Description:FORM 2

THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
(SEE SEC 10 AND RULE 13)
COMPLETE SPECIFICATION

1. TITLE OF THE INVENTION:
A SEMI-AUTOMATIC MANUAL AND ELECTRIC CONVERTIBLE MACHINE FOR WEAVING BAMBOO SLIVER MATS
2. APPLICANT:
(a) Name : ELLIPSIS
(b) Nationality : An Indian Registered Partnership Firm
(c) Address : Flat No 401, Atharva Kunj Apt, Kanchan Nagar, 19, Kanchan Nagar, Nakshatrawadi, Paithan Road, Aurangabad-431002, Maharashtra India

THE FOLLOWING SPECIFICATION DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF THE INVENTION:
[0001] The present invention relates to a machine for weaving bamboo sliver mats. More particularly, the present invention relates to a semi-automatic manual and electric convertible machine
BACKGROUND OF THE INVENTION:
[0002] Woven bamboo mats and products made from it, deeply rooted in India's cultural heritage, not only serve decorative and utility purposes but also contribute significantly to the livelihoods of numerous artisans across the nation. Bamboo products, being eco-friendly, are good alternatives to plastics, metals and wood. The traditional method of manually weaving bamboo mats, carried out by skilled artisans, has been a time-consuming and labour-intensive process. This manual approach not only hampers the artisans' earnings due to its low production rate but has also contributed to a decline in the number of artisans, despite the evident market demand for these products.
[0003] While a few automated machines for mat weaving do exist, particularly designed for bamboo mat boards, they face limitations in terms of adaptability for craft purposes and affordability for individual artisans. Moreover, challenges such as irregular power availability in remote areas hinder the widespread adoption and effective use of electric-powered machines.
[0004] IN214386 relates to the electricity-driven machine to weave mats from bamboo slivers. It has pneumatically operated sliver lifting mechanism, by means of which alternate sets of slivers can be lifted to provide space for threading the cross sliver to form the weave pattern. Some of the levers face the entry end of the machine and the others the exit end of the machine. The bars have been provided across the width of the machine, one bar to engage the sliver lifting levers facing the entry end of the machine and the other bar to engage with the sliver lifting levers facing the exit end of the machine. Thus, the said art is capable of weaving mats of limited patterns of 2 steps only, i.e., the plain weave and its variations, where there are only two sets of slivers to be lifted alternately. This is a major drawback in terms of suitability for craft purpose.
[0005] CN109421121, CN207105167 relate to the electricity driven machine for automatic bamboo mat weaving. It is operated and controlled by electric motor and controller only. Also, to adapt customization in the width of weft sliver, it requires customization of sizes of the feeding conveying belt, the guide piece and feeding port along with the programming of the controller. Manufacturing of these parts for custom requirements in low quantity is resource consuming to the manufacturer and thus cost-intensive to the artisans.
[0006] CN107443513 relates to electricity driven automatic weaving machine for rattan or bamboo mat that is specially developed for and so limited to polygonal holes pattern.
[0007] Additionally, few electricity driven machines exist in the market. These machines use series of radial cams attached to the driving shaft to lift the set of levers holding warp slivers for creating shed to allow the weft slivers to be inserted through it. In these machines, customization of weaving pattern and/or width of warp sliver requires customization of the cams and shaft assembly and sliver holders. As process of manufacturing of these parts is resource consuming it becomes difficult for a manufacturer to cater such low quantity special requirements. Thus, cost of customization becomes high and procurement of machine parts that are related to customization of pattern, mat shape and warp sliver width becomes difficult for artisans.
[0008] All the aforementioned prior arts are cost-prohibitive for the low-income artisans of country and are also unsuitable for craft purpose. So, mostly such automation is limited to industrial use like bamboo mat boards. And traditional artisans are still weaving mats needed for their craft manually. In manual mat weaving there are two most time-consuming and skill demanding processes, firstly initial setup of warp slivers and maintaining the distance between them throughout weaving, and secondly remembering and lifting appropriate combination of warp slivers at each step to weave as per the pattern. These also affect production rate, quality and cost.
[0009] Thus, there is unmet need for a cost-effective machine, that can be operated manually or by electric power or convertible, and that facilitate to weave mats of versatile patterns, shapes and sliver widths.

OBJECT OF THE INVENTION
[0010] The main object of the present invention is to provide a novel craft-focused, semi-automatic manual and electric convertible machine designed specifically for weaving bamboo sliver mats with versatile patterns, shapes, and sliver widths.[0011] Another objective of the invention is to provide a machine for weaving bamboo sliver mats in which the time-consuming and skill-demanding operations are automated while providing an easy convertible function to do these operations by manual or electric power.

[0012] Yet another objective of the invention is to provide a bamboo mat weaving machine that is more ergonomic for operators than conventional practices that causes physical strain by constantly bending over.
[0013] Yet another objective of the invention is to design the functionality of the machine components that are related to customization of width of warp sliver and/or pattern and/or gap between warp slivers, the way they can be manufactured with small-volume-friendly methods to make the customization of mat design cost-effective and easy for the manufacturer to cater to.
[0014] Yet another objective of the invention is to provide a cost-effective machine for weaving fine and uniform quality bamboo sliver mats with higher productivity than manual mat weaving.
[0015] Still another object of the present invention is to provide a method for weaving bamboo sliver mats using a semi-automatic manual and electric convertible machine.

SUMMARY OF THE INVENTION
[0016] The present invention relates to a novel craft-focused, semi-automatic manual and electric convertible machine designed specifically for weaving bamboo sliver mats with versatile patterns, shapes, and sliver widths.
[0017] The most time-consuming and skill-demanding process in manual mat weaving is selecting and lifting the right combinations of warp slivers for each step of the pattern. So, to achieve higher productivity and consistency in product quality, this new machine is designed with primary focus on providing automation of sequencing of combinations of warp slivers to be lifted as per the pattern. This can be achieved through manual or electric power with an easy convertible functionality. Whereas other operations like inserting weft sliver in the shed created by lifted warp slivers and beating of weft slivers for tightening the weave are kept manual. Still the machine is designed for easy adaptation of automation of these processes too.
