Description:FIELD OF THE INVENTION

[0001] The present invention relates to an aggregate processing device that is capable of automatically filtering, grinding, and conditioning recycled aggregates by efficiently removing debris, controlling moisture levels, and ensuring uniform particle size by streamlining the processing process, adaptable for use in construction and industrial applications.

BACKGROUND OF THE INVENTION

[0002] Recycled aggregates play an important role in the field of civil engineering, as they are used to create strong and durable structures. These aggregates, such as sand, gravel, and crushed stone, provide stability and support for buildings, roads, and bridges. By binding together with cement or asphalt, constructional aggregates form the foundation of various infrastructure projects. Their composition and quality directly impact the strength and longevity of the structures they are used in. Therefore, it is crucial for civil engineers to carefully select and test constructional aggregates to ensure the safety and reliability of the final construction. Proper maintenance and monitoring of these aggregates throughout the lifespan of a structure is also essential to prevent any potential failures.

[0003] Traditionally, the users use tools for preparing recycled aggregates by filtering, grinding, and conditioning recycled aggregates includes crushing machines, sieves, and water sprayers. These tools help to remove impurities and ensure that the recycled aggregates meet quality standards for use in construction projects. By using these tools, the recycled aggregates are being processed efficiently and effectively, resulting in a sustainable alternative to traditional construction materials. Additionally, this process helps to reduce the environmental impact of construction by reusing materials that would otherwise end up in landfills.

[0004] WO2010110563A2 discloses a method for manufacturing recycled aggregates, wherein said recycled aggregates are manufactured using a reaction of rapid carbonation to achieve significantly reduced absorption and increased density, which satisfy the quality standards of recycled aggregates. As opposed to conventional strong alkaline recycled aggregates, the recycled aggregates of the present invention have a low pH level, and thus minimize alkali-aggregate reactions and drying shrinkage when used in concrete, and minimize the influences on soil, on a marine environment, and on an ecosystem.

[0005] CN113968687B discloses a method for pre-treating and strengthening recycled aggregate and a method for preparing recycled concrete, wherein the method for pre-treating and strengthening recycled aggregate comprises the steps of firstly washing the recycled aggregate by using low-pressure water, naturally airing, then placing the recycled aggregate into an aggregate strengthening solution for soaking for 6-12 h, taking out the recycled aggregate and naturally airing to obtain the strengthened recycled aggregate; the preparation method of the recycled concrete comprises the steps of sequentially standing, precipitating and filtering the washing liquid obtained after washing to obtain recycled liquid; and then stirring the regenerated liquid, cement, EVA rubber powder, a polycarboxylic acid water reducing agent and the reinforced regenerated aggregate to obtain the regenerated concrete. Compared with the prior art, the invention can improve the strength of the recycled aggregate, effectively improve the performance of the recycled aggregate concrete prepared by the recycled aggregate and is beneficial to expanding the application range of the recycled aggregate.

[0006] Conventionally, many devices are disclosed in prior art that provides a way to prepare recycled aggregates by incorporating various mechanisms for crushing, sorting, and cleaning the materials to produce high-quality recycled aggregates, however lacks in efficiency and cost-effectiveness. Moreover, such devices also lack in automating the handling, by grinding to a uniform size, and removing metallic contaminants, all within a single step.

[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 automatically processing recycled aggregates by filtering out debris, controlling moisture levels, grinding the aggregates to a uniform size, and removing metallic contaminants, all within a single step that enhances efficiency and ensures consistent material quality.

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 processing recycled aggregates by filtering out debris, controlling moisture levels, grinding to a uniform size, and removing metallic contaminants, ensuring consistent material quality for construction and industrial applications.

[0010] Another object of the present invention is to develop a device that is capable of optimizing aggregate processing process by improving overall efficiency, accuracy, and consistency of the recycled aggregate used in various industrial and construction applications.

[0011] Yet another object of the present invention is to develop a device that is capable of providing a means to ensure proper grinding of the aggregates and collection of the grinded aggregates as per user requirement to utilize for various constructions application.

