Description:FIELD OF THE INVENTION

[0001] The present invention relates to an autonomous industrial defect detection and rectification device that is capable of automatically detecting and correcting defects on industrial products in real-time, improving quality, reducing downtime, and enhancing safety and efficiency in various manufacturing industries.

BACKGROUND OF THE INVENTION

[0002] The manufacturing industry plays a vital role in the global economy, producing goods that meet consumer demands. Ensuring product quality and reliability is crucial to maintaining customer satisfaction, preventing costly recalls, and upholding brand reputation. Defects in industrial products lead to significant economic losses, compromised safety, and environmental hazards.

[0003] Traditionally, defect detection and rectification rely on manual inspection and correction techniques, including visual inspections, basic measurement tools, offline quality control checks, and manual repair. However, these methods are plagued by limitations, including human error, time-consuming processes, limited scalability, safety risks, lack of real-time feedback, and inconsistent quality.

[0004] US20180211373A1 discloses a method for detecting a defect in an object includes: capturing, by one or more depth cameras, a plurality of partial point clouds of the object from a plurality of different poses with respect to the object; merging, by a processor, the partial point clouds to generate a merged point cloud; computing, by the processor, a three-dimensional (3D) multi-view model of the object; detecting, by the processor, one or more defects of the object in the 3D multi-view model; and outputting, by the processor, an indication of the one or more defects of the object.

[0005] US11724315B2 discloses a system and method of additive manufacturing is disclosed herein which when run or performed form a product with a powder-based additive manufacturing device by adding sequential layers of material on top of one another. As each sequential layer of material is added, the system and method can include monitoring the sequential layer with a defect analysis subsystem to detect whether the sequential layer has any defects. For a detected defect, it can be determined whether defect correction is required. For a required defect correction, one or more correction parameters for the required defect correction can be identified; and a correction command including the one or more correction parameters can be sent to the additive manufacturing device, the correction command causing the additive manufacturing device to help correct the detected defect in the sequential layer according to the correction parameters prior to moving on to a next sequential layer.

[0006] Conventionally, there exists many devices that are capable of monitoring defects on industrial products, however these existing devices are incapable of providing real-time alerts, intuitive guidance, and seamless monitoring capabilities. In addition, these existing devices also fail in lowering the costs associated with manual defect correction processes.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to be capable of automating defect detection and correction to optimize industrial product quality, productivity, and safety. Furthermore, the developed device also needs to be potent enough of facilitating informed decision-making among industrial personnel.

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 automatically identifying and classifying various defects on industrial products with high precision, ensuring consistent quality control and minimizing the risk of defective products entering the market.

[0010] Another object of the present invention is to develop a device that is capable of rapidly and effectively correcting detected defects for reducing production downtime, increasing overall productivity, and lowering the costs associated with manual defect correction processes.

[0011] Yet another object of the present invention is to develop a device that is capable of providing real-time alerts, intuitive guidance, and seamless monitoring capabilities, ultimately ensuring operator safety, streamlining defect management workflows, and facilitating informed decision-making among industrial personnel.

[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 autonomous industrial defect detection and rectification device that is capable of real-time defect detection and correction, which enhances quality, reduces downtime, and optimizes manufacturing efficiency.

[0014] According to an embodiment of the present invention, an autonomous industrial defect detection and rectification device, comprising a cuboidal body designed to be placed over a ground surface within industrial areas, such as factories, warehouses, or manufacturing facilities, a four-bar linkage arrangement with the body that provides stability and support, a pair of continuous tracks that are driven by the wheels allowing the body to move over various terrains within industrial areas, an artificial intelligence-based imaging unit installed on the body to capture high-quality images of industrial products, particularly casting products, for accurate defect detection, a sensing module, which integrated in the body to detect various defects on casting products, an extendable link arranged with a slider-crank mechanism, installed on the body to move the link for removal of burrs from the surface of product and an electromagnetic clamp installed on end effector of the link for removing burr and providing finishing to the surface.

