A Rice Husk Processing Machine and Method of Operating the Same

Abstract

ABSTRACT: Title: A Rice Husk Processing Machine and Method of Operating the Same The present disclosure proposes a rice husk processing machine (100) that ensures efficient and consistent processing of rice husks into a moulded product, thereby improving production efficiency, cost-effectiveness, and environmental sustainability. The rice husk processing machine (100) comprises a container (102), an elongated key shaft (116), a driving unit (114), plurality of upper shearing blades (118) and lower shearing blades (120), a hydraulic cylinder (110), a molding unit (140), and a controller (158). The proposed rice husk processing machine (100) eliminates the need for separate powdering, mixing, and moulding machines, reducing both initial capital investment and long-term operational costs. The proposed rice husk processing machine (100) requires a less floor space for installation, streamlines the workflow, leading to faster production cycles and reduced energy consumption. The proposed rice husk processing machine (100) minimizes the risk of contamination and allows for more consistent product quality.

Specification

Description:DESCRIPTION:
Field of the invention:
[0001] The present disclosure generally relates to the technical field of rice husk processing systems, and in specific, relates to a rice husk processing machine that ensures efficient and consistent processing of rice husks into a moulded product, thereby improving production efficiency, cost-effectiveness, and environmental sustainability.
Background of the invention:
[0002] Rice husk is a by-product of rice cultivation, and it is considered a waste product. Rice husk is separated from the grains after the plants are threshed either manually using stationery threshers or by using common harvesters. Rice husk is a lignocellulosic biomass comprised of three components are lignin, cellulose, and hemicelluloses. The rice husks are typically moulded in a desired shape to reduce space. Typically, the rice husks convert into usable products. First, the rice husks are collected and cleaned to remove any impurities. Next, the husks are processed into a fine powder or granulated form. The fine powder is mixed with a binder or adhesive to improve its cohesiveness, thereby forming a mixture. The mixture is fed into a mould, where it is subjected to high pressure and temperature to shape it into the desired form. The moulded product is then cooled and solidified. This process not only creates durable and eco-friendly items but also utilizes rice husks effectively, reducing waste and environmental impact.
[0003] Using different powder, mixing, and moulding equipment can present several drawbacks. Firstly, the need for multiple machines that lead to increased capital and operational costs, as each piece of equipment requires maintenance, calibration, and space. Additionally, the compatibility of different machines can be a challenge, potentially leading to inefficiencies and quality issues if the equipment does not seamlessly integrate. Variations in powder properties or inconsistent mixing can result in product defects or variations in quality, impacting overall reliability. Moreover, managing and training staff to operate diverse machines can be complex and time-consuming. Finally, the process of transitioning between different stages of production might introduce delays and increase the likelihood of contamination, thereby affecting the final product's consistency and performance.
[0004] Several alternatives to using different powder, mixing, and moulding equipment exist, aimed at simplifying the production process and improving efficiency. One approach is to use integrated systems that combine powder processing, mixing, and moulding into a single unit. These all-in-one machines streamline production, reduce the need for equipment transitions, and minimize space requirements. Another alternative is to employ advanced automated systems that enhance precision and consistency across all stages of production, reducing human error and improving product quality. Additionally, modular equipment allows for flexible adaptation to different materials and processes, enabling quick adjustments and reducing the need for multiple specialized machines. Finally, leveraging technologies such as 3D printing can provide highly customized and on-demand production capabilities, potentially eliminating the need for traditional moulding processes and equipment.
[0005] Conventionally, a method for making packing containers from rice husks presents several disadvantages. At first, the process involves multiple complex stages, including pulverizing, stirring, rolling, moulding, and drying, which lead to high energy consumption and operational costs. The need for specialized equipment at each stage, including mixers, rollers, and heat-baking devices, adds to capital investment and maintenance expenses. Additionally, the process's reliance on a specific binder, such as carboxymethyl cellulose (CMC), limits flexibility and increases material costs. The drying stage requires precise temperature control, which could extend production times and potentially affect the consistency and quality of the final product.
[0006] Therefore, there is a need for a rice husk processing machine that ensures efficient and consistent processing of rice husks into a molded product, thereby improving production efficiency, cost-effectiveness, and environmental sustainability. There is also a need for a rice husk processing machine that requires a less floor space for installation, streamlines the workflow, leading to faster production cycles and reduced energy consumption. Furthermore, there is also a need for a rice husk processing machine that promotes sustainable production by utilizing rice husks as a waste product of rice milling, thereby reducing waste and contributing to a circular economy.
