An Automatic Sandbag Filling and Knotting Machine for Trucks and Method of Operating the Same

Abstract

ABSTRACT: Title: An Automatic Sandbag Filling and Knotting Machine for Trucks and Method of Operating the Same The present disclosure relates to an automatic sandbag filling and knotting machine (100) designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags. The automatic sandbag filling and knotting machine (100) comprises a mounting frame (102), a sandbag storage rack (106), a sandbag holding unit (108), a conveyor unit (112), a support flap (116), and a control unit (160). The automatic sandbag filling and knotting machine (100) enhances operational efficiency and enables effective allocation of resources during critical situations by streamlining workflows and minimizing reliance on human operators. The automatic sandbag filling and knotting machine (100) provides increased safety for operators by reducing physical strain and the risk of injury associated with manual handling, while ensuring consistent quality and reliability in sandbag production.

Specification

Description:DESCRIPTION:
Field of the invention:
[0001] The present invention relates to the technical field of sandbag filling and knotting systems, and more particularly relates to, an automatic sandbag filling and knotting machine designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags.
Background of the invention:
[0002] In recent years, the need for efficient sandbag filling solutions has become increasingly important, particularly in construction and flood prevention applications. The growing frequency and severity of natural disasters, alongside urban development projects, have heightened the demand for rapid and effective methods of sandbag deployment. Traditional sandbag filling machines have been developed to automate certain aspects of the filling process, ostensibly providing a solution to these pressing challenges.
[0003] However, many of these conventional machines still rely heavily on manual labour, undermining the core principle of automation and leading to inefficiencies that can delay critical responses during emergencies. Despite advancements in technology, the automation offered by these machines often falls short of fully alleviating the labour-intensive demands placed on operators.
[0004] Conventional sandbag filling devices typically require significant operator involvement, which limits their overall effectiveness and efficiency. For instance, most existing machines necessitate that workers manually place empty bags onto the filling apparatus, shovel sand into the machine, and subsequently stitch or seal the filled bags. This labour-intensive process often results in approximately 80% of the work being performed by human operators, with only 20% of the tasks automatic.
[0005] Furthermore, many machines marketed as automatic still depend on external equipment, such as excavators or loaders, to gather and transport sand to the filling unit. This reliance on additional machinery not only contradicts their claimed automation capabilities but also increases operational complexity and costs, ultimately reducing the intended benefits of such devices.
[0006] Prior art also includes accessories designed to enhance the functionality of existing filling machines, often requiring multiple workers to operate effectively and efficiently. For example, portable sandbag filling accessories, while intended to be more flexible and user-friendly, typically involve manual bag placement and still necessitate additional personnel for tasks such as bag fitting, sealing, and transporting filled bags to their intended locations. These existing solutions provide only partial automation and still depend on significant human intervention, thereby failing to achieve the desired efficiency and labour reduction. As a result, the burden on operators remains substantial, leading to potential delays in filling and deploying sandbags when time is of the essence.
[0007] Therefore, there is a need for an automatic sandbag filling and knotting machine designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags. There is also a need for an automatic sandbag filling and knotting machine that enhances operational efficiency and enables more effective allocation of resources during critical situations by streamlining workflows and minimizing reliance on human operators. Further, there is also a need for an automatic sandbag filling and knotting machine that provides increased safety for operators by reducing physical strain and the risk of injury associated with manual handling, while ensuring consistent quality and reliability in sandbag production to meet urgent demands in various applications.
Objectives of the invention:
[0008] The primary objective of the invention is to provide an automatic sandbag filling and knotting machine designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags.
[0009] Another objective of the invention is to provide an automatic sandbag filling and knotting machine that enhances operational efficiency by streamlining the workflows associated with sandbag loading, filling, and sealing, thereby allowing for a more effective allocation of resources during critical situations such as flood response or construction projects.
[0010] The other objective of the invention is to provide an automatic sandbag filling and knotting machine that minimizes reliance on human operators by automating key processes, thereby reducing the physical strain and risk of injury associated with manual handling and improving safety for operators.
[0011] The other objective of the invention is to provide an automatic sandbag filling and knotting machine that ensures consistent quality and reliability in the production of sandbags, thereby enabling rapid deployment in urgent applications while maintaining high standards for filled bags.