[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 aggregate processing device that is capable of automatically processing recycled aggregates by filtering out debris, controlling moisture levels, grinding to a uniform size, and removing metallic contaminants that enhances efficiency and ensures consistent material quality.

[0014] According to an embodiment of the present invention, an aggregate processing device, comprises of a cylindrical housing having four perpendicularly installed telescopic rods with motorized omnidirectional wheels at the ends attached underneath the housing, for a locomotion of the housing, a touch enabled display unit, linked with a microcontroller mounted on the housing, to enable operation of the device a hopper configured with an iris lid configured with an upper portion of the housing, to enable feeding of recycled aggregates into a chamber in the housing, a mesh filter frame disposed within the chamber, for filtering debris from the aggregates, a rotatable manner, to enable rotation of the chamber to expedite filtration, multiple articulated L-shaped arms having an impact hammers at the end attached in the housing for breaking aggregate pieces having dimensions greater than a threshold dimension, as detected by an ultrasonic sensor embedded in the chamber, a pair of articulated L-shaped telescopic links having electromagnets at the ends for removal of metallic debris from the aggregates, a moisture sensor embedded in the chamber to detect moisture in the aggregate, a heating coil embedded in the chamber to heat the chamber and remove the moisture from the aggregate, a temperature sensor is embedded in the chamber to detect temperature of the aggregate, a motorized blade incorporated within the chamber for grinding of the aggregate, and a battery associated with the device to supply power to all components of the device to operate accordingly.

[0015] 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

[0016] 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 aggregate processing device.

DETAILED DESCRIPTION OF THE INVENTION

[0017] 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.

[0018] 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.

[0019] 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.

[0020] The present invention relates to an aggregate processing device that is capable of providing a means to prepare recycled aggregates by filtering out debris, controlling moisture levels, grinding to a uniform size in a sequential manner that enhances efficiency and ensures consistency of the aggregate for construction and industrial applications.

[0021] Referring to Figure 1, an isometric view of an aggregate processing device is illustrated, comprising a cylindrical housing 101 having four perpendicularly installed telescopic rods 102 with motorized omnidirectional wheels 103 at the ends, a hopper 104 configured with an iris lid 105 configured with an upper portion of the housing 101, a chamber 106 in the housing 101, a mesh filter frame 109 having telescopic links 110 having hinges at the ends disposed within the chamber 106, multiple articulated L-shaped arms 111 having an impact hammers 112 at the end, attached in the housing 101, a heating coil 113 embedded in the chamber 106, a motorized blade 114 incorporated within the chamber 106, a touch enabled display unit 115 mounted on the housing 101, an iris aperture 116 integrated underneath the chamber 106, a container 117 arranged beneath the chamber 106, and an electronic nozzle 107 connected with container 117 via a duct 108 passing through the housing 101.

[0022] The proposed device comprises of a cylindrical housing 101 encased with various components associated with the device arrange in sequential manner that aids in preparing aggregate. Upon placing the housing 101 over a surface, the user activates the device manually by pressing a switch button associated with the device and integrated with the housing 101. The button mentioned herein is a type of a switch that is internally connected with the device via multiple circuits that upon pressing by the user, the circuits get closed and starts conducting electricity that tends to activate the device and vice versa. After activation of the device by the user, a microcontroller associated with the device generates a commands to operate the device accordingly.

[0001] After activating of the device, the microcontroller activates a touch enabled display unit 115, mounted on the housing 101 to enable operation of the device for preparing aggregate. The display unit 115 works by using LCD (liquid crystals) that are manipulated by electric currents to control the passage of light through the display unit 115. When an electric current is applied, the liquid crystals align in a way that either allows light to pass through or blocks it, creating the images and colors that is being visible in the LCD of the display unit 115 regarding operation of the device to prepare the aggregate that is further store to process the input.