Objectives of the invention:
[0007] The primary objective of the present invention is to provide a rice husk processing machine that ensures efficient and consistent processing of rice husks into a moulded product, thereby improving production efficiency, cost-effectiveness, and environmental sustainability.
[0008] Another objective of the present invention is to provide a rice husk processing machine that eliminates the need for separate powdering, mixing, and moulding machines, reducing both initial capital investment and long-term operational costs.
[0009] Another objective of the present invention is to provide a rice husk processing machine that requires a less floor space for installation, streamlines the workflow, leading to faster production cycles and reduced energy consumption.
[0010] Another objective of the present invention is to provide a rice husk processing machine that minimizes the risk of contamination and allows for more consistent product quality.
[0011] Another objective of the present invention is to provide a rice husk processing machine that utilizes a user interface to simplify the controlling to a semi-skilled person, thereby requiring less training and reducing the risk of operator error.
[0012] Another objective of the present invention is to provide a rice husk processing machine that promotes sustainable production by utilizing rice husks as a waste product of rice milling, thereby reducing waste and contributing to a circular economy.
[0013] Another objective of the present invention is to provide a rice husk processing machine that automates multiple steps, thereby reducing labor requirements and the need for manual handling.
[0014] Yet another objective of the present invention is to provide a rice husk processing machine that integrated with a planetary gear mechanism, efficiently handling multiple operation to ensure opposite rotation of upper and lower blades.
[0015] Further objective of the present invention is to provide a a rice husk processing machine that utilizes a hydraulic cylinder allow for precise control over the compression and shaping of the rice husk mixture, improving the final product's quality.
Summary of the invention:
[0016] The present disclosure proposes a rice husk processing machine and method of operating the same. The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview. It is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0017] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide a rice husk processing machine that ensures efficient and consistent processing of rice husks into a moulded product, thereby improving production efficiency, cost-effectiveness, and environmental sustainability.
[0018] According to one aspect, the invention provides the rice husk processing machine. In one embodiment, the rice husk processing machine comprises a container, an elongated key shaft, a driving unit, plurality of upper shearing blades and lower shearing blades, a hydraulic cylinder, a molding unit, and a controller. In one embodiment, the container having an inlet for receiving rice husks and adhesive materials and an outlet for dispensing a processed mixture. In another embodiment, the container is configured to be supported by plurality of supporting legs, which stabilizes the rice husk processing machine during the powdering, mixing, and molding processes.
[0019] In one embodiment, the elongated key shaft having a keyway vertically is positioned within the container at a center portion and extended through a bottom portion. In one embodiment, the driving unit is mounted on the container at a top portion. The driving unit is configured to rotatably connect to the elongated key shaft through a gear unit.
[0020] In one embodiment, the plurality of upper shearing blades and lower shearing blades are mounted over the elongated key shaft within the container. The plurality of upper shearing blades and lower shearing blades are configured to connect to a planetary gear unit mounted on the elongated key shaft between the plurality of upper shearing blades and lower shearing blades. The plurality of upper shearing blades and lower shearing blades are adapted to rotate at controlled speeds in opposite directions, thereby creating a shearing action that optimizes a powdering process for powdering the rice husks and a mixing process for obtaining the processed mixture of the rice husks and the adhesive materials.
[0021] In one embodiment, the hydraulic cylinder is mounted over the elongated key shaft at a top portion. The hydraulic cylinder is configured to enable downward and upward movements of the elongated key shaft, thereby allowing the outlet of the container to be closed and opened, respectively, upon actuation.
[0022] In one embodiment, the molding unit is positioned beneath the container. The molding unit is configured to receive the processed mixture through the outlet upon actuation of the hydraulic cylinder and convert it into a desired molded shape, thereby performing a molding process. In one embodiment, the controller is configured to receive one or more inputs from a user through a user interface for controlling an operation of the rice husk processing machine for performing the powdering process, the mixing process, and the molding process, respectively.
[0023] In one embodiment, the planetary gear unit comprises a sun gear, plurality of planet gears, and a ring gear. The sun gear is rotatably connected to the elongated key shaft through a bearing. The sun gear is connected to the plurality of lower shearing blades. The plurality of planet gears are rotatably connected to the sun gear. The plurality of planet gears is connected to the plurality of upper shearing blades through connectors. The ring gear is affixed to an inner surface of the container through connecting members. In one embodiment, the upper shearing blades having one or more holes that adapted to secure movement of the plurality of planet gears with the connectors.
