Description:FIELD OF THE INVENTION

[0001] The present invention relates to a blockchain integrated IIoT enabled vertical centrifugal casting monitoring system that enhances the monitoring and quality assurance of vertical centrifugal casting operations by integrating real-time tracking of critical parameters and seeks to ensure the data's immutability and traceability, thereby improving process reliability and accountability.

BACKGROUND OF THE INVENTION

[0002] Monitoring vertical centrifugal casting is crucial for ensuring the quality and integrity of cast components, particularly in industries where precision and performance are paramount, such as aerospace and automotive manufacturing. This casting technique, which involves rotating a mold around a vertical axis while molten metal is poured in, demands meticulous oversight to achieve uniform material distribution and optimal mechanical properties. Monitoring help track parameters such as rotational speed, temperature, and metal flow rates, which are vital for controlling the solidification process and preventing defects like porosity, segregation, or inclusions. Sensors and real-time data analytics play a key role in this process by providing instant feedback and enabling adjustments to maintain optimal conditions. Additionally, regular inspection of the mold and cast components, often facilitated by non-destructive testing methods, helps in early detection of potential issues, thereby reducing the likelihood of costly rework or product failure. By integrating these monitoring practices, manufacturers enhance the reliability and performance of their cast products, ensuring they meet stringent industry standards and customer expectations.

[0003] Traditional methods of monitoring vertical centrifugal casting often involve manual checks and basic measurement techniques, such as visual inspections, temperature readings, and rotational speed monitoring. These approaches typically rely on human observation and simple instruments to ensure that the casting parameters remain within acceptable limits. Visual inspections, for instance identify obvious defects but miss subtler issues that develop during the casting process.

[0004] Furthermore, traditional methods often lack real-time data integration, making this challenging to respond swiftly to fluctuations in the casting environment. These methods also tend to be less precise and involve considerable manual effort, increasing the potential for human error. As a result, the castings suffer from inconsistencies such as uneven density, defects like porosity or inclusions, and compromised mechanical properties. The reliance on manual inspection and single-point measurements lead to inefficiencies and higher rejection rates, ultimately impacting product quality and production costs. Therefore, while traditional methods have been foundational, their limitations highlight the need for more automated monitoring systems that offer real-time, comprehensive data and greater accuracy in controlling the casting process.

[0005] CN1035628A discloses about an invention that on the framework of vertical centrifugal-casting machine, hang support plate, the parts of bearings that has mold, the anchor clamps that clamp mold and to the driven member that also has the drive unit of rotational mold less with pliable and tough elasticity drag-line. The length of pliable and tough elasticity drag-line can be regulated. Framework is by vertical pillars and transmit stand formation, and pliable and tough elasticity drag-line just is fixed on the column. Although, CN’628 discloses about an invention that describes a vertical centrifugal casting machine featuring a framework with vertical pillars, support plates, and adjustable drag-lines for holding and rotating molds. However, the cited invention has several limitations such as absence of real-time data collection and analysis of critical parameters such as rotational speed, furnace temperature, and environmental conditions are not actively monitored or managed due to which any variations in these parameters go unnoticed, potentially leading to inconsistencies in casting quality and increased risk of defects.

[0006] KR20110026175A discloses about a vertical centrifugal casting method using a hollow core, for increasing productivity than the producing method using forging or welding, is provided to simultaneously form finished products in standard size by using a large size gear and flange. CONSTITUTION: A vertical centrifugal casting method using a hollow core comprises follows. A core is partitioned into a lower core and an upper core. The upper and lower cores are made of molding sands. The upper and lower core is fixed to the center area of upper and lower molds of a vertical centrifugal casting mold, respectively. The inside of the upper core is formed in cavity. Molten metal is inserted through a hollow. The upper and lower cores are separated in a vertical direction. The molten metal charged in the hollow of the upper core is filled in the inside of the mold through a space between cores. Though, KR’175 discloses about an invention that introduces a vertical centrifugal casting method using a hollow core to improve productivity and produce standard-sized components more efficiently. However, the cited invention lacks in continuous monitoring of critical parameters like mold rotational rate, furnace temperature, and environmental conditions. Consequently, the absence of such monitoring and data integration limits the ability to ensure consistent quality and traceability throughout the casting process.

[0007] Conventionally, many methods are available for VCC (vertical centrifugal casting) specifically the support and rotation of molds, but lacks monitoring capabilities. Both inventions fail to offer integrated systems for continuous parameter monitoring and traceability which are crucial for ensuring consistent quality and effective quality assurance in casting operations. The mentioned invention does not provide comprehensive, real-time data management and immutable record-keeping, thus compromising the ability to maintain high standards of quality and process reliability.