[0018] In a preferred embodiment, the present invention provides a semi-automatic manual and electric convertible machine for weaving bamboo sliver mats of versatile patterns, sliver widths and shapes, comprising a mounting frame supporting the functional mechanisms of the machine, a sliver lifting levers and guides assembly, a linear lever lifting unit with a mechanical indexer facilitating vertical movement and controlled lifting of the levers to create sheds in warp slivers in accordance with a predetermined weaving pattern, a set of pulleys, ropes/cables, a pivoting handle, a beater attached to the mounting frame for manually beating the weft slivers against the previously woven rows, ensuring tight packing and secure interlacing with the warp slivers, a warp fixing clamp, and error proofing and guiding systems like a mechanical pattern step counter and a mechanical length control guide for manual operable setup and electronic pattern step counter, object detection sensor, electronic controller with alarm and buzzer for missing weft insertion and laser line marker for generating length control guides for electric operable setup.
[0019] In another embodiment, the present invention provides the sliver lifting levers and guides assembly comprising sliver guides for guiding warp slivers during the weaving process, lever guides with holes for an arrangement of levers and their vertical movement, and a free sliding lever guide that moves up and down with the levers to maintain alignment during vertical movement. The linear lever lifting unit positioned crosswise to warp slivers and aligned down the levers comprises a shaft, ratchets on each side of the shaft, and profile cut lever lifting plates fixed latitudinally on the shaft, the linear lever lifting unit further comprises a mechanical indexer with an indexing flat cam engaging an indexer guide and a guide stopper with an elastic element for controlling upward movement.
[0020] In another embodiment, the present invention provides a machine which is operable manually or electrically for lifting combinations of warp slivers as per a predefined pattern. The manual operation of the machine is enabled by pulling a pivoting handle or the convertible electric operation by interchanging the ropes attached to the ratchets of linear lever lifting assembly with the ropes or connecting levers of an electric lifting device. The warp fixing clamp is attached to the mounting frame by simple telescopic pipe arrangement at the left and right sides, levers and sliver guides designed to rotate at desired angles enabling adjustment of warp sliver orientation at straight or skewed angles, contributing to the creation of mats with versatile shapes including trapezoid, isosceles trapezoid, parallelogram, rhombus, and others, by changing the orientation angle of the warp slivers, beater and the clamp. Components designed for customization of the width of warp slivers, pattern, and gap between warp slivers, with manufacturing capabilities through computerized 2D cutting and additive manufacturing methods, further supported by a system for automatic generation of drawings based on user inputs. The machine has a capability to weave mats from compatible raw materials other than bamboo slivers, whether organic or synthetic, extends its versatility in material usage.
[0021] The present invention addresses drawbacks associated with limited patterns, limited shapes, complex customization requirements, and cost-prohibitive machinery for low-income artisans. The machine's adaptability, convertible functionality, and focus on craft-oriented weaving make it an innovative and cost-effective solution for artisans engaged in bamboo mat weaving. The detailed design ensures ease of use, enhanced productivity, and expanded creative possibilities for traditional artisans, bridging the gap between tradition and technology in the craft industry.

BRIEF DESCRIPTION OF THE DRAWINGS
Objects, features, and advantages of the invention will best be understood from the following description of various embodiments thereof, selected for the purposes of illustration, and shown in the accompanying drawings, which:
[0022] Fig. 1 illustrates a perspective view of a manually operated machine and the orientation of operation;
[0023] Fig. 2 illustrates a front view of the machine;
[0024] Fig. 3 illustrates a side elevation of the machine in an idle state (Figure 3-1) as well as an in-process state (Figure 3-2 and Figure 3-3);
[0025] Fig. 4 illustrates a plan view of the machine;
[0026] Fig. 5 illustrates a sliver lifting system including a linear lever lifting unit with a mechanical indexer;
[0027] Fig. 6 illustrates a pivoting handle for rope pulling;
[0028] Fig. 7 illustrates a convertible function of a machine with an electric lifting device;
[0029] Fig. 8 illustrates some sample shapes of mats and arrangements of warp setup; and
[0030] Fig. 9 illustrates some components of the machine that are specific to customization of warp sliver size, patterns, and distance between slivers; and refers to the system that creates drawings for 2D profile cutting and 3D printing.
[0031] Fig. 10 illustrates a perspective view of an automatic machine and the orientation of operation.

DETAILED DESCRIPTION OF THE INVENTION
[0032] The invention will now be described in detail in connection with certain preferred and optional embodiments, so that various aspects thereof may be more fully understood and appreciated.
[0033] The present invention relates to a novel craft-focused, semi-automatic manual and electric convertible machine designed specifically for weaving bamboo sliver mats with versatile patterns, shapes, and customizable sliver widths.
[0034] Fig. 1 illustrates a perspective view of a manually operated machine and orientation of operation.
[0035] Fig. 2 illustrates a front view of the machine.
[0036] Fig. 3 illustrates a side elevation of the machine in an idle state (Figure 3-1) as well as an in-process state (Figure 3-2 and Figure 3-3).
[0037] Fig. 4 illustrates a plain view of the machine.
[0038] Fig. 5 illustrates a sliver lifting system including linear lever lifting unit with a mechanical indexer.
[0039] Fig. 6 illustrates a pivoting handle for rope pulling.
[0040] Fig. 7 illustrates a convertible function of a Machine with an electric motorized lifting device.
[0041] Fig. 8 illustrates some sample shapes of mats and arrangements of warp setup.
[0042] Fig. 9 illustrates some components of the machine that are specific to customization of warp sliver size, patterns, and distance between slivers; and refers to the system that creates drawings for 2D profile cutting and 3D printing.
[0043] Fig. 10 illustrates a perspective view of an automatic machine and the orientation of operation.