[0015] According to another embodiment of the present invention, the proposed device further comprises of an augmented reality (AR) LED holographic projector installed over apex portion of the body that projects detected defect images, safety alerts, and guidance for authorized personnel in proximity to the body, a robotic arm installed with an electronic nozzle on the body to provide movement to the nozzle for marking location of large defects a marking ink, a storage vessel connected with the nozzle stored with the ink over the housing by means of a conduit, a spring hammer mechanism installed on the body to impart controlled vibrations or impacts onto casting products, the hammer is powered by BLDC (Brushless Direct Current) motor, a GPS (Global Positioning System) module is integrated with the microcontroller to monitor the location of the body and a battery is associated with the device to supply power to electrically powered components which are employed herein.

[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 autonomous industrial defect detection and rectification 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 autonomous industrial defect detection and rectification device that is capable of automatically detecting and correcting industrial product defects, streamlining production, improving quality, and ensuring operator safety.

[0022] Referring to Figure 1, an isometric view of an autonomous industrial defect detection and rectification device is illustrated, comprising a cuboidal body 101 installed with a four-bar linkage arrangement 102, a pair of continuous tracks 103 is provided on bottom portion of the body 101, driven by wheels 104, an artificial intelligence-based imaging unit 105 installed on the body 101, an extendable link 106 integrated with a slider-crank mechanism 107, provided on the body 101, an electromagnetic clamp 108 mounted on end effector of the link 106, an augmented reality (AR) LED holographic projector 109 mounted on upper section of body 101, an electronic nozzle 110 mounted on a robotic arm 111 installed on the body 101, a dedicated storage chamber 112 is provided with the body 101, a storage vessel 113 is provided on the body 101 and a spring hammer mechanism 114 is mounted on the body 101.

[0023] The device disclosed herein, comprises of a cuboidal body 101, which serves as a main structure of the device and designed to be placed over a ground surface within industrial areas, such as factories, warehouses, or manufacturing facilities. The body 101 arranged with a four-bar linkage arrangement 102, which is a mechanical arrangement, consisting of four linked bars that provides stability and support. The four-bar linkage arrangement 102 enables the device to maintain its structure and balance while navigating uneven terrains.

[0024] To facilitate movement, the bottom portion of the cuboidal body 101 is equipped with a pair of continuous tracks 103, which are driven by wheels 104, allowing the device to navigate over various terrains within industrial areas. The continuous tracks 103 provide traction, stability, and mobility on different surfaces, including smooth floors, rough terrain, or inclined planes. The track wheels 104 consist of rugged threads or cleats that provide traction and prevent slipping of the body 101. The wheels 104 are connected to an electric motor which propels the body 101 forward or backward. This allows the body 101 to move efficiently across surfaces like gravel, dirt, mud, or uneven terrain.

[0025] An artificial intelligence-based imaging unit 105 installed on the cuboidal body 101, designed to capture high-quality images of industrial products, particularly casting products, for accurate defect detection. The artificial intelligence based imaging unit 105 is constructed with a camera lens and a processor. The processor carries out a sequence of image processing operations including pre-processing, feature extraction, and classification.

[0026] The image captured by the imaging unit 105 is real-time images. The processor analyzes images captured by the imaging unit 105, applies artificial intelligence and machine learning protocols for defect detection, and identifies defects. The artificial intelligence based imaging unit 105 in communication with a microcontroller, wherein the microcontroller used herein is an Arduino Uno microcontroller. The artificial intelligence based imaging unit 105 transmits the captured image signal in the form of digital bits to the microcontroller. The microcontroller upon receiving the image signals scans the images for real-time defect detection on industrial products.

[0027] After scanning the images, the microcontroller actuates a sensing module, which integrated in the body 101 to detect various defects on casting products. The sensing module comprises multiple sensors, including an ultrasonic sensor, thermal imaging sensor, and acoustic emission sensor. The ultrasonic sensor detects internal defects, such as porosity, inclusions, internal cracks, and voiding.