[0008] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that requires to integrate IIoT capabilities to address both real-time monitoring and data management challenges by continuously tracking critical parameters such as the rotational rate of the mold, furnace temperature, ambient temperature, and humidity levels. Additionally, the developed system needs to provide robust traceability and enhanced quality assurance in VCC casting operations for improving transparency and reliability.

OBJECTS OF THE INVENTION

[0009] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0010] An object of the present invention is to develop a system that encompasses real-time detection and recording of operational parameters of vertical centrifugal casting (VCC) such as monitoring the rotational rate, ambient temperature, and humidity levels to ensure optimal casting conditions.

[0011] Another object of the present invention is to develop a system that captures and record data for assessing and adjusting casting parameters for improved quality and efficiency.

[0012] Another object of the present invention is to develop a system that facilitates real-time transfer of recorded data in view of providing remote access to operational data, thereby enabling ongoing analysis and timely decision-making to enhance process.

[0013] Another object of the present invention is to develop a system that provides immutable and verified record of all VCC operations, thus guaranteeing traceability and enhancing quality assurance measures.

[0014] Another object of the present invention is to develop a system that allows users to monitor VCC operations and review historical data for operational management and oversight.

[0015] Yet another object of the present invention is to develop a system that streamlines the transactions related to VCC operations by secured handling and transferring in view of secured data storage.

[0016] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0017] The present invention relates to a blockchain integrated IIoT enabled vertical centrifugal casting monitoring system that continuously tracks essential parameters for improving monitoring and quality control of vertical centrifugal casting processes, thus enhancing the process's reliability and accountability.

[0018] According to an embodiment of the present invention, a blockchain integrated IIoT enabled vertical centrifugal casting monitoring system, comprises of a VCC assembly with a rotating mold and a bottom-pouring furnace, equipped with a sensing module linked to a microcontroller. This setup continuously monitors critical parameters such as the mold's rotational rate, furnace temperature, ambient temperature, and humidity levels. The data collected by the sensing module is processed and recorded by a processor, which then streams this information to a cloud-based server through a communication module. The cloud server temporarily holds the data before it is transmitted to a blockchain network for immutable storage, ensuring data integrity and traceability. Users interact with the system via a user interface module, such as TronLink, which connects to the blockchain network. This interface facilitates data management, transactions through a blockchain-based digital wallet, and the creation of smart contracts using a code editor. These contracts are processed by a virtual machine, specifically the Tron Virtual Machine, which converts them into executable bytecode and manages their deployment on the blockchain.

[0019] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates a schematic diagram of a VCC assembly associated with a blockchain integrated IIoT enabled vertical centrifugal casting monitoring system;
Figure 2 illustrates a schematic diagram of the proposed system;
Figure 3 illustrates a flow diagram depicting workflow of the proposed system; and
Figure 4 illustrates a flow chart of smart contract associated with the proposed system.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0022] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0023] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0024] The present invention relates to a blockchain integrated IIoT enabled vertical centrifugal casting monitoring system for monitoring and controlling quality of vertical centrifugal casting processes by real-time measurements, thereby improving overall reliability and accountability of the casting process.

[0025] Referring to Figure 1, a schematic diagram of VCC assembly associated with a blockchain integrated IIoT enabled vertical centrifugal casting monitoring system is illustrated, comprising of a VCC assembly 101 having a mold 102 configured to rotate about a vertical axis and a bottom pouring resistance melting furnace 103 for melting a material.

[0026] The system disclosed herein includes a VCC assembly 101 which consists of a rotating mold 102 and a bottom-pouring resistance melting furnace 103. The mold 102 is developed to rotate around a vertical axis, which is crucial for achieving the desired casting properties. The vertical centrifugal casting (VCC) process is a specialized technique used for producing high-quality, cylindrical metal parts with uniform properties and minimal defects. The mold 102 is usually cylindrical and is made from materials that withstand high temperatures and mechanical stress. The rotation of the mold 102 creates a centrifugal force that pushes the molten metal towards the outer walls of the mold 102. This centrifugal force ensures that the casting material fills the mold 102 uniformly and solidifies in a controlled manner, minimizing defects such as porosity and inclusions.

[0027] The bottom-pouring resistance melting furnace 103 is installed below the mold 102 which is responsible for melting the metal to be cast. This furnace 103 employs resistance heating elements that generate the necessary heat to melt the metal. The resistance melting furnace 103 operates by passing an electric current through a resistive heating element, which generates heat due to electrical resistance. This heat is then transferred to the metal, causing it to melt and become a molten liquid. The design of the furnace 103 ensures that the metal is heated to the appropriate temperature for casting which aids in achieving the desired material properties in the final mold 102.

