System and method for monitoring and controlling magnetic separators

Abstract

Methods, systems, and devices for monitoring and controlling magnetic separators with real-time data and predictive maintenance are described. In some implementations, a system may receive real-time performance data from at least one magnetic separator, including saturation levels, temperature, and signal strength. The system may process the performance data to determine operational status and predict maintenance requirements using historical data and machine learning algorithms. Alerts may be transmitted when the performance data meets predefined thresholds, such as saturation levels, temperature, or connectivity issues. The system may display the performance data and alerts on a graphical user interface, which may be configured to allow remote configuration of the magnetic separator, enabling efficient management and maintenance.

Description

Docket No. 67674-0043SYSTEM AND METHOD FOR MONITORING AND CONTROLLING MAGNETIC SEPARATORSCROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present Application for Patent claims the benefit of U.S. Provisional Patent Application Number 63 / 715,001 filed on November 1, 2024, which is assigned to the assignee hereof, and which is hereby incorporated by reference in its entirety.FIELD OF TECHNOLOGY

[0002] Embodiments described herein generally relate to industrial magnetic separators, and specifically monitoring, controlling and managing data of magnetic separators in real-time, for example, by way of a mobile application.BACKGROUND

[0003] Magnetic separators are essential components in various industries where tramp metal must be removed to ensure product quality and protect machinery. These industries include, for example, food processing, pharmaceuticals, and manufacturing. The magnetic separators are used to remove ferrous contaminants from materials, ensuring product purity and protecting downstream equipment from damage. The efficiency and reliability of magnetic separators are critical to maintaining the quality and safety of the final product. However, traditional methods of monitoring and maintaining these separators often involve manual inspections and reactive maintenance, which can lead to unplanned downtime and increased operational costs. Hence, an improved way to monitor and maintain magnetic separators is desired.SUMMARY

[0004] The described techniques relate to improved methods, systems, devices, and apparatuses that support techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance. Some implementations may provide a system and method for monitoring and controlling magnetic separators using advanced sensors and a software application. The system may equip magnetic separators with sensors to collect realtime performance data, including saturation levels, temperature, and signal strength. This data may be transmitted wirelessly to a software application, which may process the information to provide operators with real-time updates, performance alerts, and detailed insights through aDocket No. 67674-0043 graphical user interface. The application may support remote configuration, allowing operators to set customizable thresholds for alerts and adjust operational parameters from any location.

[0005] Some implementations may incorporate predictive maintenance capabilities by leveraging machine learning algorithms to analyze historical and real-time data. This may enable the system to forecast maintenance needs, reducing unplanned downtime and improving operational efficiency. The software application may also support integration with external systems via application programming interfaces, facilitating seamless connectivity with industrial Internet of Things platforms, enterprise resource planning systems, and other data management tools. By combining real-time monitoring, predictive analytics, and remote accessibility, some implementations may address the limitations of traditional magnetic separators and enhance their functionality in modern industrial environments.

[0006] In some implementations, a performance monitoring interface is also accessible via a cloud-based web application that presents substantially similar controls and displays as the mobile application.

[0007] In some implementations, the application includes support for multiple user profiles with tiered access permissions based on user roles.

[0008] In some implementations, the data logging module is configured to create entries in response to event triggers, including threshold alerts, calibration changes, or separator cleaning activities.

[0009] In some implementations, the controller includes predictive logic based on historical separator performance to forecast future saturation levels or cleaning needs.

[0010] In some implementations, the application or controller supports remote or over-the- air software or firmware updates.

[0011] In some implementations, the controller includes diagnostics logic to detect sensor anomalies, signal loss, or system malfunctions and generate corresponding alerts.

[0012] A method for monitoring and controlling magnetic separators with real-time data and predictive maintenance is described. The method may include receiving real-time performance data from at least one magnetic separator, the performance data including saturation levels, temperature, and signal strength. The method may include processing the performance data to determine operational status and predict maintenance requirements based on historical data and machine learning algorithms. The method may include transmitting alertsDocket No. 67674-0043 in response to the performance data meeting predefined thresholds, the alerts including saturation levels, temperature, and connectivity issues. The method may include displaying the performance data and alerts on a graphical user interface, the interface configured to allow remote configuration of the at least one magnetic separator.

[0013] A system configured for monitoring and controlling magnetic separators with realtime data and predictive maintenance is described. The system may include a processor and memory coupled with the processor. The memory may store instructions executable by the processor to cause the system to receive real-time performance data from at least one magnetic separator, where the performance data may include saturation levels, temperature, and signal strength. The system may process the performance data to determine operational status and predict maintenance requirements based on historical data and machine learning algorithms. The system may transmit alerts in response to the performance data meeting predefined thresholds, where the alerts may include saturation levels, temperature, and connectivity issues. The system may display the performance data and alerts on a graphical user interface, where the interface may be configured to allow remote configuration of the at least one magnetic separator.

[0014] Another system for monitoring and controlling magnetic separators with real-time data and predictive maintenance is described. The system may include means for receiving real-time performance data from at least one magnetic separator, the performance data including saturation levels, temperature, and signal strength. The system may include means for processing the performance data to determine operational status and predict maintenance requirements based on historical data and machine learning algorithms. The system may include means for transmitting alerts in response to the performance data meeting predefined thresholds, the alerts including saturation levels, temperature, and connectivity issues. The system may include means for displaying the performance data and alerts on a graphical user interface, the interface configured to allow remote configuration of the at least one magnetic separator.

[0015] A non-transitory computer-readable medium storing code for monitoring and controlling magnetic separators is described. The code may include instructions executable by a processor to receive real-time performance data from at least one magnetic separator, the performance data may include saturation levels, temperature, and signal strength. The code may include instructions executable by a processor to process the performance data to determine operational status and predict maintenance requirements based on historical data andDocket No. 67674-0043 machine learning algorithms. The code may include instructions executable by a processor to transmit alerts in response to the performance data meeting predefined thresholds, the alerts may include saturation levels, temperature, and connectivity issues. The code may include instructions executable by a processor to display the performance data and alerts on a graphical user interface, the interface may be configured to allow remote configuration of the at least one magnetic separator.

[0016] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for transmitting a notification to a remote device in response to the performance data indicating saturation levels below a predefined threshold. The notification may include a graphical representation of historical saturation trends and recommended actions for maintaining operational efficiency.

[0017] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for aggregating temperature data from multiple sensors within the at least one magnetic separator and displaying a heat map on the graphical user interface to identify localized overheating zones.

[0018] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for logging connectivity issues in a maintenance record. The record may include timestamps, signal strength variations, and corrective actions taken to restore wireless communication.

[0019] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for analyzing historical maintenance records to identify recurring patterns in performance data and generating predictive alerts for future maintenance requirements based on those patterns.

[0020] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for configuring saturation thresholds remotely through the graphical user interface. The thresholds may be adjustable for different operational modes, including high-capacity and low-capacity processing scenarios.

[0021] In some examples of the method, systems, and non-transitory computer-readable medium described herein, the graphical user interface may display a color-coded statusDocket No. 67674-0043 indicator for saturation levels. The indicator may transition between green, yellow, and red based on predefined saturation thresholds.

[0022] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for providing alerts that include visual notifications on the graphical user interface and audible signals transmitted to a remote device in response to the performance data exceeding predefined thresholds.

[0023] In some examples of the method, systems, and non-transitory computer-readable medium described herein, the predictive maintenance requirements may be determined by analyzing saturation trends and temperature variations over a predefined time period.

[0024] In some examples of the method, systems, and non-transitory computer-readable medium described herein, the graphical user interface may provide a summary view of multiple magnetic separators. The view may include saturation levels, temperature data, and connectivity status for each separator.

[0025] In some examples of the method, systems, and non-transitory computer-readable medium described herein, the performance data may include signal strength metrics displayed as a percentage value on the graphical user interface to indicate wireless communication reliability.

[0026] Some examples of the method, systems, and non-transitory computer-readable medium described herein may further include operations, features, means, or instructions for transmitting alerts to a remote device in response to the performance data indicating temperature levels exceeding predefined safety thresholds.

[0027] In some examples of the method, systems, and non-transitory computer-readable medium described herein, the graphical user interface may allow remote configuration of operational parameters, including saturation thresholds, temperature limits, and connectivity settings for the at least one magnetic separator.BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1A illustrates an example of a system for data processing that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with aspects of the present disclosure.Docket No. 67674-0043

[0029] FIG. IB illustrates another example of a system for data processing that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with aspects of the present disclosure

[0030] FIG. 2 shows an example device status interface which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0031] FIG. 3 shows an example setup wizard interface which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0032] FIG. 4 shows an example calibration user interface which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0033] FIG. 5 shows an example capacity setup interface which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0034] FIG. 6 shows an example monitoring dashboard UI which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0035] FIG. 7 shows an example monitoring dashboard interface which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0036] FIG. 8 shows a flowchart illustrating a method for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0037] FIG. 9 shows a block diagram of an apparatus that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0038] FIG. 10 shows a block diagram of a magnetic separator monitoring component that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.Docket No. 67674-0043

[0039] FIG. 11 shows a diagram of a system including a device that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.

[0040] FIG. 12 shows a flowchart illustrating a method that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure.DETAILED DESCRIPTION

[0041] The disclosure will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made to various embodiments without departing from the spirit and scope of the present disclosure. Thus, the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments but should be defined only in accordance with the following claims and their equivalents. The terms magnetic separator and separator have been used interchangeably throughout the disclosure.

[0042] In some implementations, a system may include one or more devices designed to separate magnetic materials from non-magnetic materials, with sensors that may collect realtime data about their operation. These sensors may measure parameters such as the amount of magnetic material collected, expressed as a percentage of the device’s maximum capacity, the operating temperature of the device, and the strength of the wireless connection between the device and a software application. The data collected by the sensors may be transmitted to controllers within the devices, which may aggregate the data and send it to a software application for further processing. The system may include a network that facilitates the transmission of data from the devices to the software application, supporting multiple wireless communication methods such as Bluetooth for short-range communication and Wi-Fi or cellular networks for long-range communication. Additionally, the system may include a display device, such as a mobile device, tablet, or computer, which may present real-time data and alerts to an operator through a graphical interface, while a processor and memory may execute the software application to process the received data and enable remote configuration and control of the devices.Docket No. 67674-0043

[0043] The software application may process real-time data received from the devices and provide actionable insights to operators, allowing them to adjust settings and thresholds remotely without needing to interact directly with the devices. The application may analyze historical data using algorithms that may identify patterns and trends to predict when maintenance may be needed, enabling proactive management of the devices. These algorithms may forecast future maintenance requirements and help operators optimize maintenance schedules. The application may also integrate with external systems through interfaces that may allow for centralized data management and remote monitoring. These external systems may include platforms for managing industrial devices, systems for planning resources, and platforms for managing quality, enhancing the overall functionality and interoperability of the system.

[0044] The system may also include user account profiles with tiered permission levels, enabling different access capabilities based on user roles for an operator-user. For example, a maintenance technician may be granted access to saturation and cleaning records, while a quality supervisor may also have authority to adjust alert thresholds, perform recalibration, and view historical trends.