[0024] In one embodiment, the molding unit comprises a top die and a bottom die. The top die having a slot for receiving the processed mixture from outlet of the container upon actuation of the hydraulic cylinder, thereby allowing the processed mixture to further process. The bottom die with a mold pattern is movably coupled with the top die via spring cylinders. The mold pattern is configured to receive the processed mixture from the slot of the top die, thereby enabling the vertical movement of the elongated key shaft for closing the outlet and compressing the processed mixture with the top die in order to create a desired molded shape.
[0025] In one embodiment, the bottom die having a heating element that is configured to heat the mold pattern at a selectively temperature by the controller to solidify the processed mixture during the molding process and facilitate removing of the desired molded shape from the bottom die. In one embodiment, the spring cylinders are positioned between the top die and the bottom die. The spring cylinders are configured to provide vertical movement to the top die for compressing the processed mixture upon actuation of the hydraulic cylinder.
[0026] In one embodiment, the holding frame is mounted over the container. The holding frame is configured to support the hydraulic cylinder and the gear unit. In one embodiment, the gear unit having a worm shaft that is rotatably connected to the driving unit and a spur gear is securely coupled to the key shaft that allows to receive the rotational motion from the worm shaft to process the rice husks.
[0027] According to another aspect, the invention provides a method for operating the rice husk processing machine. At one step, the user loads the rice husks into the container through the inlet and activates the driving unit via the controller by enabling the user interface to rotate the elongated key shaft in at least one direction. At another step, the elongated key shaft drives the planetary gear unit to rotate the plurality of upper shearing blades and lower shearing blades at controlled speeds in the opposite directions, thereby creating the shearing action that optimizes a powdering process for powdering the rice husks.
[0028] At another step, the user adjusts the rotational motion of the plurality of upper shearing blades and lower shearing blades via the user interface to achieve the rice husk powder consistency, and adds the adhesive materials into the powdered rice husks via the inlet, thereby performing the mixing process for obtaining the processed mixture of the rice husks. At another step, the controller activates the hydraulic cylinder to lift the elongated key shaft selectively via the lever that allows to open the outlet of the container for dispensing the processed mixture onto the mold pattern of the molding unit.
[0029] At another step, the user controls the vertical movement of the key shaft in the downward direction by the lever that allows to close the outlet of the container and compresses the processed mixture with the top die in order to create the desired molded shape. Further, at another step, the controller activates the heating element to heat the mold pattern at a selectively temperature to form the desired molded shape within the molding unit.
[0030] Further, objects and advantages of the present invention will be apparent from a study of the following portion of the specification, the claims, and the attached drawings.
Detailed description of drawings:
[0031] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, explain the principles of the invention.
[0032] FIG. 1 illustrates an isometric view of a rice husk processing machine, in accordance to an exemplary embodiment of the invention.
[0033] FIG. 2A illustrates a schematic view of an elongated key shaft of the rice husk processing machine, in accordance to an exemplary embodiment of the invention.
[0034] FIG. 2B illustrates a cross-sectional view of a container with a gear unit, in accordance to an exemplary embodiment of the invention.
[0035] FIG. 2C illustrates a cross-sectional view of the container with a molding unit, in accordance to an exemplary embodiment of the invention.
[0036] FIG. 3A illustrates an isometric view of the rice husk processing machine that is adapted to receive rice husks, in accordance to an exemplary embodiment of the invention.
[0037] FIG. 3B illustrates an isometric view of the rice husk processing machine that is adapted to powdered the rice husks, in accordance to an exemplary embodiment of the invention.
[0038] FIG. 3C illustrates an isometric view of the rice husk processing machine that is adapted to form a processed mixture, in accordance to an exemplary embodiment of the invention.
[0039] FIG. 3D illustrates an isometric view of the rice husk processing machine that is adapted to transfer the processed mixture to the molding unit, in accordance to an exemplary embodiment of the invention.
[0040] FIG. 3E illustrates an isometric view of the molding unit that is adapted to form a desired shape of the processed mixture, in accordance to an exemplary embodiment of the invention.
[0041] FIG. 4 illustrates a flowchart of a method for operating the rice husk processing machine, in accordance to an exemplary embodiment of the invention.
Detailed invention disclosure:
[0042] Various embodiments of the present invention will be described in reference to the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.
[0043] The present disclosure has been made with a view towards solving the problem with the prior art described above, and it is an object of the present invention to provide a rice husk processing machine 100 that ensures efficient and consistent processing of rice husks into a moulded product, thereby improving production efficiency, cost-effectiveness, and environmental sustainability.
