An IoT and Wi-Fi enabled smart industrial hydraulic proportional pressure reducing valve system

Abstract

An IoT and Wi-Fi enabled smart industrial hydraulic proportional pressure reducing valve system consisting of: a robotic arm equipped with a gripper, the robotic arm being configured to detect, identify and retrieve utensils in a predefined area using an artificial intelligence (AI)-based vision system; a washing chamber configured to receive the utensils placed by the robotic arm; a cleaning mechanism within the washing chamber comprising high-torque rotating brushes and multi-angle high-pressure water jets configured to remove food residue from the utensils; a detergent dosing unit configured to deliver temperature-controlled detergents during a rinse cycle; a drying module that includes a HEPA-filtered hot air circulation system for disinfecting and drying the utensils; a mobile application interface configured to remotely control and monitor the operation of the dishwasher; and An IoT-based control unit configured to enable integration into a smart home and provide predictive maintenance alerts. The system as claimed in claim 1, wherein the ESP32 microcontroller is programmable using Python or Arduino IDE, enabling flexible implementation of custom control logic and algorithms.

Description

[0001] The present invention relates to the field of industrial automation and electro-hydraulic control systems. More specifically, it relates to an IoT and Wi-Fi-enabled smart industrial hydraulic proportional pressure reducing valve system.

[0002] In industrial automation, electro-hydraulic drive systems are widely used to control fluid pressure in heavy machinery such as test benches, cranes, excavators, mixers, and rolling mills. These systems typically use proportional pressure-reducing valves controlled by programmable logic controllers (PLCs) to regulate the direction and intensity of hydraulic force. Although effective, traditional PLC-based systems face significant limitations in modern smart manufacturing environments, particularly when integrating the Internet of Things (IoT), artificial intelligence (AI), machine learning (ML), predictive maintenance, and nonlinear control algorithms. Existing systems lack the flexibility, remote access capabilities, and adaptive control features required by Industry 4.0 and 5.0 standards.Furthermore, traditional electro-hydraulic models do not support Wi-Fi-enabled or IoT-compatible platforms, limiting their scalability and the ability to utilize real-time data. These shortcomings necessitate a more intelligent, connected, and adaptable solution that enables remote monitoring, AI integration, and seamless deployment in smart industrial infrastructures.

[0003] The system offers an intelligent industrial hydraulic proportional pressure reducing valve system with IoT and Wi-Fi connectivity for remote control and monitoring in electro-hydraulic applications.

[0004] The system integrates an ESP32 microcontroller for wireless communication, programmability, and compatibility with AI and machine learning algorithms, enabling intelligent control and predictive maintenance.

[0005] The system includes a signal conditioning circuit that converts the microcontroller's low-voltage DAC output into standard analog control voltages compatible with industrial-grade hydraulic valves.

[0006] The system offers a cost-effective, compact and scalable alternative to conventional PLC-based systems and is suitable for Industry 4.0 and 5.0 environments.

[0007] The system ensures easy integration with open source platforms, thus increasing flexibility and adaptability for various industrial use cases.

[0008] In one embodiment, the present invention provides an IoT and Wi-Fi-enabled smart industrial hydraulic proportional pressure reducing valve system that improves the performance, flexibility, and remote accessibility of electrohydraulic actuator systems. The system includes an ESP32 microcontroller programmed for wireless communication and data processing, a signal conditioning circuit for voltage level translation, and an industrial-grade proportional pressure reducing valve from Bosch Rexroth. The ESP32 generates control signals via its DAC output, which are conditioned using an op-amp-based circuit to conform to the 0-10 V analog input range required by industrial hydraulic valves. This configuration enables real-time pressure control and remote control via IoT-enabled platforms.Furthermore, the system supports integration with artificial intelligence (AI) and machine learning (ML) algorithms, enabling predictive maintenance and intelligent control strategies. The invention offers a compact, cost-effective, and scalable alternative to PLC-based systems and is suitable for use in Industry 4.0 and 5.0 environments. Its open-source compatibility also facilitates its use in a wide range of industrial applications.

