AUTOMATED CEMENT BALLAST LEVELLING DEVICE

Abstract

An automated cement ballast levelling device, comprising an extendable inverted U-shaped frame 1 positioned by a user over a surface covered with cement ballast, plurality of motorized wheels 2 for providing movement to the frame 1 on the surface, an imaging unit 3 evaluates a 3D (three-dimension) of the surroundings, a display panel 4 allowing the user to select a portion of the surface where the user desires to perform levelling of the cement ballast, an ultrasonic sensor for monitoring level of the surface along with determining accumulation of the cement ballast over the surface, plurality of motorized hinges 5 for facilitating in levelling of the cement ballast to an optimum level and a motorized disc 6 via a telescopically operated rod 7 to rotate for levelling the cement ballast.

Specification

Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated cement ballast levelling device that is capable of carrying out levelling of cement ballast at an optimum level in an automated manner thereby reducing manual efforts and time-consumption. In addition, the proposed device is capable of detecting hardness of the cement ballast and accordingly regulates the operation for preventing any chances of causing damage to the surface.

BACKGROUND OF THE INVENTION

[0002] Cement ballast leveling is a crucial step in construction infrastructure projects primarily used in the installation of railway tracks, highways, and building foundations. It involves the application of a mixture of cement and ballast to create a stable level surface. The process begins with the excavation of the area to the required depth followed by the spreading and compacting of the ballast material. Cement is then mixed with water and pored over the compacted ballast creating a durable and solid foundation. The cement binds with the ballast providing stability and prevent shifting or settling over time. Proper leveling ensures the even distribution of weight and load-bearing capacity essential for supporting structures and maintaining safety standards.

[0003] Traditionally, cement ballast leveling relied on manual labor and basic tools such as shovels, rakes, and compactors. Workers should excavate the site to the required depth manually spread the ballast material and compact it using handheld or mechanical compactors. Cement would then be mixed on-site and poured over the compacted ballast followed by manual leveling using screeds or wooden boards. While these methods has been effective in many construction projects, it is labor-intensive, time-consuming and prone to inconsistencies in leveling and compaction. So, there is need for such device that is capable of carrying out levelling of cement ballast at an optimum level in an automated manner thereby reducing manual efforts and time-consumption.

[0004] US6309457B1 discloses a self-levelling composition for floor toppings, characterized in that it is based on Portland cement or on cement mix CM II or CM III, and in that it further comprises at least sand, water and at least one plasticizer which is a water-soluble or water-dispersible organic compound (I) containing at least one aminodi (alkylenephosphonic) group and at least one polyoxyalkyl chain, or at least one salt of compound (I).

[0005] US8226762B2 discloses a self-levelling fluid screed cement composition with limited shrinkage, formed by a mixture of a cement binder, a fluidizing adjuvant, granulates and water, is characterized in that the binder includes 70% to 85% by weight of Portland cement, 7% to 18% by weight of sulfo-aluminous clinker, and 6% to 14% by weight of calcium sulphate, with a calcium sulfate C$/calcium sulfo-aluminate C4A3$ molar ratio of between 5 and 7 and a water/binder ratio by weight of between 0.60 and 0.90. The self-levelling fluid screed that is thus produced has a mechanical resistance to its compression at 24 hours that is at least equal to 1 MPa, shrinkage at 7 days, measured under a relative hygrometry of 50%, less than 500 μm/m, and an endogenic expansion value that is measured at 7 days, less than 1,000 μm/m, as well as a

[0006] Conventionally, many devices are exist that are capable of levelling cement ballast. However, these devices fail in carrying out levelling of cement ballast at an optimum level in an automated manner by reducing manual efforts and time-consumption. These devices do not re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of carrying out levelling of cement ballast at an optimum level in an automated manner by reducing manual efforts and time-consumption. The device also re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast.

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 that is capable of carrying out levelling of cement ballast at an optimum level in an automated manner thereby reducing manual efforts and time-consumption.

[0010] Another object of the present invention is to develop a device that is capable of re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast.

[0011] Yet another object of the present invention is to develop a device that is capable of detecting hardness of the cement ballast and accordingly regulates the operation for preventing any chances of causing damage to the surface.

[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 cement ballast levelling device that is capable of carrying out levelling of cement ballast at an optimum level in an automated manner thereby reducing manual efforts and time-consumption.

[0014] According to an embodiment of the present invention, an automated cement ballast levelling device comprises an extendable inverted U-shaped frame associated with the device developed to be positioned by a user over a surface covered with cement ballast, multiple motorized wheels is arranged on lateral ends of the frame for providing movement to the frame on the surface, an artificial intelligence-based imaging unit installed on the frame evaluates a 3D (three-dimension) of the surroundings, a touch interactive display panel mapped on the frame for displaying the evaluated mapping that is accessed by the user for allowing the user to select a portion of the surface where the user desires to perform levelling of the cement ballast in accordance to which the microcontroller actuates the wheels to maneuver the frame over the user-specified portion, an ultrasonic sensor mapped on the frame for monitoring level of the surface along with determining accumulation of the cement ballast over the surface.