[0012] The other objective of the invention is to provide an automatic sandbag filling and knotting machine that can be operated effectively with minimal training and can be maintained without specialized skills, thus facilitating ease of use and maintenance.
[0013] Yet another objective of the invention is to provide an automatic sandbag filling and knotting machine that integrates advanced monitoring systems, which provide real-time feedback on the filling process, thereby allowing for adjustments to be made promptly to maintain accuracy and efficiency.
[0014] The further objective of the invention is to provide an automatic sandbag filling and knotting machine that provides a versatile and adaptable solution, which can accommodate various types and sizes of sandbags, thereby catering to different operational needs and requirements in diverse environments.
Summary of the invention:
[0015] The present disclosure proposes an automatic sandbag filling and knotting machine for trucks 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 or 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.
[0016] In order to overcome the deficiencies of the prior art, the present disclosure is to solve the technical problem of providing an automatic sandbag filling and knotting machine designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags.
[0017] According to one aspect, the invention discloses an automatic sandbag filling and knotting machine that enhances operational efficiency and enables more effective allocation of resources during critical situations by streamlining workflows and minimizing reliance on human operators. The automatic sandbag filling and knotting machine provides increased safety for operators by reducing physical strain and the risk of injury associated with manual handling, while ensuring consistent quality and reliability in sandbag production to meet urgent demands in various applications. In one embodiment herein, the automatic sandbag filling and knotting machine comprises a mounting frame, a sandbag storage rack, a sandbag holding unit, a conveyor unit, and a support flap.
[0018] In one embodiment herein, the mounting frame is mounted onto a side wall of the truck. The mounting frame includes a hopper that is configured to receive sand from the truck. The mounting frame comprises plurality of caster wheels configured to enable movement of the mounting frame along the side wall of the truck.
[0019] In one embodiment herein, the sandbag storage rack is securely affixed to the mounting frame. The sandbag storage rack is configured to hold a vertically aligned stack of sandbags, thereby facilitating sequential filling operations. The sandbag storage rack comprises a central support and at least two lateral supports that are positioned on opposite sides of the central support to maintain the stack of sandbags in an upright orientation. The central support extends toward the sandbag holding unit to guide the each sandbag into the sandbag holding unit for filling.
[0020] In one embodiment herein, the sandbag holding unit is securely attached to the mounting frame. The sandbag holding unit comprises plurality of jaws configured to grip each sandbag during the filling operation. Each jaw comprises a worm gear that is rotatably engaged with a main gear, which is rotatably connected to a first driving unit via an intermediate gear. The each worm gear is configured to rotate upon activation of the first driving unit, thereby moving the each jaw between a locked position and an unlocked position to hold and release the each sandbag.
[0021] In one embodiment herein, the conveyor unit is positioned adjacent to the mounting frame. The conveyor unit is configured to transport the sand from the truck to the hopper for sequential filling of the each sandbag. The conveyor unit comprises a drive roller that is rotatably connected to a second driving unit via a primary gear and a secondary gear. The drive roller is configured to rotate upon activation of the second driving unit.
[0022] In one embodiment herein, the conveyor unit also comprises a passive roller that is rotatably connected to the drive roller through a conveyor belt. The passive roller is configured to rotate in response to the rotation of the drive roller. The conveyor belt comprises plurality of protrusions along its length for effectively holding and transporting the sand to the hopper. The conveyor unit also comprises a pair of wheel supports with wheels that is securely affixed at both ends of the passive roller. The pair of wheel supports is configured to facilitate movement of the conveyor unit on the truck.
[0023] In one embodiment herein, the each sandbag comprises a rope element that is threaded through an opening around a perimeter of its mouth. The rope element is pre-configured with a noose-like knot that automatically tightens upon release of the filled sandbag. One end of the rope element is secured to a base of a subsequent sandbag in the stack of sandbags, thereby automatically positioning the subsequent sandbag for filling upon the release of the filled sandbag.
[0024] In one embodiment herein, the support flap is movably connected to a bottom of the mounting frame. The support flap is configured to transition between a support position that holds the each sandbag during filling and a release position that drops the each sandbag upon reaching a predetermined weight. The support flap comprises a semi-circular gear that is rotatably connected to a third driving unit via a transition gear. The semi-circular gear is configured to rotate the support flap between the support position and the release position upon activation of the third driving unit.
