AUTOMATED BRICK MANUFACTURING DEVICE

Abstract

An automated brick manufacturing device, comprising a platform 1 positioned on a fixed surface by means of multiple suction cups 2, a display panel 3 for receiving input, a chamber 4 for storing sand, a linear actuator 5 connected to a plate 6 to transfer an appropriate quantity of the sand into a container 7 arranged on the platform 1, an imaging unit 9 installed on the platform 1 to determine presence of debris on the sheet 8, multiple nozzles 10 arranged in the container 7 for dispensing water in the container 7, a stirrer 11 installed in the container 7 for mixing the dispensed water and sand, two sliding units 15 to provide upward translation to a plank 14 for removing structure from a tray 12, an inverted U-shaped frame 17 equipped with multiple metallic strings 18 arranged on the platform 1 to cut the structure into the bricks.

Specification

Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated brick manufacturing device which is capable of manufacturing bricks in automatic manner according to user-desired number of bricks by taking appropriate amount of sand and water and also helps in removing the debris present in the mixture used to prepare the brick to manufacture proper bricks.

BACKGROUND OF THE INVENTION

[0002] Bricks were commonly used by people in construction, as they give a strong foundation to the structure of the building. People use to manufacture bricks manually via using some handheld tools like brick press as this is a tool that is specifically designed for compressing and shaping clay into bricks with consistent size and density. However, the tool is labor-intensive as well as are limited to precision. So, people use an equipment that manufactures the brick in an automated manner, thus saves time as well as manual efforts of the person in the overall process.

[0003] Conventionally, some ways were used by people for carrying out manufacturing of bricks. People use to manufacture bricks manually via using some handheld tools like brick press as this is a tool that is specifically designed for compressing and shaping clay into bricks with consistent size and density. However, the tool is labor-intensive as well as are limited to precision. Therefore, they also use some machines like brick production machine, for manufacturing desired number of bricks. But these machines needs maintenance as well as a skilled worker is required for operating such machines efficiently.

[0004] CN210233403U discloses about an invention that includes a brick making machine, which comprises a brick pressing device, a material distributing device, a discharging device, a stacking device, a circulating device and a control system; the utility model discloses a brickmaking machine mould can customize and change as required, adopts circulating device, and degree of automation is high.

[0005] CN103570299A discloses about an invention that includes a production method of bricks. The production method of bricks comprises the following steps, preparing equipment and materials, stirring and mixing the materials, forming bricks, curing the bricks; and detecting and drying the bricks. The production method of bricks provided by the invention has the advantages that a computer is adopted to automatically control the procedures of weighing, mixing, stirring and compression molding, and the productive process is automated, so that the time is saved, and the production efficiency is high; when the bricks are subjected to steam curing, solar energy is utilized to heat hot water, and thus a fuel is saved; the steam curing and the productive process of bricks do not generate waste water, exhaust gas and waste residue, the energy is saved, and the production method has an environment-friendly effect.

[0006] Conventionally, many devices have been developed that are capable of carrying out manufacturing of bricks. However, these devices are incapable of manufacturing bricks in user-desired number of bricks and fails to achieve high precision in the overall process. Additionally, these existing devices also lack in determining the presence of any debris in the mixture of sand and water which is used to prepare the brick and are insufficient in removing the debris to prepare a solid brick with no presence of debris.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of performing manufacturing of bricks in an automated manner, thereby achieve high precision in the overall process. In addition, the developed device should also determine the presence of any debris in the mixture of sand and water used to prepare the brick and accordingly remove the debris to prepare a solid brick with no presence of debris.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device which is capable of manufacturing bricks in automatic manner according to user-desired number of bricks in order to achieve high precision.

[0010] Another object of the present invention is to develop a device which is capable of determining the appropriate amount of water and sand required to manufacture a proper brick to reduce the wastage of resources.

[0011] Yet another object of the present invention is to develop a device which is capable of determining the presence of any debris in the mixture of sand and water used to prepare the brick and accordingly remove the debris to prepare a solid brick with no presence of debris.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to an automated brick manufacturing device that is capable of providing a means for carrying out manufacturing of bricks in a self-sufficient manner, thereby reduces manual efforts as well as consumption of time of the user in the overall process. Additionally, the proposed device also determines the appropriate amount of water and sand required to manufacture a proper brick to reduce the wastage of resources.