[0045] The graphical interface may provide a user-friendly way for operators to interact with the system, offering both summary and detailed views of device performance, including one or more dashboards. The summary view may display a list of all connected devices, showing key metrics such as the amount of magnetic material collected, the strength of the wireless connection, the operating temperature, and the date of the last cleaning. The amount of material collected may be visually represented using a color-coded bar graph, where green may indicate low levels, yellow may indicate medium levels, and red may indicate levels that exceed the device’s capacity. The detailed view may provide additional insights for individual devices, such as trends over time, current and maximum temperature readings, maintenance logs with timestamps and descriptions, and information for integrating the device into broader systems. This interface may allow operators to monitor and manage devices efficiently, ensuring optimal performance and timely maintenance.

[0046] In some embodiments, the system may further support a remote-access cloud dashboard accessible via a secure internet connection. This remote interface may mirror the software application, allowing users to monitor separator status, review logs, configure alert settings, and access maintenance data from a desktop environment or control room terminal.Docket No. 67674-0043The cloud dashboard may synchronize with the software application data to provide consistent user experience across platforms.

[0047] The system may provide alerts based on thresholds set by the operator, ensuring that critical issues are addressed promptly. These alerts may include notifications when the amount of material collected approaches or exceeds a defined percentage of the device’s capacity, when the operating temperature exceeds a predefined safe level, or when the wireless connection becomes weak. Alerts may be displayed on the graphical interface and may activate indicators on the devices, such as lights or display outputs, to draw the operator’s attention. The software application may also automatically log maintenance activities, such as cleaning cycles and repairs, with timestamps and detailed descriptions. These logs may be reviewed locally or remotely and may be stored in systems that are either cloud-based or integrated with programmable controllers, providing a comprehensive record of device maintenance.

[0048] In some embodiments, the logging functionality may support both time-based intervals (e.g., every 5 minutes) and event-triggered entries, where specific actions (such as a cleaning event, capacity exceeding a user-defined threshold, or sudden temperature change) automatically generate log entries. These logs may include separator identifier, timestamp, relevant sensor readings, and user identity (if applicable), to support FDA 21 CFR Part 11 auditability.

[0049] The system may support multiple wireless communication methods to ensure seamless data transmission between the devices and the software application (“application”), enabling operators to access real-time data both on-site and remotely. The application may include a setup wizard that may guide operators through adding new devices, configuring network addresses, calibrating the devices, and setting alert thresholds. This setup wizard may also support integration with platforms for managing industrial devices and other systems, simplifying the process of expanding and configuring the system. The application may use algorithms to analyze historical data and predict future maintenance needs, providing advanced analytics to identify trends and patterns, forecast maintenance requirements, and help prevent failures. These capabilities may enhance the system’s scalability and interoperability, allowing operators to manage devices within a broader framework.

[0050] In some embodiments, the system may further include predictive analytics or machine learning algorithms to analyze historical separator performance and recommend optimal cleaning intervals, flag anomalous trends, or predict component failure.Docket No. 67674-0043

[0051] The application may communicate with individual sensors within a device, enabling detailed monitoring of specific components. For example, the application may monitor individual tubes in a device that uses a drawer-like structure or individual poles in a device that uses a flat structure. This component-level monitoring may provide detailed insights into the performance of specific parts of the device, allowing operators to identify and address issues at a granular level. The application may also support system-level monitoring by aggregating data from all sensors within a device, with controllers processing this aggregated data and transmitting it to the application for a comprehensive view of the device’s performance. This dual-level monitoring capability may ensure that both individual components and overall device performance are optimized.

[0052] In some embodiments, the system may also perform self-diagnostics, monitoring sensor connectivity, signal stability, and sensor activity patterns to detect malfunctions or data anomalies. In such cases, the system may generate alerts for review or escalate issues to supervisory users.

[0053] The system may be designed to scale with the number of connected devices, supporting both small-scale and large-scale operations. Remote monitoring capabilities may allow operators to manage and maintain devices from any location, ensuring flexibility and convenience. The application may store program instructions and data on storage media that may retain information even when powered off, including data about performance metrics, maintenance logs, and configuration settings. The graphical interface may be customizable, allowing operators to adjust how performance metrics and alerts are displayed. Customization options may include setting thresholds visually and configuring the interface for ease of use, ensuring that the system meets the specific needs of different operators and use cases.

[0054] The system may integrate with cloud-based services to provide scalable computing resources, long-term data storage, and advanced analytics, enhancing its capabilities for remote monitoring and centralized management. These services may enable operators to access and analyze data from multiple devices, ensuring that the system remains efficient and effective as the number of connected devices grows. The application may connect to multiple devices simultaneously, displaying data for each device in a summary view and allowing operators to select individual devices for detailed information and specific actions. This real-time processing may ensure that operators have access to the most current information, enabling dynamic updates and immediate alerts. By supporting integration with platforms for managingDocket No. 67674-0043 industrial devices, the system may enhance connectivity and data sharing across devices and systems, providing a robust and scalable solution for managing industrial operations.

[0055] In some embodiments, the system may include over-the-air (OTA) firmware updates, allowing MPI to remotely update controller logic or application software to enhance security, improve user interface features, or introduce new analytics tools without requiring direct technician access.

[0056] Aspects of the subject matter described in this disclosure can be implemented to realize one or more of the following potential advantages. The described techniques may be implemented to support enhanced operational efficiency by enabling real-time adjustments to device parameters based on dynamically updated performance data. The system may provide operators with the ability to define and modify operational thresholds remotely, which may reduce the need for on-site interventions and minimize downtime. The use of predictive algorithms may allow for the identification of maintenance needs before failures occur, which may extend the lifespan of the devices and reduce overall maintenance costs. The system may facilitate seamless integration with external platforms, which may streamline workflows and improve data accessibility across various operational domains. The graphical interface may be designed to present complex data in an intuitive format, which may improve decision-making and reduce the likelihood of operator error. The ability to monitor both individual components and overall system performance may provide a comprehensive understanding of device health, which may enhance reliability and ensure consistent output quality. The system may support scalable deployment across diverse operational environments, which may make it suitable for both small-scale and large-scale industrial applications.

[0057] Aspects of the disclosure are initially described in the context of networked computing systems. Aspects of the disclosure are additionally illustrated by and described with reference to example implementations. Aspects of the disclosure are further illustrated by and described with reference to apparatus diagrams, system diagrams, and flowcharts that relate to monitoring and controlling magnetic separators with real-time data and predictive maintenance.

[0058] FIG. 1A illustrates an example of a system 100 that supports monitoring and controlling machines (e.g., magnetic separators) with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The system 100 includes cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. CloudDocket No. 67674-0043 platform 106 may be an example of a public or private cloud network. A cloud client 102 may access cloud platform 106 over one or more network connections 112 and 114. The network connection 114 may include a wired connection, a wireless connection, or both. The network may implement transfer control protocol and internet protocol (TCP / IP), such as the Internet, or may implement other network protocols. A cloud client 102 may be an example of a computing device, such as a wearable device (e.g., cloud client 102-a), a smartphone (e.g., cloud client 102- >), or a server (e.g., cloud client 102-c). In other examples, a cloud client 102 may be a desktop or laptop computer, a tablet, a sensor, or another computing device or system capable of generating, analyzing, transmitting, or receiving communications. In some examples, a cloud client 102 may be part of a business, an enterprise, a non-profit, a startup, or any other organization type.

[0059] A cloud client 102 may facilitate communication between the data center 108 and one or multiple user devices 104 to implement an online environment. The network connection 112 may include communications, opportunities, purchases, sales, or any other interaction between a cloud client 102 and a user device 104. The network connection 112 may include a wired connection, a wireless connection, or both. A cloud client 102 may access cloud platform 106 to store, manage, and process the data communicated via one or more network connections 112. In some cases, the cloud client 102 may have an associated security or permission level. A cloud client 102 may have access to certain applications, data, and database information within cloud platform 106 based on the associated security or permission level and may not have access to others.

[0060] The user device 104 may include a magnetic separator monitoring component 118. The user device 104 may interact with the cloud client 102 over network connection 112. The network may implement transfer control protocol and internet protocol (TCP / IP), such as the Internet, or may implement other network protocols. The network connection 112 may facilitate transport of data via email, web, text messages, mail, or any other appropriate form of electronic interaction (e.g., network connections 112-a, 112-Z>, 112-c, and 1 12-t / ) via a computer network. In an example, the user device 104 may be computing device such as a wearable device 104-a, a smartphone 104- >, a laptop 104-c or a server 104-t / . In other cases, the user device 104 may be another computing system. In some cases, the user device 104 may be operated by a user or group of users. The user or group of users may be a customer, associated with a business, a manufacturer, or any other appropriate organization.Docket No. 67674-0043

[0061] Cloud platform 106 may offer an on-demand database service to the cloud client 102. In some cases, cloud platform 106 may be an example of a multi -tenant database system. In this case, cloud platform 106 may serve multiple cloud clients 102 with a single instance of software. However, other types of systems may be implemented, including but not limited to client-server systems, mobile device systems, and mobile network systems. In some cases, cloud platform 106 may support an online application. This may include support for sales between buyers and sellers operating user devices 104, service, marketing of products posted by buyers, community interactions between buyers and sellers, analytics, such as userinteraction metrics, applications (e.g., computer vision and machine learning), and the Internet of Things (loT). Cloud platform 106 may receive data associated with generation of an online environment from the cloud client 102 over network connection 114, and may store and analyze the data. In some cases, cloud platform 106 may receive data directly from a user device 104 and the cloud client 102. In some cases, the cloud client 102 may develop applications to run on cloud platform 106. Cloud platform 106 may be implemented using remote servers. In some cases, the remote servers may be located at one or more data centers 108.

[0062] Data center 108 may include multiple servers. The multiple servers may be used for data storage, management, and processing. Data center 108 may receive data from cloud platform 106 via connection 116, or directly from the cloud client 102 or via network connection 112 between a user device 104 and the cloud client 102. The connection 116 may include a wired connection, a wireless connection, or both. Data center 108 may utilize multiple redundancies for security purposes. In some cases, the data stored at data center 108 may be backed up by copies of the data at a different data center (not pictured).

[0063] Server system 110 may include cloud clients 102, a cloud platform 106, a magnetic separator monitoring component 118, and a data center 108 that may coordinate with cloud platform 106 and data center 108 to implement an online environment. In some cases, data processing may occur at any of the components of server system 110, or at a combination of these components. Thus, the magnetic separator monitoring component 118 may be included in the user device 104, server system 110, or in part or in whole in both. In some cases, servers may perform the data processing. The servers may be a cloud client 102 or located at data center 108.

[0064] Some or all of the functionality attributed to the magnetic separator monitoring component 118 may be embodied or performed by one or more user devices 104, one or more components of server system 110 (e.g., cloud clients 102, a cloud platform 106, and / or a dataDocket No. 67674-0043 center 108), and / or other components of system 100. The magnetic separator monitoring component 118 may receive signals and inputs from user device 104 directly, via cloud clients 102, and / or via cloud platform 106 or data center 116.