[0044] According to one exemplary embodiment of the invention, FIG. 1 refers to an isometric view of the rice husk processing machine 100. In one embodiment herein, the rice husk processing machine 100 eliminates the need for separate powdering, mixing, and moulding machines, reducing both initial capital investment and long-term operational costs. The rice husk processing machine 100 requires a less floor space for installation, streamlines the workflow, leading to faster production cycles and reduced energy consumption. The rice husk processing machine 100 minimizes the risk of contamination and allows for more consistent product quality.
[0045] In another embodiment herein, the rice husk processing machine 100 comprises a container 102, a holding frame 108, a driving unit 114, an elongated key shaft 116. In one embodiment herein, the container 102 having inlet 104 for receiving rice husks and adhesive materials and an outlet 106 (as depicted in FIG. 2B) for dispensing a processed mixture. In one embodiment herein, the holding frame 108 is mounted on the container 102. The holding frame 108 is configured to support the hydraulic cylinder 110 at a top portion and a gear unit 112 at a bottom portion. In one embodiment herein, the driving unit 114 is mounted on the container 102. The driving unit 114 is configured to rotatably connect to the elongated key shaft 116 through the gear unit 112.
[0046] Additionally, the hydraulic cylinder 110 is coupled to the elongated key shaft 116 for controlling a vertical movement upon actuation, which allows to open and close the outlet 106 of the container 102 for dispensing the processed mixture while performing a molding process. Additionally, the container 102 having plurality of stairs 138 is adapted to allow the user to add the adhesive materials into the container 102 upon obtaining a powdered rice husk by the rotation of the elongated key shaft 116.
[0047] Furthermore, the container 102 having plurality of supporting legs 103 are configured to support and stabilize the rice husk processing machine 100 during the powdering, mixing, and molding processes of the rice husks. In one embodiment herein, the molding unit 140 is positioned beneath the container 102. The molding unit 140 is configured to receive the processed mixture from the container 102 and convert it into a desired molded shape by applying pressure, thereby performing the molding process. In one example, the rice husk processing machine 100 is manufactured with, but not limited to, durable material, including cast iron, stainless steel, malleable material, aluminum, and other composite materials.
[0048] In one embodiment herein, the rice husk processing machine 100 comprises a user interface 154 that is attached to an external surface of the container 102. The user interface 154 having a controller 158, plurality of buttons, and a lever 156. Additionally, the user interface 154 is configured to receive one or more inputs from the user to operate the rice husk processing machine 100. The plurality of buttons are positioned within the user interface 154. The plurality of buttons are configured to allow the user to activate and deactivate the rice husk processing machine 100, adjust the speed of the elongated key shaft 116, and adjust a temperature of a heating element 145 (as depicted in FIG. 2C) for the molding unit 140 to solidify the processed mixture into the desired mold shape. In one embodiment herein, the lever 156 is configured to enable the user to control the vertical movement of the elongated key shaft 116 through the hydraulic cylinder 110, thereby forming the rice husks into the desired molded shape.
[0049] According to another exemplary embodiment of the invention, FIG. 2A refers to a schematic view of the elongated key shaft 116 of the rice husk processing machine 100. In one embodiment herein, the elongated key shaft 116 is operably positioned within the container 102. The driving unit 114 is configured to rotate the elongated key shaft 116 in at least one direction upon actuation, and the hydraulic cylinder 110 is configured to provide the vertical movement to the elongated key shaft 116 during the operation of the rice husk processing machine 100.
[0050] In one embodiment herein, the gear unit 112 having a worm shaft 150 that is rotatably connected to the driving unit 114, and a spur gear 152 is securely coupled to the key shaft 116 that allows to receive the rotational motion from the worm shaft 150 to process the rice husks. Additionally, the spur gear 152 having a groove that securely fits the key shaft 116 for transferring a relative rotational motion from the worm shaft 150 of the driving unit 114. The hydraulic cylinder 110 is configured to operate the vertical movement of the key shaft 116 for dispensing the processed mixture to the molding unit 140 for solidifying the processed mixture into the desired shape, thereby eliminating the space for storage the rice husks.
[0051] In one embodiment herein, the rice husk processing machine 100 comprises plurality of upper shearing blades 118 and lower shearing blades 120 mounted over the elongated key shaft 116 within the container 102. The plurality of upper shearing blades 118 and lower shearing blades 120 are adapted to rotate at controlled speeds in opposite directions, thereby creating a shearing action that optimizes a powdering process for powdering the rice husks and a mixing process for obtaining the processed mixture of the rice husks and the adhesive materials.
