Description:FIELD OF THE INVENTION

[0001] The present invention relates to a workpiece manufacturing device that fabricates workpiece with user-defined dimensions, ensuring precision and efficiency by carving a design specified by the user onto the workpiece. In addition, the proposed device is equipped with a means for smoothening and polishing of the surface of the work piece to impart a finished look.

BACKGROUND OF THE INVENTION

[0002] The requirement for manufacturing workpieces has evolved significantly with advancements in technology and increasing demands for precision, customization, and efficiency in various industries. Workpieces, which serve as the base material or structure for creating finished products, are essential in sectors like aerospace, automotive, electronics, and medical device manufacturing. As industries progress, the need for workpieces with specific dimensions, complex geometries, and detailed designs has intensified. Traditional manufacturing methods, such as machining or casting, often struggle to meet these demands, particularly when it comes to rapid prototyping and small batch production.

[0003] Equipment used in manufacturing workpieces includes a variety of machines such as CNC (Computer Numerical Control) machines, lathes, milling machines, grinders, and presses. These machines are essential for shaping, cutting, drilling, and finishing materials like metals, plastics, and composites into precise components. CNC machines are especially popular for their automation and ability to perform complex tasks with high precision. Lathes are used to shape cylindrical parts, while milling machines are employed for cutting and drilling operations. Grinders help in achieving fine finishes, and presses are used for shaping or forming materials under pressure. The use of robotic arms for assembly or inspection is also common in modern manufacturing. However, these machines come with several drawbacks. The high initial cost of advanced machinery like CNC machines and robotic arms can be prohibitive for small businesses. Additionally, they require skilled operators and regular maintenance, which adds to operational costs. The complexity of these systems may lead to breakdowns or malfunctions if not properly maintained. The equipment also generates significant noise, vibrations, and waste materials, which possesses safety and environmental concerns. Furthermore, the reliance on these machines reduces flexibility in adapting to sudden design changes or customizations, leading to longer lead times for product modifications.

[0004] CN107297504A discloses an invention discloses a workpiece hammering reinforcing device during metal additive manufacturing and an application method thereof. The device comprises a hammering reinforcing device body, a linear motion part, a motion regulating part, a locking part, a hammering executing part, a hammering regulating support, a data processing and measuring control unit and a base and is characterized in that workpiece follow-up hammering reinforcing operation during the metal additive manufacturing is achieved by using the linear motion part and control flow based on process and working condition data. The workpiece hammering reinforcing device and the application method thereof have the advantages that the optimized process control flow is provided, a forming process can be favorably improved on the basis of an existing additive manufacturing system, and workpiece quality can be increased; the structure homogeneity of a formed part is increased, mechanical performance is improved while plasticity is enhanced, crack generation is inhibited, the fatigue life of the formed part is prolonged, the flatness of the surface of a formed layer is improved, and the dimensional precision of the formed part is increased effectively.

[0005] CN109108505A discloses an invention discloses an aluminum alloy workpiece additive manufacturing method implemented through friction stir welding. On the basis of an existing electric arc additive manufacturing aluminum alloy workpiece, the characteristic that aluminum alloy is soft in property is combined, after an aluminum alloy workpiece is manufactured from electric arc additives layer by layer, friction stir welding intensification treatment is conducted on each layer, and therefore, defects such as pass gaps, interlayer incomplete fusion, air holes and the like can be eliminated through friction stir welding when each layer is manufactured. Compared with the pure electric arc additive manufacturing aluminum alloy workpiece, by means of the method, the structural state of the aluminum alloy workpiece obtained through additive manufacturing can be improved; the grains can be finer; second-phase grains are finer and are distributed more uniformly; and the dislocation density achieved in the aluminum alloy additive manufacturing workpiece is increased. Compared with existing friction stir welding intensification, grain refining and defect elimination are conducted on each layer of the workpiece so that the strength of the whole workpiece can be improved rather than only surface modification, namely surface intensification, is conducted.

[0006] Conventionally, many devices have been developed to manufacture workpieces, however the devices mentioned in the prior arts have limitations pertaining to carving of user specified designs on the work piece with custom dimensions. Additionally, these existing devices also lack in providing a finished look to the workpiece after designs are being carved.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to fabricate workpiece with user-defined dimensions, ensuring precision and efficiency by carving a design specified by the user onto the workpiece. In addition, the developed device needs to be equipped with a means for smoothening and polishing of the surface of the work piece to impart a finished look.