[0044] In a preferred embodiment, the present invention provides a semi-automatic manual and electric convertible machine for weaving bamboo sliver mats of versatile patterns, sliver widths and shapes, comprising a mounting frame (126), a sliver lifting levers and guides assembly (103), a linear lever lifting unit with a mechanical indexer (109), a set of pulleys (117), ropes/cables (118), a pivoting handle (119), a beater (122), a warp fixing clamp (131), and error proofing and guiding systems like a mechanical pattern step counter (132) and a mechanical length control guide (435, 436, 437) for manual operable setup and electronic pattern step counter (740), object detection sensor (741), electronic controller with alarm and buzzer (738) for electric operable setup. The machine is operable manually or electrically for lifting combinations of warp slivers (101) as per a predefined pattern. The sliver lifting levers and guides assembly comprises lever guides (305) with holes for an arrangement of sliver lifting levers (304) and their vertical movement, and a free sliding lever guide (306). The linear lever lifting unit (109) comprises a shaft (510), ratchets (511) on each side of the shaft, and profile cut lever lifting plates (512) fixed latitudinally on the shaft. The linear lever lifting unit further comprising a mechanical indexer with an indexing flat cam (513) engaging an indexer guide (514), and a guide stopper (515) with an elastic element (516) for controlling upward movement.
[0045] According to the preferred embodiment of the present invention, one end of plurality of warp slivers (101) is clamped with warp fixing clamp (131) at operator end and the other end of these slivers is passed through the beater wires (224) and further through the sliver guides (307) that are attached to the sliver lifting levers (304). These sliver lifting levers are in perpendicular axis to the warp slivers (301). They are inserted in and move vertically through corresponding holes in the lever guides (305) that are attached to the mounting frame (126) horizontally crosswise to warp slivers (101). These levers are also inserted through the corresponding holes of the free sliding lever guide (306) which moves up and down with the levers and maintains their alignment during the vertical movement.
[0046] Referring to figures 1, 3 and 5, the vertical lifting of the levers is facilitated by linear lever lifting unit (109) that is crosswise to warp slivers (101) and aligned down the levers. The lever lifting unit (109) moves vertically in the slot made in left and right sides of the mounting frame (126). It is comprised of a shaft (510), rachet (511) on each side of the shaft (510) and the profile cut lever lifting plates (512) fixed latitudinally on the shaft at angles corresponding to the number of steps of the weaving patterns. The linear lever lifting unit (109) has a mechanical indexer. The indexing flat cam (513) is attached to the shaft (510) whereas the indexer guide (514) and guide stopper (515) are fixed on the mounting frame (126) beside the slot in it. The indexing flat cam (313, 513) and the indexer guide (314, 514) has a functional alignment. The guide stopper (515) is fixed above the indexer guide (314, 514) to stop upward movement of the guide. A spring or other elastic element (516) is connected between the Indexer guide (514) and the guide stopper (515).
[0047] Referring to figures 1, 2, 3, 4, and 6, a pair of ropes or cables (118) is attached to the body of ratchets (211). These ropes are passed through the set of pulleys (117) fixed on the bottom-side of the top of mounting frame (127). Further, the ropes (118) are attached to the mounting disc (620) of the pivoting handle (119, 619). The handle (621) is pivoted on a mounting disc (620) to absorb pulling angle variation and wrist angle variation for achieving smooth lifting motion by load and tension balancing.
[0048] A beater (122) is attached to the mounting frame (126) at the bottom side of its top (127) with an elastic element like elastic rope or spring rope (125). The components of error proofing and guiding systems like a mechanical pattern step counter (132) and a mechanical length control guide (435, 436, 437) for manual operable setup and electronic pattern step counter (740), electronic controller with alarm and buzzer (738) for electric operable setup are attached to the mounting frame (126). The object detection sensor (741) with a motion platform is attached to the mounting frame (126) at space under the weaving area.
[0049] Referring to figure 1, 2, and 7, the semi-automatic manual and electric convertible machine of the present invention is manually operable with the ropes (118, 218) attached to the ratchets (211) of the linear lever lifting unit (109), enabling manual operation by pulling the pivoting handle (119) to lift the warp slivers (101). A manual operation of lifting the linear lever lifting unit is achieved by pulling it by hand using ropes or a foot-operated mechanism. The machine is convertible to electric power, featuring a mounting frame top (727) with a fastening arrangement for an electric-powered lifting device (728) such as a hoist, winch, pneumatic, mechanical or electric actuator or other rotary to linear mechanism etc., with the ropes (118) attached to the ratchets interchangeable with ropes or connecting levers (729) of electric lifting device (728), allowing electric-powered sliver lifting.
[0050] The semi-automatic manual and electric convertible machine comprises a mechanical pattern step counter (132, 232) where one end of a mechanical linkage of levers (233) is attached to the counter (232) and another end with a spring-loaded lever is attached to the mounting frame (226) at the bottom of the slot in left or right sides of the mounting frame through which the shaft (510) of linear lever lifting unit (109) moves upward and downward. When the shaft (510) moves downward, it pushes against the spring-loaded lever and activates the counting mechanism. The counter (232) increments the count in loop by one for each downward movement of the shaft (510). When the shaft (510) moves upward, the spring-loaded lever (233) returns to its original position. The mechanical step counter (132, 232) helps the operator in detecting missed weft insertion in manual machine operations.
[0051] The semi-automatic manual and electric convertible machine comprise an electronic missed weft insertion alarm and control system in an electric operable setup. It is comprised of an electronic pattern step counter (740), object detecting sensor (741) like but not limited to IR sensor or laser sensor, ultrasonic sensor etc., motion platform and electronic controller. The object-detecting sensor (741) is fixed on a motion platform under the weaving area. The electronic controller controls the lengthwise movement of the object-detecting sensor (741) and detects the presence of a weft sliver (402) at each pattern step while reading the pattern step count from the electronic pattern step counter (740). It matches both and activates the alarm and buzzer (738) in case of discrepancy and stops the downward movement of the linear lever lifting unit (109).