[0065] As described herein, the magnetic separator monitoring component 118 may collect real-time performance data from magnetic separators, including saturation levels, temperature, and signal strength, and may transmit this data to the cloud platform 106 for processing. The cloud platform 106 may analyze the data using machine learning algorithms to determine operational status and predict maintenance requirements based on historical trends. Alerts may be generated when predefined thresholds are met and may be transmitted to user devices 110, where they may be displayed on a graphical user interface. The graphical user interface may allow users to remotely configure the magnetic separators and address any identified issues.

[0066] It should be appreciated by a person skilled in the art that one or more aspects of the disclosure may be implemented in a system 100 to additionally or alternatively solve other problems than those described above. Furthermore, aspects of the disclosure may provide technical improvements to “conventional” systems or processes as described herein. However, the description and appended drawings only include example technical improvements resulting from implementing aspects of the disclosure, and accordingly do not represent all of the technical improvements provided within the scope of the claims.

[0067] Turning to FIG. IB, another exemplary embodiment of a system 101 for monitoring and controlling magnetic separators is shown and includes an operator device 111, an app (i.e., software application) 115, a graphical user interface (GUI) 119, a network 130, a first magnetic separator 140, a first sensor 145, a first controller 147, a second magnetic separator 150, a second sensor 155 and a second controller 157, and a cloud engine / application programming interface (“API”) engine 160. Although two magnetic separators are shown, it should be noted that any number of magnetic separators may be used in the system.

[0068] Operator device 111 (e.g., on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108) may include a mobile device, a tablet, a laptop device, a personal desktop computer, or the like. The operator device 111 includes one or more processors and memory that communicate with each other, and with other components, via a bus. The operator device 111 is communicably coupled to network 130. It should be noted that other types of devices may be used.Docket No. 67674-0043

[0069] Operator device 111 includes an application (“app”) 115 that interfaces with first and second magnetic separators 140, 150 via network 130. App 115 may be implemented software (e.g., instructions stored on a non-volatile storage medium such as a hard disk, flash drive, or DVD-ROM), but hardware implementations are possible. Software implementations of app 115 may be written in one or more programming languages or combinations thereof, including low-level or high-level languages, with examples including Java, Ruby, JavaScript, Python, C, C++, C#, or Rust. The program code may execute entirely on the operator device 111, or partly on the operator device 111 and partly on another computer device within system 100. In some implementations, app 115 may interface with cloud engine / API engine 160. Moreover, the operator device may include a graphical user interface (“GUI”) 119 that receives inputs from an operator and that displays outputs to an operator.

[0070] App 115 communicates wirelessly with magnetic separators 140 and 150. It will be appreciated, however, that the app 115 may communicate via a wired connection to one or more separators 140, 150 in certain circumstances. The 115 app receives performance data from the magnetic controllers 147 and 157, such as, for example, saturation levels, temperature, signal strength and maintenance history. The app 115 processes the received data to provide real-time updates, performance alerts, and maintenance reminders to the operator. In some implementations, app 115 includes predictive maintenance capabilities based on historical performance data and utilizing machine learning algorithms to forecast future maintenance needs.

[0071] Further, app 115 allows an operator to set customizable saturation thresholds to receive an alert. So, for example, when a magnetic separator reaches the defined threshold (e.g., 50% of its capacity), the operator is alerted through the app and an indicator light (e.g., HDMI output or LED) on the separator may also be activated. The alerts may be adjusted at any time through the app’s settings. This provides flexibility to the operator depending on operational needs. The alerts may be triggered based on i.) saturation level thresholds, (which are customizable by the operator, allowing them to receive notifications when the separator is approaching capacity) ii.) temperature alerts, (which may be sent as notifications when the separator exceeds safe operating temperatures) and iii.) signal strength alerts, (which are alerts for weak wireless connectivity, ensuring operators are informed of potential communication issues).

[0072] Additionally, app 115 performs data logging and maintenance tracking. The app automatically logs all maintenance events, such as cleaning cycles and repairs. Each log entryDocket No. 67674-0043 may include a timestamp and a detailed description of the event. The logged data may be stored locally on the operator device 111 and / or may be transmitted to cloud engine / API engine 160 for further analysis and long-term storage. App 115 may provide reminders for upcoming maintenance based on pre-set intervals or historical performance data. Moreover, app 115 may utilize machine learning algorithms to analyze historical data and predict when future maintenance will be required, providing potential savings with respect to machine downtime and avoidance of catastrophic failure.

[0073] App 115 also supports integration with external systems (e.g., cloud engine / API engine 160) and cloud-based services via application programming interfaces (APIs). This integration may provide scalability and remote monitoring capabilities, allowing operators to manage and maintain magnetic separators efficiently, whether on-site or remotely. Wireless communication technologies, such as Bluetooth, Wi-Fi, and cellular networks, may be used to facilitate communication between the application and the magnetic separators. This wireless communication may enable the seamless transmission of data to the app, ensuring that operators have access to up-to-date information at all times.

[0074] In addition, app 115 uses GUI 119 to present various windows, such as the content shown in FIGS. 2-7, to an operator or user.

[0075] GUI 119 is a display -based interface that enables an operator to interact with a system through visual elements rather than command-line inputs. The GUI typically includes graphical components such as icons, menus, buttons, status indicators, and data visualizations, which are presented on a display device. The operator provides input through interaction mechanisms such as a keyboard, mouse, touchscreen, or other input device. The GUI presents system information in an intuitive and organized manner, allowing the operator to monitor system status, receive alerts or notifications, and configure operational parameters in real time.

[0076] GUI 119 provides operators with clear and concise information about one or more magnetic separators, presented in both summary and detailed views. In the summary view, shown for example in FIG. 6 described below, GUI 119 displays a list of all connected magnetic separators, with each separator represented by a graphical bar indicator showing its current saturation percentage. The saturation indicator is color-coded according to predefined thresholds (e.g., green for safe operating range, yellow for approaching capacity, and red for full or over-capacity). Alongside the saturation indicator, the summary view presents additionalDocket No. 67674-0043 real-time metrics such as current temperature values, wireless signal strength, and the date and time of the most recent maintenance event, such as cleaning.

[0077] In the detailed view, shown for example in FIG. 7 described below, GUI 119 enables drill-down functionality when an operator selects a specific separator from the summary list. The detailed view presents a time-series graph showing saturation levels over a user-defined time interval, a thermometer-style visual for temperature tracking, and a maintenance log panel listing prior cleaning cycles, repairs, and associated operator notes with timestamps. GUI 119 also provides interactive controls that allow the operator to remotely set or adjust saturation threshold alerts, reset baseline calibration values, and configure operational parameters such as temperature limits or wireless connectivity preferences.

[0078] GUI 119 further incorporates interactive elements including sliders, dropdown menus, and toggle switches for configuration, as well as visual alert icons and pop-up notifications that appear when thresholds are exceeded. In some implementations, GUI 119 is customizable by the operator, allowing rearrangement of dashboard elements, adjustment of alert display formats (visual, audible, or both), and integration with external supervisory systems through API-based widgets. This combination of summary and detailed presentation, together with operator-configurable controls, enables efficient monitoring and proactive management of multiple magnetic separators from a single interface.

[0079] Network 130 may include any one of or a combination of multiple different types of networks, such as, for example, Bluetooth, cable networks, the Internet, wireless networks, and other private and / or public networks. In some instances, network 130 may include cellular, Wi-Fi, or Wi-Fi direct. Network 130 may comprise any combination of local area and / or wide area networks, using both wired and wireless communication systems.

[0080] Magnetic separators 140 and 150 may each be equipped with at least one sensor 145 and 155 and a controller 147 and 157. Each magnetic separator is configured to collect ferrous contaminants by separating magnetic materials from non-magnetic ones using a magnetic field. Each sensor 145 and 155 may measure various performance metrics, such as, for example, saturation levels, temperature, signal strength and maintenance history. This data is processed by controllers 147 and 157 and transmitted to app 115. The saturation level represents the amount of ferrous material collected by a corresponding magnetic separator. The temperature sensor monitors the temperature of a corresponding separator to prevent overheating and degradation of the magnets. The signal strength indicates the strength of theDocket No. 67674-0043 wireless connection between the magnetic separator and the mobile application. The maintenance history tracks the cleaning cycles and other maintenance events to ensure optimal performance of the separator. Each controller 147 and 157 includes at least one processor, a memory, and executable code to perform data aggregation.

[0081] Cloud engine / API engine 160 may include a cloud-based platform that provides scalable computing resources and services over the internet. The cloud engine may leverage distributed networks, allowing resources to scale up or down as needed and provide various services, such as virtual machines, databases, storage, and processing power. Further, the cloud engine / API engine may include a platform or software that facilitates the creation, management, deployment, and monitoring of APIs (Application Programming Interfaces). The APIs streamline interactions between applications (e.g., from external systems).

[0082] FIG. 2 shows an example device status interface 200 which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The device status interface may be presented on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. As depicted in FIG. 2, the device status interface 200 may include a device name or identifier “HCI5 - 2345897023”, a percent full indicator, a clean status indicator, a temperature indicator, a signal strength indicator, a set up new device button, and / or other components.

[0083] The device status interface 200 may include a user interface for interacting with device status information. The user interface may be implemented as a graphical user interface (GUI) on a mobile device, tablet, or computer. The graphical user interface may display realtime data related to magnetic separators, such as saturation levels, temperature, and maintenance history. The graphical user interface may interact with other components, such as the percent full indicator and the clean status indicator, to present a comprehensive view of the system’s status. In some implementations, the graphical user interface may include customizable elements, such as adjustable alert thresholds or user-defined settings for monitoring parameters.

[0084] The percent full indicator may represent the current saturation level of a magnetic separator as a percentage. The percent full indicator may be displayed as a bar graph or numerical value on the device status interface. The percent full indicator may dynamically update based on real-time data received from sensors within the magnetic separator. TheDocket No. 67674-0043 percent full indicator may work in conjunction with the clean status indicator to inform operators when cleaning is required. In some implementations, the percent full indicator may include color-coded visual cues, such as green for low saturation, yellow for medium saturation, and red for high saturation.

[0085] The clean status indicator may display the cleaning status of a magnetic separator. The clean status indicator may show whether a magnetic separator has been recently cleaned or if cleaning is overdue. The clean status indicator may receive data from maintenance logs stored in the application and update its status accordingly. The clean status indicator may be presented alongside the percent full indicator on the graphical user interface to provide a complete overview of the separator’s operational state. In some implementations, the clean status indicator may include timestamps of the last cleaning event for operator reference.

[0086] The temperature indicator may show the operating temperature of a magnetic separator. The temperature indicator may display the current temperature as a numerical value or graphical representation, such as a thermometer-style graphic. The temperature indicator may receive data from temperature sensors embedded in the magnetic separator. The temperature indicator may alert operators if the temperature exceeds predefined thresholds, which may be set through the graphical user interface. In some implementations, the temperature indicator may include historical temperature trends to help operators monitor longterm performance.