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 features automated process to fabricate workpiece of a user-specified dimensions.

[0010] Another object of the present invention is to develop a device that is capable of carving a designs over the workpiece as desired by the users efficiently.

[0011] Yet another object of the present invention is to develop a device that is capable of polishing the workpiece to smoothen and provide finished look to the surface of the carved design.

[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 workpiece manufacturing device that produces workpiece based on the user's specified dimensions by efficiently carving custom designs, and polishes the surface to achieve a smooth, finished look.

[0014] According to an embodiment of the present invention, a workpiece manufacturing device, comprises of a housing positioned over a fixed surface and mapped with a touch interactive display panel to enable a user to provide input regarding a design that is to be carved over a workpiece of specific dimensions that is to be manufactured using fused deposition modelling (FDM) process along with materials that are to be used for manufacturing the workpiece, a multi-sectioned chamber stored with the materials in melted state and arranged within the housing, each of the sections are installed with an electronically controlled valve and a pump that are actuated by a microcontroller linked with the display panel to dispense the user-specified materials into a conduit linked with each of the valves, plurality of extrusion nozzles each connected with the conduits via a primary extendable robotic link, the microcontroller actuates the nozzles for dispensing a regulate amount of the user-specified materials over a platform arranged beneath the nozzles, in a successive manner for depositing the user-specified materials layer by layer onto the platform to initiate manufacturing the workpiece.

[0015] According to another embodiment of the present invention, the proposed device further comprises of plurality of plates configured with periphery of the platform each by means of a telescopic rod that actuates to extend and shape the dispensed materials via the plates in accordance with user-specified dimensions, an ultrasonic sensor is installed within the housing to monitor dimensions of the workpiece based on which the microcontroller regulates extension and retraction of the rods, plurality of robotic arms installed within the housing and directed by the microcontroller to provide multi-directional movement to multiple sharp needles of various dimensions and each configured with the arms, the microcontroller directs the arms to carve the user-specified design over the workpiece via the sharp needles.

[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 workpiece manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

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

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

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

[0021] The present invention relates to a workpiece manufacturing device that is capable of manufacturing workpieces of custom dimensions in accordance to instructions of a user by efficiently carving designs.

[0022] Referring to Figure 1, an isometric view of a workpiece manufacturing device is illustrated, comprises of a housing 101 mapped with a touch interactive display panel 102, a multi-sectioned chamber 103 arranged within the housing 101, each of the sections are installed with an electronically controlled valve 104, plurality of extrusion nozzles 105 each connected with the conduits via a primary extendable robotic link 106, a platform 107 arranged beneath the nozzles 105, plurality of plates 108 configured with periphery of the platform 107 each by means of a telescopic rod 109, plurality of robotic arms 110 installed within the housing 101, multiple sharp needles 111 of various dimensions and each configured with the arms, an air blower 112 installed within the housing 101, and plurality of secondary extendable robotic links 113 installed within the housing 101 and each configured with a motorized polishing unit 114.

[0023] The proposed invention includes a housing 101 preferably in cuboidal shape incorporating various components associated with the device, developed to be positioned on a fixed surface. The housing 101 is utilized to manufacture workspace of different dimensions using fused deposition modelling (FDM) process along with materials that are to be used for manufacturing the workpiece. The housing 101 is made up of any material selected from but not limited to metal or alloy that ensures rigidity of the housing 101 for longevity of the device.

[0024] A user is required to access and presses a switch button arranged on the housing 101 to activate the device for associated processes of the device. The switch button when pressed by the user, opens up an electrical circuit and allows currents to flow for powering an associated microcontroller of the device for operating of all the linked components for performing their respective functions upon actuation.

[0025] The microcontroller, mentioned herein, is preferably an Arduino microcontroller. The Arduino microcontroller used herein controls the overall functionality of the components linked to it. The Arduino microcontroller is an open-source programming platform 107.

[0026] After the activation of the device, the user accesses a touch interactive display panel 102 installed over the housing 101 for providing input regarding a design that is to be carved over a workpiece of specific dimensions. When the user touches the surface of the touch interactive display panel 102 to enter the input details, then an internal circuitry of the touch interactive display panel 102 senses the touches of the displayed option and synchronically, the internal circuitry converts the physical touch into the form of electric signal. The microcontroller processes the received signal from the display panel 102 in order to process the signal and determine the user selection and store the user response to a linked database for further associated functions related to the user input.