[0028] The ultrasonic sensor emits high-frequency waves toward the tire and measures the time it takes for the waves to bounce back after hitting the industrial products. The sensor is typically oriented in a way that it measures the defects of the industrial products. The ultrasonic sensor collects a significant amount of data by scanning the entire surface of the industrial products and forms a 3D point cloud, which represents the defects. The ultrasonic sensor sends the data to a microcontroller which processes the acquired data and detects the defects of the industrial products.

[0029] Where, the thermal imaging sensor detects heat patterns in castings, indicating temperature anomalies, cooling rate irregularities, and material inconsistencies. Inside a thermal imaging sensor, there is a special sensor called a microbolometer, which is made up of tiny pixels that can detect infrared radiation, which is the heat patterns in casting. When the infrared radiation hits the pixels, it causes a change in electrical resistance. The thermal imaging sensor then measures this change in resistance for each pixel and converts it into a temperature value.

[0030] Simultaneously, the acoustic emission sensor detects material failure, deformation, or crack formation, including high-frequency sound waves emitted by crack growth, material deformation or plasticity, and impact or stress-induced damage. When a material undergoes stress, deformation, or fracture, it releases energy in the form of high-frequency sound waves. These sound waves propagate through the material and are detected by the acoustic emission sensor. The sensor captures the sound waves, amplifies the signal, and processes the information. The resulting data is analyzed by the microcontroller to identify material failure, deformation, or crack formation.

[0031] An extendable link 106 arranged with a slider-crank mechanism 107, installed on the body 101. After detecting the defects, the microcontroller actuates the slider-crank mechanism 107 to move the link for removal of burrs from the surface of product. The slider crank mechanism consists of a motor connected to a crank that rotates around a fixed pivot. As the motor turns the crank, it moves a connecting link attached to a slider. This slider moves linearly along a track or rail, converting the rotational motion of the crank into linear motion. The length of the crank and the position of the pivot determine the range and speed of the slider's movement. This mechanism is commonly used in applications requiring precise linear actuation, such as in mechanical units for lifts or assistive devices, providing controlled movement and stability to link.

[0032] After moving the link 106, the microcontroller actuates an electromagnetic clamp 108 installed on end effector of the link for removing burr and providing finishing to the surface. The clamp 108 includes a pair of flaps which are pivoted with each other for allowing the axial motion of the flaps required for clasping the burr, wherein the clamp 108 is powered by an electromagnet to clasp the burr for initiating removal process.

[0033] The electromagnet consists of a core material typically made of iron or steel wrapped with an insulated wire. The wire is coiled around the core to form a solenoid. The electromagnet is connected to a power source, usually a battery or a low-voltage power supply. When an electric current flows through the wire, it creates a magnetic field around the solenoid. The direction of the magnetic field depends on the direction of the current flow and as the electromagnets activates, the burr attached with the clamp 108, thereby gripping the burr from surface and providing surface finishing. Herein, a storage chamber 112 installed with the body 101 that stores different types of sanding files. As per the detected surface defects such as scratches/dents, the microcontroller selects the accurate grade.

[0034] The device features an augmented reality (AR) LED holographic projector 109, which is installed over apex portion of the body 101 for projecting detected defect images, safety alerts, and guidance for authorized personnel in proximity to the body 101. On actuation of holographic projecting unit by the microcontroller, the light source emits various combination of lights towards the lens which is further portrayed in front of the authorized personnel to project the virtual images depicting defect images, safety alerts, and guidance for authorized personnel near the body 101.

[0035] Synchronously, the microcontroller generates notification over a computing unit, which is wirelessly linked with the microcontroller, of a concerned personnel to allow the concerned personnel to determine real-time defect, reporting, assign and take control over activities of the body 101. The computing unit is linked wirelessly with the microcontroller via a communication module which includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The user interface serves as a bridge between the concerned personnel and the microcontroller, allowing for a user-friendly way to allow the concerned personnel to determine real-time defect, reporting, assign and take control over activities of the body 101.