[0087] The signal strength indicator may provide information about the wireless connection strength between the application and a magnetic separator. The signal strength indicator may display the connection status as a bar graph or numerical value. The signal strength indicator may update in real-time based on data received from the wireless communication module. The signal strength indicator may assist operators in diagnosing connectivity issues that may affect data transmission. In some implementations, the signal strength indicator may include alerts for weak or lost connections to ensure continuous monitoring.

[0088] The set up new device button may allow an operator to initiate the configuration process for adding a new magnetic separator to the system. The set up new device button may be accessible through the graphical user interface and may guide the operator through a setup wizard. The set up new device button may enable the operator to configure parameters such as IP addresses, wireless protocols, and alert thresholds. The set up new device button mayDocket No. 67674-0043 interact with the application to register the new magnetic separator and integrate it into the monitoring system. In some implementations, the setup new device button may include options for calibrating the separator’s sensors during the setup process.

[0089] In some implementations, the device identifier may be displayed as a unique identifier for each magnetic separator, allowing operators to distinguish between multiple devices within the GUI. The percent full indicator may visually represent the saturation level of the separator, with a bar graph that dynamically adjusts based on real-time data received from the sensors. The clean status indicator may display a warning symbol when the separator requires cleaning, based on the saturation threshold set by the operator.

[0090] In some implementations, the temperature indicator may show the current operating temperature of the separator, which may be measured by integrated temperature sensors. The signal strength indicator may reflect the quality of the wireless connection between the separator and the application, with varying levels of signal strength displayed as graphical bars. The set up new device button may allow operators to initiate the configuration process for adding additional separators to the system, which may include steps such as calibrating sensors and setting alert thresholds.

[0091] FIG. 3 shows an example setup wizard interface 300 which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The setup wizard interface 300 may be presented on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. As depicted in FIG. 3, the setup wizard interface 300 may include one or more of a setup wizard logo, a device IP address field, a device name or identifier, a PLC setup toggle, a next button, a set up device button, a cancel button, a back button, a help icon, a home icon, a favorites icon, a settings icon, and / or other components.

[0092] The setup wizard logo may include a graphical representation to identify the setup interface. The setup wizard logo may be displayed prominently at the top of the setup interface to help users recognize the configuration process. The setup wizard logo may include text, symbols, or icons that represent the application or the magnetic separator system. In some implementations, the setup wizard logo may be customizable to reflect the branding of the operator’s organization or facility.

[0093] The device IP address field may allow input of an IP address for configuring network connectivity. The device IP address field may be presented as a text box or dropdownDocket No. 67674-0043 menu within the setup interface. The device IP address field may allow operators to manually enter or select an IP address to establish communication between the application and the magnetic separator. In some implementations, the device IP address field may include validation mechanisms to ensure the entered IP address conforms to standard formats.

[0094] The device name or identifier may represent a specific parameter or identifier related to the device setup. The device name or identifier may be displayed as a labeled input field within the setup interface. The device name or identifier may allow operators to input or modify a predefined parameter associated with the magnetic separator configuration. In some implementations, the device name or identifier may be linked to other fields or settings within the setup interface to ensure consistency across the configuration process.

[0095] The PLC setup toggle may enable the activation or deactivation of programmable logic controller integration. The PLC setup toggle may be presented as a switch or checkbox within the setup interface. The PLC setup toggle may allow operators to determine whether the magnetic separator should be integrated with a programmable logic controller for advanced control and monitoring. In some implementations, the PLC setup toggle may include a confirmation prompt to prevent accidental changes to the integration settings.

[0096] The next button may allow progression to the subsequent step in the setup process. The next button may be displayed as a clickable element within the setup interface. The next button may allow operators to move forward in the setup process after completing the current step. In some implementations, the next button may be disabled until all required fields in the current step are completed.

[0097] The set up device button may initiate the configuration process for the selected device. In some implementations, the set up device button may be the same as or similar to the set up new device button, as described herein.

[0098] The cancel button may terminate the current setup process without saving changes. The cancel button may be displayed as a clickable element within the setup interface. The cancel button may allow operators to exit the setup process if they decide not to proceed with the configuration. In some implementations, the cancel button may include a confirmation prompt to ensure operators do not accidentally lose unsaved changes.

[0099] The back button may navigate to the previous step in the setup process. The back button may be displayed as a clickable element within the setup interface. The back button may allow operators to return to the previous step if they need to review or modify earlierDocket No. 67674-0043 settings. In some implementations, the back button may be disabled if the operator is already at the first step of the setup process.

[0100] The help icon may provide access to assistance or guidance related to the setup interface. The help icon may be displayed as a clickable element within the setup interface. The help icon may allow operators to access documentation, tutorials, or troubleshooting tips related to the setup process. In some implementations, the help icon may include a dropdown menu with links to frequently asked questions or contact information for technical support.

[0101] The home icon may navigate to the main interface or dashboard of the application. The home icon may be displayed as a clickable element within the setup interface. The home icon may allow operators to exit the setup process and return to the application’s main dashboard. In some implementations, the home icon may include a confirmation prompt to ensure operators do not accidentally leave the setup process.

[0102] The favorites icon may allow quick access to frequently used or bookmarked features. The favorites icon may be displayed as a clickable element within the setup interface. The favorites icon may allow operators to access a list of bookmarked features or settings for faster navigation. In some implementations, the favorites icon may include a dropdown menu with customizable options for adding or removing bookmarks.

[0103] The settings icon may open a menu for adjusting application preferences or configurations. The settings icon may be displayed as a clickable element within the setup interface. The settings icon may allow operators to access a menu for modifying application preferences, such as language settings or notification preferences. In some implementations, the settings icon may include a submenu for advanced configuration options related to the magnetic separator system.

[0104] In some implementations, the setup wizard logo may be displayed prominently at the top of the graphical user interface to indicate the active configuration process. The device IP address field may allow operators to input or verify the network address of the magnetic separator being configured, while the device name or identifier may display a unique identifier for the device. The PLC setup toggle may enable operators to activate or deactivate programmable logic controller integration during the setup process.

[0105] In some implementations, the next button may allow operators to proceed to subsequent steps in the setup wizard, while the set up device button may initiate the configuration process for the magnetic separator. The cancel button may provide an option toDocket No. 67674-0043 terminate the setup process at any stage. The back button may allow operators to return to previous steps in the wizard, enabling adjustments to prior configurations.

[0106] In some implementations, the help icon may offer access to informational resources or troubleshooting guides related to the setup process. The home icon may serve as a navigation tool to return to the main interface of the application, while the favorites icon may allow operators to access frequently used features or devices. The settings icon may provide access to additional configuration options, such as network preferences or alert thresholds, which may be relevant during the setup process.

[0107] FIG. 4 shows an example calibration user interface 400 which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The calibration user interface may be presented on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. As depicted in FIG. 4, the calibration user interface 400 may include one or more of a navigation bar, a settings icon, a home icon, a favorites icon, a help icon, a notifications icon, a progress bar, a circular indicator, an action button, and / or other components.

[0108] The navigation bar may include interactive elements (e.g., “Back” and “Cancel”) to support user navigation within the calibration user interface 400. The navigation bar may be positioned at the top or bottom of the calibration user interface 400 and may include a series of icons or buttons that represent different functionalities. The navigation bar may allow users to switch between various sections of the application, such as settings, home, or notifications. The navigation bar may be visually distinct, with color coding or labels to help users identify its purpose. In some implementations, the navigation bar may include touch-sensitive areas or haptic feedback to enhance user interaction.

[0109] The settings icon may represent a configurable option for accessing system preferences or calibration parameters. In some implementations, the settings icon may be the same as or similar to the settings icon shown in FIG. 3, as described herein.

[0110] The home icon may include a visual indicator for returning to the main interface of the application. In some implementations, the home icon may be the same as or similar to the home icon shown in FIG. 3, as described herein.[OHl] The favorites icon may represent a feature for accessing frequently used or bookmarked settings within the calibration user interface. In some implementations, theDocket No. 67674-0043 favorites icon may be the same as or similar to the favorites icon shown in FIG. 3, as described herein.

[0112] The help icon may provide access to assistance or guidance related to the setup interface. The help icon may be displayed as a clickable element within the setup interface. In some implementations, the help icon may be the same as or similar to the help icon shown in FIG. 3, as described herein.

[0113] The notifications icon may include a visual cue for alerting users to system updates or performance alerts. The notifications icon may be located within the navigation bar and may display a badge or highlight when new alerts are available. The notifications icon may allow users to view a list of recent alerts, such as maintenance reminders or system warnings. The notifications icon may be customizable, allowing users to filter the types of alerts they wish to receive. In some implementations, the notifications icon may include an animation or sound to draw the user’s attention.

[0114] The progress bar may represent a visual indicator of the calibration process status within the calibration user interface 400. The progress bar may be displayed as a horizontal or vertical bar that fills incrementally as the calibration process advances. The progress bar may include numerical percentages or labels to indicate the current stage of the process. The progress bar may be color-coded to reflect different stages, such as green for initial stages and yellow for nearing completion. In some implementations, the progress bar may reset automatically when a new calibration task is initiated.

[0115] The circular indicator may include a graphical element to display real-time calibration metrics or progress. The circular indicator may be located centrally within the calibration user interface 400 and may rotate or change color to reflect ongoing activity. The circular indicator may include numerical values or icons within its boundary to represent specific metrics, such as temperature or saturation levels. The circular indicator may interact with the progress bar to provide a comprehensive view of the calibration process. In some implementations, the circular indicator may include a pulsating effect to signify active monitoring.

[0116] The action button may represent an actionable element for confirming or initiating specific calibration tasks within the calibration user interface 400. The action button may be prominently displayed and may include text or an icon to indicate its function, such as “Set Zero Capacity” or “Next.” The action button may change appearance, such as color or size,Docket No. 67674-0043 when pressed to provide visual feedback to the user. The action button may interact with other components, such as the progress bar, to trigger updates or transitions within the interface. In some implementations, the button may include a double-tap or long-press feature to prevent accidental activation.

[0117] In some implementations, the navigation bar may be positioned at the bottom of the graphical user interface (GUI) and may include multiple icons such as the settings icon, the home icon, the favorites icon, and the notifications icon, which may allow operators to access different sections of the application. The progress bar may be displayed prominently within the GUI and may visually represent the current saturation level of a magnetic separator as a percentage of its capacity. The circular indicator may be located adjacent to the progress bar and may provide a visual cue, such as a color change, to reflect the current operational status of the separator.

[0118] In some implementations, the action button may be situated near the progress bar and may allow operators to perform specific actions, such as setting the zero capacity level for calibration. The settings icon within the navigation bar may enable operators to access configuration options, including the ability to adjust alert thresholds or modify network settings. The home icon may return the operator to the main summary view of all connected separators, while the favorites icon may display a curated list of frequently monitored separators. The notifications icon may indicate the presence of alerts or updates related to the performance metrics of the separators.

[0119] FIG. 5 shows an example capacity setup interface 500 which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The capacity setup interface 500 may be presented on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. As depicted in FIG. 5, the capacity setup interface 500 may include one or more of a confirm setup button, a progress bar, a slider, a next button, an operational capacity graph, a saturation level indicator, a temperature indicator, a signal strength indicator, a connectivity indicator, and / or other components.

