Field of the Invention
This invention relates to IOT enabled industrial devices/laboratory equipment’s condition monitoring & predictive maintenance system
Background of the Invention
US6735549B2: A display system in which subsequent failures of plant equipment and plant systems are predicted to occur and in which the probability of failure before a specified date and the probability of failure after a specified date is determined and displayed and in which the calendar date is determined and displayed when the desired probability that the equipment not fail prior to the calendar date is specified. The system includes an Equipment Failure And Degradation Module that determines the remaining equipment/system life; a Probability-of-Failure Predictor Module that determines the probability of the equipment/system failing prior to a specified date and the probability of the equipment/system failing after a specified date; and a Date-of-Failure Predictor Module that determines the calendar date that corresponds to a specified probability that equipment not fail prior to the date.
Research Gap: In the present invention an attempt is made to monitor the real time machining based on factors in which the machines running and an alarm will activate if any changes done on the machine or by an error made by operator during the operation.
WO2005086760A2: A method and system for the maintenance and monitoring of equipment and machinery by monitoring equipment and machinery conditions, maximizing equipment and monitor utilization or disposition, and thereby maximizing the net effective value.
Research Gap: As current invention is based on cloud, web and mobile monitoring and therefore a constant monitoring could be done on the manufacturing process and it can save from creating a big loss. And hence net effective value will be enhanced.
US20040167686A1: A system is disclosed for monitoring condition of a railways installation such as a point’s machine. The system includes a plurality of sensors (S1, S2, S3 - - - SN) associated with elements of the installation for monitoring parameters indicative of operating capability of the installation. The system includes means (12, 23) for processing the monitored parameters to determine whether the parameters are changing relative to reference values and to determine whether the changes are indicative of an increased risk of malfunction in the installation. The processing means may include a digital computer programmed with condition monitoring and fault detection software. A method of monitoring condition of a railways installation is also disclosed.
Research Gap: The invention is equipped with advanced system. Local Controller are placed at necessary locations, which in turn transmits data of the real time to cloud server or android based application placed at distant places, which will interact with Web or Android based Application and prevent any malfunctions of the system by activating the alarm.
CN109765033B: The invention relates to an intelligent monitoring system and method for a lens of optical measurement measuring equipment. The system comprises an analysis processing system, wherein the analysis processing system is connected with at least one data acquisition and control unit, and the data acquisition and control unit is connected with at least one of a motor parameter acquisition unit, an optical structure position parameter acquisition unit and a limiting state and pressure feedback unit; the analysis processing system includes: the device comprises a data storage unit, a historical data storage unit and a lens health condition analysis unit. The method comprises the following steps: acquiring working parameters of a lens; and determining the health condition of the lens according to the comparison between the current working parameters and the set threshold value. The invention provides an intelligent lens monitoring system and method for optical measurement measuring equipment, which are used for collecting the current working state of a lens to judge the health state of the lens.
Research Gap: The inventor shows intelligent monitoring system by microcontroller system which is connected to RF and WiFi Modem to transmit the data directly to cloud server. The data and hence the machine monitoring can be done through web or android based applications. The access of the data is with ease as the controllers makes it easy for storage and distribution.
US7702401B2: A system for preserving process variable data relating to the operation of a process is provided. The system is adapted to preserve process variable data obtained before, during, and after the occurrence of an abnormal situation or event. The preserved process variable data maybe communicated from smart field devices or other intelligent equipment relating to the control of the process to a process controller or other higher level control device. The process controller or other higher level control device may then cause the preserved data to be displayed for an operator or other maintenance personnel. The preserved data may also be provided to other process control modules or abnormal situation prevention systems for further analysis to develop methods for preventing the abnormal situation from recurring in the future, or for taking additional steps based on the abnormal situation data to minimize or prevent a further deterioration of the process operation.

Research Gap: The system is equipped with computing unit to store the data during real run timing of the machine with the help of sensors to measure machine vibration, deviation in temperature, hydraulic pressure, coolant temperature and pump pressure etc. This system while recording the data also equipped to notify any abnormal data storage and hence displayed on the monitoring device which can be used from any remote location.
US20150158511A1: A method and system for monitoring a point’s machine obtains operating characteristics of the point’s machine that are representative of operations of the point’s machine during a movement event of rails at a switch. A waveform of the operating characteristics is examined to at least one of identify or predict a problem with the operations of the points machine. The waveform is examined by comparing the operating characteristics during the first movement event with at least one of: the operating characteristics obtained during a previous movement event; an expected value of the operating characteristics; or an expected duration of a moving time period during which the first rail is expected to move from or to an unlocked position.