[0027] The housing 101 incorporates a multi-sectioned chamber 103 stored with the materials in melted state and arranged within the housing 101. The materials include thermoplastic material, metals etc. Each of the sections are integrated with a heating element and that is actuated by the microcontroller to maintain the materials at appropriate melting temperature in accordance with type of the materials. Each of the heating elements work when current is passed through the element, the element becomes hot and produces heat energy. This heat energy of the heating element is transferred to the wire thereby heating the sections in order to maintain the melting temperature of the materials.

[0028] The bottom portion of each sections of the chamber 103 are equipped with an electronically controlled valve 104 and a pump. A primary extendable robotic link 106 is arranged within the housing 101 configured with multiple extrusion nozzles 105. The nozzles 105 are connected with the electronically controlled valve 104 s by means of conduits.

[0029] Upon receiving of the user input, the microcontroller generates a command to actuate each of the electronically controlled valve 104 s to dispense the user-specified materials into a conduit linked with each of the valves. Each of the electronically controlled valve 104 s operate by using sensors and actuators to manage the flow of materials. When the microcontroller activates an associated solenoid valve, the valve open and allow the materials to flow.

[0030] The electric pump is used to induce flow or raise the pressure of the material. The working principle of pump involves imparting energy to the water by means of a centrifugal force developed by the rotation of an impeller that has several blades or vanes. The impeller of the pump is rotated by an electric DC (Direct Current) motor. The flow is regulated by varying the size of the flow passage as directed by a signal from the microcontroller. This enables the direct control of flow rate and the consequential control of process quantities such as pressure, and materials level in view of dispensing the materials as per the determined requirement.

[0031] Simultaneously, the microcontroller actuates the primary extendable robotic link 106 to provide articulated movement to the nozzles 105. The primary extendable robotic link 106 comprises, motor controllers, arm, end effector and sensors. All these parts are configured with the microcontroller. The elbow is at the middle section of the arm 110 that allows the upper part of the arm 110 to move the lower section independently. Lastly, the wrist is at the tip of the upper arm 110 and attached to the end effector thereby the end effector works as a hand for positioning the nozzles 105 over a platform 107 arranged within the housing 101.

[0032] The microcontroller synchronously, actuates the nozzles 105 to dispense a regulated amount of user-specified materials over the platform 107 in view of making the workpiece. The working of the nozzles 105 is similar to the working of the electronically controlled valve 104 as mentioned above.

[0033] The dispensing of material over the platform 107 is done in a successive manner for depositing the user-specified materials layer by layer onto the platform 107 to initiate manufacturing the workpiece. The platform 107 is configured with multiple telescopic rods 109 and each of the ends of the rods 109 are integrated with a plate. The rods 109 are pneumatically powered by a pneumatic arrangement associated with the device such that provides extension/retraction of the rods 109 as per requirement.

[0034] The microcontroller actuates an air compressor and air valve associated with the pneumatic arrangement consisting of an air cylinder, air valve and piston which works in collaboration to aid in extension and retraction of the rods. The air valve allows entry/exit of compressed air from the compressor. Then, the valve opens and the compressed air enters inside the cylinder thereby increasing the air pressure of the cylinder. The piston is connected to the rods 109 and due to the increase in the air pressure, the piston extends. For the retraction of the piston, air is released from the cylinder to the air compressor via the valve. Thus, providing the required extension/retraction of the to position the plate for shaping the dispensed material in accordance to the user-specified dimensions.

[0035] The actuation of the rods 109 via the pneumatic arrangement is provided in sync with an ultrasonic sensor is installed within the housing 101. The ultrasonic sensor monitors the dimensions of the workpiece. The ultrasonic sensor disclosed herein, consists of an emitter and a receiver that acts as a transducer. The emitter emits ultrasonic sound waves towards workpiece. Then, the radiation strike to the workpiece and reflect back which are captured by the receiver. The signal is sent to the microcontroller. The microcontroller processes the received signal from the ultrasonic sensor and on the basis of time lapse in between the sent and received radiations, the microcontroller determines the dimensions of the workpiece. Accordingly, the microcontroller regulates extension and retraction of the rods 109 via the pneumatic arrangement.

[0036] The temperature of the workpiece is monitored by a temperature sensor is installed within the housing 101. The temperature sensor used herein, is composed of two type of metal wire joint together when the sensor experiences a heat then a voltage is generated in the two terminal of the temperature sensor that is proportional to the temperature and the signal is sent to the microcontroller. The microcontroller calibrates the voltage in terms of temperature from the received signal of the temperature sensor in order to monitor the temperature of the workpiece.

