounted on the tie rods. The extruding machine comprises a hollow cylindrical container, which is mounted to the frame via the crosshead container fixture. The container defines a press chamber having a longitudinal axis and has a first open end and an opposite second open end communicating with the press chamber. The second end of the container is adapted to receive a die, which is held in a die holder. The die holder is axially slidably mounted to the frame via a slide assembly that extends from the front platen.
RESEARCH GAP: ZigBEe based Wireless Hydraulic Oil Monitoring for Hydraulic Ram Extrusion 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.
This technical innovation makes it easier to monitor, analyze, and show hydraulic system data in real-time within the die-making sector by seamlessly integrating hardware components, cloud-based IoT solutions, and wireless communication technologies like ZigBee. The invention uses a two-node system, with the transmitting node (TZHREH_OMNode) and the receiving node (RZHREH_OMNode) having distinct hardware features and functions. The field-based TZHREH_OMNode is equipped with an ATmega2560 Board and multiple sensors, including as a liquid temperature sensor, velocity sensor, and NAS sensor. These are connected to a ZigBee RF Module via wireless communication. During the die-making process, this node is in charge of collecting real-time data on hydraulic oil conditions. This includes pressure, temperature, and velocity data that are essential for determining the effectiveness and condition of the hydraulic system.
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 technical innovation makes it easier to monitor, analyze, and show hydraulic system data in real-time within the die-making sector by seamlessly integrating hardware components, cloud-based IoT solutions, and wireless communication technologies like ZigBee. The invention uses a two-node system, with the transmitting node (TZHREH_OMNode) and the receiving node (RZHREH_OMNode) having distinct hardware features and functions. The field-based TZHREH_OMNode is equipped with an ATmega2560 Board and multiple sensors, including as a liquid temperature sensor, velocity sensor, and NAS sensor. These are connected to a ZigBee RF Module via wireless communication. During the die-making process, this node is in charge of collecting real-time data on hydraulic oil conditions. This includes pressure, temperature, and velocity data that are essential for determining the effectiveness and condition of the hydraulic system.
Conversely, the RZHREH_OMNode is situated at a distance and is equipped with an ESP8266 WiFi Module, ATmega2560 Board, ZigBee RF Module, Display, and Power Supply. The data transmitted by the TZHREH_OMNode is received centrally by the RZHREH_OMNode. It makes use of the ESP8266 Wifi Module to connect to the internet and the ZigBee RF Module to create a wireless connection with the broadcasting node. Operators are given instant access to information on the state of the hydraulic system thanks to the local processing of the incoming data and its presentation on a screen attached to the RZHREH_OMNode.
The cloud-based Internet of Things system is the basis of this breakthrough. The TZHREH_OMNode transmits the gathered data to a cloud server that has been specially configured for this invention. Predefined machine learning algorithms in the cloud environment evaluate the incoming data, producing trend charts and, using analytics, flagging significant alerts. An operator-specific web dashboard provides access to the processed data. Operators can log in to this dashboard, which is available through user accounts, and track the hydraulic system's performance with real-time and historical data. With the use of this interface, operators are able to decide with knowledge and react quickly to any urgent notifications that the system may have detected.
BEST METHOD OF WORKING
During the ram extrusion processes, real-time data on pressure, temperature, and velocity from hydraulic systems are collected by the TZHREH_OMNode, which is outfitted with an ATmega2560 Board, a ZigBee RF Module, a NAS Sensor, a Velocity Sensor, and a Power Supply. This allows for the seamless transmission of vital data to the cloud-based IoT platform for thorough analytics and monitoring.
To receive and process data transmitted by the TZHREH_OMNode, operators can utilize the RZHREH_OMNode, which is outfitted with an ATmega2560 Board, a ZigBee RF Module, an ESP8266 WiFi Module, a display, and a power supply. This allows for seamless integration with the cloud-based IoT platform, which enables comprehensive hydraulic system monitoring in the die-making industry. Operators can access real-time insights and critical alerts displayed on a local screen.
The central processing unit (CPU) in both motes is the ATmega2560 Board, which coordinates the integration of communication modules, sensor data, and system control to guarantee smooth operation and coordination between the RZHREH_OMNode and TZHREH_OMNode in monitoring hydraulic conditions during ram extrusion processes.
Both of the innovations make use of the ZigBee RF Module, which is used to enable wireless communication between the TZHREH_OMNode and RZHREH_OMNode. This allows for the effective transmission of real-time sensor data and helps the hydraulic oil condition monitoring system in the die-making industry integrate seamlessly.
This innovation uses the Liquid Temperature Sensor, Velocity Sensor, and NAS Sensor together to acquire extensive amounts of data. These sensors are connected to a TZHREH_OMNode and provide vital real-time data on temperature, pressure, and velocity within hydraulic systems during ram extrusion processes, ensuring precise monitoring of the hydraulic oil condition in the die-making industry.