[0025] In one embodiment herein, the support flap includes at least two cutting blades that are positioned opposite each other. The at least two cutting blades are configured to sever the rope element between the dropped sandbag and the subsequent sandbag, thereby ensuring a smooth transition between the filling operations. In one embodiment herein, the support flap comprises a weight sensor that is configured to monitor the weight of the sandbag on the support flap and trigger the release of the filled sandbag upon reaching the predetermined weight.
[0026] In one embodiment herein, the automatic sandbag filling and knotting machine comprises a control unit that is configured to activate the first driving unit, the second driving unit, and the third driving unit to coordinate the operations of the filling, securing, and releasing the sandbags.
[0027] According to an aspect, a method is disclosed for operating the automatic sandbag filling and knotting machine. First, at one step, a user mounts the mounting frame of the automatic sandbag filling and knotting machine onto the side wall of a truck. The user vertically aligns the stack of sandbags on the sandbag storage rack and secures at least one sandbag within the sandbag holding unit using the plurality of jaws. At another step, the control unit activates the first driving unit to operate the conveyor unit to transport sand from the truck to the hopper affixed to the mounting frame.
[0028] At another step, the control unit activates the third driving unit to transition the support flap from the support position to the release position to drop the filled sandbag upon detecting the predetermined weight via the weight sensor, thereby enabling the knotting of the filled sandbag and positioning the subsequent sandbag into the sandbag holding unit. At another step, the control unit activates the second driving unit to secure the subsequent sandbag in the sandbag holding unit using the plurality of jaws.
[0029] Further, at another step, the control unit activates the third driving unit to rotate the support flap from the release position to the support position to sever the rope element between the dropped sandbag and the subsequent sandbag, thereby preparing the subsequent sandbag for next filling operation.
[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 a perspective view of an automatic sandbag filling and knotting machine, in accordance to an example embodiment of the invention.
[0033] FIG. 2 illustrates a perspective view of a mounting frame of the automatic sandbag filling and knotting machine, in accordance to an example embodiment of the invention.
[0034] FIG. 3 illustrates an exploded view of a sandbag holding unit of the automatic sandbag filling and knotting machine, in accordance to an example embodiment of the invention.
[0035] FIG. 4 illustrates an exploded view of a conveyor unit of the automatic sandbag filling and knotting machine, in accordance to an example embodiment of the invention.
[0036] FIG. 5 illustrates a perspective view of sandbags that are connected to one another, in accordance to an example embodiment of the invention.
[0037] FIG. 6 illustrates a perspective view of a support flap of the automatic sandbag filling and knotting machine, in accordance to an example embodiment of the invention.
[0038] FIG. 7 illustrates a perspective view of the automatic sandbag filling and knotting machine secured to the truck, in accordance to an example embodiment of the invention.
[0039] FIG. 8 illustrates a perspective view of the automatic sandbag filling and knotting machine depicting an operation of the conveyor unit, in accordance to an example embodiment of the invention.
[0040] FIG. 9 illustrates a perspective view of the automatic sandbag filling and knotting machine depicting the operations of the sandbag holding unit and the support flap, in accordance to an example embodiment of the invention.
[0041] FIG. 10 illustrates a perspective view of the automatic sandbag filling and knotting machine depicting knotting of a filled sandbag's mouth, in accordance to an example embodiment of the invention.
[0042] FIG. 11 illustrates a perspective view of the automatic sandbag filling and knotting machine depicting separation of the filled sandbag and subsequent sandbag, in accordance to an example embodiment of the invention.
[0043] FIG. 12 illustrates a flowchart of a method for operating the automatic sandbag filling and knotting machine, in accordance to an example embodiment of the invention.
Detailed invention disclosure:
[0044] Various embodiments of the present invention will be described with reference to the accompanying drawings. Wherever possible, the same or similar reference numerals are used in the drawings and the description to refer to the same or similar parts or steps.
[0045] 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 an automatic sandbag filling and knotting machine designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags.
