Description:FIELD OF THE INVENTION

[0001] The present invention relates to a concrete production device that is capable of optimizing concrete production through automated and precise mixing, ensuring consistent quality and also enables real-time monitoring and adjustment, allowing precise control over the mixing process, thereby minimizing downtime and optimizing overall performance.

BACKGROUND OF THE INVENTION

[0002] Concrete is a fundamental construction material used globally, with its quality and consistency playing a critical role in determining the structural integrity and longevity of buildings, infrastructure, and other civil engineering projects. The production of high-quality concrete requires precise mixing of various ingredients, including cement, aggregates, and water, in specific ratios.

[0003] Traditionally, concrete production has relied on manual or semi-automated processes, where ingredients are measured and mixed on-site or in batching plants. These methods involve manual weighing and measurement of ingredients, visual inspection for mix consistency, and trial-and-error adjustments to achieve desired properties. However, traditional methods are plagued by several drawbacks. The manual measurement and mixing processes lead to inconsistencies in concrete quality, compromising structural integrity. Additionally, trial-and-error adjustments result in wasted materials, time, and labor. Visual inspections are also subjective and often ineffective in detecting mix inconsistencies, while manual processes struggle to meet the demands of large-scale construction projects.

[0004] US5804175A discloses a method for producing cement useful for preparing pastes, mortars, concretes and other cement-based materials, having a high workability with reduced water content, high strength and density, and a rapid development of strength, which method includes a mechanicochemical treatment of cement. The method includes a two-stage mechanicochemical treatment of a mixture of cement and at least one of two components, the first component being a SiO2 -containing microfiller and the second component being a polymer in the form of a powdery water-reducing agent. In the first stage the cement and the first and/or the second component are intensively mixed in a dry state, whereby particles of the first and/or the second component are adsorbed on the cement particles. In the second stage the mixture obtained in the first stage is treated in milling equipment where the particles in the mixture receive in quick succession a large number of direct-changed impact impulses resulting in modification of the surface properties of the cement particles in the form of substantial increase of surface energy and chemical reactivity. The treatment in the second stage is carried out during a sufficiently long period of time in order that a 1-day compressive strength of a 20 millimeter per side cube of cement paste, which has been properly compacted under vibration and hardened at +20° C. in sealed conditions, at least equals 60 MPa.

[0005] US20230390960A1 discloses a device for producing a concrete includes a cement premixer for mixing a cement suspension, the cement premixer having an ultrasonic probe for preparing a cement suspension, a crystallization tank arrangement with the first crystallization tank, for increasing the early strengths of the concrete, and a concrete mixer for producing a concrete mixture from the premixed cement suspension, in particular with the addition of aggregates.

[0006] Conventionally, there exists many devices that are capable of manufacturing concrete through mixing, however these existing devices fail in ensuring consistent concrete production by mixing ingredients in a specific ratio, which causes issue in quality. In addition, these existing devices also fail in providing real-time monitoring, which causes adjustment issues and increase downtime.

[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 concrete production for consistent quality by mixing ingredients in specific ratio and also needs to provides real-time control, and optimal efficiency at the same time.

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 ensuring accurate and consistent mixing of concrete ingredients such as (cement, quarry dust, rubber crumb, crushed stones, and water) in specific ratios to achieve desired properties, thereby ensuring consistent and high-quality concrete production.

[0010] Another object of the present invention is to develop a device that is capable of allowing continuous monitoring of mixing process and makes adjustments as required to maintain optimal quality, thereby ensuring the produced concrete meets required specifications.

[0011] Yet another object of the present invention is to develop a device that is capable of streamlining operation, monitoring, and maintenance tasks, minimizing downtime and optimizing overall performance, thereby increasing overall efficiency.

[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 a concrete production device that is capable of ensures accurate and consistent mixing of concrete ingredients such as (cement, quarry dust, rubber crumb, crushed stones, and water) in specific ratios to achieve desired properties, thereby ensuring consistent and high-quality concrete production.