[0037] In accordance to the evaluated temperature of the workpiece, the microcontroller actuates an air blower 112 installed within the housing 101 to cool the workpiece. The air blower 112 is connected with multiple cooling conduits to direct cool air over the workpiece in view of solidifying the workpiece. The air blower 112 works by increasing velocity of air when the air is passed through equipped impellers, thereby blows a stream of concentrated air towards the workpiece, thereby cools down the workpiece.

[0038] The housing 101 is equipped with multiple robotic arms 110 such that the arms 110 are configured with sharp needles 111 of various dimensions. Post shaping the dispensed material, the microcontroller actuates the robotic arms 110 to provides multi-directional movement to the needles 111. The movement of the needles 111 over the workpiece carves a user-specified design in an efficient manner. The working of the robotic arms 110 is similar to the working of the robotic links 113 as mentioned above.

[0039] The platform 107 is embedded with a tactile sensor to monitor hardness of the manufactured workpiece. The tactile sensor detects the hardness of the workpiece by measuring the force of contact between the sensor and the workpiece. The sensor is typically a small, flat component that is placed against the workpiece and then pressed down. As the force of contact increases, the sensor measures the amount of pressure being applied and sends a signal to the microcontroller. The microcontroller then interprets the signal and determines the hardness of the workpiece. In accordance to the hardness of the workpiece, the microcontroller evaluates a threshold pressure to be applied over the workpiece for carving the user-specified design.

[0040] Each of the needles 111 are embedded with a pressure sensor monitor pressure applied by each of the needle over the workpiece while carving the user specified design. The pressure sensor comprises of a sensing element known as diaphragm that experiences a force exerted by the needle over the workpiece. This force leads to deflection in the diaphragm that is measured and converted into an electrical signal which is sent to the microcontroller for monitoring the applied pressure. In accordance to the detected pressure applied while carving, the microcontroller directs the arms 110 to apply the threshold pressure over the workpiece.

[0041] The housing 101 is installed with plurality of secondary extendable robotic links 113 such that each links 113 is configured with a motorized polishing unit 114. The polishing units 114 are equipped with varied dimensions for polishing the workpiece in accordance to the carved design. Post carving design pattern over the workpiece, the microcontroller actuates the polishing unit 114 for polishing the workpiece.

[0042] The polishing unit 114 works by using abrasive materials and mechanical motion to smooth and refine the surface of the workpiece. The polishing unit 114 comprise a polishing wheel, often coated with abrasive compounds, makes contact with the surface of the workpiece. A direct current (DC) motor rotates the wheel for creating friction and abrasion when comes in contact with the surface of the workpiece, thereby remove surface imperfections, scratches, and oxidation. The polishing unit 114 speed, pressure, and abrasive material are adjusted based on the material and desired finish, resulting in a shiny, smooth surface.

[0043] The arms 110 and the links 113 are integrated with an angle and proximity sensor to monitor distance of the arms 110 and links 113 from the workpiece corresponding angle.

[0044] The angle sensor used herein is preferably an optical angle sensor (not shown in figure) that use light beams and optical detectors to measure changes in light reflection or transmission caused by the angle of the arms 110 and links 113 with respect to the workpiece. As the angle changes, the amount of light reflected or transmitted varies, allowing the sensor to calculate the angle. The angle sensor provides an output signal that represents the detected angle of the arms 110 and links 113 with respect to the workpiece. and transmits the signal to the microcontroller. The microcontroller processes the signal to monitor the inclination angle of the arms 110 and links 113 with respect to the workpiece.

[0045] Synchronously, the proximity sensor emits infrared rays towards the workpiece and receives the bounced back rays from the workpiece and convert the detected data into an electric signal that is sent to the microcontroller. The microcontroller processes the received signal from the proximity sensor in order to monitor distance of the workpiece from the arms 110 and links.

[0046] In accordance to the monitored angle and the distance of the arms 110 and links 113 from the workpiece, the microcontroller regulates operation of the arms 110 and links 113 for appropriate positioning of the needles 111, nozzles 105 and polishing unit 114 over the workpiece in view of manufacturing the workpiece.

[0047] A battery (not shown in figure) is associated with the device to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrodes named as a cathode and an anode. The battery uses a chemical reaction of oxidation/reduction to do work on charge and produce a voltage between their anode and cathode and thus produces electrical energy that is used to do work in the device.