[0046] According to an exemplary embodiment of the invention, FIG. 1 refers to a perspective view of an automatic sandbag filling and knotting machine 100. In one embodiment herein, the automatic sandbag filling and knotting machine 100 enhances operational efficiency and enables more effective allocation of resources during critical situations by streamlining workflows and minimizing reliance on human operators. The automatic sandbag filling and knotting machine 100 provides increased safety for operators by reducing physical strain and the risk of injury associated with manual handling, while ensuring consistent quality and reliability in sandbag production to meet urgent demands in various applications. The automatic sandbag filling and knotting machine 100 comprises a mounting frame 102, a sandbag storage rack 106, a sandbag holding unit 108, a conveyor unit 112, a support flap 116, and a control unit 160. In one embodiment herein, the mounting frame 102 is mounted onto a side wall of the truck 10 as shown in FIG. 7.
[0047] According to an exemplary embodiment of the invention, FIG. 2 refers to a perspective view of the mounting frame 102 of the automatic sandbag filling and knotting machine 100. In one embodiment herein, the mounting frame 102 is configured to serve as a robust and stable base for the automatic sandbag filling and knotting machine 100. The mounting frame 102 includes a hopper 104 that is configured to receive sand from the truck, thereby streamlining a sand loading process into the sandbag. The hopper 104 comprises a wide opening that ensures the sand is funneled into the automatic sandbag filling and knotting machine 100 efficiently, thereby preventing spillage and loss of material. Additionally, the mounting frame 102 may be equipped with plurality of caster wheels 150 to enable movement of the mounting frame 102 along the side wall of the truck 10.
[0048] In one embodiment herein, the sandbag storage rack 106 is securely affixed to the mounting frame 102. The sandbag storage rack 106 is configured to hold a vertically aligned stack of sandbags for efficient and sequential filling operations. The sandbags are stacked in such a manner that the lowest sandbag is always ready for filling, thereby eliminating the need for manual positioning. The sandbag storage rack 106 comprises a central support 120 and at least two lateral supports 122 that are positioned on opposite sides of the central support 120. The lateral supports 122 can maintain the vertical alignment of the sandbags and the central support 120 is extended toward the sandbag holding unit 108 for guiding the each sandbag into the sandbag holding unit 108 as needed.
[0049] According to an exemplary embodiment of the invention, FIG. 3 refers to an exploded view of the sandbag holding unit 108 of the automatic sandbag filling and knotting machine 100. In one embodiment herein, the sandbag holding unit 108 is securely affixed to the mounting frame 102. The sandbag holding unit 108 comprises plurality of jaws 110 configured to grip and hold the sandbags during the filling process. The jaws 110 are configured to transition between a locked position, in which they securely grip the sandbags, and an unlocked position, in which the sandbags are released after filling. Each jaw 110 is equipped with a worm gear 124 that is rotatably engaged with a centrally positioned main gear 126. The main gear 126 is operatively connected to a first driving unit 128 via an intermediate gear 130. Upon activation of the first driving unit 128, the worm gears 124 rotate, thereby causing the jaws 110 to move between the locked position and the unlocked position. By automating the gripping and releasing actions, the automatic sandbag filling and knotting machine 100 enhances operational efficiency, thus allowing for rapid, consistent sandbag production with minimal human effort.
[0050] According to an exemplary embodiment of the invention, FIG. 4 refers to an exploded view of the conveyor unit 112 of the automatic sandbag filling and knotting machine 100. In one embodiment herein, the conveyor unit 112 is positioned adjacent to the mounting frame 102 as shown in FIG. 1. The conveyor unit 112 is configured to transport the sand from the truck 10 to the hopper 104. The conveyor unit 112 is driven by a drive roller 132 connected to a second driving unit 134 via a primary gear 136 and a secondary gear 138. Upon activation, the drive roller 132 rotates to initiate the movement of the sand along the conveyor unit 112. The conveyor unit 112 is positioned to ensure the smooth and efficient transport of sand, thus significantly speeding up the filling operation by eliminating the need for manual shoveling.