[0052] The semi-automatic manual and electric convertible machine comprises a mechanical length control guide (435, 436, 437) attached on the side of the mounting frame (126) beside the weaving area. It has a two-roller thread spooling mechanism. Physical markers/ pointers (437) are attached to the thread (436). The two-roller thread spooling mechanism allows the operator to control the movement and direction of the thread (436) by rotating the handles of the spool rollers (435). Using this the operator can set up length control guides for weft slivers (402). The positioning of a marker is further made easy with scale markings (434) at both sides of the weaving area. It helps in creating unwoven windows in a mat or in changing of colour and/or pattern at specific lengths while maintaining production consistency. In electric operation mode, it is achieved through the laser line marker (739) attached at the bottom of the mounting frame top (727). The laser line marker (739) generates a laser line over the weaving area which acts as a length control guide helping the operator.
[0053] Referring to Figure 9, the components related to customization of the width of the warp sliver, pattern, and the gap between warp slivers are designed for manufacturing through computerized two-dimensional (2D) cutting and additive manufacturing methods including three-dimensional (3D) printing and are supported by a system generating drawings based on user inputs. The semi-automatic manual and electric convertible machines are configured to be operable for weaving mats from raw materials other than bamboo slivers, including organic or synthetic materials. The convertible function allows seamless transition between manual and electric operation.
[0054] The semi-automatic manual and electric convertible machine comprises an adjustable warp fixing clamp (131) attached to the mounting frame (126) by simple telescopic pipe arrangement at left and right sides allowing straight or skewed angles, and rotatable levers and sliver guides, enabling the creation of mats with various shapes such as trapezoid, isosceles trapezoid, parallelogram, rhombus, and diagonal sliver setups.
[0055] In another embodiment, the present invention provides a method for weaving bamboo sliver mats using a semi-automatic manual, an automated, and electric convertible machine comprising the steps of providing a machine having a mounting frame (326), sliver lifting levers and guides assembly (103), linear lever lifting unit with a mechanical indexer (109), set of pulleys (117), ropes/cables (318), pivoting handle (319), beater (122), and warp fixing clamp (131), wherein the machine is operable either manually or electrically. The weaving process is initiated by setting up the warp slivers (101) by clamping operator end of plurality of warp slivers and the other end of these slivers passing through the beater wires (224) and further through the sliver guides (307, 807) that are attached to the sliver lifting levers. Further an operator pulling the pivoting handle (119, 319), causing the attached pair of ratchets (211) to move up, holding the linear lever lifting unit (109). The vertical movement of the shaft (510) is guided and secured with the pair of ratchets (511), through the slot made in the left and right sides of the mounting frame (126, 326). The indexing flat cam (313) is engaged with the indexer guide (314) during the up-stroke followed by initiating the rotation of the shaft (510) until disengagement. The profile of the indexing cam (313, 513) determines the angle of rotation. The corresponding lever lifting plate (312, 512) is lifted under the sliver lifting levers (304, 504), where the continuous section of the lever lifting plate (312, 512) serves as a hook, lifting the levers (304, 504) above it while keeping levers above the void area stationary. The unidirectional rotating function of the ratchets (511) is utilized to prevent backward rotation of the shaft (510) while the levers are hooked, resulting in the lifting of corresponding warp slivers (301) to create a shed. Weft slivers (402) are inserted crosswise into the shed created by the lifted warp slivers (101, 301). The weft slivers (402) are beaten using the beater (122) inwards against the previous rows of woven mats, ensuring tight packing and secure interlacing with the warp slivers (101). The beater (122) is returned to its original position by aiding on release by an elastic rope (125) attached to the beater. The pull or tension off the pivoting handle (119) is released which initiates the downward movement of the linear lever lifting unit (109). The shaft (510) is engaged with the indexer guide (314) in the down-stroke followed by rotating the indexer guide (314), and moving down by disengaging itself. The linear lever lifting unit (109) is brought back to its initial position, disengaging the shaft (510), and allowing the spring (516) to return the indexer guide (314, 514) to its original position. The ratchets (511) are utilized to prevent the backward rotation of the shaft (510) during the downward movement. One stroke of weaving completes and repeating the process for the entire weaving of the mat.
[0056] The method further comprises the step of converting the sliver lifting operation from manual to electric powered by interchanging the ropes (118) attached to the ratchets (211) with the ropes or connecting levers (729) of an electric lifting device (728), the top of the mounting frame (727) having a fastening arrangement for the electric lifting device. The sliver lifting levers (304) holding warp slivers (301) and sliver guides (307) can rotate at desired angles, allowing for the creation of mats with various shapes, including trapezoid, isosceles trapezoid, parallelogram, rhombus, and others, by changing the orientation angle of the warp slivers (101) and the warp fixing clamp (131). Components related to customization of the width of warp slivers, pattern, and gap between warp slivers are designed for manufacturing through computerized 2D profile cutting and additive manufacturing methods. Additionally, these profiles can be cut manually too.
[0057] The method further comprises the step of utilizing a system (942) for the automatic generation of drawings (figure 9-1, 9-2) based on user inputs allowing for 2D cutting and 3D printing of components to achieve customization.
[0058] In another embodiment (900), the present invention provides a system for creating drawings of components related to the customization of the machine, generating 2D cutting drawings (905, 906, 912, 923) and 3D printing drawings (907) based on user inputs such as pattern selection, warp sliver width, and distance between slivers.
[0059] In another embodiment (1000), the present invention provides an automatic machine for weaving bamboo sliver mats of versatile patterns, sliver widths and shapes. The, automatic machine comprises a mounting frame (1026), a sliver lifting levers and guides assembly (1003), a linear lever lifting unit with a mechanical indexer (1009), an electric lifting device (1028) such as a hoist, winch, pneumatic, mechanical or electric actuator or other rotary to linear mechanism fixed on the top of mounting frame (1026), an electric sliver feeder (1043) with a controller, an electric beater (1044), clamping rollers (1045), foot switches (1030) and error proofing and guiding systems comprising an electronic pattern step counter (1040), object detection sensor (1041), electronic controller with alarm and buzzer (1038), laser line marker (1039).
[0060] The sliver lifting levers and guides assembly comprises lever guides (305) with holes for an arrangement of sliver lifting levers (304) and their vertical movement, and a free sliding lever guide (306). The linear lever lifting unit (109) comprises a shaft (510), ratchets (511) on each side of the shaft, and profile-cut lever lifting plates (512) fixed latitudinally on the shaft. The linear lever lifting unit further comprises a mechanical indexer with an indexing flat cam (513) engaging an indexer guide (514), and a guide stopper (515) with an elastic element (516) for controlling upward movement.