Research Gap: A computing unit is installed directly to measure and record operating characteristics which identify or predict a problem with the operations of the point’s machine by comparing the present data with the data recorded in previous cycle. The characteristic curve shown are directly linked with the alarming system to decide whether to activate the alarm. The sensors located for measuring any change in vibration, pressure, temperature and coolant pump pressure, the alarming system of the equipment not only measures but also specifically notify for particular parameter malfunctions.
GB2537863A: A computer-implemented method for detecting a fault in an electromechanical system in a railway infrastructure, the method comprising receiving electrical usage data indicative of the value of an electrical usage parameter associated with the electromechanical system; receiving temperature measurement data indicative of the present temperature of the electromechanical system; determining, based on a predetermined relationship between the electrical usage parameter and the temperature, whether or not the value of the electrical usage parameter is indicative of a fault in the electromechanical system and if so, issuing an alert to indicate the presence of the fault. The electromechanical system may be a railway points system. The electrical usage parameter may be current, voltage, or power used by the system. The determining step may comprise using a linear correlation between the temperature and the current to determine a threshold value to which the current measurement is compared.
Research Gap: Computer based central monitoring of the performance of the parameters selected on which the machine is running. The selected parameters are significant as they produces good quality products.
The computer unit comprises of to advise if the inserted value is in use. During hours of machining this facilitates condition monitoring and allows the machine to work to their maximum efficiency and predicts any failure in near future.
None of the prior art indicate above either alone or in combination with one another disclose what the present invention has disclosed. Present invention is IOT framework and a user interface allow a user to configure a machine condition monitoring system. In this model every computation based on machine attributes is represented as an input-output system. A simple computation can be easily defined by specifying the computation type, number of inputs, structure, and parameters. The user can use the determined output attributes of computations as input attributes in computations. Ultimately, the computations are aggregated by the framework configured by the user to produce an output computation attribute that indicates a machine condition or predicts a machine condition.
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.
Various industrial equipment needs continuous monitoring to enhance the safety, reliability, and availability and to decrease the cost of maintenance of modern industrial systems. IOT framework and a user interface allow a user to configure a machine condition monitoring system. In this model every computation based on machine attributes is represented as an input-output system. A simple computation can be easily defined by specifying the computation type, number of inputs, structure, and parameters. The user can use the determined output attributes of computations as input attributes in computations. Ultimately, the computations are aggregated by the framework configured by the user to produce an output computation attribute that indicates a machine condition or predicts a machine condition. The Internet of Things (IoT) has enormous development in recent trends of industrial, environmental, and medical applications. The availability of massive amount of processing power in the cloud, new opportunities have emerged for complete automation of industrial devices.

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: Different machines/equipment in an Industry/ Laboratory communicating to Local Controller which in turn transmits data to Cloud Server which interacts with Web or Android based Application
The Internet of Things (IoT) has enormous development in recent trends of industrial, environmental, and medical applications. The availability of massive amount of processing power in the cloud, new opportunities have emerged for complete automation of industrial devices.
Figure 2: Internal components of a Machine Monitoring unit for a CNC Lathe.
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.
The above figures show the block diagrams and the process flowchart of the IoT enabled Machine/Equipment Health Monitoring and Preventive Maintenance Suggestion system. The detailed description of the same is mentioned below.
[1 – 9] Machine Sensors: These are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer. These variables and the respective sensors can differ from one machine/equipment to another for a particular Industry shop floor/laboratory. For a CNC Lathe sensor used are [1] Machine Vibration sensor, [2] Chuck Motor Winding temperature sensor,[3]Hydraulic pressure sensor, [4] Arbor Servomotor Temperature sensor, [5] System Alarms sensor, [6] Coolant Temperature Sensor, [7] Coolant Level Sensor, [8] Coolant pump pressure sensor,[9] Decibel Sensor. [10] Computing Unit: All the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device. [11] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit. [12] Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer. These values are compared to the values received from the sensors deployed in machine monitoring unit which will help to determine the need of predictive maintenance of the entire machine or a component of the machine timely so the production does not halt. [13] RF Modem-1: This is used to transmit data from the control unit to a Local Controller for further data processing. [14] Local Controller: It comprise of [18] RF Modem which receives the signals from the nearby machine monitoring units, [19] Microcontroller collects the data from RF Modem and stores in [20] Data Storage Device, then gives the modified output through a [22] Wi Fi Modem to Cloud Server. [21] Power Supply -2: It fulfills the power requirement of all the components of Local Controller i.e. [18], [19], [20] and [22]. The data from the local Controller is feed to the [15] Cloud Server which in turn transmit the data to a [17] Web based application and [16] Android based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance.