[0052] According to another exemplary embodiment of the invention, FIG. 2B refers to a cross-sectional view of the container 102 with the gear unit 124. In one embodiment herein, the plurality of upper shearing blades 118 and lower shearing blades 120 are positioned within the container 102 and operably coupled to the gear unit 124 via the elongated key shaft 116. The upper shearing blades 118 and lower shearing blades 120 are configured to rotate in opposite directions at controlled speeds, generating the shearing action that enhances the powdering process for the rice husks and the mixing process to produce the processed mixture of rice husks and adhesive materials.
[0053] The rice husk processing machine 100 comprises plurality of supporting members 128 that are positioned within the container 102. The plurality of supporting members 128 are configured to hold a ring gear 126 of the gear unit 124 and stabilize the rotation of the plurality of upper shearing blades 118 and lower shearing blades 120 during the vertical movement of the elongated key shaft 116. In one embodiment herein, the gear unit 124 comprises a sun gear 130 and plurality of planet gears 132. The sun gear 130 is securely coupled to the plurality of lower shearing blades 120 and rotatably coupled to the key shaft 116 via a bearing 134.
[0054] The plurality of planet gears 132 are rotatably connected to the sun gear 130. The plurality of planet gears 132 is connected to the plurality of upper shearing blades 118 through connectors 136. The plurality of upper shearing blades 118 is configured to be rotated in at least one direction upon actuating the driving unit 114 that allows the plurality of planet gears 132 to rotate the sun gear 130, thereby rotating the plurality of lower shearing blades 120 in the opposite direction for powdering the rice husks.
[0055] In one example, the driving unit 114 is configured to rotate the elongated key shaft 116 in a clockwise direction. The plurality of upper shearing blades 118 is configured to be rotated in the clockwise direction that allows to rotate the plurality of planet gears 132 in the similar direction via the connectors 136. The plurality of planet gears 132 are rotated and engaged with the ring gear 126 for transferring the relative rotational motion to the sun gear 130. Additionally, the sun gear 130 is securely coupled to the plurality of lower shearing blades 120 and operably coupled to the elongated key shaft 116 via the bearing 134 that allows to receive the rotational motion from the plurality of planet gears 132, thereby rotating the sun gear 130 in an anti-clockwise direction.
[0056] In one embodiment herein, the hydraulic cylinder 110 is mounted over the elongated key shaft 116 at the top portion. The hydraulic cylinder 110 is configured to enable the downward and upward movements of the elongated key shaft 116, thereby allowing the outlet 106 of the container 102 to be closed and opened, respectively, upon actuation.
[0057] According to another exemplary embodiment of the invention, FIG. 2C refers to a cross-sectional view of the container 102 with the molding unit 140. Referring to FIG. 2B, the molding unit 140 is positioned beneath the container 102. The molding unit 140 is configured to receive the processed mixture and convert it into the desired molded shape. The molding unit 140 comprises a bottom die 142, and a top die 146. The bottom die 142 with a mold pattern 144 is configured to receive the processed mixture from the container 102 for shaping the processed mixture.
[0058] In one embodiment herein, the top die 146 having a slot 147 for receiving the processed mixture from outlet 106 of the container 102 upon actuation of the hydraulic cylinder 110, thereby allowing the processed mixture to further process. For example, the hydraulic cylinder 110 is configured to lower the top die 146 with the key shaft 116 for compressing the processed mixture into the desired molded shape and raise the top die 146 for removing the desired molded shape from the molding unit 140.
[0059] In one embodiment herein, the bottom die 142 with a mold pattern 144 is movably coupled with the top die 146 via spring cylinders 148. The mold pattern 144 is configured to receive the processed mixture from the slot 147 of the top die 146, thereby enabling the vertical movement of the elongated key shaft 116 for closing the outlet 106 and compressing the processed mixture with the top die 146 in order to create the desired molded shape. In one embodiment herein, the spring cylinders 148 are positioned between the top die 146 and the bottom die 142. The spring cylinders 148 are configured to provide vertical movement to the top die 146 for compressing the processed mixture upon actuation of the hydraulic cylinder 110.
[0060] According to another exemplary embodiment of the invention, FIG. 3A refers to an isometric view of the rice husk processing machine 100 that is adapted to receive rice husks. In one embodiment herein, the rice husk processing machine 100 is configured to enable the user to load the rice husks into the container 102 through the inlet 104. Next, the user needs to activate the rice husk processing machine 100 by pressing at least one button on the user interface 154. Next, the user needs to activate the driving unit 114 to rotate the elongated key shaft 116 along with the plurality of upper shearing blades 118 and lower shearing blades 120 in the opposite directions to create the shearing action. Initially, the elongated key shaft 116 is configured to close the outlet 106 of the container 102.