[0061] Referring to figure 10 and 5, the automatic machine of the present invention is electrically operable. Electric-powered warp sliver lifting is achieved using the foot switch (1030) that operates an electric lifting device (1028) having ropes or connecting levers (1029) attached to the ratchets of a linear lever lifting unit with a mechanical indexer (1009). It further activates an electric sliver feeder (1043) to feed weft slivers in the shed created by lifted warp slivers. The operator then presses another foot switch (1030) that operates an electric beater to beat weft slivers (402) against the previously woven rows, ensuring tight packing and secure interlacing with the warp slivers (401). The clamping rollers (1045) clamp warp slivers (401) in the initial setup as well as rolls the woven mat after each step of weaving. The rotation of electric operating clamping rollers (1045) is controlled by an electronic controller and the amount of rolling of the woven mat corresponds with the width of the weft sliver.
[0062] While the present invention is described herein by way of example, using various embodiments and illustrative drawings, those skilled in the art will recognize that the invention is neither intended to be limited to the embodiment of drawings neither described nor designed to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated with specific figures, for ease of illustration, and such omissions do not limit the embodiment outlined in any way. The drawings and detailed description of it are not intended to restrict the invention to the form disclosed, but on the contrary, the invention covers all modification/s, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
[0063] Before explaining the invention in detail, it is to be understood that the present invention is not limited in its application to the details outlined in the following description or exemplified by the examples. The invention is capable of other embodiments or of being practiced or carried out in various ways. Any discussion of documents acts, materials, devices, articles, and the like are included in the specification solely to provide a context for the present invention. Also, it is to be understood that the phraseology and terminology employed herein is for description and should not be regarded as limiting.
EXAMPLES
[0064] As illustrated in figure 1 to 9, the present invention provides a craft-focused semi-automatic manual and electric convertible machine for weaving bamboo sliver mats of versatile patterns and shapes. The reference numerals given to parts in illustrations are kept consistent throughout all figures.
[0065] Referring to figures 1, 2, 3, and 4, the semi-automated manually operated bamboo sliver mat weaving machine comprises major components like a mounting frame (126) to which the functional mechanisms are mounted, sliver lifting levers and guides assembly (103), linear lever lifting unit with a mechanical indexer (109), set of pulleys (117), ropes/ cables (118), pivoting handle (119), beater (122) and warp fixing clamp (131).
[0066] According to the preferred embodiment of the present invention, one end of the plurality of warp slivers (101) is clamped with a warp fixing clamp (131) at the operator end and the other end of these slivers is passed through the beater wires (224) and further through the sliver guides (507) that are attached to the sliver lifting levers (504). These sliver lifting levers are in a perpendicular axis to the warp slivers (101). They are inserted in and move vertically through corresponding holes in the lever guides (505) that are attached to the mounting frame (126) horizontally crosswise to warp slivers (101). These levers are also inserted through the corresponding holes of the free sliding lever guide (506) which moves up and down with the levers and maintains their alignment throughout the vertical movement.
[0067] Referring to figures 1, 3 and 5, the vertical lifting of the levers is facilitated by a linear lever lifting unit (109) that is crosswise to warp slivers (101) and aligned down the levers. The linear lever lifting unit (109) moves vertically in the slot made in the left and right sides of the mounting frame (326). It is comprised of a shaft (510), rachet (511) on each side of the shaft (510) and the profile cut lever lifting plates (512) fixed latitudinally on the shaft at angles corresponding to the number of steps of the weaving patterns. The linear lever lifting unit (109) has a mechanical indexer. The indexing flat cam (513) is attached to the shaft (510) whereas the indexer guide (514) and guide stopper (515) are fixed on the mounting frame (126) beside the slot in it. The indexing flat cam (513) and the indexer guide (514) have a functional alignment. The guide stopper (515) is fixed above the indexer guide (514) to stop the upward movement of the guide. A spring or other elastic element (516) is connected between the Indexer guide (514) and the guide stopper (515).
[0068] Referring to Figures 1, 2, and 6, a pair of ropes or cables (118) is attached to the body of ratchets (211). These ropes are passed through the set of pulleys (117) fixed on the bottom side of the top of the mounting frame (127). Further, the ropes (118) are attached to the mounting disc (620) of the pivoting handle (119, 619). The handle (621) is pivoted on a mounting disc (620) to absorb pulling angle variation and wrist angle variation for achieving smooth lifting motion by load and tension balancing.
[0069] A beater (122) is attached to the mounting frame (126) at the bottom side of its top (127) with an elastic element like elastic rope or spring rope (125).
Working of the machine
[0070] Referring to Figure 3 (3-1, 3-2, 3-3), 4, 5 and 6, when the operator pulls the pivoting handle (119, 219) the attached pair of ratchets (211) moves up holding the linear lever lifting unit (109). The vertical movement of the shaft, which is secured with the pair of ratchets (211), is guided by the slot made in the left and right sides of the mounting frame (126). In this up-stroke, the indexing flat cam (313) engages with the indexer guide (314) and starts rotating the shaft in a direction allowed by the ratchets (211), until it disengages. The profile of the indexing cam (313, 513) determines the angle of rotation. It brings the corresponding lever lifting plate (312, 512) under the sliver lifting levers (304, 504). Further, the lever lifting plate (312) lifts the levers (304, 504) according to its cut profile. Its continuous section serves as a hook and lifts the levers above it while the levers above the void area remain stationary. Here, the unidirectional rotating function of the rachets (211, 511) prevents the shaft from rotating backwards while the levers are hooked. The combination of lifted levers eventually lifts the corresponding warp slivers (101) required for the particular step of the pattern and a shed is created into which the operator inserts weft slivers (402) crosswise. Then, using a beater (122, 422), the operator beats the weft slivers (402) inwards against the previous rows of woven mats. It ensures the weft slivers (402) are tightly packed and securely interlaced with the warp slivers (101, 401), resulting in a well-formed mat. The elastic rope (125) attached to the beater (122) aids it to get back to its original position on release.