[0028] Once the metal reaches the required molten state, this is poured into the mold 102 through a bottom pouring process. This pouring process is carefully controlled to ensure that the molten metal flows smoothly into the rotating mold 102. The molten metal is introduced into the mold 102 from below, and as the mold 102 rotates, the centrifugal force causes the molten metal to spread out evenly against the inner surface of the mold 102. This continuous rotation and pouring process allow for the formation of a solidified casting with consistent density and mechanical properties.

[0029] The VCC assembly 101 is embedded with a sensing module for monitoring and measuring several key parameters such as rotational rate of the mold 102, a furnace temperature of the melting furnace 103, an ambient temperature and a humidity level that are critical to the casting process. Thie sensing module is equipped with various sensors and connected to a microcontroller which processes and manages the data collected from the sensing modules. The sensing module incorporates a rotary encoder that is mounted on the mold’s rotating shaft.

[0030] The rotary encoder consists of a disk with evenly spaced lines or slots, and a sensor that reads these lines as the disk rotates. As the mold 102 turns, the disk spins, and the sensor detects the interruptions or changes in light passing through the slots. This generates a series of electrical pulses. The frequency of these pulses is directly proportional to the rotational speed of the mold 102. The microcontroller connected to the encoder counts these pulses over a specific time interval to determine the rotational rate, usually expressed in revolutions per minute (RPM) or degrees per second. Rotary encoders provide high-resolution measurements and are ideal for applications requiring precise speed and position tracking.

[0031] According to another embodiment of the present invention, the rotational rate of the mold 102 in vertical centrifugal casting (VCC) assembly 101 is also measured by a tachometer. The tachometer is used to measure the rotational speed of the mold 102 which include but not limited to contact or non-contact tachometer. The contact tachometer uses a mechanical probe that directly touches the rotating shaft to measure its speed, wherein the non-contact tachometer employes optical or laser technology to measure the rotational speed by detecting the reflection of light from a rotating surface or using laser pulses directed at the rotating mold 102. The tachometer calculates the rotational rate based on the time taken for the mold 102 to complete one full rotation or a series of rotations. This data is converted into an electrical signal that represents the mold's speed. Tachometers are valued for their ability to provide real-time speed measurements and are particularly useful when precise control over rotational speed is necessary.

[0032] The furnace temperature of the melting furnace 103 is monitored using temperature sensor such as resistance temperature detectors (RTDs). The RTDs are temperature sensors that change resistance in response to temperature changes. The microcontroller measures the resistance change and calculates the furnace temperature. Accurate monitoring of the furnace temperature is essential for maintaining the metal at the correct melting point which directly affects the quality of the castings. Herein, to measure the ambient temperature, the sensing module incorporates a separate temperature sensor such as a thermistor whose resistance varies significantly with temperature. The microcontroller reads the resistance and converts it into a temperature reading. This measurement helps in understanding the environmental conditions surrounding the VCC assembly 101, which influence the cooling rate and overall casting process.

[0033] The humidity level around the VCC assembly 101 is determined by a humidity sensor such as a capacitive hygrometer. The capacitive humidity sensor measure changes in capacitance caused by variations in moisture content in the air. The microcontroller processes the sensor’s output to determine the relative humidity level. Monitoring humidity is important as this affects the casting process and the material properties of the final product especially in terms of oxidation and moisture-related defects. The microcontroller serves as the central unit that collects data from all these sensors, performs necessary calculations, and processes the information which ensures that the measurements are accurate and timely, allowing for real-time adjustments to the casting parameters.

[0034] Upon receiving readings from the sensing module, at least one processor and a memory work in collaboration to manage and execute various steps crucial to the monitoring and documentation of VCC operations. The processor interacts with the sensing module integrated into the VCC assembly 101. This module, comprising sensors for measuring furnace temperature, ambient temperature, and humidity levels, feeds real-time data to the processor. When the processor receives this data, the processor executes a series of predefined instructions stored in the memory that involves recording the collected data, which includes the temperature of the melting furnace 103, the ambient temperature around the VCC assembly 101, and the relative humidity in the environment. This data is essential for maintaining the appropriate casting conditions and ensuring the quality of the final mold 102.

[0035] Once the data is recorded, the processor then initiates streaming the recorded data to a cloud-based server. This is achieved through a communication module linked with the processor. The communication module is responsible for transferring the data from the local system to the cloud infrastructure in view of ensuring that the data is transmitted securely and efficiently. The cloud-based server provides a scalable and accessible platform for storing large volumes of data. By transferring data to the cloud, the system enables remote access and analysis for facilitating ongoing monitoring and evaluation of VCC operations.