[0061] According to another exemplary embodiment of the invention, FIG. 3B refers to an isometric view of the rice husk processing machine 100 that is adapted to powdered the rice husks. Referring to FIG. 3A, the user needs to activate the driving unit 114 to rotate the elongated key shaft 116 along with the plurality of upper shearing blades 118 and lower shearing blades 120 in the opposite directions to create the shearing action that efficiently powdered the rice husks. In one embodiment herein, the user needs to ensure the powder consistency of the rice husks based on the requirement, enabling the user interface 154 to reduce the speed of the elongated key shaft 116 via the controller 158.
[0062] According to another exemplary embodiment of the invention, FIG. 3C refers to an isometric view of the rice husk processing machine 100 that is adapted to form the processed mixture. Referring to FIG. 3B, the user needs to add the adhesive materials into the powdered rice husks for improved cohesiveness through the inlet 104 of the container 102. The plurality of upper shearing blades 118 and lower shearing blades 120 are efficiently mix the powdered rice husks into the processed mixture. Additionally, the plurality of upper shearing blades 118 and lower shearing blades 120 are still rotated within the container 102 to achieve the uniform processed mixture based on the user requirement.
[0063] According to another exemplary embodiment of the invention, FIG. 3D refers to an isometric view of the rice husk processing machine 100 that is adapted to transfer the processed mixture to the molding unit 140. Referring to FIG. 3C, the user achieves the uniform processed mixture. Next, the user activates the hydraulic cylinder 110 to lift the elongated key shaft 116 by operating the lever 156, thereby adjusting the vertical movement of the elongated key shaft 116 selectively that allows to open the outlet 106 of the container 102 for dispensing the processed mixture onto the mold pattern 144 of the molding unit 140.
[0064] In one embodiment herein, the spur gear 152 is movably positioned on the elongated key shaft 116, and configured to receive the rotational motion from the worm shaft 150, thereby rotating the plurality of upper shearing blades 118 and lower shearing blades 120 within the container 102 during the vertical movement of the elongated key shaft 116. In one embodiment herein, the elongated key shaft 116 having a supporting shaft at a bottom portion that allows to restrict the movement of the processed mixture within the container 102 upon deactivating the hydraulic cylinder 110. The supporting shaft is movably attached to the top die 146 of the molding unit 140 for compressing the molding unit 140.
[0065] In one embodiment herein, the top die 146 is flexibly positioned above the bottom die 142 via the spring cylinders 148, thereby allowing the processed mixture to be dispensed on the mold pattern 144 of the bottom die 142. The top die 146 is movably positioned on the bottom die 142 and is configured to be moved according to the movement of the elongated key shaft 116, thereby compressing the processed mixture within the mold pattern 144.
[0066] According to another exemplary embodiment of the invention, FIG. 3E refers to an isometric view of the molding unit 140 that is adapted to form the desired shape of the processed mixture. Referring to FIG. 3D, the processed mixture reaches the desired consistency as in a semi-solid state. Next, the user needs to control the vertical movement of the elongated key shaft 116 in the downward direction by the lever 156 that allows to close the outlet 106 of the container 102 and compresses the processed mixture into the desired molded shape with the top die 146. Next, the user needs to activate the heating element 145 to heat the mold pattern 144 at the selective temperature to solidify the desired molded shape within the molding unit 140.
[0067] In one example, the top die 146 is flexibly positioned above the bottom die 142 by using the spring cylinders 148, allowing the processed mixture to be dispensed on the mold pattern 144 of the bottom die 142. The top die 146 is movably positioned on the bottom die 142 and is configured to move in accordance with the movement of the elongated key shaft 116, thereby compressing the processed mixture inside the mold pattern 144.
[0068] Next, the user needs to operate the lever 156 to lift the elongated key shaft 116 in the upward direction that allows to release the pressure on the top die 146, which causes it to retract into an initial position for removing the desired shape of the rice husks from the molding unit 140. In one embodiment herein, the molded rice husk serves as eco-friendly alternatives to plastic for packaging materials, such as trays, or protective packaging inserts. The molded rice husk is used in the construction industry to create boards, panels, and bricks that are strong, lightweight, and have good insulation properties.
[0069] Additionally, the molded rice husk is used to manufacture eco-friendly furniture components, such as chair seats, table surfaces, or decorative items. The molded rice husk is used in the production of pots, planters, or trays for seedling cultivation, especially in sustainable farming practices. The molded rice husk is used to form biofuel briquettes or pellets, which are used as an alternative to traditional fuels for heating and cooking. Furthermore, the rice husk materials might be molded into everyday household items like plates, bowls, utensils, or even biodegradable containers for food storage.