[0023] Upon processing the input, the microcontroller actuates an iris lid 105 configured inside a hopper 104 assembled with an upper portion of the housing 101 to open for feeding recycled aggregates into a chamber 106 in the housing 101. The iris lid 105 operates by using a motorized mechanism that controls a series of interlocking, curved segments arranged in a circular pattern, similar to the aperture of a camera. When the microcontroller determines the processing of the aggregates, the microcontroller sends a signal to the motor, which rotates or translates to adjust the position of the segments. This movement either opens the iris lid 105 to feed the recycled aggregates into the chamber 106.

[0024] After that the recycled aggregates passes over a mesh filter frame 109 disposed within the chamber 106 for filtering debris from the aggregates, wherein the frame 109 is segmented into two parts and deployed by telescopic links 110 with hinges at the ends to separate larger pieces. The chamber 106 is designed to rotate, allowing for efficient filtration by accelerating the separation of debris and ensuring that only appropriately sized aggregates proceed to the next stages of processing. The mesh filter frame 109 works by trapping larger debris and particles while allowing smaller, appropriately sized aggregates to pass through.

[0025] As the chamber 106 rotates, the movement helps to dislodge debris that is larger than the desired aggregate size, enhancing the filtration process. The segmented design of the filter frame 109, which is deployed by the telescopic links 110 with hinges. Herein, based on input, the microcontroller actuates a pneumatic unit integrated with each of the links 110 to extend. The pneumatic unit comprises of comprises of an air compressor, air cylinder, air valves i.e. Inlet and outlet valve and piston that works in collaboration to aid extension and retraction of the links 110. The air compressor is coupled with a motor that gets activated by the microcontroller to compress the air from surroundings upon entering from the inlet valve to compressed and pumped out via the outlet valve.

[0026] The air valve allows entry or exit of the compressed air from the compressor. Furthermore, the valve opens and the compressed air enters inside the cylinder thereby increasing the air pressure of the cylinder. The piston is connected to the cylinder and due to the increase in the air pressure, the piston extends. And upon closing of the valve, the compressed air exits out from the cylinder thereby decreasing the air pressure of the cylinder. The increasing and decreasing of the air pressure from the cylinder aids in extension and retraction of the piston that turns in aiding extension and retraction of the links 110 for adjusting height of the mesh filter frame 109 to enable rotation of the chamber 106 to expedite filtration. Herein, chamber 106 is attached within the housing 101 by means of a motor to enable rotation of the chamber 106 activated by the microcontroller to rotate for filtering the recycled aggregate.

[0027] During filtration of the recycled aggregate, an ultrasonic sensor embedded in the chamber 106 detects dimensions of the aggregates. The ultrasonic sensor works by emitting high-frequency sound waves and measuring the time it takes for the reflected waves to return after hitting the aggregate’s surface. This time-of-flight measurement allows the sensor to calculate precise distances and identify the fabric's boundaries and contours. Based on the aggregate’s boundaries and contours, the sensor calibrates the data to detect dimensions of the aggregates. Based on detection, if the detected dimensions exceed a threshold dimension, then the microcontroller actuates multiple articulated L-shaped arms 111 having an impact hammer 112 at the end, attached in the housing 101, for breaking aggregate pieces. The articulated arms 111 work by utilizing ng a series of joints and motors that allow for flexible, precise movement. Each arm is equipped with an impact hammer at its end, which is used to break down larger aggregate pieces. The articulated design of the arms 111 allows them to extend, retract, and pivot in multiple directions, providing the versatility needed to target and strike the aggregate pieces accurately, breaking the pieces down into smaller, more manageable sizes.

[0028] After that the microcontroller actuates pair of articulated L-shaped telescopic links 110 having electromagnets at the ends for removal of metallic debris from the aggregates. Herein, the electromagnet works by generating a magnetic field that attracts and lifts metallic particles or debris from the aggregates as they pass through the chamber 106. The electromagnet is activated and deactivated based on the detected presence of metallic materials, effectively removing any metal contaminants from the aggregates before further processing.