[0036] After the data is successfully uploaded to the cloud, this is held on the server for a predetermined period. This retention period is defined based on operational requirements and regulatory standards. During this time, the data remains accessible for review and analysis. This step ensures that historical data is preserved, providing a valuable resource for trend analysis, troubleshooting, and performance optimization. The cloud server's architecture supports robust data management practices, including backup and recovery options to safeguard against data loss.

[0037] Following the retention period, the data is transmitted to a blockchain server within a blockchain network. This involves sending the data to a decentralized ledger where the data is stored in an immutable format. The blockchain technology used herein is specifically the Tron blockchain platform which ensures that once the data is recorded, the recorded data is not susceptible to any alteration or deletion. This immutability aids for maintaining data integrity in view of ensuring traceability and upholding quality assurance throughout the VCC process. The use of blockchain network provides a transparent and verifiable record of all operational data which is significant for audits and compliance purposes (as illustrated in Figure 2).

[0038] The immutability is achieved through cryptographic techniques and the decentralized nature of blockchain networks. Each transaction or data entry is grouped into a block which is then linked to the previous block forming a chain. Once a block is added to the chain, this becomes part of the permanent ledger. This structure ensures that any attempt to modify past data require altering all subsequent blocks and gaining consensus from the network, which is virtually impossible. This immutability provides a high level of data integrity and security, making ideal for applications that require a transparent and verifiable record, such as in the monitoring of VCC operations where quality assurance and traceability are crucial.

[0039] The Tron blockchain platform mentioned herein is a prominent blockchain network developed to support decentralized applications (dApps) and smart contracts (as shown in Fig.4). Developed with a focus on scalability and high throughput, Tron is known for its ability to process a high volume of transactions quickly and efficiently. Tron utilizes a consensus mechanism called Delegated Proof-of-Stake (DPoS), which enables this to achieve faster block generation times and lower transaction costs compared to some other blockchain platforms.

[0040] To facilitate user interaction with the blockchain network, a user interface module is employed such as TronLink, is configured with a computing unit that allows users to access and manage data stored on the blockchain. Through this interface, users are able to view real-time data, access historical records, and perform various functions related to the VCC process. The user interface provides a platform for engaging with the blockchain network, ensuring that users effectively monitor operations and make informed decisions based on the available data.

[0041] A digital wallet is associated with the blockchain network that is accessible via the user interface module and is used for holding and transacting tokens native to the blockchain network. The digital wallet facilitates transactions related to VCC operations, such as paying for services or managing digital assets. This provides a secure and convenient method for handling blockchain-based transactions, enhancing the efficiency of financial operations within the VCC system. These tokens are integral to the network's operations and ecosystem that are used as a medium of exchange, a means of accessing certain functionalities, or a way to represent ownership or rights within the blockchain system. Native tokens serve various purposes, such as facilitating transactions, paying for services, or executing smart contracts. For example, on the Tron blockchain, native tokens are used to settle payments for VCC-related services or manage digital assets associated with the VCC system. Their native status means they are deeply embedded in the blockchain's infrastructure, ensuring compatibility and seamless interaction with the network's protocols and applications. This inherent integration provides a secure and efficient way to handle digital transactions and interactions within the blockchain ecosystem.

[0042] The user interface is embedded with a code editor that enables users to write and manage smart contracts. The Smart contracts are self-executing agreements with the terms of the contract directly written into code. These contracts automatically enforce and execute their terms when predefined conditions are met, eliminating the need for intermediaries and reducing the potential for human error. In the VCC system, these contracts govern various aspects of operations, such as the conditions under which payments are made, service agreements, or compliance with quality standards. The code editor provides a user-friendly interface where users draft smart contracts compatible with the blockchain platform. This editor allows users to input the contract's logic, specify conditions and actions, and test the contract's functionality before deployment. Once written, the smart contracts are compiled into bytecode which is a low-level code that is executed by the blockchain network's virtual machine (as illustrated in Figure 3).

[0043] The smart contracts are processed and executed by the virtual machine, such as the Tron Virtual Machine, which is part of the blockchain network. The virtual machine converts written smart contracts into bytecode, a low-level code that the blockchain network execute. This bytecode is then deployed on the blockchain, where this performs the defined actions as stipulated in the smart contracts. The virtual machine ensures that the contracts are executed consistently and reliably, providing a secure means for automating various aspects of the VCC process.