[0070] According to another exemplary embodiment of the invention, FIG. 4 refers to a flowchart 400 of a method for operating the rice husk processing machine 100. At step 402, the user loads the rice husks into the container 102 through the inlet 104 and activates the driving unit 114 via the controller 158 by enabling the user interface 154 to rotate the elongated key shaft 116 in at least one direction. At step 404, the elongated key shaft 116 drives the planetary gear unit 124 to rotate the plurality of upper shearing blades 118 and lower shearing blades 120 at controlled speeds in the opposite directions, thereby creating the shearing action that optimizes a powdering process for powdering the rice husks.
[0071] At step 406, the user adjusts the rotational motion of the plurality of upper shearing blades 118 and lower shearing blades 120 via the user interface 154 to achieve the rice husk powder consistency, and adds the adhesive materials into the powdered rice husks via the inlet 104, thereby performing the mixing process for obtaining the processed mixture of the rice husks. At step 408, the controller 158 activates the hydraulic cylinder 110 to lift the elongated key shaft 116 selectively via the lever 156 that allows to open the outlet 106 of the container 102 for dispensing the processed mixture onto the mold pattern 144 of the molding unit 140.
[0072] At step step 410, the user controls the vertical movement of the key shaft 116 in the downward direction by the lever 156 that allows to close the outlet 106 of the container 102 and compresses the processed mixture with the top die 146 in order to create the desired molded shape. Further, at step 412, the controller 128 activates the heating element 145 to to heat the mold pattern 144 at a selectively temperature to form the desired molded shape within the molding unit 140.
[0073] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the rice husk processing machine 100 is disclosed. The proposed rice husk processing machine 100 eliminates the need for separate powdering, mixing, and moulding machines, reducing both initial capital investment and long-term operational costs. The proposed rice husk processing machine 100 requires a less floor space for installation, streamlines the workflow, leading to faster production cycles and reduced energy consumption. The proposed rice husk processing machine 100 minimizes the risk of contamination and allows for more consistent product quality.
[0074] The proposed rice husk processing machine 100 utilizes the user interface 154 to simplify the controlling to a semi-skilled person, thereby requiring less training and reducing the risk of operator error. The proposed rice husk processing machine 100 promotes sustainable production by utilizing rice husks as a waste product of rice milling, thereby reducing waste and contributing to a circular economy. The proposed rice husk processing machine 100 automates multiple steps, thereby reducing labor requirements and the need for manual handling. The proposed rice husk processing machine 100 integrated with the gear unit 124, efficiently handling multiple operation to ensure opposite rotation of the plurality of upper shearing blades 118 and lower shearing blades 120. The rice husk processing machine 100 utilizes the hydraulic cylinder 110 allow for precise control over the compression and shaping of the rice husk mixture, improving the final product's quality.
[0075] It will readily be apparent that numerous modifications and alterations can be made to the processes described in the foregoing examples without departing from the principles underlying the invention, and all such modifications and alterations are intended to be embraced by this application.
, Claims:CLAIMS:
I/We Claim:
1. A rice husk processing machine (100), comprising:
a container (102) having an inlet (104) for receiving rice husks and adhesive materials and an outlet (106) for dispensing a processed mixture;
an elongated key shaft (116) having a keyway vertically positioned within the container (102) at a center portion and extended through a bottom portion;
a driving unit (114) mounted on the container (102) at a top portion, wherein the driving unit (114) is configured to rotatably connect to the elongated key shaft (116) through a gear unit (112);
plurality of upper shearing blades (118) and lower shearing blades (120) mounted over the elongated key shaft (116) within the container (102), wherein the plurality of upper shearing blades (118) and lower shearing blades (120) are configured to connect to a planetary gear unit (124) mounted on the elongated key shaft (116) between the plurality of upper shearing blades (118) and lower shearing blades (120),
wherein the plurality of upper shearing blades (118) and lower shearing blades (120) are adapted to rotate at controlled speeds in opposite directions, thereby creating a shearing action that optimizes a powdering process for powdering the rice husks and a mixing process for obtaining the processed mixture of the rice husks and the adhesive materials;
a hydraulic cylinder (110) mounted over the elongated key shaft (116) at a top portion, wherein the hydraulic cylinder (110) is configured to enable downward and upward movements of the elongated key shaft (116), thereby allowing the outlet (106) of the container (102) to be closed and opened, respectively, upon actuation;
a molding unit (140) positioned beneath the container (102), wherein the molding unit (140) is configured to receive the processed mixture through the outlet (106) upon actuation of the hydraulic cylinder (110) and convert it into a desired molded shape, thereby performing a molding process; and
a controller (158) configured to receive one or more inputs from a user through a user interface (154) for controlling an operation of the rice husk processing machine (100) for performing the powdering process, the mixing process, and the molding process, respectively.