[0036] After successful detection of defects over the casting product, the microcontroller actuates a robotic arm 111 having an electronic nozzle 110, which is mounted on the body 101 to provide movement to the nozzle 110 for marking location of large defects such as inclusions, blowholes, metal penetration with a marking ink over the casting product. The robotic arm 111 is a type of mechanical arm which is usually available with similar function to a human arm.

[0037] The segments of such a manipulator are connected by joints allowing either rotational motion or translational displacement. The robotic arm 111 contains several segments that are attached together by joints also referred to as axes. The robotic arm 111 contains several segments that are attached together by motorized joints also referred to as axes. Each joints of the segments contains a step motor that rotates and allows the robotic arm 111 to complete a specific motion in translating the equipped nozzle 110 over the casting product.

[0038] After positioning the nozzle 110 over the casting product, the microcontroller actuates the nozzle 110 to dispense the ink for marking location, wherein the nozzle 110 connected with a storage vessel 113 stored with the ink over the housing by means of a conduit. The electronic nozzle 110 works by utilizing electrical energy to automize the flow solution in a controlled flow pattern by converting the pressure energy of a fluid into kinetic energy, which increases the fluid's velocity. The electric nozzle 110 is connected to a liquid source, i.e., ink. Upon actuation of nozzle 110 by the microcontroller, the electric motor or the pump pressurizes the incoming ink, increasing its pressure significantly. High pressure enables the ink to be dispensed out with a high force, thereby marking location of large defects on the casting product.

[0039] A spring hammer mechanism 114 installed on the body 101, designed to impart controlled vibrations or impacts onto casting products. The spring hammer mechanism 114 is powered by a BLDC (Brushless Direct Current) motor, known for its high efficiency, reliability, and precision control.

[0040] The BLDC (Brushless Direct Current) motor enables the spring hammer to operate with precise force and speed, crucial for inducing consistent vibrations. Upon activation, the spring hammer rapidly drops onto the casting product, generating controlled impacts. These impacts produce high-frequency sound waves that travel through the product. Simultaneously, an acoustic emission sensor, integrated into the device, detects and maps these sound waves in real-time.

[0041] The spring hammer mechanism 114 consists of several key components, including a spring, hammer, BLDC (Brushless Direct Current) motor, gearbox, and trigger mechanism. The spring, typically a compression or torsion spring, stores energy when compressed or twisted, which stored energy is then released rapidly to generate the hammer's striking motion. The hammer itself is usually made of a durable material, such as metal or ceramic, and is designed to withstand repeated impacts.

[0042] The operation of the spring hammer mechanism 114 begins with the charging phase. During this phase, the BLDC motor slowly rotates, compressing the spring via a gearbox (if present) or directly. The gearbox adjusts the motor's speed and torque to achieve the desired force and speed. Once the spring is fully compressed, the trigger mechanism locks it in place, storing potential energy.

[0043] When the trigger mechanism releases the compressed spring, the stored energy is rapidly unleashed, propelling the hammer forward, which results in a high-speed impact, essential for inducing controlled vibrations in the casting product. The spring then returns to its compressed state, ready for the next cycle. This process is repeated at a controlled frequency, allowing for consistent and precise testing.

[0044] A GPS (Global Positioning System) module is integrated with the microcontroller to monitor the location of the body 101. The GPS (Global Positioning System) module consists of a receiver that communicates with the satellites to determine the exact location of the body 101 in the industrial area. The GPS (Global Positioning System) module constantly receives signals from the satellites and calculates the coordinates. The GPS module works by receiving signals from multiple satellites orbiting the Earth. The GPS module uses the timing of these signals and trilateration to calculate the precise location of the body 101 in the industrial area. The microcontroller linked with the GPS (Global Positioning System) module processes the data received from the GPS (Global Positioning System) module and transmits the body 101’s precise location data including the latitude and the longitude of the body 101. The real-time location coordinates of the body 101 are then sent to the computing unit to enable the concerned personnel to monitor the body 101’s positioning and location inside the industrial area.

[0045] 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 electrode 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.