[0014] According to an embodiment of the present invention, a concrete production device, comprising a rectangular base with a plurality of chambers for storing items such as cement, quarry dust, rubber crumb, crushed stones, and water, a mixing box provided on the base receives these items via conduits configured with nozzles, connecting the chambers with the box, a motorized helical blade within the mixing box combines the items to prepare concrete, a wireless communication unit on the base enables users to wirelessly connect with a microcontroller, inputting required load-bearing characteristics of the concrete, then the microcontroller determines specific ratios of the items based on these inputs, a touch-enabled display unit mounted on the base displays the mixing ratios determined by the microcontroller, allowing users to provide touch input for adjustments.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a database connected to the microcontroller, storing mixing ratios of the items against various load-bearing characteristics, a testing compartment on the base, connected to the mixing box via a pipe with an iris opening, receives a sample of the mixed concrete for testing by a slump measurement sensor to detect the slump of the concrete, enabling adjustments to maintain it within a predetermined range, each nozzle is configured with a flowmeter for accurate item flow, while a viscosity sensor embedded in the mixing box detects the viscosity of the concrete to adjust the flowmeters and nozzles to maintain the required viscosity range, multiple water sprayers within the mixing box facilitate cleaning, and a vibration unit dislodges residual concrete, an artificial intelligence-based imaging unit installed with the base, records and processes images in the vicinity of the base to detect potential malfunctions.

[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 a concrete production 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 a concrete production device that is capable of ensuring consistent quality and maximizing efficiency in concrete production through automated mixing, real-time monitoring, and precise adjustments.

[0022] Referring to Figure 1, an isometric view of a concrete production device is illustrated, comprising a rectangular base 101 having a plurality chambers 102, a mixing box 103 connected with the chambers 102 via conduits 107, a motorized helical blade 104 in the box 103, a touch enabled display unit 105 mounted on the base 101, a testing compartment 106 is provided on the base 101, and connected with the box 103 by means of a pipe 108, plurality of water sprayers 109 are mounted within the box 103 and an artificial intelligence-based imaging unit 110 installed on the base 101.

[0023] The device disclosed herein, comprises of a rectangular base 101 constructed with multiple chambers 102 to store items such as cement, quarry dust, rubber crumb, crushed stones and water. The process begins, where a user provides input commands over a wireless communication unit, which installed on the base 101 regarding requirement of load bearing characteristics of the concrete.

[0024] The communication unit linked with a microcontroller wirelessly. The communication unit 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 user and the microcontroller, allowing for a user-friendly way to input requirement of load bearing characteristics of the concrete.

[0025] After the user provides input, the microcontroller processes these commands and accordingly evaluates particular ratio of the items for making concrete in accordance with the user-desired load bearing characteristics. As the microcontroller evaluates the ratio and displays it on a touch enabled display unit 105, which is mounted on the housing. The touch enabled display unit 105 as mentioned herein is typically an LCD (Liquid Crystal Display) screen that presents output in a visible form.

[0026] The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers. A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated to allow the user to access the display unit 105 by simple touch. In case the displayed ratio does not meet the user requirement then the user is also allowed to change the ratio as per their requirement, wherein a database linked with the microcontroller that have mixing ratios of the items correspond to various load bearing characteristics to decide mixing ratio of the items.

[0027] A mixing box 103 installed on the base 101, designed to receive the items with the help of multiple conduits 107, configured with nozzle that connects the box 103 with each of the chambers 102. Simultaneously, the microcontroller actuates the nozzle to release the items on the box 103 via the conduits 107.

[0028] The electronic nozzle 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. Upon actuation of nozzle by the microcontroller, the electric motor or the pump pressurizes the incoming items, increasing its pressure significantly. High pressure enables the items to dispense out with a high force in the box 103.

[0029] Each of the nozzles installed with a flowmeter that allows precise flow of the items into the mixing box 103. The flowmeter mentioned herein typically a turbine flowmeter measures fluid flow rate using a rotating turbine. The turbine is placed with the nozzle, and as item passes through, it causes the turbine to rotate. The rotation speed is directly proportional to the item flow rate. The turbine flowmeter consists of a turbine wheel, magnetic or optical sensor, and electronic circuitry. The turbine wheel is positioned in the center of the conduit 107, where item flows through.