[0029] Additionally, a moisture sensor embedded in the chamber 106 to detect moisture in the aggregate. The moisture sensor works by mmeasuring the electrical conductivity or dielectric properties of the aggregates, as moisture affects these properties. The sensor sends data to the microcontroller, which then analyzes the moisture level. If the moisture content exceeds a predetermined threshold, then the microcontroller activates a heating coil 113 embedded in the chamber 106 to remove the excess moisture and bring the aggregate to the required moisture level for optimal processing. Based on detection, if the aggregate contains required amount of moisture level, then the microcontroller activate a heating coil 113 embedded in the chamber 106 to heat the chamber 106 and remove the moisture from the aggregate if the detected moisture is above a threshold moisture level.

[0030] The heating coil 113 works by generating heat when electrical current passes through it, thereby raising the temperature within the chamber 106. This heat is transferred to the aggregates, causing moisture to evaporate from the material. The microcontroller monitors the moisture sensor’s data and, if the detected moisture level exceeds the threshold, activates the heating coil 113 to remove excess moisture, ensuring that the aggregates reach the optimal moisture level for further processing and ensuring consistent results in the processing process. Herein, a temperature sensor is embedded in the chamber 106 to detect temperature of the aggregate.

[0031] The temperature sensor works by measuring the temperature within the chamber 106 using a thermocouple or thermistor, which detects changes in temperature as it responds to the heat generated by the heating coil 113. The sensor sends real-time temperature data to the microcontroller. If the temperature exceeds a certain threshold, indicating that the aggregates have reached the desired heat level for moisture removal, then the microcontroller deactivate the heating coil 113 to prevent overheating.

[0032] Moreover, if the user desires to provide control over actuation of the grinding to control particle size, then the user accesses the display unit 115 to give input regarding the same based on that the microcontroller actuates a motorized blade 114 incorporated within the chamber 106 for grinding of the aggregate. The blade 114 works by rotating at a variable speed, as controlled by the microcontroller to grind the aggregates into smaller particles. The rotation of the blade 114 is driven by a motor, and its speed is adjusted based on the input provided by the user through the display unit 115. This allows the user to control the particle size of the aggregates. The blade's cutting edges break down larger pieces of aggregate, ensuring uniform particle size according to the desired specifications. The microcontroller continually monitors and adjusts the blade’s operation to maintain consistency in the grinding process. Herein, the the blade 114 is rotated at a rate determined by the microcontroller as per particle size of the aggregates detected by the ultrasonic sensor, to create a uniform aggregate.

[0033] After creating uniform aggregate as detected by the ultrasonic sensor, the microcontroller deactivates the motor and align an iris aperture 116 in alignment with a container 117 installed beneath the chamber 106 to open and dispense the grind aggregate in the container 117. The iris aperture 116 works by smoothly sliding its blades over one another to form a circular opening, whose size is being precisely adjusted. Upon activation by the microcontroller, the blades retract to create an opening aligned with the container 117 beneath the chamber 106, allowing the controlled release of the uniform grind aggregate in the chamber 106.

[0034] Additionally, if the user desires the grind aggregates, then the user accesses the computing unit to give input commands regarding the requirement of the aggregates. Based on that the microcontroller processes the input and activates an electronic nozzle 107 connected with the container 117 via a duct 108 passing externally through the housing 101 to dispense out the aggregates in an auxiliary receptacle in which the user desires to collect. The nozzle 107 operates by using an electronically controlled valve unit that precisely regulates the flow of grind aggregates. Upon receiving input commands from the user through the computing unit, the microcontroller processes the request and sends a signal to the nozzle's valve mechanism. The valve then opens to allow the aggregates to flow through the externally connected duct 108 and into the auxiliary receptacle thereby allow the user to utilize in various constructional application.

[0035] Moreover, if the user desires to move the housing 101 over the surface, the user accesses the computing unit to give input commands regarding the locomotion of the housing 101. Based on the given input, the microcontroller processes the input and activates another pneumatic unit integrated with each of four perpendicularly installed telescopic rods 102 with motorized omnidirectional wheels 103 at the ends for extension and retraction. Simultaneously, the microcontroller actuates the wheels 103 to move the housing 101 over the surface to relocate the device to different locations. Each of the wheels 103 are coupled with a motor that is activated by the microcontroller to rotate the wheels 103 with specified speed in order to move the housing 101 to different locations as per user requirement.