[0015] According to another embodiment of the present invention, the proposed device also comprises a multiple motorized hinges integrated within the frame to modulate shape of the frame for facilitating in levelling of the cement ballast to an optimum level, a motorized disc installed with the frame via a telescopically operated rod, the microcontroller actuates the rod to extend, followed by actuation of the disc to rotate for levelling the cement ballast in synchronization with actuation of the wheels for maneuvering the frame over entire user-specified area, a pair of motorized shovel are arranged with the frame for re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast, a tactile sensor is arranged on the frame for detecting hardness of the cement ballast in accordance to which the microcontroller regulates operation of the disc to rotate at an optimum speed in view of preventing any chances of causing damage to the surface.

[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 cement ballast levelling 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 cement ballast levelling device that is capable of carrying out levelling of cement ballast at an optimum level in an automated manner by reducing manual efforts and time-consumption. Additionally, the proposed device also capable of re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast.

[0022] Referring to Figure 1, an isometric view of an automated cement ballast levelling device is illustrated, comprising an extendable inverted U-shaped frame 1 associated with the device, plurality of motorized wheels 2 is arranged on lateral ends of the frame 1, an artificial intelligence-based imaging unit 3 installed on the frame 1, a touch interactive display panel 4 mapped on the frame 1, plurality of motorized hinges 5 integrated within the frame 1, a motorized disc 6 installed with the frame 1 via a telescopically operated rod 7 and a pair of motorized shovel 8 are arranged with the frame 1.

[0023] The device disclosed herein includes an extendable inverted U-shaped frame 1 associated with the device that is developed to be positioned by a user over a surface covered with cement ballast. The frame 1 is light in weight and compatible in nature allowing the user to place the frame 1 from one position to another, as per the requirement of the user. The frame 1 is equipped with plurality of motorized wheels 2 is arranged on lateral ends of the frame 1 for providing movement to the frame 1 on the surface.

[0024] The motorized wheels 2 are a circular object that revolves on an axle to enable the frame 1 to move easily over the ground surface. For maneuvering the frame 1 each of the wheels 2 need to rotate and which is governed by a hub motor fit in the hub of each of the wheels. The hub motor is an electric motor that is integrated into the hub of the wheels. The hub motor comprises of a series of permanent magnets and electromagnetic coils. When the motor is activated, a magnetic field is set up in the coil and when the magnetic field of the coil interacts with the magnetic field of the permanent magnets, a magnetic torque is generated causing the stator of the motor to turn and that provides the rotation motion to the wheels for maneuvering the frame 1 on the ground surface.

[0025] Further, an artificial intelligence-based imaging unit 3 installed on the frame 1 in order to capture multiple images of surroundings for evaluating a 3D (three-dimension) of the surroundings. The artificial intelligence (AI)-based imaging unit 3 refers to a camera that incorporates AI protocols to enhance its functionality and capabilities. AI protocols are used to process and analyses the images or videos captured by the camera, enabling it to perform various tasks beyond traditional image capturing. The AI analysis is performed locally on the camera itself and the real-time processing on the camera enables immediate responses and faster decision- making. The camera captures images or records videos by the help of specialized lenses designed to capture high-quality visuals.

[0026] The captured data is pre-processed to enhance its quality and prepare it for AI analysis. This pre-processing involves tasks such as noise reduction, images stabilization, or color correction. The processed data 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 such as evaluating 3D (three-dimension) of the surroundings. Also, an inbuilt microcontroller is pre-fed with the instructions required to control the operation of various components associated with the proposed device.

[0027] Upon generating the 3D (three-dimension) of the surroundings, the microcontroller actuates a touch interactive display panel 4 mapped on the frame 1 for displaying the evaluated mapping that is accessed by the user for allowing the user to select a portion of the surface where the user desires to perform levelling of the cement ballast based on which the microcontroller actuates the wheels 2 to maneuver the frame 1 over the user-specified portion. The touch interactive display panel 4 mapped herein consists of multiple tiny electrically active wires. When user touch the mapping illustrated over the panel, the wires are pressed together and circuit is completed. Which results in flow of voltages across the circuit. That voltage flow is detected by the microcontroller linked with the panel in form of electric signals. Further the signals are processed by the microcontroller to determine the user's input regarding the portion of the surface where the user desires to perform levelling of the cement ballast.

[0028] After reaching the user-specified portion, the microcontroller activates an ultrasonic sensor mapped on the frame 1 for monitoring level of the surface along with determining accumulation of the cement ballast over the surface. The ultrasonic sensor comprises of an ultrasonic emitter and a receiver. On actuation the ultrasonic emitter emits the ultrasonic waves towards the surface and the ultrasonic waves got reflected back after striking with the surface which are received by the receiver. Now the receiver detects the reflected waves that bounce back from the surface and converts them back into electrical signals. The sensor measures the time it takes for the ultrasonic waves to travel from the sensor to the surface and back. It starts a timer when the waves are emitted and stops it when the reflected waves are detected. The elapsed time is known as the "time of flight" (TOF). Using the known speed of sound in the medium through which the waves are travelling, the level of the surface along with determining the accumulation of the cement ballast over the surface is determined.