[0030] The magnetic or optical sensor detects the turbine's rotation speed. As item flows through the conduit 107, it impinges on the turbine blades, causing the turbine to rotate. The rotation speed increases with increasing item flow rate. The magnetic or optical sensor detects the turbine's rotation speed and sends a signal to the electronic circuitry. The electronic circuitry processes the signal from the sensor, converting the rotation speed to a flow rate measurement. The flow rate is then transmitted to the microcontroller that allows the accurate flow of the items into the mixing box 103.

[0031] As the items positioned in the box 103, the microcontroller actuates a motorized helical blade 104 in the box 103 for blending the items to prepare concrete. The motorized helical blade 104 powered by a motor that rotates the blade 104 within the box 103. As the motor turns the blade 104, it creates a three-dimensional mixing action. The helical shape of the blade 104 ensures efficient blending of materials, lifting and folding them repeatedly.

[0032] When the motor is activated, the helical blade 104 begins to rotate, creating a spiral flow pattern within the box 103. The blade 104 pitch and angle are precisely designed to lift and tumble the materials, ensuring uniform distribution. The materials are drawn upward along the blade 104 helical path and then dropped back down, creating a continuous folding action. As the materials move through the box 103, the helical blade 104cutting edges break down items and ensure thorough mixing. The blade 104 curved surface also helps to scrape the box 103 walls, preventing material buildup. This results in a consistent and homogeneous mix.

[0033] A viscosity sensor installed in the box 103 to monitor viscosity of the concrete being mixed. The viscosity sensor accesses the viscosity of the mixture by determining the torque or the force required to rotate the blade 104 immersed in the mixture. As the blade 104 rotates within the mixture, the resistance encountered relates to the viscosity of the mixture. Higher viscosity corresponds to greater resistance. The measured torque data is processed by the microcontroller to determine the viscosity value of the mixture. Based on the detected viscosity, the microcontroller actuates the nozzles and flowmeter for adjusting ratios of the item dispensed for managing the viscosity in threshold value for better quality.

[0034] After the items get mixed thoroughly, a testing compartment 106 installed, which is designed to receive a small sample of the mixed concrete for testing purpose through a pipe 108 assembled with an iris opening. After the sample dispensed in the testing compartment 106, a slump measurement sensor gets actuated to monitor slump of the concrete. The slump measurement sensor typically weights Based slump measurement that uses a sensing probe to measure the weight of the concrete as it settles. This method is widely used due to its simplicity and accuracy.

[0035] The freshly mixed concrete is poured into the testing compartment 106. The sensing probe is lowered into the concrete, and the measurement process begins. As the concrete settles, the load cell or strain gauge measures the decrease in weight. The electronic circuitry transmits the signal to the microcontroller, which processes the signal and calculates the slump value to adjust the ratio of the items in the box 103 to maintain slump as per the threshold range.

[0036] Multiple water sprayers 109 are strategically mounted within the mixing box 103, providing comprehensive coverage. These sprayers 109 are designed to distribute water evenly throughout the box 103, targeting areas prone to material accumulation. As the mixing process concludes, the water sprayers 109 are activated, releasing a controlled amount of water to loosen and flush out residual concrete. In conjunction with the water sprayers 109, a vibration unit is integrated into the mixing box 103, which generates controlled vibrations, dislodging stubborn concrete residue and enhancing the cleaning process. The vibrations help break down adhesive forces between the concrete and box 103 surfaces, allowing the water sprayers 109 to effectively remove remaining material.

[0037] Simultaneously, an artificial intelligence-based imaging unit 110 mounted on the base 101 to capture multiple images in proximity of the base 101, to determine malfunction of the device. The artificial intelligence-based imaging unit 110 is constructed with a camera lens and a processor, wherein the camera lens is adapted to capture a series of images of the surrounding present in proximity to the base 101. The processor carries out a sequence of image processing operations including pre-processing, feature extraction, and classification. The image captured by the imaging unit 110 is real-time images of the base’s 101 surrounding. The artificial intelligence-based imaging unit 110 transmits the captured image signal in the form of digital bits to the microcontroller. The microcontroller upon receiving the image signals compares the received image signal with the pre-fed data stored in a database and constantly determines malfunction of the device and displays it on the display unit 105.