[0046] The present invention works best in following manner, where the cuboidal body 101 as disclosed in the invention is developed to be placed over the ground surface within industrial areas, such as factories, warehouses, or manufacturing facilities, the four-bar linkage that provides stability and support, the pair of continuous tracks 103 that are driven by the wheels 104 allowing the body 101 to move over various terrains within industrial areas, the artificial intelligence-based imaging unit 105 to capture high-quality images of industrial products, particularly casting products, for accurate defect detection, the sensing module to detect various defects on casting products, the extendable link 106 with the slider-crank mechanism 107 to move the link for removal of burrs from the surface of product. Further, the electromagnetic clamp 108 for removing burr and providing finishing to the surface, the augmented reality (AR) LED holographic projector 109 projects defect images, safety alerts, and guidance for authorized personnel in proximity to the body 101, the robotic arm 111 to provide movement to the nozzle 110 for marking location of large defects the marking ink, the storage vessel 113 stored with the ink over the housing by means of the conduit, the spring hammer mechanism 114 to impart controlled vibrations or impacts onto casting products. Herein, the hammer is powered by BLDC (Brushless Direct Current) motor, the GPS (Global Positioning System) module to monitor the location of the body 101 and the battery to supply power to electrically powered components which are employed herein.

[0047] 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. , C , Claims:1) An autonomous industrial defect detection and rectification device, comprising:

i) a cuboidal body 101 developed to be positioned on a ground surface and installed with a four-bar linkage arrangement 102, wherein a pair of continuous tracks 103 is provided on a bottom portion of said body 101, driven by wheels 104 for movement, allowing said body 101 to navigate to move over different terrains within industrial areas;

ii) an artificial intelligence-based imaging unit 105 installed on said body 101 and paired with a processor for accurate image scanning and real-time defect detection on industrial products, wherein a sensing module is installed on said body 101 that detects various defects over various casting products, along with determining surface defects, including burrs, scratches, rough finishes, or dents on surface of industrial product;

iii) an extendable link 106 integrated with a slider-crank mechanism 107, provided on said body 101 that is actuated by said microcontroller for simulating toggle movements to assist in removing burrs from product surfaces, wherein an electromagnetic clamp 108 mounted on end effector of said link to interact with sanding files for burr removal and surface finishing;

iv) an augmented reality (AR) LED holographic projector 109 mounted on upper section of body 101 that projects defect images, safety alerts, and guidance for authorized personnel near said body 101, wherein synchronously said microcontroller sends alert notification on a computing unit accessed by a concerned personnel, providing a user interface to monitor, assign, and control body 101’s activities, including real-time defect detection and reporting; and

v) an electronic nozzle 110 mounted on a robotic arm 111 installed on said body 101, wherein post detection of defects over said casting product, said microcontroller collectively actuates said robotic arm 111 and nozzle 110 for marking locations of large defects (e.g., inclusions, blowholes, metal penetration) on said casting product with a marking ink; and

2) The device as claimed in claim 1, wherein said sensing module includes an ultrasonic sensor for detecting internal defects, a thermal imaging sensor for detecting heat patterns in castings, and an acoustic emission sensor for detecting material failure, deformation, or crack formation.

3) The device as claimed in claim 1, wherein a dedicated storage chamber 112 is provided with said body 101 for various grades of sanding files, and said microcontroller selects appropriate grade based on detected surface irregularities like scratches or dents.

4) The device as claimed in claim 1, wherein a storage vessel 113 is provided on said body 101 to store marking ink, which is connected to said nozzle 110 via a conduit for precise application to marked defect areas.

5) The device as claimed in claim 1, wherein a spring hammer mechanism 114 is mounted on said body 101, said spring hammer is powered by a BLDC (Brushless Direct Current) motor, and is configured to drop rapidly onto said casting products to induce controlled vibrations or impacts, and during impact, said acoustic emission sensor maps resulting high-frequency sound waves to detect cracks or deformations based on sound characteristics.

6) The device as claimed in claim 1, wherein a GPS (Global Positioning System) module is integrated with said microcontroller to receive location data and transmit to said computing unit for real-time tracking of body 101’s position within said industrial area.