The RZHREH_OMNode's ESP8266 WiFi Module is used to connect the device to the internet, allowing for smooth data transfer to the cloud-based IoT platform and enabling remote monitoring and analysis of hydraulic system conditions in the die-making sector.
The Display, which is interfaced with the RZHREH_OMNode, is used to give operators locally-based analytics, critical alerts, and real-time visual insights. This improves situational awareness and speeds up decision-making when it comes to the monitoring of hydraulic oil conditions during ram extrusion processes in the die-making sector.
ADVANTAGES OF THE INVENTION
1. As the primary hub for data collecting in this innovation, the TZHREH_OMNode is essential. It collects data on pressure, temperature, and velocity in real time from hydraulic systems during ram extrusion processes by combining sensors with ZigBee technology. This makes it possible for vital data to be seamlessly sent to an IoT platform hosted in the cloud for in-depth analysis and monitoring in the die-making sector.
2. The RZHREH_OMNode serves as a crucial receiving and display unit in this innovation. The TZHREH_OMNode transmits data, which it gathers and processes using WiFi and ZigBee connectivity. This feature makes it possible for operators to monitor hydraulic system conditions in the die-making business in great detail by integrating easily with the cloud-based IoT platform. It also gives them access to real-time insights and important alerts that are presented on a local screen.
3. The TZHREH_OMNode and RZHREH_OMNode's ability to communicate wirelessly is made possible in large part by the ZigBee RF Module. This module makes it easier to transmit real-time sensor data efficiently, which helps the hydraulic fluid condition monitoring system in the die-making industry integrate smoothly.
4. The Liquid Temperature Sensor, Velocity Sensor, and NAS Sensor work together to provide thorough data collection in this innovation. They give hydraulic systems' vital real-time pressure, temperature, and velocity data during ram extrusion operations. This guarantees precise hydraulic oil condition monitoring in the die-making sector.
5. The RZHREH_OMNode's ability to connect to the internet is mostly dependent on the ESP8266 Wifi Module. This module facilitates remote monitoring and analysis of hydraulic system conditions in the die-making industry by enabling smooth data transmission to the cloud-based IoT platform.
6. The Display is an essential interface on the RZHREH_OMNode that gives operators local analytics, important alerts, and real-time insights. This improves situational awareness and speeds up decision-making when it comes to the die-making industry's monitoring of hydraulic oil conditions during ram extrusion procedures.
, Claims:1. A system of wireless hydraulic oil condition monitoring in die making industry using zigbee technology for hydraulic ram extrusion comprises TZHREH_OMNode (10), which is outfitted with an ATmega2560 Board (10F), a ZigBee RF Module (10A), a NAS Sensor (10E), a Velocity Sensor (10C), and a Power Supply (10B), this allows for the seamless transmission of vital data to the cloud-based IoT platform for thorough analytics and monitoring.
2. The system as claimed in claim 1, wherein to receive and process data transmitted by the TZHREH_OMNode, operators can utilize the RZHREH_OMNode, which is outfitted with an ATmega2560 Board, a ZigBee RF Module, an ESP8266 WiFi Module, a display, and a power supply, this allows for seamless integration with the cloud-based IoT platform, which enables comprehensive hydraulic system monitoring in the die-making industry, operators can access real-time insights and critical alerts displayed on a local screen.
3. The system as claimed in claim 1, wherein the central processing unit (CPU) in both motes is the ATmega2560 Board, which coordinates the integration of communication modules, sensor data, and system control to guarantee smooth operation and coordination between the RZHREH_OMNode and TZHREH_OMNode in monitoring hydraulic conditions during ram extrusion processes.
4. The system as claimed in claim 1, wherein both of the innovations make use of the ZigBee RF Module, which is used to enable wireless communication between the TZHREH_OMNode and RZHREH_OMNode, this allows for the effective transmission of real-time sensor data and helps the hydraulic oil condition monitoring system in the die-making industry integrate seamlessly.
5. The system as claimed in claim 1, wherein this innovation uses the Liquid Temperature Sensor, Velocity Sensor, and NAS Sensor together to acquire extensive amounts of data, these sensors are connected to a TZHREH_OMNode and provide vital real-time data on temperature, pressure, and velocity within hydraulic systems during ram extrusion processes, ensuring precise monitoring of the hydraulic oil condition in the die-making industry.
6. The system as claimed in claim 1, wherein the RZHREH_OMNode's ESP8266 WiFi Module is used to connect the device to the internet, allowing for smooth data transfer to the cloud-based IoT platform and enabling remote monitoring and analysis of hydraulic system conditions in the die-making sector.
7. The system as claimed in claim 1, wherein the Display, which is interfaced with the RZHREH_OMNode, is used to give operators locally-based analytics, critical alerts, and real-time visual insights, this improves situational awareness and speeds up decision-making when it comes to the monitoring of hydraulic oil conditions during ram extrusion processes in the die-making sector.

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