[0014] According to an embodiment of the present invention, an automated brick manufacturing device comprises of, a platform developed to be positioned on a fixed surface, plurality of suction cups is arranged underneath the platform to adhere to the surface for securing the platform on the surface, a touch interactive display panel installed on the platform for enabling a user to provide input specifications regarding a user-desired number of bricks, a chamber is arranged on the platform for storing sand and configured with a linear actuator connected to a plate, to extend/retract for providing a pushing force on the plate to transfer an appropriate quantity of the sand into a container arranged on the platform and configured with a meshed on top portion, an artificial intelligence-based imaging unit installed on the platform to determine presence of debris on the sheet, a vibration unit integrated with the sheet to produce vibrational sensations for filtering out the debris from the sand, wherein the filtered sand is collected in the container, plurality of electronically controlled nozzles arranged in the container for dispensing an appropriate quantity of water from a vessel configured with the container, in the container, a motorized stirrer installed in the container to rotate for mixing the dispensed water and sand in view of obtaining an optimally consistent mixture, and a motorized hinge joint integrated in between the container and the platform for tilting the container to pour the mixture in a tray arranged on the platform.

[0015] According to another embodiment of the present invention, the proposed device further comprises of, a motorized flap is integrated on the tray to get closed for covering the poured mixture, in view of allowing settling of the mixture to form a semi-solid structure, to get opened, a plank arranged on bottom portion of the tray by means of a pair of motorized sliding units to provide upward translation to the plank for removing the structure from the tray, an extendable rod is integrated in between the plank and one of the sliding unit for tilting the plank in view of positioning the structure on a conveyer belt integrated on the platform, an inverted U-shaped frame arranged on the platform for assembling plurality of metallic strings, to move the structure underneath the frame, a motorized ball and socket joint integrated in between the platform and one end of the frame to provide required movement to the frame, which in turn moves the strings through the structure, for cutting the structure into sections, thereby allowing the user to collect the user-specified number of bricks, a tactile sensor is embedded on the container for monitoring consistency of the mixture, a weight sensor is embedded in the container to measure weight of the transferred sand, and a battery is configured with the device for providing a continuous power supply to electronically powered components associated with the device.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of an automated brick manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises," and the like (which are synonymous with "including," "having" and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms "a," "an," and "the" designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to an automated brick manufacturing device that is capable of performing manufacturing of bricks in an automated manner, thereby achieve high precision in the overall process. In addition, the proposed device should determine the presence of any debris in the mixture of sand and water used to prepare the brick and accordingly remove the debris to prepare a solid brick with no presence of debris.

[0022] Referring to Figure 1, an isometric view of an automated brick manufacturing device is illustrated, comprising a platform 1 positioned on a fixed surface, plurality of suction cups 2 arranged underneath the platform 1, a touch interactive display panel 3 installed on the platform 1, a chamber 4 arranged on the platform 1, a linear actuator 5 connected to a plate 6 configured on the chamber 4, a container 7 configured with a meshed sheet 8 on top portion arranged on the platform 1, an imaging unit 9 installed on the platform 1, multiple nozzles 10 arranged in the container 7, a stirrer 11 installed in the container 7, a tray 12 arranged on the platform 1, a motorized flap 13 integrated on the tray 12, a plank 14 arranged on bottom portion of the tray 12 by means of a pair of motorized sliding units 15, a conveyer belt 16 integrated on the platform 1, an inverted U-shaped frame 17 arranged on the platform 1 with multiple metallic strings 18.

[0023] The proposed device comprises of a platform 1 developed to be positioned on a fixed surface. The platform 1 is made up of material not restricted to wood, metal etc. that provides durability to the components and comfortably accommodate all the components required to perform the specified operation. Additionally, multiple suction cups 2 are arranged underneath the platform 1 to adhere to the surface for securing the platform 1 on the surface.

[0024] The suction cups 2 use the atmospheric pressure to vacuum and hold the platform 1 at one place on the surface of the front bumper. The suction cups 2 are consisting of a circular disc which are made of a flexible material mostly rubber with a rounded edge, whenever the pressure is applied by the concerned person in the center of the disc, a concave shape is generated and when the cups is forced against the bumper's surface, a vacuum is created in the cups which causes the cups to stick strongly with the surface for securing the platform 1 on the surface.

[0025] Upon securing the platform 1 on the surface, a touch interactive display panel 3 is installed on the platform 1 for enabling a user to provide input specifications regarding a user-desired number of bricks. The touch interactive display panel 3 mapped herein consists of multiple tiny electrically active wires. When user touch the options illustrated over the display panel 3, the wires are pressed together and circuit is completed. Which results in flow of voltages across the circuit. This voltage flow is detected by an inbuilt microcontroller in form of electric signals. Further the signals are processed by the microcontroller to determine the user's input regarding the user-desired number of bricks.