[0038] The present invention works best in the following manner, where the rectangular base as disclosed in the invention possesses multiple chamber and the process begins with material storage, where cement, quarry dust, rubber crumb, crushed stones, and water are stored in separate chambers 102 on the rectangular base 101. Next, the user wirelessly connects to the microcontroller via the wireless communication unit and inputs the required load-bearing characteristics of the concrete. The microcontroller then calculates the specific ratios of the items based on the user's input, retrieving the corresponding mixing ratios from the database. The microcontroller subsequently actuates the flowmeters and nozzles to dispense the required amounts of materials from the chambers 102 into the mixing box 103. Here, the motorized helical blade 104 combines the dispensed materials to prepare the concrete. A sample of the mixed concrete is then diverted to the testing compartment 106, where the slump measurement sensor detects its slump. Simultaneously, the viscosity sensor embedded in the mixing box 103 detects the viscosity of the mixed concrete. Based on the slump and viscosity measurements, the microcontroller adjusts the flowmeters and nozzles to maintain the required consistency and slump range. The touch-enabled display unit 105 shows the mixing ratios and any adjustments made, allowing the user to monitor and adjust the process as needed. After each use, the water sprayers 109 and vibration unit facilitate cleaning of the mixing box 103 and removal of residual concrete. Throughout operation, the artificial intelligence-based imaging unit 110 continuously monitors the system, detecting any potential malfunctions and triggering a visual alert on the display unit 105. This integrated feedback loop ensures precise, efficient, and automated concrete mixing, with real-time monitoring and adjustment capabilities.

[0039] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A concrete production device, comprising:

i) a rectangular base 101 having a plurality chambers 102 for storing items including cement, quarry dust, rubber crumb, crushed stones and water;
ii) a mixing box 103 provided on said base 101, receives said items via conduits 107 configured with nozzles, connecting said chambers 102 with said box 103, wherein a motorized helical blade 104 in said box 103 mixes said items to prepare concrete;
iii) a wireless communication unit provided on said base 101 to enable a user to wirelessly connect with a microcontroller associated with said base 101 to, input required load bearing characteristics of said concrete to enable said microcontroller to determine specific ratios of said items to prepare concrete as per inputted load bearing characteristics;
iv) a touch enabled display unit 105 mounted on said base 101 displays mixing ratios of said items determined by said microcontroller to enable said user to provide touch input regarding changing said ratio as per requirement;
v) a database connected with said microcontroller, stores mixing ratios of said items against various load bearing characteristics, wherein said database is referred to decide mixing ratio of said items; and
vi) a testing compartment 106 is provided on said base 101, and connected with said box 103 by means of a pipe 108 configured with an iris opening, to receive a sample of said concrete being mixed for testing by a slump measurement sensor which detects slump of said concrete to enable adjustment of ratio of said items in said box 103 to maintain slump within a predetermined slump range.

2) The device as claimed in claim 1, wherein each of said nozzles is configured with a flowmeter to enable an accurate flow of items into said mixing box 103.

3) The device as claimed in claim 1, wherein a viscosity sensor embedded in said box 103 detects a viscosity of said concrete being mixed to trigger said microcontroller to actuate said flowmeters and said nozzles to adjust ratios of said items to maintain viscosity of said concrete within require range of viscosity.

4) The device as claimed in claim 1, wherein a plurality of water sprayers 109 are mounted within said box 103, for spraying water and a vibration unit incorporated with said box 103 to dislodge and clean residual concrete in said box 103.

5) The device as claimed in claim 1, wherein an artificial intelligence-based imaging unit 110, installed on said base 101 and integrated with a processor for recording and processing images in a vicinity of said base 101, to determine malfunction of said device to trigger said microcontroller to actuate said display unit 105 to show a visual alert regarding said malfunction.