[0120] The confirm setup button may include an interactive element for confirming the configuration of operational parameters. The confirm setup button may be located within the setup interface of the application and may be visually represented as a clickable icon or button. The confirm setup button may allow an operator to finalize the setup process after entering orDocket No. 67674-0043 adjusting specific parameters. The confirm setup button may work in conjunction with other components, such as the slider, to ensure that all required settings are properly configured before proceeding. In some implementations, the confirm setup button may include a label or icon to indicate its function, such as a checkmark or the word “Confirm”.

[0121] The progress bar may represent the current status of the capacity setup process. In some implementations, the progress bar may be the same as or similar to the progress bar shown in FIG. 4, as described herein.

[0122] The slider may include an adjustable control for setting specific saturation thresholds. The slider may be displayed as a horizontal or vertical bar with a movable handle that an operator may drag to adjust the threshold value. The slider may allow for precise adjustments by displaying numerical values corresponding to the selected threshold. The slider may interact with the saturation level indicator to reflect changes in the threshold setting in real-time. In some implementations, the slider may include a tooltip or label to display the current value being set.

[0123] The next button may provide an option to proceed to subsequent steps in the setup interface. In some implementations, the next button may be the same as or similar to the next button shown in FIG. 3, as described herein.

[0124] The operational capacity graph may represent data related to the magnetic separator’s operational limits. The operational capacity graph may be displayed as a line graph, bar chart, or other graphical representation to visually convey capacity data. The operational capacity graph may dynamically update to reflect real-time data from the magnetic separator, such as changes in saturation levels. The operational capacity graph may be linked to the slider, allowing operators to see how adjustments to thresholds impact the operational limits. In some implementations, the operational capacity graph may include color-coded sections to indicate different capacity ranges.

[0125] The saturation level indicator may display the current saturation percentage of the magnetic separator. The saturation level indicator may be represented as a numerical value, a progress bar, or a combination of both. The saturation level indicator may update in real-time based on data received from sensors within the magnetic separator. The saturation level indicator may work in conjunction with the operational capacity graph to provide a comprehensive view of the separator’s status. In some implementations, the saturation level indicator may include a color-coded display to indicate low, medium, or high saturation levels.Docket No. 67674-0043

[0126] The temperature indicator may include a visual representation of the separator’s operating temperature. In some implementations, the temperature indicator may be the same as or similar to the temperature indicator shown in FIG. 2, as described herein.

[0127] The signal strength indicator may represent the wireless connectivity status between the separator and the application. In some implementations, the signal strength indicator may be the same as or similar to the signal strength indicator shown in FIG. 2, as described herein.

[0128] The connectivity indicator may display the status of the network connection for the magnetic separator. The connectivity indicator may be represented as an icon, such as a Wi-Fi or cellular signal symbol, to visually convey the connection status. The connectivity indicator may update in real-time to reflect changes in the network connection, such as signal strength or disconnection. The connectivity indicator may work in conjunction with the signal strength indicator to provide detailed information about the wireless communication status. In some implementations, the connectivity indicator may include additional details, such as the type of network being used (e.g., Wi-Fi, Bluetooth, or cellular).

[0129] In some implementations, the confirm setup button may be positioned near the top of the graphical user interface to allow operators to finalize configuration settings for the magnetic separators. The progress bar may be displayed adjacent to the confirm setup button and may visually represent the completion status of the setup process. The slider may be located below the progress bar and may allow operators to adjust the operational capacity of the separators by selecting a desired value along a predefined range.

[0130] In some implementations, the next button may be situated near the bottom of the interface and may enable operators to proceed to subsequent steps in the setup process. The operational capacity graph may be displayed centrally within the interface and may visually depict the current operational capacity of the separators relative to their defined thresholds. The saturation level indicator may be integrated into the operational capacity graph and may use color-coded segments to represent varying levels of saturation.

[0131] In some implementations, the temperature indicator may be positioned alongside the saturation level indicator and may display the current operating temperature of the separators. The signal strength indicator may be located near the temperature indicator and may represent the quality of the wireless connection between the separators and the application. The connectivity indicator may be displayed near the signal strength indicator and may provide a visual representation of the network status for the separators.Docket No. 67674-0043

[0132] FIG. 6 shows an example monitoring dashboard UI 600 which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The monitoring dashboard UI 600 may be presented on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. As depicted in FIG. 6, the monitoring dashboard UI 600 may include one or more of a navigation bar, a favorites icon, a capacity icon, a home icon, a settings icon, a percent full bar, an alert icon, a signal strength indicator, a temperature indicator, a last cleared timestamp, and / or other components.

[0133] The navigation bar may include interactive elements for accessing different sections of the monitoring dashboard UI 600. In some implementations, the navigation bar may be the same as or similar to the navigation bar shown in FIG. 4, as described herein.

[0134] The favorites icon may represent a shortcut to frequently accessed features or separators within the monitoring dashboard UI 600. In some implementations, the favorites icon 604 may be the same as or similar to the favorites icon shown in FIGS. 3 and 4, as described herein.

[0135] The capacity icon may provide a visual representation of the current operational capacity of connected magnetic separators. The capacity icon may include a graphical element, such as a bar or pie chart, that dynamically updates based on real-time data received from the magnetic separators. The capacity icon may interact with the percent full bar to display detailed capacity metrics for individual separators. In some implementations, the capacity icon may include customizable settings to adjust the display format or update frequency.

[0136] The home icon may include a link to return to the main dashboard view of the monitoring dashboard UI 600. In some implementations, the home icon may be the same as or similar to the home icon shown in FIGS. 3 and 4, as described herein.

[0137] The settings icon may include options for configuring parameters and preferences within the monitoring dashboard UI 600. In some implementations, the settings icon may be the same as or similar to the settings icon shown in FIGS. 3 and 4, as described herein.

[0138] The percent full bar may represent the saturation level of a magnetic separator as a percentage of its maximum capacity. The percent full bar may include a color-coded indicator that transitions from green to yellow to red based on the saturation level. The percent full bar may interact with the alert icon to notify operators when the saturation level exceeds aDocket No. 67674-0043 predefined threshold. In some implementations, the percent full bar may include a tooltip or label displaying the exact percentage value.

[0139] The alert icon may indicate notifications related to performance thresholds or maintenance requirements of magnetic separators. The alert icon may include a visual cue, such as a flashing light or color change, to draw the operator’s attention. The alert icon may interact with the settings icon to allow operators to configure notification preferences. In some implementations, the alert icon may include a dropdown menu displaying a list of recent alerts.

[0140] The signal strength indicator may represent the wireless connectivity status between the monitoring dashboard UI 600 and connected magnetic separators. In some implementations, the signal strength indicator may be the same as or similar to the signal strength indicator shown in FIGS. 2 and 5, as described herein.

[0141] The temperature indicator may display the current operating temperature of connected magnetic separators. In some implementations, the temperature indicator 618 may be the same as or similar to the temperature indicator shown in FIGS. 2 and 5, as described herein.

[0142] The last cleared timestamp may include the recorded time of the most recent cleaning or maintenance event for a magnetic separator. The last cleared timestamp may display the date and time in a format configurable by the operator. The last cleared timestamp may interact with the maintenance log to provide a historical record of cleaning events. In some implementations, the last cleared timestamp may include an option to manually update the timestamp if the cleaning event was performed offline.

[0143] In some implementations, the navigation bar may be positioned at the top of the graphical user interface and may include icons such as the favorites icon, the capacity icon, the home icon, and the settings icon, which may allow operators to switch between different views or functionalities within the application. The percent full bar may be displayed as a horizontal bar graph adjacent to the name of each magnetic separator, and it may visually represent the saturation level of the separator using color-coded segments. The alert icon may be located near the percent full bar and may indicate whether a predefined threshold has been reached for a specific parameter.

[0144] In some implementations, the signal strength indicator may be displayed as a series of bars or symbols near the separator’s name, and it may represent the quality of the wireless connection between the separator and the application. The temperature indicator may be shownDocket No. 67674-0043 as a numerical value or graphical element, and it may reflect the current operating temperature of the separator. The last cleared timestamp may be displayed as a date and time value, and it may indicate when the separator was last cleaned or reset. These components may operate together to present real-time data for multiple separators in a consolidated view, allowing operators to monitor key metrics at a glance.

[0145] FIG. 7 shows an example monitoring dashboard interface 700 which supports techniques for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The monitoring dashboard interface 700 may be presented on any one or more of cloud clients 102, user devices 104, a cloud platform 106, and a data center 108. As depicted in FIG. 7, the monitoring dashboard interface 700 may include one or more of a capacity indicator, a capacity-intensity graph, a temperature indicator, a signal strength indicator, a maintenance log, and / or other components.

[0146] The capacity indicator may display the current saturation level of the magnetic separator as a percentage of its total capacity. The capacity indicator may be represented as a visual element on the graphical user interface 119, such as a bar graph or numerical display. The capacity indicator may dynamically update in real-time based on data received from sensors 145 and 155 within the magnetic separators 140 and 150. In some implementations, the capacity indicator may be color-coded to reflect saturation levels, transitioning from green for low saturation to yellow for medium saturation and red for high saturation. The capacity indicator may be similar to the percent full bar shown in FIG. 6 and / or the percent full indicator shown in FIG. 2, as described herein.

[0147] The capacity-intensity graph may represent the saturation trends of the magnetic separator over a defined time period. The capacity-intensity graph may be displayed as a line graph or other graphical representation on the graphical user interface 119. The capacityintensity graph may allow operators to determine saturation patterns and predict future cleaning requirements based on historical data. In some implementations, the capacity-intensity graph 704 may be similar to the operational capacity graph shown in FIG. 5, as described herein.

[0148] The temperature indicator may show the current operating temperature of the magnetic separator in relation to predefined thresholds. In some implementations, the temperature indicator may be the same as or similar to the temperature indicator shown in FIGS. 2, 5 and 6, as described herein.Docket No. 67674-0043

[0149] The signal strength indicator may indicate the strength of the wireless connection between the magnetic separator and the monitoring application. In some implementations, the signal strength indicator may be the same as or similar to the signal strength indicator shown in FIGS. 2, 5 and 6, as described herein.

[0150] The maintenance log may include a record of past maintenance activities, such as cleaning cycles and service events, with corresponding timestamps. The maintenance log may be accessible through the graphical user interface 119 and may allow operators to review and update maintenance records. The maintenance log may store data locally on the operator device 111 or transmit it to the cloud engine / API engine 160 for long-term storage. In some implementations, the maintenance log may include additional fields for operator comments or notes related to specific maintenance events. The maintenance log may be similar to the last cleared timestamp shown in FIG. 6, as described herein.

[0151] In some implementations, the capacity indicator may visually represent the saturation levels of a magnetic separator through a horizontal bar that transitions between color- coded segments to signify varying levels of ferrous material accumulation. The capacityintensity graph may display a time-based trend of saturation levels, with data points plotted along a line graph to indicate changes in capacity over a defined period. The temperature indicator may include a vertical thermometer-style graphic that dynamically adjusts to reflect the current operating temperature of the magnetic separator.