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.
These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
The above figures show the block diagrams and the process flowchart of the IoT enabled Machine/Equipment Health Monitoring and Preventive Maintenance Suggestion system. [1 – 9] Machine Sensors: These are the integral part of the machine Monitoring Unit, where more than one sensor based on the variables that needs to be monitored as per the rated values by the equipment manufacturer. These variables and the respective sensors can differ from one machine/equipment to another for a particular Industry shop floor/laboratory. For a CNC Lathe sensor used are [1] Machine Vibration sensor, [2] Chuck Motor Winding temperature sensor,[3] Hydraulic pressure sensor, [4] Arbor Servomotor Temperature sensor, [5] System Alarms sensor, [6] Coolant Temperature Sensor, [7] Coolant Level Sensor, [8] Coolant pump pressure sensor,[9] Decibel Sensor. [10] Computing Unit: All the sensors employed give their respective inputs to this device. Along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device. [11] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit. [12] Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer. These values are compared to the values received from the sensors deployed in machine monitoring unit which will help to determine the need of predictive maintenance of the entire machine or a component of the machine timely so the production does not halt. [13] RF Modem-1: This is used to transmit data from the control unit to a Local Controller for further data processing. [14] Local Controller: It comprise of [18] RF Modem which receives the signals from the nearby machine monitoring units, [19] Microcontroller collects the data from RF Modem and stores in [20] Data Storage Device, then gives the modified output through a [22] Wi Fi Modem to Cloud Server. [21] Power Supply -2: It fulfills the power requirement of all the components of Local Controller i.e. [18], [19], [20] and [22]. The data from the local Controller is feed to the [15] Cloud Server which in turn transmit the data to a [17] Web based application and [16] Android based application so as to monitor the condition of the machine from a remote location and take the necessary action for the machine maintenance.

We Claims:

1. An IOT enabled monitoring & predictive maintenance suggesting system for industrial devices/laboratory equipment’s condition comprises Vibration sensor (1); Chuck motor winding temperature sensor (2); Hydraulic Pressure sensor (3); Arbour servomotor temperature sensor (4); System alarm sensor (5); Coolant temperature sensor (6); Coolant level sensor (7); Coolant pump pressure sensor (8); Decibel sensor (9); Computing unit (10); Power supply (11); Keyboard user input parameter (12); RF Modem(13); Local controller (14); Cloud server (15); Android & web application(16 &17); RF &WiFi modem (18 &22); Microcontroller (19); Data Storage (20); Machine monitoring (23 to 28);
2. The system as claimed in claim 1, wherein which is consists of CNC Lathe sensor used are [1] Machine Vibration sensor, [2] Chuck Motor Winding temperature sensor,[3] Hydraulic pressure sensor, [4] Arbor Servomotor Temperature sensor, [5] System Alarms sensor, [6] Coolant Temperature Sensor, [7] Coolant Level Sensor, [8] Coolant pump pressure sensor,[9] Decibel Sensor.
3. The system as claimed in claim 1, wherein which is consists of [10] Computing Unit: All the sensors employed give their respective inputs to this device; along with the inputs from the sensors it also receives the data from a user entered Rated Values of the Device.
4. The system as claimed in claim 1, wherein which is consists of [11] Power Supply 1: This is the power supply unit for the Machine Monitoring Unit which fulfils the power requirements of all the sensors, Keyboard, RF Modem as well as Computing unit.
5. The system as claimed in claim 1, wherein which is consists of [12] Keyboard: It is a user interface used to feed the Rated Device values as per the prescribed values from the manufacturer.
6. The system as claimed in claim 1, wherein which is consists of [14] Local Controller: It comprise of [18] RF Modem which receives the signals from the nearby machine monitoring units, [19] Microcontroller collects the data from RF Modem and stores in [20] Data Storage Device, then gives the modified output through a [22] Wi Fi Modem to Cloud Server. [21] Power Supply -2: It fulfills the power requirement of all the components of Local Controller i.e. [18], [19], [20] and [22].