[0036] A battery (not shown in figure) is associated with the device to offer power to all electrical and electronic components necessary for their correct operation. The battery is linked to the microcontroller and provides (DC) Direct Current to the microcontroller. And then, based on the order of operations, the microcontroller sends that current to those specific electrical or electronic components so the user effectively carry out their appropriate functions.

[0037] The present invention works best in the following manner, where the cylindrical housing 101 as disclosed in the invention possesses four perpendicularly installed telescopic rods 102 with motorized omnidirectional wheels 103 for a locomotion of the housing 101. The hopper 104 with an upper portion of the housing 101 to enable feeding of recycled aggregates into the chamber 106 in the housing 101 where the mesh filter frame 109 filters debris from the aggregates. Herein, the frame 109 is segmented into two segments, deployed by telescopic links 110 having hinges to separate larger pieces of aggregate, wherein the chamber 106 is installed in the housing 101 in a rotatable manner, to enable rotation of the chamber 106 to expedite filtration. The articulated L-shaped arms 111 having an impact hammer 112 at the end, breaks aggregate pieces having dimensions greater than a threshold dimension, as detected by the ultrasonic sensor. Also, the articulated L-shaped telescopic links 110 having electromagnets removes metallic debris from the aggregates. Herein, the moisture sensor detects moisture in the aggregate to trigger a microcontroller to determine if the aggregate contains required amount of moisture level, and activate the heating coil 113 to heat the chamber 106 and remove the moisture from the aggregate if the detected moisture is above a threshold moisture level. After that the motorized blade 114 grinds the aggregate. Herein, the blade 114 is rotated at a rate determined by the microcontroller as per particle size of the aggregates detected by the ultrasonic sensor, to create a uniform aggregate.

[0038] 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) An aggregate processing device, comprising:

i) a cylindrical housing 101 having four perpendicularly installed telescopic rods 102 with motorized omnidirectional wheels 103 at the ends, attached underneath said housing 101, for a locomotion of said housing 101;
ii) a hopper 104 configured with an iris lid 105 configured with an upper portion of said housing 101, to enable feeding of recycled aggregates into a chamber 106 in said housing 101;
iii) a mesh filter frame 109 disposed within said chamber 106, for filtering debris from said aggregates, wherein said frame 109 is segmented into two segments, deployed by telescopic links 110 having hinges at the ends, to separate larger pieces of aggregate, wherein said chamber 106 is installed in said housing 101 in a rotatable manner, to enable rotation of said chamber 106 to expedite filtration;
iv) a plurality of articulated L-shaped arms 111 having an impact hammer 112 at the end, attached in said housing 101, for breaking aggregate pieces having dimensions greater than a threshold dimension, as detected by an ultrasonic sensor embedded in said chamber 106;
v) a pair of articulated L-shaped telescopic links 110 having electromagnets at the ends for removal of metallic debris from said aggregates;
vi) a moisture sensor embedded in said chamber 106 to detect moisture in said aggregate to trigger a microcontroller to determine if said aggregate contains required amount of moisture level, and activate a heating coil 113 embedded in said chamber 106 to heat said chamber 106 and remove said moisture from said aggregate if said detected moisture is above a threshold moisture level; and
vii) a motorized blade 114 incorporated within said chamber 106 for grinding of said aggregate, wherein said blade 114 is rotated at a rate determined by said microcontroller as per particle size of said aggregates detected by said ultrasonic sensor, to create a uniform aggregate.
2) The device as claimed in claim 1, wherein said chamber 106 is attached within said housing 101 by means of a motor to enable rotation of said chamber 106.

3) The device as claimed in claim 1, wherein a temperature sensor is embedded in said chamber 106 to detect temperature of said aggregate to enable regulation of said heating element.

4) The device as claimed in claim 1, wherein a touch enabled display unit 115, linked with said microcontroller is, mounted on said housing 101, to enable operation of said device via touch input and provide control over actuation of said grinding to control particle size.