[0026] Further, a chamber 4 is arranged on the platform 1 for storing sand and configured with a linear actuator 5 connected to a plate 6. The linear actuator 5 is actuated by the microcontroller to extend/retract for providing a pushing force on the plate 6 to transfer an appropriate quantity of the sand into a container 7 arranged on the platform 1 and configured with a meshed on top portion. The linear actuator 5 converts the rotational motion into linear motion (in a straight line). The linear actuator 5 involves lead screw's threads that act as a continuous ramp which allows a small rotating force to be applied over a long distance to move a large load over a short distance, wherein the actuator has a switch to reverse the polarity of the motor which makes the actuator change its motion and the linear actuator 5 applies the pushing force on the plate 6 and transfers the appropriate quantity of the sand into the container 7.

[0027] Simultaneously, a weight sensor is embedded in the container 7 to measure weight of the transferred sand. The weight sensor comprises of a convoluted diaphragm and a sensing module. Due to the weight of transferred sand in the chamber 4, the size of the diaphragm changes which is detected by the sensing module. The sensing module detects the deformation and on the basis of the changes in sizes of the diaphragm, the acquired data is forwarded to the microcontroller in the form of a signal for further processing. The microcontroller upon processing the acquired data detects the weight of transferred sand. Based on this, the microcontroller regulates actuation of the linear actuator 5 transfers the appropriate quantity of the sand into the container 7.

[0028] After transferring the appropriate quantity of the sand into the container 7, an artificial intelligence-based imaging unit 9 installed on the platform 1 and paired with a processor starts capturing and processing multiple images in vicinity of the platform 1 to determine presence of debris on the sheet 8. The artificial intelligence-based imaging unit 9 used herein incorporates AI protocols to enhance its functionality and capabilities to enables immediate responses and faster decision-making. The imaging unit 9 captures images or records videos n vicinity of the platform 1 by the help of specialized lenses. The captured data is pre-processed and is fed into AI protocols for analysis which utilizes machine learning techniques, such as deep learning neural networks, to extract meaningful information from the visual data. This acquired data is processed by the processor and then the microcontroller analysed the processed data to determine presence of debris on the sheet 8.

[0029] Based on the presence of debris on the sheet 8, the microcontroller actuates a vibration unit integrated with the sheet 8 to produce vibrational sensations for filtering out the debris from the sand. The vibration unit consists of a motor that is not correctly balanced. This force causes the motor to shake due to its high-speed dislocation that gets regulated by the microcontroller. The attached weight mass, the distance to the shaft, and the speed at which the spinning of the motor gets adjusted. The centrifugal force created by the uneven weight rotation causes the engine to throb in two axes and generates the vibrational sensations in the sheet 8 that further filters out the debris from the sand, wherein the filtered sand is collected in the container 7.

[0030] Upon collecting the filtered sand in the container 7, multiple electronically controlled nozzles 10 arranged in the container 7 are actuated by the microcontroller for dispensing an appropriate quantity of water from a vessel configured with the container 7, in the container 7. The electronic nozzle is a pipe or tube of varying cross sectional area that is used to direct or modify the flow of a fluid. The nozzle works by converting the pressure energy of a water into kinetic energy by the help of electrical energy, which increases the water's velocity and thus dispensed the appropriate quantity of water from a vessel in the container 7.

[0031] Before actuating the nozzle, a tactile sensor is embedded on the container 7 for monitoring consistency of the mixture. The tactile sensor determined the consistency of the mixture by assessing the pressure exerted on sensing elements upon coming in contact with the area. The degree of deformation in these elements corresponds to the consistency of the mixture and converts this deformation data in signal form. The tactile sensor sends the deformation data in signal form to the microcontroller. the microcontroller processes the acquired data and determines the consistency of the mixture. Based on this, the microcontroller regulates actuation of the nozzles 10 to dispense the appropriate quantity of water from a vessel in the container 7.

[0032] After dispensing the appropriate quantity of water in the container 7, a motorized stirrer 11 is installed in the container 7 that is actuated by the microcontroller to rotate for mixing the dispensed water and sand in view of obtaining an optimally consistent mixture. The stirrer 11 is connected to a bi-directional direct current motor that is capable of converting direct current into mechanical work by following the principle of Lorentz Law which states that, the current carrying conduction when placed in magnetic or electrical field experiences a force. Such that, the motor converts the electrical current derived from an external source into a mechanical torque for providing the required power to the stirrer 11 for stirring the sand with water in view of obtaining the optimally consistent mixture.