2. The rice husk processing machine (100) as claimed in claim 1, wherein the planetary gear unit (124) comprises:
a sun gear (130) rotatably connected to the elongated key shaft (116) through a bearing (134), wherein the sun gear (130) is connected to the plurality of lower shearing blades (120);
plurality of planet gears (132) rotatably connected to the sun gear (130), wherein the plurality of planet gears (132) is connected to the plurality of upper shearing blades (118) through connectors (136); and
a ring gear (126) affixed to an inner surface of the container (102) through connecting members (128).
3. The rice husk processing machine (100) as claimed in claim 1, wherein the holding frame (108) is mounted over the container (102), wherein the holding frame (108) is configured to support the hydraulic cylinder (110) and the gear unit (112).
4. The rice husk processing machine (100) as claimed in claim 1, wherein the upper shearing blade (118) having one or more holes (122) that adapted to secure movement of the plurality of planet gears (132) with the connectors (136).
5. The rice husk processing machine (100) as claimed in claim 1, wherein the container (102) is configured to be supported by plurality of supporting legs (103), which stabilizes the rice husk processing machine (100) during the powdering, mixing, and molding processes.
6. The rice husk processing machine (100) as claimed in claim 1, wherein the molding unit (140) comprises:
a top die (146) having a slot (147) for receiving the processed mixture from outlet (106) of the container (102) upon actuation of the hydraulic cylinder (110), thereby allowing the processed mixture to further process; and
a bottom die (142) with a mold pattern (144) movably coupled with the top die (146) via spring cylinders (148), wherein the mold pattern (144) is configured to receive the processed mixture from the slot (147) of the top die (146), thereby enabling the vertical movement of the elongated key shaft (116) for closing the outlet (106) and compressing the processed mixture with the top die (146) in order to create a desired molded shape.
7. The rice husk processing machine (100) as claimed in claim 1, wherein the bottom die (142) having a heating element (145) that is configured to heat the mold pattern (144) at a selectively temperature by the controller (158) to solidify the processed mixture during the molding process and facilitate removing of the desired molded shape from the bottom die (142).
8. The rice husk processing machine (100) as claimed in claim 1, wherein the spring cylinders (148) are positioned between the top die (146) and the bottom die (142), wherein the spring cylinders (148) are configured to provide vertical movement to the top die (146) for compressing the processed mixture upon actuation of the hydraulic cylinder (110).
9. The rice husk processing machine (100) as claimed in claim 1, wherein the gear unit (112) having a worm shaft (150) that is rotatably connected to the driving unit (114) and a spur gear (152) is securely coupled to the key shaft (116) that allows to receive the rotational motion from the worm shaft (150) to process the rice husks.
10. A method for operating a rice husk processing machine (100), comprising:
loading, by a user, rice husks into a container (102) through an inlet (104) and activating a driving unit (114) via a controller (158) by enabling a user interface (154) to rotate an elongated key shaft (116) in at least one direction;
driving, by the elongated key shaft (116), a planetary gear unit (124) to rotate plurality of upper shearing blades (118) and lower shearing blades (120) at controlled speeds in opposite directions, thereby creating a shearing action that optimizes a powdering process for powdering the rice husks;
adjusting, by the user, a rotational motion of the plurality of upper shearing blades (118) and lower shearing blades (120) via the user interface (154) to achieve rice husk powder consistency, and adding adhesive materials into the powdered rice husks via the inlet (104), thereby performing a mixing process for obtaining the processed mixture of the rice husks;
activating, by the controller (158), a hydraulic cylinder (110) to lift the elongated key shaft (116) selectively via a lever (156) that allows to open an outlet (106) of the container (102) for dispensing the processed mixture onto a mold pattern (144) of a molding unit (140);
controlling, by the user, the vertical movement of the key shaft (116) in a downward direction by the lever (156) that allows to close the outlet (106) of the container (102) and compressing the processed mixture with the top die (146) in order to create a desired molded shape; and
activating, by the controller (158), a heating element (145) to heat the mold pattern (144) at a selectively temperature to form the described molded shape within the molding unit (140).

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