[0051] In one embodiment herein, the conveyor unit 112 includes a passive roller 140, which works in conjunction with the drive roller 132. The passive roller 140 is configured to rotate in response to the rotation of the drive roller 132 through a conveyor belt 142 that connects the drive roller 132 and the passive roller 140. The conveyor belt 142 is equipped with plurality of protrusions 148 along its length. These protrusions 148 can capture and hold the sand securely as it is moved from the truck 10 to the hopper 104. This ensures that even small amounts of sand are efficiently transported without spilling, thereby improving the overall material handling. The conveyor unit 112 comprises at least two supporting members 149 positioned on opposite sides of the conveyor unit 112 to provide structural support and alignment. One end of each supporting member 149 is connected to the drive roller 132, while the other end is connected to the passive roller 140, thereby ensuring stability and proper tensioning of the conveyor belt 142. These supporting members 149 are precisely configured with a predetermined length to maintain consistent tension across the conveyor belt 142, thereby preventing slippage and ensuring smooth operation during the sand transport process.
[0052] In one embodiment herein, the conveyor unit 112 is equipped with a pair of wheel supports 144 at both ends of the passive roller 140 to further enhance the mobility of the automatic sandbag filling and knotting machine 100. These wheel supports 144 comprises wheels 146 that allow the conveyor unit 112 to be easily moved along the length of the truck 10, thereby ensuring that the sand can be fed into the hopper 104 from different points on the truck's load.
[0053] According to an exemplary embodiment of the invention, FIG. 5 refers to a perspective view of the sandbags that are connected to one another. In one embodiment herein, the each sandbag comprises a rope element 114 that is threaded through an opening around a perimeter of its mouth. This rope element 114 is pre-configured with a noose-like knot that automatically tightens when the filled sandbag is released from the jaws 110. One end of the rope element 114 is connected to a base of a subsequent sandbag in the stack, thereby ensuring that the subsequent sandbag is automatically pulled into position as soon as the filled bag is released. This automation eliminates the need for manual intervention to prepare each sandbag for filling, thus allowing the process to flow continuously and efficiently.
[0054] According to an exemplary embodiment of the invention, FIG. 6 refers to a perspective view of the support flap 116 of the automatic sandbag filling and knotting machine 100. In one embodiment herein, the support flap 116 is movably connected to a bottom of the mounting frame 102. The support flap 116 is configured to hold the sandbag during the filling process. The support flap 116 is also configured to move between a support position, where the sandbag is held securely, and a release position, where the filled sandbag is dropped. The movement of the support flap 116 is driven by a semi-circular gear 152 that is connected to a third driving unit 154 via a transition gear 156. Upon activation, the semi-circular gear rotates, thereby moving the support flap 116 between its support and release positions.
[0055] In one embodiment herein, the support flap 116 is equipped with at least two cutting blades 118, which are positioned opposite each other. These cutting blades 118 are configured to sever the rope element 114 between the filled sandbag and the subsequent sandbag. This ensures that each filled sandbag is cleanly separated from the next one, thereby allowing for a smooth transition between filling operations. In one embodiment herein, the support flap 116 includes a weight sensor 158 that continuously monitors the weight of the sandbag as it is being filled. Once the sandbag reaches a predetermined weight, the weight sensor 158 can trigger the release of the filled sandbag, thus dropping the filled sandbag and initiating the filling of the subsequent sandbag.
[0056] Referring to FIG. 1, the overall operation of the automatic sandbag filling and knotting machine 100 is controlled by the control unit 160. The control unit 160 is configured for activating and coordinating the first driving unit 128 for the jaws 110, the second driving unit 134 for the conveyor unit 112, and the third driving unit 154 for the support flap 116. The control unit 160 ensures a smooth and efficient operation by automating the entire sandbag filling, securing, and releasing operations, thus significantly reducing the manual labor and time required for sandbag deployment.
[0057] According to an exemplary embodiment of the invention, FIG. 7 refers to a perspective view of the automatic sandbag filling and knotting machine 100 secured to the truck 10. In one embodiment herein, a step-by-step process is disclosed for operating the automatic sandbag filling and knotting machine 100. The process begins by positioning the truck 10 at a designated location and the automatic sandbag filling and knotting machine 100 is secured to the truck 10 by mounting the mounting frame 102 onto the side wall of the truck 10. Once the automatic sandbag filling and knotting machine 100 is properly set, the user manually positions the first sandbag from the vertically aligned stack into the sandbag holding unit 108 for filling. The sandbag is automatically gripped and held securely in place via the jaws 110 of the sandbag holding unit 108, thus ensuring it is ready for the filling operation.
