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US 11,237,545 B2Granted
System and method for converting manual industrial machines into automatic industrial machines
AssigneeDebashis Das
InventorDebashis Das
Life of this patent
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Abstract
A system and method are provided for converting a manual industrial machine into an automatic industrial machine through an add-on module and providing predictive maintenance and navigation support to the automatic machines. The add-on module comprises several sensors to measure several parameters to predict impending malfunctions and breakdowns of machine components remotely through a continuous monitoring and analysis of measured parameters. A cloud-based navigation engine is centrally connected to the automatic machines to take real-time decisions through data optimization and navigation algorithms.
Claims14
A system for converting manual industrial machines into automated industrial machines, the system comprising:
- an add-on module configured for coupling with an existing manual industrial machine, and wherein the add-on module is configured to convert the manual industrial machine into an automated industrial machine, and wherein the add-on module comprises a plurality of sensors configured for measuring a plurality of parameters related to one or more machine components in the automated industrial machine, and wherein the plurality of sensors comprise one or more touch sensitive sensors, one or more ultrasonic sensors, one or more sensors to monitor a plurality of health parameters of the one or more machine components and sensors for motor encoders;
- a server communicatively coupled with a plurality of automated industrial machines, and wherein the server is configured for collecting the plurality of measured parameters from the plurality of sensors present in each add-on module coupled with each automated industrial machine;
- a predictive diagnosis and maintenance engine provided in the server and run on a hardware processor, and wherein the predictive diagnosis and maintenance engine is configured for predicting a plurality of impeding malfunctions and breakdowns of one or more machine components provided in each automated industrial machine by a monitoring and evaluation of the measured parameters;
- and
- a navigation engine in the server, and wherein the navigation engine is run on a hardware processor, and wherein the navigation engine is configured for directing a motor controller provided in the each add-on module to navigate the automated industrial machine to a desired location;
- wherein the predictive diagnosis and maintenance engine further comprises a rules engine, and wherein the rules engine comprises a set of pre-defined rules corresponding to the plurality of operational parameters of the one or more machine components provided in each automated industrial machine, and wherein the set of pre-defined rules are configured by a plurality of administrators based on historical analysis of the measured parameters collected from the one or more automated industrial machines, and wherein the predictive diagnosis and maintenance engine further comprises a pattern matching and semantic module, and wherein the pattern matching and semantic module is configured for matching patterns existing in the historical data for analysis, and wherein the navigation engine is further configured for determining a current location of the automated industrial machine, identifying a plurality of zones within a coverage area, navigating one zone at a time out of the identified plurality of zones, calculating a shortest path to the destination and calculating a shortest path to one of an origin and a docking point for each automated industrial machine, and wherein a web is provided to the plurality of administrators for monitoring a current position, battery percentage level, a water tank capacity, a system stability and updates of each automated industrial machine for controlling an operational parameter.
3 more elements
A computer implemented method comprising instructions stored on a non-transitory computer readable storage medium and run on a computing device provided with a hardware processor and memory for converting manual industrial machines into automated industrial machines, the method comprising the steps of:
- measuring one or more parameters related to an automated industrial machine, obtained by coupling an add-on module, by using a plurality of sensors provided in the add-on module;
- transmitting the measured data to a server and storing the data in a database provided in the server;
- predicting impending malfunctions and breakdowns of one or more individual machine components provided in each automated industrial machine through monitoring and evaluation of the measured parameters using one or more machine learning algorithms;
- computing a navigation path for automated industrial machine based on a current location and a desired location;
- directing a motor controller provided in each add-on module to navigate the automated industrial machine to the desired location;
- generating an alert signal upon detection of any anomaly by the fault diagnostic module;
- forwarding the generated alert signal to one or more users;
- estimating a corrective solution for an identified system anomaly based on historical data analysis;
- forwarding the corrective solution to the automated industrial machine for corrective action;
- determining a current location of the automated industrial machine;
- identifying a plurality of zones within a coverage area of the industry floor;
- navigating one zone at a time out of the identified plurality of zones;
- calculating a shortest path to the destination;
- and
- calculating a shortest path to any one of an origin and a docking point for each automated industrial machine.
12 more elements
Dependencies are inferred from the claim text.