[0071] Then, on releasing the pull or tension off the pivoting handle (119), the linear lever lifting unit (109) starts moving down. In this down-stroke, the shaft engages with the indexer guide (314, 514), rotates the indexer guide (314, 514) and moves down by disengaging itself. Once the shaft is disengaged the spring (516) brings back the indexer guide (314, 514) to its original position. Also, the linear lever lifting unit (109) reaches its initial position. In this downward movement, the ratchets (511) prevent the shaft (510) from rotating.
[0072] Eventually, as the linear lever lifting unit (109) goes down, all lifted warp slivers (101) also get down to their original flat position. Here, the weight of the slat (508) that is loosely attached over the row of sliver guides (507, 307) aids in smooth and in-sync down movement of the lifted slivers (101, 301). Thus, one stroke of weaving is completed. This process continues the same way for the entire weaving of the mat.
[0073] Figure 7 shows the convertible function of sliver lifting operation from manual to electric powered. The top of the mounting frame (727) has a fastening arrangement for the electric lifting device (728). The ropes attached to the ratchets (118) are to be interchanged with ropes or connecting levers (729) of the electric lifting device (728) to convert the sliver lifting operation from manual to electric powered. A footswitch (730) is given for the pulling controls.
[0074] Figure 8 shows just a few sample shapes of mats and related arrangements of warp setup.
[0075] Referring to figures 1, 3, 4 and 8, the sliver lifting levers (304) that hold warp slivers (101) and sliver guides (807) can rotate at a desired angle. The warp fixing clamp (831, 431) is attached to the mounting frame (126) by simple telescopic pipe arrangement at the left and right sides. So, the warp fixing clamp (431, 831) can be adjusted in straight as well as in skewed angles. Also, the orientation angle of the beater (822, 122) can be changed as required. Thus, the shape of the mat is not limited to rectangle only but the mats with trapezoid, isosceles trapezoid, parallelogram, rhombus etc. can be made with this machine by just changing the orientation angle of the warp slivers (101) and the clamp (831). Some weaves that require a diagonal sliver setup can also be made with this newly invented machine.
[0076] The figure 9 shows few of components of this newly invented machine that are related to customization of width of warp sliver and/or pattern and/or gap between warp slivers. They are functionally designed in a way that their manufacturing can be done through computerized 2D cutting and additive manufacturing method like 3D printing. These are precise manufacturing methods with flexibility for customization, quick turnaround, less setup time and thus highly suitable for small volume manufacturing. Additionally, a user can print the 2D profile cutting drawings (905, 906, 912, 923) and attach it as a reference over the material for manual cutting.
[0077] Further figure 9-3 refers to the system (942) developed to automatically create drawings of these components on a single click based on user inputs like selection of required pattern, warp sliver width, distance between warp slivers etc. These drawings are used for 2D cutting (figure 9-1) and 3D printing (figure 9-2). Figure 9-1 refers to 2D drawings of components viz. lever guides (905), free sliding lever guide (906), lever lifting plates (912) and beater frame (923) whereas figure 9-2 refers to the CAD drawing of sliver guides (907). Customization of mat designs can be easily achieved using the same machine by simply replacing the related components.
[0078] The present invention introduces a novel craft-focused, semi-automatic manual and electric convertible machine designed specifically for weaving bamboo sliver mats with versatile patterns, shapes, and customizable sliver widths. The intricate details of the invention are elucidated below:
Machine Components:
[0079] The machine comprises several integral components that collectively contribute to its innovative functionality. The central element is the mounting frame (126), which serves as the foundational structure for the machine. Attached to this frame are key components, including the sliver lifting levers and guides assembly (103), linear lever lifting unit with a mechanical indexer (109), set of pulleys (117), ropes/cables (118), pivoting handle (119), beater (122), warp fixing clamp (131), an electric-powered lifting device (728), mechanical pattern step counter (132), parts of mechanical length control guide (435, 436, 437), electronic pattern step counter (740), object detection sensor (741), and electronic controller with alarm and buzzer (738).
Sliver Lifting Mechanism:
[0080] The heart of the invention lies in the automated sequencing of combinations of warp slivers. The sliver lifting levers and guides assembly includes lever guides (505) with holes for arranging sliver lifting levers (504) and facilitating their vertical movement. A free sliding lever guide (506) moves in tandem with the levers, maintaining their alignment during vertical motion. Operator-end of multiple warp slivers (101) is clamped with a warp fixing clamp (131), and the other ends are passed through beater wires (224) and sliver guides (307, 507) attached to the sliver lifting levers (304, 504).
Linear Lever Lifting Unit:
[0081] Vertical lifting of the levers is facilitated by the linear lever lifting unit (109), positioned crosswise to the warp slivers. The unit moves vertically within slots on the sides of the mounting frame (126). The unit comprises a shaft (510), ratchets (511) on each side of the shaft (510), and profile cut lever lifting plates (512) fixed latitudinally on the shaft. An essential mechanical indexer, featuring an indexing flat cam (513), indexer guide (514), and guide stopper (515), ensures precise positioning of the corresponding lever lifting plate under the levers with each weaving stroke. A spring or elastic element (516) aids in the upward movement.
Operational Process:
[0082] When the operator pulls the pivoting handle (119), the attached pair of ratchets (211) moves upward, lifting the linear lever lifting unit (109). The indexing flat cam (313) engages with the indexer guide (314), rotating the shaft to position the appropriate lever lifting plate (312, 512) under the levers. This action lifts the required warp slivers (301) to create a shed for the insertion of weft slivers (402). The beater (122, 422) is manually used to beat the weft slivers (402) inward, ensuring a tightly woven mat. Releasing tension on the pivoting handle initiates the downward movement of the linear lever lifting unit. The indexer guide disengages from the shaft, and the unit returns to its initial position, lowering the lifted warp slivers. The process repeats for the entire mat-weaving cycle.