[0033] Thereafter, a motorized hinge joint is integrated in between the container 7 and the platform 1 for tilting the container 7 to pour the mixture in a tray 12 arranged on the platform 1. The motorized hinge joint comprises of a pair of leaf that is screwed with the surfaces of the container 7 and the platform 1. The leafs are connected with each other by means of a cylindrical member integrated with a shaft coupled with a DC (Direct Current) motor to provide required movement to the hinge. The rotation of the shaft in clockwise and anti-clockwise aids in opening and closing of the hinge respectively. Hence the microcontroller actuates the hinge that in turn tilted the container 7 to pour the mixture in the tray 12.

[0034] In synchronous to this, the microcontroller actuates a motorized flap 13 integrated on the tray 12 to get closed for covering the poured mixture, in view of allowing settling of the mixture to form a semi-solid structure. The flap 13 is powered by the same DC motor with which the stirrer 11 works. Thus, upon getting actuation command from the microcontroller, the DC motor starts rotating in clockwise and anticlockwise direction and provides the required movement to the flap 13 s. Hence, the flap 13 s by getting power from the motor get closed for covering the poured mixture, in view of allowing settling of the mixture to form a semi-solid structure, followed by actuation of the flap 13 to get opened after semi-solid structure is formed.

[0035] Furthermore, a plank 14 is arranged on bottom portion of the tray 12 by means of a pair of motorized sliding units 15 that is actuated by the microcontroller to provide upward translation to the plank 14 for removing the structure from the tray 12. The sliding units 15 consists of a pair of sliding rail fabricated with grooves in which the wheel of a slider is positioned that is further connected with a bi-directional motor via a shaft. The microcontroller actuates the bi-directional motor to rotate in clockwise and anti-clockwise direction that aids in rotation of shaft, wherein the shaft converts the electrical energy into rotational energy for allowing movement of the wheel to translate over the sliding rail by a firm grip on the grooves. The movement of the slider provides the upward translation to the plank 14 for removing the structure from the tray 12.

[0036] Additionally, an extendable rod is integrated in between the plank 14 and one of the sliding unit for tilting the plank 14 in view of positioning the structure on a conveyer belt 16 integrated on the platform 1. The rod is powered by a pneumatic unit which includes an air compressor, air cylinder, air valves and piston. The air compressor used herein extract the air from surrounding and increases the pressure of the air by reducing the volume of the air. The air compressor draws atmospheric air and compress to elevated pressure. The compressed air is then sent through a discharge tube into the cylinder across the valve. The compressed air in the cylinder tends to pushes out the piston to extend which extends the rod for tilting the plank 14 for positioning the structure on the conveyer belt 16.

[0037] Upon positioning the structure on the conveyer belt 16, an inverted U-shaped frame 17 is arranged on the platform 1 for assembling plurality of metallic strings 18. Herein, the microcontroller actuates the conveyer belt 16 to move the structure underneath the frame. The conveyer belt 16 consists of a belt stretched across two or more pulleys in close loop and one of the pulley is attached with a driven motor that is interlinked with the microcontroller. On actuation, the driven motor rotates the pulley which in turn results that the primary conveyer belt 16 also rotates that leads to translates the structure underneath the frame.

[0038] This is followed by actuation of a motorized ball and socket joint integrated in between the platform 1 and one end of the frame to provide required movement to the frame, which in turn moves the strings 18 through the structure for cutting the structure into sections. The ball and socket joint provides a rotation to the frame to turn at a desired angle. The ball and socket joint is a coupling consisting of a ball joint securely locked within a socket joint, where the ball joint is able to move in a 360-dgree rotation within the socket thus, providing the required rotational motion to the frame. The ball and socket joint is powered by a DC (direct current) motor that is actuated by the microcontroller thus providing multidirectional movement frame that moves the strings 18 through the structure for cutting the structure into sections, thereby allowing the user to collect the user-specified number of bricks.

[0039] In last, a battery is associated with the device to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrodes named as a cathode and an anode. The battery uses a chemical reaction of oxidation/reduction to do work on charge and produce a voltage between their anode and cathode and thus produces electrical energy that is used to do work in the device.