[0058] According to an exemplary embodiment of the invention, FIG. 8 refers to a perspective view of the automatic sandbag filling and knotting machine 100 depicting the operation of the conveyor unit 112. In one embodiment herein, after securing the first sandbag in the sandbag holding unit 108, the user activates the automatic sandbag filling and knotting machine 100 via the control unit 160, which triggers the second driving unit 134. Upon activation, the primary gear 136 connected to the second driving unit 134 rotates, which in turn rotates the secondary gear 138, thereby leading to the rotation of the drive roller 132. This movement drives the passive roller 140 through the conveyor belt 142, thus creating a continuous rotational motion of the conveyor unit 112. As the conveyor unit 112 begins its operation, the user loads the sand from the truck 10 onto the conveyor belt 142. The protrusions 148 along the conveyor belt 142 effectively transport the sand from the truck 10 to the hopper 104, where it is dispensed into the sandbags, one at a time.
[0059] According to an exemplary embodiment of the invention, FIG. 9 refers to a perspective view of the automatic sandbag filling and knotting machine 100 depicting the operations of the sandbag holding unit 108 and the support flap 116. In one embodiment herein, the sand flows from the hopper 104 into the secured sandbag, and the weight sensor 158 monitors the sandbag's weight, thereby ensuring the sandbag is filled to the predetermined amount. This automatic process eliminates the need for manual intervention and ensures smooth, continuous operation. Once the sandbag reaches the desired weight, the weight sensor 158 sends signals to the control unit 160. The control unit 160 then operates the first driving unit 128 to rotate the intermediate gear 130, which in turn rotates the main gear 126. The rotation of the main gear 126 activates the worm gears 124, thereby causing them to rotate. As the worm gears 124 rotate, the jaws 110 transition from the locked position to the unlocked position for releasing the filled sandbag.
[0060] Simultaneously, the control unit 160 operates the third driving unit 154, which rotates the transition gear 156 connected to it. The rotation of the transition gear 156 drives the semi-circular gear 152, thereby causing the support flap 116 to move to the release position. This movement allows the filled sandbag to drop from the automatic sandbag filling and knotting machine 100.
[0061] According to an exemplary embodiment of the invention, FIG. 10 refers to a perspective view of the automatic sandbag filling and knotting machine 100 depicting the knotting of the filled sandbag's mouth. In one embodiment herein, when the filled sandbag is released, the rope element 114 automatically tightens around the sandbag's mouth, thus securing the sand inside with the noose-like knot. This automatic tightening ensures the sandbag is properly sealed and ready for transport or deployment. Upon releasing the filled sandbag, the subsequent sandbag in the stack is automatically pulled into the sandbag holding unit 108 for filling. This smooth transition occurs as the rope element 114 is connected between the filled sandbag and the subsequent sandbag in the stack.
[0062] When the filled sandbag drops, the tension in the rope element 114 pulls the subsequent sandbag into place. Once the subsequent sandbag is in position within the sandbag holding unit 108, the control unit 160 activates the first driving unit 128 to rotate the intermediate gear 130 in the opposite direction, thereby rotating the main gear 126 and the corresponding worm gears 124. This action moves the jaws 110 back to the locked position for securely gripping the subsequent sandbag for the next filling operation.
[0063] According to an exemplary embodiment of the invention, FIG. 11 refers to a perspective view of the automatic sandbag filling and knotting machine 100 depicting the separation of the filled sandbag and the subsequent sandbag. In one embodiment herein, the control unit 160 operates the third driving unit 154 to rotate the transition gear 156 in the opposite direction, thereby causing the semi-circular gear 152 to move the support flap 116 back to the support position. As the support flap 116 moves, the cutting blades 118 positioned on the support flap 116 sever the rope element 114 between the released sandbag and the subsequent sandbag, thus ensuring the each sandbag is individually sealed and detached. This automatic process allows for the continuous and uninterrupted filling and knotting of sandbags without requiring manual effort between cycles.