Convertible Functionality:
[0083] The invention boasts a convertible functionality, allowing for both manual and electric-powered operation. The ropes attached to the ratchets (211) can be interchanged with ropes or connecting levers (729) of electric lifting device (728), facilitating the conversion from manual to electric-powered sliver lifting. A footswitch (730) is provided for controlling the hoist during electric operation.
Customization and Versatility:
[0084] Key components related to the customization of sliver width, pattern, and gap between warp slivers are designed for precision manufacturing with computerized 2D cutting and additive manufacturing methods like 3D printing, facilitating easy customization. A system is developed to automatically generate drawings based on user inputs, streamlining the customization process.
[0085] The orientation angle of the beater, warp sliver clamp, and levers can be adjusted, allowing for the creation of mats in various shapes, including trapezoid, isosceles trapezoid, parallelogram, rhombus, and accommodating weaves requiring diagonal sliver setups.
[0086] The present invention is a cost-effective a semi-automatic manual and electric convertible machine intended for weaving fine and uniform quality bamboo sliver mats with a diverse range of patterns, versatile patterns, shapes, and sliver widths. The machine's adaptability to both manual and electric power operation, combined with its customization features, positions it uniquely in the realm of mat weaving machinery, catering to the craft needs of artisans and manufacturers alike.
[0087] Therefore, compared to existing technologies, the present invention addresses drawbacks associated with limited patterns, complex customization requirements, and cost-prohibitive machinery for low-income artisans. The machine's adaptability, convertible functionality, and focus on craft-oriented weaving make it an innovative and cost-effective solution for artisans engaged in bamboo mat weaving. The detailed design ensures ease of use, enhanced productivity, and expanded creative possibilities for traditional artisans, bridging the gap between tradition and technology in the craft industry.
[0088] As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its essential characteristics. The present embodiments are, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the foregoing description, and all changes which come within therefore intended to be embraced therein.

, Claims:
WE CLAIM:
1. A semi-automatic manual and electric convertible machine for weaving bamboo sliver mats of versatile patterns, sliver width, and shapes, comprising:
a. a mounting frame (126),
b. a sliver lifting levers and guides assembly (103),
c. a linear lever lifting unit with a mechanical indexer (109),
d. a set of pulleys (117),
e. ropes/cables (118),
f. a pivoting handle (119),
g. a beater (122), and
h. a warp fixing clamp (131),
wherein the machine is operable manually or electrically for lifting combinations of warp slivers as per a predefined pattern;
wherein the sliver lifting levers and guides assembly comprises lever guides (305) with holes for an arrangement of levers (304) and their vertical movement, and a free sliding lever guide (306) that moves up and down with the levers to maintain alignment during vertical movement; and
wherein the linear lever lifting unit (109) comprises a shaft (510), ratchets (511) on each side of the shaft, and profile cut lever lifting plates (512) fixed latitudinally on the shaft, the linear lever lifting unit further comprising a mechanical indexer with an indexing flat cam (513) engaging an indexer guide (514), and a guide stopper (515) with an elastic element (516) for controlling upward movement.
2. The semi-automatic manual and electric convertible machine as claimed in claim 1, comprising a set of pulleys, ropes/cables, and a pivoting handle, with the ropes attached to the ratchets of the linear lever lifting unit, enabling manual operation by pulling the pivoting handle to lift the warp slivers.
3. The semi-automatic manual and electric convertible machine as claimed in claim 1, wherein the machine is convertible to electric power, featuring a mounting frame with a fastening arrangement for an electric-powered lifting device such as a hoist, winch, pneumatic, mechanical or electric actuator or other rotary to linear mechanism with the ropes attached to the ratchets interchangeable with ropes or connecting levers of electric-powered lifting device, allowing electric-powered sliver lifting.
4. The semi-automatic manual and electric convertible machine as claimed in claim 1, wherein a manual operation of lifting the linear lever lifting unit is achieved by pulling it by hand using ropes or by a foot-operated mechanism.
5. The semi-automatic manual and electric convertible machine as claimed in claim 1, wherein components related to customization of a width of warp sliver, weaving pattern, and gap between warp slivers are designed for manufacturing through computerized two-dimensional (2D) profile cutting or manual profile cutting and additive manufacturing methods including three-dimensional (3D) printing and are supported by a system for generating drawings based on user inputs.
6. The semi-automatic manual and electric convertible machine as claimed in claim 1, wherein the semi-automatic manual and electric convertible machine is configured to be operable for weaving mats from raw materials other than bamboo slivers, including organic or synthetic materials.
7. The semi-automatic manual and electric convertible machine as claimed in claim 1, wherein the operations including inserting weft sliver in the shed created by lifted warp slivers and/or beating of weft slivers for tightening the weave and/or moving or rolling of mat are automized.
8. The semi-automatic manual and electric convertible machine as claimed in claim 1, comprises an adjustable warp fixing clamp allowing straight or skewed angles, and rotatable levers and sliver guides, enabling the creation of mats with various shapes such as trapezoid, isosceles trapezoid, parallelogram, rhombus, and diagonal sliver setups.
9. An automatic machine for weaving bamboo sliver mats of versatile patterns, sliver width, and shapes, comprising:
a mounting frame (126) supporting the functional mechanisms of the machine;
a sliver lifting levers and guides assembly (103) incorporating lever guides with holes for an arrangement of levers and their vertical movement, a free sliding lever guide (306) that moves up and down with the levers, aligning the levers throughout their vertical movement, and sliver guides (307, 507) for guiding warp slivers (101) during the weaving process.
a linear lever lifting unit with a mechanical indexer (109) positioned crosswise to warp slivers (101) and aligned down the levers, facilitating vertical movement and controlled lifting of the levers to create sheds in accordance with a predetermined weaving pattern;
a set of pulleys (117) and ropes/cables (118) attached to ratchets (511) of the linear lever lifting unit, allowing for the manual operation of the machine by pulling a pivoting handle (119) or the convertible electric operation by interchanging the ropes with ropes or connecting levers of (703) an electric lifting device (728);
a beater (122) attached to the mounting frame for manually beating the weft slivers (402) against the previously woven rows, ensuring tight packing and secure interlacing with the warp slivers (101);
a warp fixing clamp (131) attached to the mounting frame, enabling adjustment of warp sliver orientation at straight or skewed angles, contributing to the creation of mats with versatile shapes;
components designed for customization of width of warp sliver, pattern, and gap between warp slivers, with manufacturing capabilities through computerized 2D cutting and additive manufacturing methods, further supported by a system for automatic generation of drawings based on user inputs;
sliver lifting levers (304, 504) and sliver guides (307, 507) designed to rotate at desired angles, allowing for the creation of mats with various shapes, including trapezoid, isosceles trapezoid, parallelogram, rhombus, and others, by changing the orientation angle of the warp slivers (101) and the clamp (131);
the automatic machine's capability to weave mats from compatible raw materials other than bamboo slivers, whether organic or synthetic, extending its versatility in material usage.