ADVANTAGES

• Comprehensive Real-Time Monitoring: The integration of the sensing module with the microcontroller enables real-time monitoring of critical parameters such as the rotational rate of the mold 102, furnace temperature, ambient temperature, and humidity levels. This continuous data collection allows for precise control and adjustment of the casting process, ensuring that conditions remain within optimal ranges for producing high-quality castings.

• Data Management and Accessibility: By streaming recorded data to the cloud-based server, the system facilitates scalable storage and remote access. This capability ensures that large volumes of data are efficiently managed and readily available for analysis. Users are able to access historical data, perform trend analysis, and make informed decisions based on comprehensive datasets.

• Data Retention and Recovery: The ability to hold streamed data in the cloud for the predetermined period supports data retention policies and compliance with regulatory standards. The cloud infrastructure’s backup and recovery options further protect against data loss, ensuring that critical information is preserved and accessible.

• Immutable Data Records: Transmitting data to the blockchain network ensures that the data is stored in immutable format. This immutability guarantees data integrity and prevents tampering or unauthorized alterations, which is crucial for maintaining accurate and trustworthy records of VCC operations.

• Traceability and Quality Assurance: The use of blockchain technology enhances traceability and quality assurance by providing the transparent and verifiable record of all data entries and transactions. This transparency is valuable for audits, compliance checks, and verifying the authenticity of the casting process.

[0044] The present invention works best in the following manner, where the VCC assembly 101 as disclosed in the proposed invention which includes the mold 102 that rotates around the vertical axis and the bottom-pouring resistance melting furnace 103 used to melt material and cast it. The sensing module, integrated with the VCC assembly 101 and connected to the microcontroller, continuously monitors critical parameters such as the rotational rate of the mold 102, the temperature of the melting furnace 103, ambient temperature, and humidity levels. This data is collected and processed by the processor with memory, which records the measurements and prepares them for transmission. The recorded data is then streamed to the cloud-based server via the communication module. The cloud-based server holds this data for predetermined period, ensuring accessibility and preservation. Subsequently, the data is transmitted to the blockchain server within the blockchain network to be stored immutably, which guarantees data integrity and enhances traceability and quality assurance of VCC operations. Users interact with this system through the dedicated user interface, such as TronLink, linked with the blockchain network. This interface allows users to view and manage data, perform transactions using the digital wallet that supports the blockchain network’s native token, and create and manage smart contracts. These contracts are written using the code editor and are then converted into bytecode and executed by the virtual machine, such as the Tron Virtual Machine, to automate and enforce agreements related to VCC operations.

[0045] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A blockchain integrated IIoT enabled vertical centrifugal casting monitoring system, comprising:

a VCC assembly 101 having a mold 102 configured to rotate about a vertical axis, and a bottom pouring resistance melting furnace 103 for melting a material and pouring said molten material into said mold 102 for casting;
characterized in that:
i) a sensing module incorporated with said VCC assembly 101, linked with an inbuilt microcontroller, for detecting a rotational rate of said mold 102, a furnace temperature of said melting furnace 103, an ambient temperature and a humidity level;
ii) at least one processor; and a memory storing executable instructions that, when executed by the at least one processor, directs the processor to perform the steps of:
a. recording data pertaining to said VCC assembly 101 by means of said sensing module, said data including a furnace temperature of said melting furnace 103, an ambient temperature and a humidity level;
b. streaming said recorded data to a cloud-based server;
c. holding said streamed data in said cloud-based server for a predetermined time period; and
d. transmitting said data to one of the blockchain servers of a blockchain network to store said data in an immutable manner to ensure traceability and quality assurance of VCC operations.

2) The system as claimed in claim 1, wherein a communication module linked with said processor, enables an upload of data to said cloud-based server.
3) The system as claimed in claim 1, wherein a user interface module configured with a computing unit linked with said blockchain server, enables said user to interact with said blockchain network.

4) The system as claimed in claim 1, wherein a digital wallet associated with said blockchain network and accessible via said user interface module, is provided to facilitate holding and transacting of a token native to said blockchain network, for executing transactions relating to VCC operations.

5) The system as claimed in claim 1, wherein a code editor is and associated with said user interface module to enable a user to write smart contracts between two or more parties pertaining to operations related to VCC.

6) The system as claimed in claim 1, wherein a virtual machine incorporated with said blockchain network, to convert written smart contracts into bytecode, and deploy and execute said smart contracts.

7) The system as claimed in claim 1, wherein said blockchain network is based on Tron blockchain platform.

8) The system as claimed in claim 1, wherein said user interface module is TronLink.

9) The system as claimed in claim 1, wherein said virtual machine is Tron Virtual Machine.