[0064] The automatic sandbag filling and knotting machine 100 operates in a repetitive cycle where, upon the release of one sandbag, the next sandbag is immediately positioned, filled, and sealed. This process continues until all the sandbags in the stack have been filled. The user can preset the automatic sandbag filling and knotting machine 100 to stop after a predetermined number of sandbags or when the required quantity of filled bags has been reached. The automatic sandbag filling and knotting machine 100 can be manually controlled or programmed for fully automatic operation, thereby making it adaptable to different operational requirements and enabling fast and efficient sandbag production.
[0065] According to an exemplary embodiment of the invention, FIG. 12 refers to a flowchart 1200 of a method for operating the automatic sandbag filling and knotting machine 100. First, at step 1202, a user mounts the mounting frame 102 of the automatic sandbag filling and knotting machine 100 onto the side wall of a truck 10. At step 1204, the user vertically aligns the stack of sandbags on the sandbag storage rack 106 and secures at least one sandbag within the sandbag holding unit 108 using the plurality of jaws 110. At step 1206, the control unit 160 activates the first driving unit 128 to operate the conveyor unit 112 to transport sand from the truck 10 to the hopper 104 affixed to the mounting frame 102.
[0066] At step 1208, the control unit 160 activates the third driving unit 154 to transition the support flap 116 from the support position to the release position to drop the filled sandbag upon detecting the predetermined weight via the weight sensor 158, thereby enabling the knotting of the filled sandbag and positioning the subsequent sandbag into the sandbag holding unit 108. At step 1210, the control unit 160 activates the second driving unit 134 to secure the subsequent sandbag in the sandbag holding unit 108 using the plurality of jaws 110. Further, at step 1212, the control unit 160 activates the third driving unit 154 to rotate the support flap 116 from the release position to the support position to sever the rope element 114 between the dropped sandbag and the subsequent sandbag, thereby preparing the subsequent sandbag for next filling operation.
[0067] The advantages of the present disclosure are evident from the discussion above. The The automatic sandbag filling and knotting machine 100 designed for trucks, which significantly reduces manual labour and operational time by fully automating the loading, filling, and sealing processes of sandbags. The automatic sandbag filling and knotting machine 100 enhances operational efficiency by streamlining the workflows associated with sandbag loading, filling, and sealing, thereby allowing for a more effective allocation of resources during critical situations such as flood response or construction projects. The automatic sandbag filling and knotting machine 100 minimizes reliance on human operators by automating key processes, thereby reducing the physical strain and risk of injury associated with manual handling and improving safety for operators.
[0068] The automatic sandbag filling and knotting machine 100 ensures consistent quality and reliability in the production of sandbags, thereby enabling rapid deployment in urgent applications while maintaining high standards for filled bags. The automatic sandbag filling and knotting machine 100 can be operated effectively with minimal training and can be maintained without specialized skills, thus facilitating ease of use and maintenance. The automatic sandbag filling and knotting machine 100 integrates advanced monitoring systems, which provide real-time feedback on the filling process, thereby allowing for adjustments to be made promptly to maintain accuracy and efficiency. The automatic sandbag filling and knotting machine 100 provides a versatile and adaptable solution, which can accommodate various types and sizes of sandbags, thereby catering to different operational needs and requirements in diverse environments.
[0069] 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. An automatic sandbag filling and knotting machine (100) for trucks (10), comprising:
a mounting frame (102) configured to mount on a side wall of a truck (10);
a hopper (104) affixed to the mounting frame (102), wherein the hopper (104) is configured to receive sand from the truck (10);
a sandbag storage rack (106) securely affixed to the mounting frame (102), wherein the sandbag storage rack (106) is configured to hold a vertically aligned stack of sandbags, thereby facilitating sequential filling operations;
a sandbag holding unit (108) securely attached to the mounting frame (102), wherein the sandbag holding unit (108) comprises plurality of jaws (110) that is configured to move between a locked position and an unlocked position for gripping and releasing each of the sandbag;
a conveyor unit (112) positioned adjacent to the mounting frame (102), wherein the conveyor unit (112) is configured to transport the sand from the truck (10) to the hopper (104) for sequential filling of each of the sandbag,
wherein each of the sandbag comprises a rope element (114) threaded through an opening around a perimeter of its mouth, wherein the rope element (114) is pre-configured with a noose-like knot that automatically tightens upon release of the filled sandbag,
wherein one end of the rope element (114) is secured to a base of a subsequent sandbag in the stack of sandbags, thereby automatically positioning the subsequent sandbag for filling upon the release of the filled sandbag; and
a support flap (116) movably connected to a bottom of the mounting frame (102), wherein the support flap (116) is configured to transition between a support position that holds the each sandbag during filling and a release position that drops the each sandbag upon reaching a predetermined weight,
wherein the support flap (116) includes at least two cutting blades (118) that are positioned opposite each other, wherein the at least two cutting blades (118) are configured to sever the rope element (114) between the dropped sandbag and the subsequent sandbag, thereby eliminating manual handling.
2. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein the sandbag storage rack (106) comprises a central support (120) and at least two lateral supports (122) that are positioned on opposite sides of the central support (120) to maintain the stack of sandbags in an upright orientation, wherein the central support (120) is configured to extend toward the sandbag holding unit (108) to guide the each sandbag into the sandbag holding unit (108) for filling.
3. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein each jaw (110) comprises a worm gear (124) that is rotatably engaged with a main gear (126), which is rotatably connected to a first driving unit (128) via an intermediate gear (130), wherein the each worm gear (124) is configured to rotate upon activation of the first driving unit (128), thereby moving the each jaw (110) between the locked position and the unlocked position to hold and release the each sandbag.
4. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein the conveyor unit (112) comprises:
a drive roller (132) rotatably connected to a second driving unit (134) via a primary gear (136) and a secondary gear (138), wherein the drive roller (132) is configured to rotate upon activation of the second driving unit (134);
a passive roller (140) rotatably connected to the drive roller (132) through a conveyor belt (142), wherein the passive roller (140) is configured to rotate in response to the rotation of the drive roller (132); and
a pair of wheel supports (144) having wheels (146) securely affixed at both ends of the passive roller (140), wherein the pair of wheel supports (144) is configured to facilitate movement of the conveyor unit (112) on the truck (10).
5. The automatic sandbag filling and knotting machine (100) as claimed in claim 4, wherein the conveyor belt (142) comprises plurality of protrusions (148) along its length for effectively holding and transporting the sand to the hopper (104).
6. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein the mounting frame (102) comprises plurality of caster wheels (150) configured to enable movement of the mounting frame (102) along the side wall of the truck (10).
7. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein the support flap (116) comprises a semi-circular gear (152) that is rotatably connected to a third driving unit (154) via a transition gear (156), wherein the semi-circular gear (152) is configured to rotate the support flap (116) between the support position and the release position upon activation of the third driving unit (154).
8. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein the support flap (116) comprises a weight sensor (158) that is configured to monitor the weight of the sandbag on the support flap (116) and trigger the release of the filled sandbag upon reaching the predetermined weight.
9. The automatic sandbag filling and knotting machine (100) as claimed in claim 1, wherein the automatic sandbag filling and knotting machine (100) comprises a control unit (160) that is configured to activate the first driving unit (128), the second driving unit (134), and the third driving unit (154) to coordinate the operations of the filling, securing, and releasing the sandbags.
10. A method of operating the automatic sandbag filling and knotting machine (100), comprising:
mounting, by a user, a mounting frame (102) of the automatic sandbag filling and knotting machine (100) onto a side wall of a truck (10);
vertically aligning, by the user, a stack of sandbags on a sandbag storage rack (106) and securing at least one sandbag within a sandbag holding unit (108) using plurality of jaws (110);
activating, by a control unit (160), a first driving unit (128) to operate a conveyor unit (112) to transport sand from the truck (10) to a hopper (104) affixed to the mounting frame (102);
activating, by the control unit (160), a third driving unit (154) to transition a support flap (116) from a support position to a release position to drop the filled sandbag upon detecting a predetermined weight via a weight sensor (158), thereby enabling the knotting of the filled sandbag and positioning a subsequent sandbag into the sandbag holding unit (108);
activating, by the control unit (160), a second driving unit (134) to secure the subsequent sandbag in the sandbag holding unit (108) using the plurality of jaws (110); and
activating, by the control unit (160), the third driving unit (154) to rotate the support flap (116) from the release position to the support position to sever a rope element (114) between the dropped sandbag and the subsequent sandbag, thereby preparing the subsequent sandbag for next filling operation.

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