[0048] The present invention works best in the following manner, where the housing 101 as disclosed in the invention is equipped with the touch interactive display panel 102, allows user to input design specifications, including the material and dimensions for the workpiece, to be manufactured using the FDM process. The multi-sectioned chamber 103 containing melted materials, such as thermoplastics or metals, is controlled by electronically actuated valves and pumps, which are linked to the display panel 102 and microcontroller. The microcontroller directs the flow of materials through conduits to extrusion nozzles 105, dispensing regulated amounts of material onto the platform 107 layer by layer. Telescopic rods 109 and plates 108 positioned around the platform 107 shape the material to match the specified dimensions, guided by the ultrasonic sensor that monitors the workpiece's size. Robotic arms 110 with sharp needles 111 carve the design into the workpiece as directed by the microcontroller. The device also includes the heating element to maintain the correct material temperature, the temperature sensor for monitoring the workpiece's temperature, and the cooling unit to solidify the workpiece. Tactile and pressure sensors adjust the force applied during carving and polishing. Finally, plurality of secondary extendable robotic links 113 with motorized polishing units 114, guided by angle and proximity sensors, are used to smooth and finish the carved design.

[0049] 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) A workpiece manufacturing device, comprising:

i) a housing 101 positioned over a fixed surface and mapped with a touch interactive display panel 102 to enable a user to provide input regarding a design that is to be carved over a workpiece of specific dimensions that is to be manufactured using fused deposition modelling (FDM) process along with materials that are to be used for manufacturing said workpiece;
ii) a multi-sectioned chamber 103 stored with said materials in melted state and arranged within said housing 101, wherein each of said sections are installed with an electronically controlled valve 104 and a pump that are actuated by a microcontroller linked with said display panel 102 to dispense said user-specified materials into a conduit linked with each of said valves;
iii) plurality of extrusion nozzles 105 each connected with said conduits via a primary extendable robotic link 106, wherein said microcontroller actuates said nozzles 105 for dispensing a regulate amount of said user-specified materials over a platform 107 arranged beneath said nozzles 105, in a successive manner for depositing said user-specified materials layer by layer onto said platform 107 to initiate manufacturing said workpiece;
iv) plurality of plates 108 configured with periphery of said platform 107 each by means of a telescopic rod 109 that actuates to extend and shape said dispensed materials via said plates 108 in accordance with user-specified dimensions, wherein an ultrasonic sensor is installed within said housing 101 to monitor dimensions of said workpiece based on which said microcontroller regulates extension and retraction of said rods; and
v) plurality of robotic arms 110 installed within said housing 101 and directed by said microcontroller to provide multi-directional movement to multiple sharp needles 111 of various dimensions and each configured with said arms, wherein said microcontroller directs said arms 110 to carve said user-specified design over said workpiece via said sharp needles 111.

2) The device as claimed in claim 1, wherein said materials includes thermoplastic material and metals.

3) The device as claimed in claim 1, wherein each of said sections are installed with a heating element that are commanded by said microcontroller to maintain said materials at appropriate melting temperature in accordance with type of said materials.

4) The device as claimed in claim 1, wherein a temperature sensor is installed within said housing 101 to monitor temperature of said workpiece based on which said microcontroller actuates an air blower 112 installed within said housing 101 and integrated with multiple cooling conduits to direct cool air over said workpiece in view of solidifying said workpiece.

5) The device as claimed in claim 1, wherein a tactile sensor is installed with said platform 107 to monitor hardness of said manufactured workpiece based on which said microcontroller evaluates a threshold pressure to be applied over said workpiece for carving said user-specified design.

6) The device as claimed in claim 1, wherein a pressure sensor is integrated with each of said needle to monitor pressure applied by each of said needle over said workpiece while carving said user specified design based on which said microcontroller directs said arms 110 to apply said threshold pressure over said workpiece.

7) The device as claimed in claim 1, wherein plurality of secondary extendable robotic links 113 installed within said housing 101 and each configured with a motorized polishing unit 114 for various dimensions that are commanded by said microcontroller to polish said workpiece in accordance with said carved design.

8) The device as claimed in claim 1, wherein an angle and proximity sensor are integrated with each of said arms 110 and links 113 to monitor distance of said arms 110 and links 113 from said workpiece corresponding angle based on which said microcontroller regulates operation of said arms 110 and links 113 for appropriate positioning of said needles 111, nozzles 105 and polishing unit 114 over said workpiece.