[0152] In some implementations, the signal strength indicator may use a series of bars to represent the quality of the wireless connection between the magnetic separator and the application, with the number of illuminated bars corresponding to the detected signal strength. The maintenance log may present a chronological list of recorded maintenance activities, with timestamps and optional operator comments displayed in a scrollable format. These components may operate together by aggregating real-time data from the magnetic separator sensors and presenting it in a unified graphical user interface for monitoring and control.

[0153] FIG. 8 shows an exemplary flowchart 800 illustrating a method for monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. Operations illustrated in the flowchart 800 may involve a user device 104, a cloud platform 106, an operator device 111, and / or other participants, which may be examples of corresponding devices described herein.Docket No. 67674-0043

[0154] At 802, the operator device 111 may receive real-time data from one or more magnetic separators. The data may include saturation levels, temperature, signal strength, and maintenance history collected by sensors 145 and 155 within magnetic separators 140 and 150. In some implementations, the operator device 111 may receive the real-time data through wireless communication protocols such as Bluetooth, Wi-Fi, or cellular networks, which may be configured based on the facility’s infrastructure. The real-time data may be aggregated by controllers 147 and 157 within the magnetic separators 140 and 150 before being transmitted to the user device 104. In some implementations, the operator device 111 may receive the real time data from individual sensors within a magnetic separator, allowing for component-level monitoring, such as individual tubes in a drawer magnet or poles in a plate magnet.

[0155] At 804, the operator device 111 may display performance data on the GUI. The GUI 119 may present a summary view that includes a bar graph visually representing the saturation percentage of magnetic separators 140 and 150, color-coded to indicate status, with green for low saturation, yellow for medium saturation, and red for full saturation or over-capacity. In some implementations, the GUI 119 may display additional metrics such as the signal strength of the wireless connection, current temperature, and the last cleaning date of magnetic separators 140 and 150. The GUI 119 may allow operators to drill down into individual separator details, such as saturation trends over time, current and maximum temperature, and maintenance logs. In some implementations, the GUI 119 may include integration information such as IP addresses and PLC addresses to assist with remote monitoring and control.

[0156] At 806, the operator device 111 may receive and process operator customizable parameters. The operator may use the GUI 119 to set saturation thresholds for magnetic separators 140 and 150, which may trigger alerts when the defined thresholds are reached. In some implementations, the operator may configure temperature alerts to notify when magnetic separators 140 and 150 exceed safe operating temperatures. The operator may adjust signal strength alerts through the GUI 119 to monitor wireless connectivity issues with magnetic separators 140 and 150. In some implementations, the operator may use the GUI 119 to rename devices, change IP addresses, and set up PLC integration for magnetic separators 140 and 150.

[0157] At 808, the operator device 111 may track maintenance history and provide alerts. The application 115 may automatically log maintenance events such as cleaning cycles and repairs for magnetic separators 140 and 150, including timestamps and detailed descriptions of the events. In some implementations, the application 115 may analyze historical maintenance data to determine upcoming maintenance intervals for magnetic separators 140 and 150. TheDocket No. 67674-0043 application 115 may display maintenance reminders on the GUI 119 based on pre-set intervals or historical performance data. In some implementations, the application 115 may allow operators to review and update maintenance logs for magnetic separators 140 and 150 through the GUI 119.

[0158] At 810, the cloud platform 160 may integrate with external systems through APIs for remote monitoring and control. The cloud platform 160 may support integration with industrial loT platforms, enterprise resource planning systems, and quality management platforms for centralized data management and analytics. In some implementations, the cloud platform 160 may provide scalable computing resources and services, such as virtual machines, databases, storage, and processing power, to support the application 115. The cloud platform 160 may enable remote access to performance data and maintenance logs of magnetic separators 140 and 150 through the application 115. In some implementations, the cloud platform 160 may facilitate communication between the application 115 and external systems, allowing operators to manage magnetic separators 140 and 150 efficiently.

[0159] FIG. 9 shows a block diagram 900 of an apparatus 902 that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The apparatus 902 may include an input module 904, magnetic separator monitoring component 906, and an output module 908. The apparatus 902 may also include a processor. Each of these components may be in communication with one another (e.g., via one or more buses). In some cases, the apparatus 902 may be an example of a user terminal, a database server, or a system containing multiple computing devices.

[0160] The input module 904 may manage input signals for the apparatus 902. For example, the input module 904 may identify input signals based on an interaction with a modem, a keyboard, a mouse, a touchscreen, or a similar device. These input signals may be associated with user input or processing at other components or devices. In some cases, the input module 904 may utilize an operating system such as iOS®, ANDROID®, MS-DOS®, MS-WINDOWS®, OS / 2®, UNIX®, LINUX®, or another known operating system to handle input signals. The input module 904 may send aspects of these input signals to other components of the apparatus 902 for processing. In some cases, the input module 904 may be a component of an input / output (I / O) controller 1106 as described with reference to FIG. 11.

[0161] The magnetic separator monitoring component 906 may include one or more of a performance data receiving component 910, a data processing component 912, an alertDocket No. 67674-0043 transmission component 914, a graphical interface display component 916, and / or other components. The magnetic separator monitoring component 906 may be an example of aspects of the magnetic separator monitoring component 1002 or 1104 described with reference to FIGS. 10 and 11.

[0162] The performance data receiving component 910 may be configured as or otherwise support a means for receiving real-time performance data from at least one magnetic separator, the performance data including saturation levels, temperature, and signal strength. The data processing component 912 may be configured as or otherwise support a means for processing the performance data to determine operational status and predict maintenance requirements based on historical data and machine learning algorithms. The alert transmission component 914 may be configured as or otherwise support a means for transmitting alerts in response to the performance data meeting predefined thresholds, the alerts including saturation levels, temperature, and connectivity issues. The graphical interface display component 916 may be configured as or otherwise support a means for displaying the performance data and alerts on a graphical user interface, the interface configured to allow remote configuration of the at least one magnetic separator.

[0163] The output module 908 may manage output signals for the apparatus 902. For example, the output module 908 may receive signals from other components of the apparatus 902, such as the magnetic separator monitoring component 906, and may transmit these signals to other components or devices. In some specific examples, the output module 908 may transmit output signals for display in a user interface, for storage in a database or data store, for further processing at a server or server cluster, or for any other processes at any number of devices or systems. In some cases, the output module 908 may be a component of an I / O controller 1106 as described with reference to FIG. 11.

[0164] FIG. 10 shows a block diagram 1000 of a magnetic separator monitoring component 1002 that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with various aspects of the present disclosure. The magnetic separator monitoring component 1002 may be an example of aspects of a magnetic separator monitoring component 906, a magnetic separator monitoring component 1104, or both, as described herein. The magnetic separator monitoring component 1002, or various components thereof, may be an example of means for performing various aspects of monitoring and controlling magnetic separators with real-time data and predictive maintenance as described herein. For example, the magnetic separator monitoring component 1002 mayDocket No. 67674-0043 include one or more of a performance data receiving component 1004, a data processing component 1006, an alert transmission component 1008, a graphical interface display component 1010, a notification transmission component 1012, a temperature aggregation component 1014, a connectivity logging component 1016, a maintenance analysis component 1018, a threshold configuration component 1020, and / or other components. Each of these components may communicate, directly or indirectly, with one another (e.g., via one or more buses).

[0165] The performance data receiving component 1004 may be configured as or otherwise support a means for receiving real-time performance data from at least one magnetic separator, the performance data may include saturation levels, temperature, and signal strength. In some implementations, the performance data receiving component 1004 may receive saturation levels as a percentage of the magnetic separator’s capacity, which may be dynamically updated based on the amount of ferrous material collected. The performance data receiving component 1004 may determine temperature readings from one or more locations within the magnetic separator, which may include areas prone to overheating. The performance data receiving component 1004 may assess signal strength to monitor the stability of the wireless connection between the magnetic separator and the application.

[0166] The data processing component 1006 may be configured as or otherwise support a means for processing the performance data to determine operational status and may predict maintenance requirements based on historical data and machine learning algorithms. In some implementations, the data processing component 1006 may determine operational status by analyzing saturation levels in relation to predefined thresholds, which may vary based on the type of magnetic separator. The data processing component 1006 may process temperature data to identify trends that may indicate overheating risks in specific areas of the magnetic separator. In some implementations, the data processing component 1006 may assess signal strength fluctuations to determine whether connectivity issues may impact real-time monitoring capabilities.

[0167] The data processing component 1006 may predict maintenance requirements based on historical data and machine learning algorithms. In some implementations, the data processing component 1006 may analyze historical saturation patterns to predict when cleaning cycles may be necessary to maintain performance. The data processing component 1006 may incorporate temperature trends over time to forecast potential component failures that may result from prolonged exposure to high temperatures. In some implementations, the dataDocket No. 67674-0043 processing component 1006 may utilize historical signal strength data to predict when wireless communication modules may require inspection or replacement.

[0168] The alert transmission component 1008 may be configured as or otherwise support a means for transmitting alerts in response to the performance data meeting predefined thresholds, the alerts may include saturation levels, temperature, and connectivity issues. In some implementations, the alert transmission component 1008 may transmit alerts via a mobile application to notify operators of a magnetic separator reaching a user-defined saturation percentage. The alert transmission component 1008 may send notifications through multiple communication channels, such as SMS or email, to ensure operators are informed regardless of their location. In some implementations, the alert transmission component 1008 may activate physical indicators, such as LED lights or HDMI outputs, on the magnetic separator to provide on-site visual alerts. The alert transmission component 1008 may include customizable settings that allow operators to define specific thresholds for triggering alerts, such as a temperature exceeding a predefined value. In some implementations, the alert transmission component 1008 may transmit alerts related to connectivity issues, such as weak signal strength, to prompt operators to inspect the wireless communication module.

[0169] The graphical interface display component 1010 may be configured as or otherwise support a means for displaying the performance data and alerts on a graphical user interface, the interface may be configured to allow remote configuration of the at least one magnetic separator. In some implementations, the graphical interface display component 1010 may present a summary view that includes a bar graph visually representing saturation levels, with color-coded indicators such as green for low saturation, yellow for medium saturation, and red for over-capacity. The graphical interface display component 1010 may include a detailed view that displays historical trends for saturation levels, temperature fluctuations, and maintenance logs for a selected magnetic separator. In some implementations, the graphical interface display component 1010 may allow operators to rename magnetic separators or assign unique identifiers for easier tracking and management. The graphical interface display component 1010 may support integration with industrial loT platforms, enabling operators to configure IP addresses and PLC addresses directly through the interface. In some implementations, the graphical interface display component 1010 may include a setup wizard to guide operators through initial device configuration, including calibration of saturation levels and setting alert thresholds.Docket No. 67674-0043

[0170] In some examples, the notification transmission component 1012 may be configured as or otherwise support a means for transmitting a notification to a remote device in response to the performance data indicating saturation levels below a predefined threshold, the notification may include a graphical representation of historical saturation trends and recommended actions for maintaining operational efficiency. In some implementations, the notification transmission component 1012 may transmit notifications to multiple remote devices simultaneously, allowing operators across different locations to access the same performance data. In some implementations, the notification transmission component 1012 may include options for customizing the format of the graphical representation, such as bar graphs, line charts, or heat maps, based on operator preferences.