[0009] The invention is explained again below. It shows: The present invention discloses an IoT and Wi-Fi-enabled smart industrial hydraulic proportional pressure reducing valve system that enables remote, intelligent, and precise control of hydraulic pressure in electro-hydraulic systems. The system is particularly suitable for applications in industrial automation, robotics, heavy machinery, and test equipment, where programmable and adaptive pressure control is critical. The system consists of three main components: a Wi-Fi-enabled ESP32 microcontroller board, a signal conditioning circuit, and a 3-way proportional pressure reducing valve. The ESP32 microcontroller is a low-cost dual-core 32-bit microcontroller unit equipped with integrated Wi-Fi and Bluetooth capabilities. It is programmed to generate an analog control voltage in the range of 0 to 3.3 V via its DAC output pin.This microcontroller supports Python and Arduino programming environments and can communicate wirelessly with remote computing devices such as smartphones, tablets, and computers. The analog output of the ESP32 DAC is fed into a signal conditioning circuit that amplifies and shifts the voltage to meet industry standards. The signal conditioning circuit consists of an operational amplifier (op-amp) powered by ±12 V DC and configured with precision resistors (e.g., 10 kΩ, 50 kΩ, 1 kΩ) to produce an output voltage in the range of -10 V to +10 V. This output is compatible with the control input of industrial hydraulic proportional valves. The op-amp operates in a non-inverting amplifier configuration to ensure linear amplification of the input signal.The output of the signal conditioning circuit (Vc) is connected to the control input of a 3-way proportional pressure reducing valve, specifically a Bosch Rexroth model (3DREPE6C-2X / 45EG24N9K31 / A1V). This valve is powered by 24 V DC and has two solenoid coils, labeled "a" and "b," located at either end of a pressure control spool.

[0010] The 3-way valve consists of functional ports: pressure ports (P), tank return lines (T), and regulated outputs (A and B). When de-energized, internal springs center the control spool so that ports A and B are connected to the tank (T). Applying a positive voltage (+u) to solenoid "a" moves the spool to the right, regulating the flow through port B. Conversely, applying a negative voltage (-u) to solenoid "b" moves the spool to the left, regulating the flow through port A. The magnitude and direction of the control voltage directly influence the output pressure at ports A and B, enabling proportional control. The ESP32's wireless communication capability enables remote control and monitoring of the entire system via Wi-Fi.The system supports real-time operation and is capable of integrating artificial intelligence (AI) and machine learning (ML) algorithms for predictive maintenance, nonlinear control, and adaptive optimization of hydraulic parameters. The invention enables compatibility with open-source platforms and offers flexibility and scalability for integration into existing industrial control architectures. The system replaces conventional PLC-based control schemes with a more compact, programmable, and intelligent solution, thus complying with the paradigms of Industry 4.0 and 5.0. The novelty of the invention lies in the integration of a programmable microcontroller, signal conditioning hardware, and industrial-grade hydraulic control components in a remotely controlled, AI-compatible framework.This configuration provides an innovative solution that improves automation, reduces manual intervention, and enables data-driven operations in modern industrial environments.

Claims

[1] An IoT and Wi-Fi enabled smart industrial hydraulic proportional pressure reducing valve system consisting of: a robotic arm equipped with a gripper, the robotic arm being configured to detect, identify and retrieve utensils in a predefined area using an artificial intelligence (AI)-based vision system; a washing chamber configured to receive the utensils placed by the robotic arm; a cleaning mechanism within the washing chamber comprising high-torque rotating brushes and multi-angle high-pressure water jets configured to remove food residue from the utensils; a detergent dosing unit configured to deliver temperature-controlled detergents during a rinse cycle; a drying module that includes a HEPA-filtered hot air circulation system for disinfecting and drying the utensils; a mobile application interface configured to remotely control and monitor the operation of the dishwasher; and An IoT-based control unit configured to enable integration into a smart home and provide predictive maintenance alerts. The system as claimed in claim 1, wherein the ESP32 microcontroller is programmable using Python or Arduino IDE, enabling flexible implementation of custom control logic and algorithms. [2] The system of claim 1, wherein the signal conditioning circuit comprises a non-inverting operational amplifier configuration with a gain determining resistor network. [3] The system of claim 1, wherein the proportional pressure reducing valve is a Bosch Rexroth 3DREPE6C or equivalent model designed for industrial electro-hydraulic systems. [4] The system of claim 1, wherein the control voltage applied to the solenoid coils is in the range of -10 V to +10 V and enables bidirectional control of the valve spool. [5] The system of claim 1, wherein the Wi-Fi functionality enables the system to communicate with external devices such as smartphones, tablets, or cloud platforms for remote monitoring, diagnostics, or firmware updates.