[0029] Moreover, a motorized disc 6 installed with the frame 1 by means of a telescopically rod 7 . Herein, the microcontroller actuates the rod 7 to extend upon actuation of the disc 6 to rotate for levelling the cement ballast in synchronization with actuation of the wheels 2 for maneuvering the frame 1 over entire user-specified area. The telescopically operated rod 7 are powered by a pneumatic unit including a pneumatic cylinder, air compressor, electronic valve, cylinder and piston. The valve is an electronic valve that allows entry/exit of compressed air from the compressor. Furthermore, the valve opens and the compressed air enters inside the cylinder thereby increasing the air pressure of the cylinder. The piston is connected to the cylinder and due to the increase in the air pressure, the piston extends. For the retraction of the piston, air is released from the cylinder to the air compressor via the valve. Thus, providing the required extension/retraction of the rod 7 .

[0030] Herein, a pair of motorized shovel 8 are arranged with the frame 1 that are actuated by the microcontroller for re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast. Also, a tactile sensor is arranged on the frame 1 for detecting hardness of the cement ballast based on which the microcontroller regulates operation of the disc 6 to rotate at an optimum speed for preventing any chances of causing damage to the surface.

[0031] The tactile sensor is an electronic sensor that detects the hardness through touch arising from physical interaction with its environment. The sensor comprises of two parallel conductors with an insulator arranged between them and a transducer. When the cement ballast comes in contact with the conductors leading to an increase in capacitance. The change in capacitance is detected by the transducer for determining the hardness of the cement ballast. The transducer further converts the obtained data into an electric signal that is received by the microcontroller.

[0032] The device is associated with a battery integrated with the device for supplying a continuous DC (direct current) voltage to the components such as motors, microcontrollers and various other components that are associated with it. The battery used in the invention is preferably Lithium-ion battery that is rechargeable once again after getting drained out for proper functioning of the components.

[0033] The present invention works best in the following manner, where the extendable inverted U-shaped frame 1 positioned by a user over a surface covered with cement ballast as disclosed in the proposed invention is fabricated with plurality of motorized wheels 2 for providing movement to the frame 1 on the surface. Now, the artificial intelligence-based imaging unit 3 captures multiple images of surroundings for evaluating a 3D (three-dimension) of the surroundings and the touch interactive display panel 4 displays the evaluated mapping for allowing the user to select a portion of the surface where the user desires to perform levelling of the cement ballast. Also, the ultrasonic sensor monitors the level of the surface along with determining accumulation of the cement ballast over the surface according to which plurality of motorized hinges 5 to modulate shape of the frame 1 for facilitating in levelling of the cement ballast to an optimum level. Further, the motorized disc 6 via telescopically operated rod 7 to extend and allow the disc 6 to rotate for levelling the cement ballast in synchronization with actuation of the wheels 2 for maneuvering the frame 1 over entire user-specified area. Also, the pair of motorized shovel 8 for re-positioning extra cement ballast from user-specified portion during levelling of the cement ballast.

[0034] 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 individuals skilled in the art upon reference to the description of the invention. , Claims:1) An automated cement ballast levelling device, comprising:

i) an extendable inverted U-shaped frame 1 associated with said device, developed to be positioned by a user over a surface covered with cement ballast, wherein plurality of motorized wheels 2 is arranged on lateral ends of said frame 1 for providing movement to said frame 1 on said surface;
ii) an artificial intelligence-based imaging unit 3 installed on said frame 1 and paired with a processor for capturing and processing multiple images of surroundings, wherein an inbuilt process said captured images and evaluates a 3D (three-dimension) of said surroundings;
iii) a touch interactive display panel 4 mapped on said frame 1 for displaying said evaluated mapping, that is accessed by said user for allowing said user to select a portion of said surface where said user desires to perform levelling of said cement ballast, in accordance to which said microcontroller actuates said wheels 2 to maneuver said frame 1 over said user-specified portion;
iv) an ultrasonic sensor mapped on said frame 1 for monitoring level of said surface along with determining accumulation of said cement ballast over said surface, wherein based on detected level and accumulation of cement ballast, said microcontroller actuates plurality of motorized hinges 5 integrated within said frame 1 to modulate shape of said frame 1 for facilitating in levelling of said cement ballast to an optimum level; and
v) a motorized disc 6 installed with said frame 1 via a telescopically operated rod 7 , wherein said microcontroller actuates said rod 7 to extend, followed by actuation of said disc 6 to rotate for levelling said cement ballast in synchronization with actuation of said wheels 2 for maneuvering said frame 1 over entire user-specified area.

2) The device as claimed in claim 1, wherein a pair of motorized shovel 8 are arranged with said frame 1 that are actuated by said microcontroller for re-positioning extra cement ballast from user-specified portion during levelling of said cement ballast.

3) The device as claimed in claim 1, wherein a tactile sensor is arranged on said frame 1 for detecting hardness of said cement ballast, in accordance to which said microcontroller regulates operation of said disc 6 to rotate at an optimum speed in view of preventing any chances of causing damage to said surface.

4) The device as claimed in claim 1, wherein a battery is associated with said device for powering up electrical and electronically operated components associated with said device.

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