10. The automatic machine for weaving bamboo sliver mats of versatile patterns, sliver widths and shapes as claimed in claim 9, further comprises:
a mounting frame (1026), a sliver lifting levers and guides assembly (1003), a linear lever lifting unit with a mechanical indexer (1009), an electric lifting device (1028) such as a hoist, winch, pneumatic, mechanical or electric actuator or other rotary to linear mechanism fixed on the top of mounting frame (1026), an electric sliver feeder (1043) with a controller, an electric beater (1044), clamping rollers (1045), foot switches (1030) and error proofing and guiding systems comprising an electronic pattern step counter (1040), object detection sensor (1041), electronic controller with alarm and buzzer (1038), laser line marker (1039).
11. The automatic machine as claimed in claim 10, wherein the sliver lifting levers and guides assembly comprises lever guides (305) with holes for an arrangement of sliver lifting levers (304) and their vertical movement, and a free sliding lever guide (306).
12. The automatic machine as claimed in claim 10, wherein the linear lever lifting unit (109) comprises a shaft (510), ratchets (511) on each side of the shaft, and profile-cut lever lifting plates (512) fixed latitudinally on the shaft.
13. The automatic machine as claimed in claim 10, wherein the linear lever lifting unit further comprises a mechanical indexer with an indexing flat cam (513) engaging an indexer guide (514), and a guide stopper (515) with an elastic element (516) for controlling upward movement.
14. A method for weaving bamboo sliver mats using a semi-automatic manual, an automated, and an electric convertible machine as claimed in claims 1, 9, and 10 comprising the steps of:
a. providing a machine having a mounting frame (126), sliver lifting levers and guides assembly (103), linear lever lifting unit with a mechanical indexer (109), set of pulleys (117), ropes/cables (118), pivoting handle (119), beater (122), and warp fixing clamp (131), wherein the machine is operable either manually or electrically;
b. setting up the warp slivers (101) by clamping operator end of plurality of warp slivers and the other end of these slivers passing through the beater wires (224) and further through the sliver guides (307, 807) that are attached to the sliver lifting levers.
c. initiating the weaving process by an operator pulling the pivoting handle (119), causing the attached pair of ratchets (211) to move up, holding the linear lever lifting unit (109);
d. guiding the vertical movement of the shaft (510), secured with the pair of ratchets (511), through the slot made in the left and right sides of the mounting frame (126);
e. engaging the indexing flat cam (313) with the indexer guide (314) during the up-stroke followed by initiating the clockwise rotation of the shaft (510) until disengagement, wherein the profile of the indexing flat cam (313) determines the angle of rotation;
f. lifting the corresponding lever lifting plate (312, 512) under the sliver lifting levers (304, 504), where the continuous section of the lever lifting plate (312, 512) serves as a hook, lifting the levers (304, 504) above it while keeping levers above the void area stationary;
g. utilizing the unidirectional rotating function of the ratchets (511) to prevent backward rotation of the shaft (510) while the levers are hooked, resulting in the lifting of corresponding warp slivers (301) to create a shed;
h. inserting weft slivers (402) crosswise into the shed created by the lifted warp slivers (301, 401);
i. beating the weft slivers (402) using the beater (122) inwards against the previous rows of woven mat, ensuring tight packing and secure interlacing with the warp slivers (101);
j. returning the beater (122) to its original position by aiding on release by an elastic rope (125) attached to the beater;
k. releasing the pull or tension off the pivoting handle (119), initiating the downward movement of the linear lever lifting unit (109);
l. engaging the shaft (510) with the indexer guide (314, 514) in the down-stroke followed by rotating the indexer guide (314, 514), and moving down by disengaging itself;
m. bringing back the linear lever lifting unit (109) to its initial position, disengaging the shaft (510), and allowing the spring (516) to return the indexer guide (314, 514) to its original position;
n. utilizing the ratchets (511) to prevent the backward rotation of the shaft (510) during the downward movement; and
o. completing one stroke of weaving and repeating the process for the entire weaving of the mat.
15. The method as claimed in claim 14, the method further comprises the step of converting the sliver lifting operation from manual to electric powered by interchanging the ropes attached to the ratchets (511) with ropes or connecting levers (729) of an electric lifting device (728), the top of the mounting frame (727) having a fastening arrangement for the electric motorized lifting device.
16. The method as claimed in claim 14, wherein the sliver lifting levers (304) holding warp slivers (101) and sliver guides (307, 807) can rotate at desired angles, allowing for the creation of mats with various shapes, including trapezoid, isosceles trapezoid, parallelogram, rhombus, and others, by changing the orientation angle of the warp slivers (801) and the warp fixing clamp (831).
17. The method as claimed in claim 14, wherein components related to customization of a width of warp sliver, pattern, and gap between warp slivers are designed for manufacturing through computerized or manual 2D cutting and additive manufacturing methods.
18. The method as claimed in claim 14, comprises the step of utilizing a system for the automatic generation of drawings based on user inputs such as pattern selection, warp sliver width, and distance between warp slivers allowing for 2D cutting and 3D printing of components to achieve customization.
19. A system for creating drawings of components related to customization of the machine, generating 2D cutting and 3D printing drawings based on user inputs such as pattern selection, warp sliver width, and distance between slivers.

DATED: 5th day of April, 2024

AGENT FOR APPLICANT

Dr. Suryawanshi Mohini K.
(IN/PA-2023)