[0171] In some implementations, the notification transmission component 1012 may determine additional metrics, such as temperature trends or signal strength fluctuations, to include in the notification for a more comprehensive overview of the magnetic separator’s status. In some implementations, the notification transmission component 1012 may allow operators to set specific time intervals for receiving notifications, such as hourly updates or real-time alerts, depending on operational requirements. In some implementations, the notification transmission component 1012 may support integration with third-party communication platforms, such as email or SMS services, to transmit notifications through alternative channels.

[0172] In some examples, the temperature aggregation component 1014 may be configured as or otherwise support a means for aggregating temperature data from multiple sensors within the at least one magnetic separator and may display a heat map on the graphical user interface to identify localized overheating zones. In some implementations, the temperature aggregation component 1014 may determine temperature variations across individual tubes in a drawer magnet to pinpoint specific areas prone to overheating. In some implementations, the temperature aggregation component 1014 may aggregate temperature data from sensors positioned at different depths within the magnetic separator to assess thermal gradients.

[0173] In some examples, the temperature aggregation component 1014 may display a heat map on the graphical user interface to identify localized overheating zones. In some implementations, the temperature aggregation component 1014 may display temperature data as a color-coded grid, with warmer zones represented in shades of red and cooler zones in shades of blue. In some implementations, the temperature aggregation component 1014 mayDocket No. 67674-0043 allow operators to adjust the temperature scale on the heat map to focus on specific ranges relevant to operational thresholds.

[0174] In some examples, the connectivity logging component 1016 may be configured as or otherwise support a means for logging connectivity issues in a maintenance record, the record may include timestamps, signal strength variations, and corrective actions that may be taken to restore wireless communication. In some implementations, the connectivity logging component 1016 may determine the duration of connectivity interruptions and include this information in the maintenance record to assist in identifying recurring patterns. In some implementations, the connectivity logging component 1016 may log the specific wireless protocol in use, such as Bluetooth, Wi-Fi, or cellular, to help operators identify which communication method may be experiencing instability.

[0175] In some implementations, the connectivity logging component 1016 may include details about environmental factors, such as interference from nearby devices, that may contribute to signal strength variations. In some implementations, the connectivity logging component 1016 may record the geographic location of the magnetic separator at the time of the connectivity issue, which may assist in diagnosing location-specific problems. In some implementations, the connectivity logging component 1016 may log the frequency of connectivity issues over a defined period to help operators determine whether hardware inspections may be necessary.

[0176] In some examples, the maintenance analysis component 1018 may be configured as or otherwise support a means for analyzing historical maintenance records to identify recurring patterns in performance data and may generate predictive alerts for future maintenance requirements based on those patterns. In some implementations, the maintenance analysis component 1018 may determine trends in cleaning cycles by examining timestamps and frequency of past maintenance events. In some implementations, the maintenance analysis component 1018 may assess variations in temperature data over time to identify potential correlations with maintenance needs. In some implementations, the maintenance analysis component 1018 may evaluate saturation levels recorded during previous maintenance events to predict when similar conditions may arise. In some implementations, the maintenance analysis component 1018 may incorporate data from multiple magnetic separators to identify shared patterns that may indicate broader operational issues.Docket No. 67674-0043

[0177] In some examples, the threshold configuration component 1020 may be configured as or otherwise support a means for configuring saturation thresholds remotely through the graphical user interface, the thresholds may be adjustable for different operational modes, including high-capacity and low-capacity processing scenarios. In some implementations, the threshold configuration component 1020 may allow operators to define specific saturation percentages tailored to the type of material being processed, such as fine powders or larger granules. In some implementations, the threshold configuration component 1020 may include options for setting thresholds based on predefined templates for common processing scenarios, which may simplify configuration for operators handling repetitive tasks.

[0178] In some implementations, the threshold configuration component 1020 may support dynamic adjustments to saturation thresholds during operation, which may accommodate unexpected changes in material flow rates. In some implementations, the threshold configuration component 1020 may allow operators to configure thresholds for individual magnetic separators within a multi -separator system, which may enable granular control over processing conditions. In some implementations, the threshold configuration component 1020 may include a calibration mode that may assist operators in determining baseline saturation levels for new separators before setting operational thresholds.

[0179] FIG. 11 shows a diagram of a system 1100 including a device 1102 that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordance with aspects of the present disclosure. The device 1102 may be an example of or include the components of a database server or an apparatus 902 as described herein. The device 1102 may include components for bi-directional data communications including components for transmitting and receiving communications, including a magnetic separator monitoring component 1104, an I / O controller 1106, a database controller 1108, memory 1110, a processor 1112, and a database 1114. These components may be in electronic communication via one or more buses (e.g., bus 1116).

[0180] The magnetic separator monitoring component 1104 may be an example of a magnetic separator monitoring component 906 or 1002 as described herein. For example, the magnetic separator monitoring component 1104 may perform any of the methods or processes described above with reference to FIGS. 9 and 10. In some cases, the magnetic separator monitoring component 1104 may be implemented in hardware, software executed by a processor, firmware, or any combination thereof.Docket No. 67674-0043

[0181] The I / O controller 1106 may manage input signals 1118 and output signals 1120 for the device 1102. The I / O controller 1106 may also manage peripherals not integrated into the device 1102. In some cases, the I / O controller 1106 may represent a physical connection or port to an external peripheral. In some cases, the I / O controller 1106 may utilize an operating system such as iOS®, ANDROID®, MS-DOS®, MS-WINDOWS®, OS / 2®, UNIX®, LINUX®, or another known operating system. In other cases, the I / O controller 1106 may represent or interact with a modem, a keyboard, a mouse, a touchscreen, or a similar device. In some cases, the I / O controller 1106 may be implemented as part of a processor. In some cases, a user may interact with the device 1102 via the I / O controller 1106 or via hardware components controlled by the I / O controller 1106.

[0182] The database controller 1108 may manage data storage and processing in a database 1114. In some cases, a user may interact with the database controller 1108. In other cases, the database controller 1108 may operate automatically without user interaction. The database 1114 may be an example of a single database, a distributed database, multiple distributed databases, a data store, a data lake, or an emergency backup database.

[0183] Memory 1110 may include random-access memory (RAM) and read-only memory (ROM). The memory 1110 may store computer-readable, computer-executable software including instructions that, when executed, cause the processor to perform various functions described herein. In some cases, the memory 1110 may contain, among other things, a basic input / output system (BIOS) which may control basic hardware or software operation such as the interaction with peripheral components or devices.

[0184] The processor 1112 may include an intelligent hardware device, (e.g., a general- purpose processor, a DSP, a central processing unit (CPU), a microcontroller, an ASIC, an FPGA, a programmable logic device, a discrete gate or transistor logic component, a discrete hardware component, or any combination thereof). In some cases, the processor 1112 may be configured to operate a memory array using a memory controller. In other cases, a memory controller may be integrated into the processor 1112. The processor 1112 may be configured to execute computer-readable instructions stored in a memory 1110 to perform various functions (e.g., functions or tasks supporting monitoring and controlling magnetic separators with real-time data and predictive maintenance).

[0185] FIG. 12 shows a flowchart illustrating a method 1200 that supports monitoring and controlling magnetic separators with real-time data and predictive maintenance in accordanceDocket No. 67674-0043 with various aspects of the present disclosure. The operations of the method 1200 may be implemented by one or more components of a networked computing system as described herein. For example, the operations of the method 1200 may be performed by a magnetic separator monitoring component as described with reference to FIGS. 9 through 11. In some examples, one or more components of a networked computing system may execute a set of instructions (e.g., a software application) to control the functional elements of the component(s) to perform the described functions. Additionally or alternatively, the one or more components of a networked computing system may perform aspects of the described functions using special-purpose hardware.

[0186] At 1202, the method 1200 may include receiving real-time performance data from at least one magnetic separator, the performance data including saturation levels, temperature, and signal strength. The operations of 1202 may be performed in accordance with examples as disclosed herein. In some examples, aspects of the operations of 1202 may be performed by a performance data receiving component 1004 as described with reference to FIG. 10.

[0187] At 1204, the method 1200 may include processing the performance data to determine operational status and predict maintenance requirements based on historical data and machine learning algorithms. Utilization of the machine learning algorithms to predict future maintenance requirements may help avoid downtime (e.g., of the magnetic separator) and / or catastrophic failure of equipment by allowing the equipment to operate at more specific runtimes instead of periodic checkups. The operations of 1204 may be performed in accordance with examples as disclosed herein. In some examples, aspects of the operations of 1204 may be performed by a data processing component 1006 as described with reference to FIG. 10.

[0188] At 1206, the method 1200 may include transmitting alerts in response to the performance data meeting predefined thresholds, the alerts including saturation levels, temperature, and connectivity issues. The operations of 1206 may be performed in accordance with examples as disclosed herein. In some examples, aspects of the operations of 1206 may be performed by an alert transmission component 1008 as described with reference to FIG. 10.

[0189] At 1208, the method 1200 may include displaying the performance data and alerts on a graphical user interface, the interface configured to allow remote configuration of the at least one magnetic separator. The operations of 1208 may be performed in accordance with examples as disclosed herein. In some examples, aspects of the operations of 1208 may beDocket No. 67674-0043 performed by a graphical interface display component 1010 as described with reference to FIG. 10.

[0190] In some embodiments, the software application described herein may be implemented in various computing environments, including as a native mobile application executable on a smartphone or tablet device, as a web-based application accessible through a browser interface, or as a cloud-hosted application deployed on a distributed computing platform. The application architecture may utilize client-server communication over a network connection, with at least a portion of the user interface and logic executing locally on a client device and another portion executing remotely on one or more servers. In certain implementations, the application may be deployed in a hybrid configuration, such that user interactions are performed through a web browser or mobile app, while computationally intensive operations, data storage, and synchronization are performed within a cloud environment to ensure scalability, security, and consistent performance across user devices.

[0191] The disclosed technology may be applied to any system or apparatus employing a magnetic field to perform a functional task and is not limited to magnetic separators. The system / method is directed to measuring, monitoring, and reporting the magnetic flux pattern within a magnet’s working airgap, that is, the region in which the magnetic field performs its intended operational effect. By sensing and analyzing the strength and distribution of magnetic flux within the working airgap, the system generates performance parameters that may be used to assess magnet condition, detect degradation, and develop adaptive algorithms for optimizing magnet performance over time. Such algorithms may be implemented as part of an Internet of Things (loT) or Industry 4.0 factory automation framework to enable predictive maintenance, automated calibration, and performance reporting. While particularly useful for magnetic separation systems, the disclosed technology is equally applicable to other magnetic systems such as conveyors, lifting or holding magnets, or other magnetic field-based devices, thereby providing a generalized platform for intelligent magnetic field analysis and control across industrial applications.