[0040] The present invention works best in the following manner, where the platform 1 as disclosed in the invention is positioned on the fixed surface by means of multiple suction cups 2. Upon positioning the platform 1 on the surface, the user accessed the touch interactive display panel 3 to provide input specifications regarding the user-desired number of bricks. Then, the linear actuator 5 is actuated by the microcontroller to extend/retract for providing the pushing force on the plate 6 to transfer the appropriate quantity of the sand detected by the weight sensor into the container 7. After transferring the sand into the container 7, the imaging unit 9 captures and processes multiple images in vicinity of the platform 1 to determine presence of debris on the sheet 8. Based on this, the microcontroller actuates the vibration unit to produce vibrational sensations for filtering out the debris from the sand, wherein the filtered sand is collected in the container 7. then, the tactile sensor monitors the consistency of the mixture. Based on this, the microcontroller regulates actuation of the nozzles 10 for dispensing the appropriate quantity of water from the vessel into the container 7. upon dispensing the water, the motorized stirrer 11 is actuated by the microcontroller to rotate for mixing the dispensed water and sand in view of obtaining an optimally consistent mixture. Thereafter, the motorized hinge joint tilts the container 7 to pour the mixture in the tray 12. Then, the motorized flap 13 is actuated by the microcontroller to get closed for covering the poured mixture, in view of allowing settling of the mixture to form a semi-solid structure, followed by actuation of the flap 13 to get opened. Further, the pair of motorized sliding units 15 are actuated by the microcontroller to provide upward translation to the plank 14 for removing the structure from the tray 12, wherein the extendable rod tilts the plank 14 in view of positioning the structure on the conveyer belt 16. In synchronous to this, the microcontroller actuates the conveyer belt 16 to move the structure underneath the frame. This is followed by actuation of the motorized ball and socket joint to provide required movement to the frame, which in turn moves the strings 18 through the structure, for cutting the structure into sections, thereby allowing the user to collect the user-specified number of bricks.

[0041] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) An automated brick manufacturing device, comprising:

i) a platform 1 developed to be positioned on a fixed surface, wherein plurality of suction cups 2 is arranged underneath said platform 1 to adhere to said surface for securing said platform 1 on said surface;

ii) a touch interactive display panel 3 installed on said platform 1 for enabling a user to provide input specifications regarding a user-desired number of bricks, wherein a chamber 4 is arranged on said platform 1 for storing sand and configured with a linear actuator 5 connected to a plate 6, that is actuated by an inbuilt microcontroller to extend/retract for providing a pushing force on said plate 6 to transfer an appropriate quantity of said sand into a container 7 arranged on said platform 1 and configured with a meshed on top portion;

iii) an artificial intelligence-based imaging unit 9 installed on said platform 1 and paired with a processor for capturing and processing multiple images in vicinity of said platform 1, respectively to determine presence of debris on said sheet 8, based on which said microcontroller actuates a vibration unit integrated with said sheet 8 to produce vibrational sensations for filtering out said debris from said sand, wherein said filtered sand is collected in said container 7;

iv) plurality of electronically controlled nozzles 10 arranged in said container 7 for dispensing an appropriate quantity of water from a vessel configured with said container 7, in said container 7, wherein a motorized stirrer 11 installed in said container 7 that is actuated by said microcontroller to rotate for mixing said dispensed water and sand in view of obtaining an optimally consistent mixture;

v) a motorized hinge joint integrated in between said container 7 and said platform 1 for tilting said container 7 to pour said mixture in a tray 12 arranged on said platform 1, wherein a motorized flap 13 is integrated on said tray 12 that is actuated by said microcontroller to get closed for covering said poured mixture, in view of allowing settling of said mixture to form a semi-solid structure, followed by actuation of said flap 13 to get opened;

vi) a plank 14 arranged on bottom portion of said tray 12 by means of a pair of motorized sliding units 15 that is actuated by said microcontroller to provide upward translation to said plank 14 for removing said structure from said tray 12, wherein an extendable rod is integrated in between said plank 14 and one of said sliding unit for tilting said plank 14 in view of positioning said structure on a conveyer belt 16 integrated on said platform 1; and

vii) an inverted U-shaped frame 17 arranged on said platform 1 for assembling plurality of metallic strings 18, wherein said microcontroller actuates said conveyer belt 16 to move said structure underneath said frame, followed by actuation of a motorized ball and socket joint integrated in between said platform 1 and one end of said frame to provide required movement to said frame, which in turn moves said strings 18 through said structure, for cutting said structure into sections, thereby allowing said user to collect said user-specified number of bricks.

2) The device as claimed in claim 1, wherein a tactile sensor is embedded on said container 7 for monitoring consistency of said mixture, based on which said microcontroller regulates actuation of said nozzles 10.

3) The device as claimed in claim 1, wherein a weight sensor is embedded in said container 7 to measure weight of said transferred sand, based on which said microcontroller regulates actuation of said linear actuator 5.

4) The device as claimed in claim 1, wherein a battery is configured with said device for providing a continuous power supply to electronically powered components associated with said device.

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