[0192] It should be noted that the methods described herein describe possible implementations, and that the operations and the steps may be rearranged or otherwise modified and that other implementations are possible. Furthermore, aspects from two or more of the methods may be combined.Docket No. 67674-0043

[0193] Aspect 1 : A method for monitoring and controlling magnetic separators with realtime data and predictive maintenance, comprising: receiving real-time performance data from at least one magnetic separator, the performance data including saturation levels, temperature, and signal strength; processing the performance data to determine operational status and predict maintenance requirements based on historical data and machine learning algorithms; transmitting alerts in response to the performance data meeting predefined thresholds, the alerts including saturation levels, temperature, and connectivity issues; and displaying the performance data and alerts on a graphical user interface, the interface configured to allow remote configuration of the at least one magnetic separator.

[0194] Aspect 2: The method of aspect 1, further comprising transmitting a notification to a remote device in response to the performance data indicating saturation levels below a predefined threshold, the notification including a graphical representation of historical saturation trends and recommended actions for maintaining operational efficiency.

[0195] Aspect 3: The method of any one of aspects 1 through 2, further comprising aggregating temperature data from multiple sensors within the at least one magnetic separator and displaying a heat map on the graphical user interface to identify localized overheating zones.

[0196] Aspect 4: The method of any one of aspects 1 through 3, further comprising logging connectivity issues in a maintenance record, the record including timestamps, signal strength variations, and corrective actions taken to restore wireless communication.

[0197] Aspect 5: The method of any one of aspects 1 through 4, further comprising analyzing historical maintenance records to identify recurring patterns in performance data and generating predictive alerts for future maintenance requirements based on those patterns.

[0198] Aspect 6: The method of any one of aspects 1 through 5, further comprising configuring saturation thresholds remotely through the graphical user interface, the thresholds being adjustable for different operational modes, including high-capacity and low-capacity processing scenarios.

[0199] Aspect 7: The method of any one of aspects 1 through 6, wherein the graphical user interface displays a color-coded status indicator for saturation levels, the indicator transitioning between green, yellow, and red based on predefined saturation thresholds.Docket No. 67674-0043

[0200] Aspect 8: The method of any one of aspects 1 through 7, wherein the alerts include visual notifications on the graphical user interface and audible signals transmitted to a remote device in response to the performance data exceeding predefined thresholds.

[0201] Aspect 9: The method of any one of aspects 1 through 8, wherein the predictive maintenance requirements are determined by analyzing saturation trends and temperature variations over a predefined time period.

[0202] Aspect 10: The method of any one of aspects 1 through 9, wherein the graphical user interface provides a summary view of multiple magnetic separators, the view including saturation levels, temperature data, and connectivity status for each separator.

[0203] Aspect 11 : The method of any one of aspects 1 through 10, wherein the performance data includes signal strength metrics displayed as a percentage value on the graphical user interface to indicate wireless communication reliability.

[0204] Aspect 12: The method of any one of aspects 1 through 11, wherein the alerts are transmitted to a remote device in response to the performance data indicating temperature levels exceeding predefined safety thresholds.

[0205] Aspect 13: The method of any one of aspects 1 through 12, wherein the graphical user interface allows remote configuration of operational parameters, including saturation thresholds, temperature limits, and connectivity settings for the at least one magnetic separator.

[0206] Aspect 14: A system for monitoring and controlling magnetic separators with realtime data and predictive maintenance, comprising a processor; memory coupled with the processor; and instructions stored in the memory and executable by the processor to cause the system to perform a method of any one of aspects 1 through 13.

[0207] Aspect 15: A system for monitoring and controlling magnetic separators with realtime data and predictive maintenance, comprising at least one means for performing a method of any one of aspects 1 through 13.

[0208] Aspect 16: A non -transitory computer-readable medium storing code for monitoring and controlling magnetic separators with real-time data and predictive maintenance, the code comprising instructions executable by a processor to perform a method of any one of aspects 1 through 13.

[0209] The description set forth herein, in connection with the appended drawings, describes example configurations and does not represent all the examples that may beDocket No. 67674-0043 implemented or that are within the scope of the claims. The term “exemplary” used herein means “serving as an example, instance, or illustration,” and not “preferred” or “advantageous over other examples.” The detailed description includes specific details for the purpose of providing an understanding of the described techniques. These techniques, however, may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the described examples. Additionally, although the system, methods, products described herein are discussed within the context of magnetic separators, it will be appreciated that the system, method, products may be employed in different applications without departing from the scope of the disclosure, including but not limited to conveyor systems and holding magnets, for example.

[0210] In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If just the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

[0211] Information and signals described herein may be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description may be represented by voltages, currents, electromagnetic waves, magnetic fields or particles, optical fields or particles, or any combination thereof.

[0212] The various illustrative blocks and modules described in connection with the disclosure herein may be implemented or performed with a general -purpose processor, a DSP, an ASIC, an FPGA or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices (e.g., a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration).

[0213] The functions described herein may be implemented in hardware, software executed by a processor, firmware, or any combination thereof. If implemented in software executed byDocket No. 67674-0043 a processor, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Other examples and implementations are within the scope of the disclosure and appended claims. For example, due to the nature of software, functions described herein can be implemented using software executed by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations. Also, as used herein, including in the claims, “or” as used in a list of items (for example, a list of items prefaced by a phrase such as “at least one of’ or “one or more of’) indicates an inclusive list such that, for example, a list of at least one of A, B, or C means A or B or C or AB or AC or BC or ABC (i.e., A and B and C). Also, as used herein, the phrase “based on” shall not be construed as a reference to a closed set of conditions. For example, an exemplary step that is described as “based on condition A” may be based on both a condition A and a condition B without departing from the scope of the present disclosure. In other words, as used herein, the phrase “based on” shall be construed in the same manner as the phrase “based at least in part on.”

[0214] Computer-readable media includes both non-transitory computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. A non-transitory storage medium may be any available medium that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, non-transitory computer-readable media can comprise RAM, ROM, electrically erasable programmable read only memory (EEPROM), compact disk (CD) ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other non- transitory medium that can be used to carry or store desired program code means in the form of instructions or data structures and that can be accessed by a general-purpose or specialpurpose computer, or a general -purpose or special-purpose processor. Also, any connection is properly termed a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. Disk and disc, as used herein, include CD, laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu- ray disc where disks usually reproduce data magnetically, while discs reproduce data opticallyDocket No. 67674-0043 with lasers. Combinations of the above are also included within the scope of computer-readable media.

[0215] The description herein is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the scope of the disclosure. Thus, the disclosure is not limited to the examples and designs described herein but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.

Claims

Docket No. 67674-0043CLAIMSWhat is claimed is:

1. A system for monitoring and controlling industrial magnetic separators, comprising: one or more magnetic separators; at least one sensor associated with each magnetic separator, the at least one sensor configured to generate real-time performance data; a controller communicably coupled to the at least one sensor, the controller configured to aggregate the real-time performance data; a network interface configured to transmit the aggregated real-time performance data; an operator device comprising: a processor; a memory storing executable instructions; a graphical user interface presented on a display; and an application executed by the processor to: receive, via the network interface, the real-time aggregated performance data; process the real-time performance data to determine operational status of each magnetic separator; generate a control signal to adjust at least one operational parameter of the magnetic separator in response to the performance data meeting a user-defined threshold; and present, on the graphical user interface, a real-time visualization of the operational status and any control action taken.

2. The system of claim 1, wherein the operator device receives the performance data via multiple wireless communication protocols selected from Bluetooth, Wi-Fi, and cellular networks.

3. The system of claim 1 or 2, wherein the processor executes a machine learning model trained on historical performance data to forecast maintenance requirements of the magnetic separator.Docket No. 67674-00434. The system of any one of claims 1 to 3, wherein the control signal triggers a physical indicator on the magnetic separator comprising at least one of: a light-emitting diode (LED), an HDMI display, or a relay output to a programmable logic controller (PLC).

5. The system of any one of the preceding claims, wherein the graphical user interface comprises: a bar graph visually representing saturation percentage of each magnetic separator, color-coded to indicate operational status; and additional metrics displayed including wireless signal strength, current operating temperature, and a timestamp of the last maintenance event.

6. The system of any one of the preceding claims, wherein the application automatically generates a maintenance log including timestamps of cleaning cycles, temperature trends, and operator-entered comments.

7. The system of any one of the preceding claims, wherein the operator device communicates with external systems via application programming interfaces (APIs), enabling integration with cloud-based services, enterprise resource planning (ERP) systems, and industrial loT platforms.

8. The system of any one of the preceding claims, wherein the application communicates directly with sensors of the magnetic separator to provide component-level monitoring, including monitoring of individual tubes in a drawer magnet or individual poles in a plate magnet.

9. The system of any one of the preceding claims , wherein the controller aggregates data from individual sensors within a magnetic separator and communicates the aggregated data to the operator device for system-level monitoring.

10. The system of any one of the preceding claims , wherein the operator device concurrently connects to a plurality of magnetic separators, presents a summary view of performance data for each separator, and enables drill-down selection to display individual separator details.Docket No. 67674-004311. The system of any one of the preceding claims , wherein each magnetic separator comprises a magnetic field generator configured to separate ferrous contaminants from a material stream.

12. The system of any one of the preceding claims , wherein the performance data comprises at least one of: saturation levels expressed as a percentage of separator capacity, temperature values indicative of operating health, wireless signal strength, and a maintenance history log.

13. A computer-implemented method for monitoring and controlling a magnetic separator, the method comprising: receiving, via a wireless communication module, performance data generated by one or more sensors of a magnetic separator, the performance data including saturation levels and temperature; processing the performance data by a processor to: compare the performance data against a user-defined saturation threshold; and determine whether a control action is required; in response to determining the control action is required, generating a control signal to adjust operation of the magnetic separator; providing, via a graphical user interface on a mobile device, a real-time display of the performance data together with the control action; and logging maintenance data in a non-transitory computer-readable memory to track operation of the magnetic separator over time.

14. The method of claim 13, wherein processing the performance data further comprises executing a predictive algorithm trained on historical sensor readings to estimate a time-to- maintenance interval for the magnetic separator.

15. The method of claim 13 or 14, wherein the graphical user interface presents the performance data as a visual display including a color-coded saturation bar graph, wireless signal strength indicator, temperature status, and timestamp of a most recent cleaning event.

16. A non-transitory computer-readable medium storing instructions, which when executedDocket No. 67674-0043 by one or more processors cause the processors to perform the method of claim 13.17 The non-transitory computer-readable medium of claim 16, wherein the instructions further cause the processors to generate a control signal to adjust an operational parameter of the magnetic separator selected from: saturation threshold reset, temperature shutdown, or wireless reconnection routine.

18. The non-transitory computer-readable medium of claim 16 or 17, wherein the instructions further cause the processors to execute a machine learning model trained on historical data to predict maintenance requirements.

19. The non-transitory computer-readable medium of any one of claims 16 to 18, wherein the instructions further cause the processors to display, via the graphical user interface, both a summary view of multiple magnetic separators and a detailed view of an individual magnetic separator including saturation trends over time, temperature, and maintenance log.

20. The non-transitory computer-readable medium of any one of claims 16 to 19, wherein the instructions further cause the processors to display, via the graphical user interface, both a summary view of multiple magnetic separators and a detailed view of an individual magnetic separator including saturation trends over time, temperature, and maintenance log.

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