Description:FIELD OF THE INVENTION

[0001] The present invention relates to a safety device for lathe machine operations that enhances the operational safety and efficiency of lathe machines by automatically tightening and loosening a three-jaw chuck and a four-jaw chuck of the lathe machine by means of a chuck key during the lathe machine operations and also guide and alert the user regarding presence of chuck key on chuck.

BACKGROUND OF THE INVENTION

[0002] A lathe machine is a versatile tool used to shape, cut, drill, or polish materials like metal, wood, or plastic by rotating the workpiece against cutting tools. The chuck of the lathe machine, which holds the workpiece in place, needs to be tightened or loosened during operation to securely fix or release the material being worked on. Proper chuck management ensures precision and prevents workpiece displacement during machining. However, risks to the user include accidental activation of the machine with a chuck key still engaged, leading to severe injuries. Flying debris and improper chuck engagement also cause accidents, emphasizing the need for caution and safety measures.

[0003] Traditionally, the chuck of a lathe machine is tightened or loosened manually using a chuck key, a T-shaped tool designed to fit into the chuck's slots. The user inserts the chuck key into one of the slots and rotates it to either tighten or loosen the jaws that secure the workpiece. This method requires manual effort and repetitive adjustments to ensure the workpiece is centered and firmly held. While this approach is straightforward and cost-effective, it has several drawbacks. Manual tightening often leads to inconsistent grip strength, risking the work piece’s displacement during machining. Additionally, forgetting to remove the chuck key after adjustment poses a significant safety hazard, as the key might be thrown at high speed when the lathe starts, that cause serious injury to the user or the operator.

[0004] CN110732692A discloses about a lathe anti-collision devices, which comprise a strong magnetic plate, a guide rail plate, a dovetail groove, a jacking screw, a movable guide rod, a connecting plate, a connecting bolt, a spring, a balance plate, an environment-friendly vibration switch and a rubber column, wherein the two ends of the strong magnetic plate are respectively connected with the guide rail plate and a rear baffle plate, the guide rail plate is provided with the dovetail groove, the movable guide rod can slide in the dovetail groove and is fixed by the jacking screw, the connecting plate is fixed at the end of the movable guide rod, the spring is connected with the connecting plate and the balance plate, the environment-friendly vibration switch is arranged on the balance plate, and the rubber column which can buffer and impact a tool rest disc is arranged at the side end.

[0005] CN202070776U discloses about a lathe operating safe protecting device, which is characterized in that: two stroke control switches of a three-lever holder for preventing a large carriage and a middle carriage from being collided with a chuck or the tail of a lathe are installed on a lathe body below an ordinary lathe surface track, and a device which is collided with the stroke control switch, when the lathe is moved by an operator to the position on which the lathe is going to collide the lathe, the device is collided with the stroke control switch, so the power supply of a main motor of the lathe can be cut off, the transmission power of the lathe can be released, the lathe feeding movement can be stopped instantaneously, and the accident can be avoided and reduced.

[0006] Conventionally, many devices have been developed that are capable of assisting a user in tightening and loosening a chuck of the lathe machine. However, these devices are incapable of automatically tightening and loosening the chuck by gripping and engaging the chuck key into the key slot of the chuck, and fails in reducing manual efforts and providing safety to the user. Additionally, these existing devices also lacks in retrieving a chuck key from the chuck in a self-sufficient manner, when the chuck key is left in place.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of providing a means to a user for remotely monitoring the lathe machine operations and remotely tighten and loosen the chuck of the machine during the operation. In addition, the developed device also retrieves a chuck key from the chuck when the chuck key is left in place.

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 providing a means to a user for tightening and loosening a chuck of a lathe machine in an automated manner by securely gripping a chuck key, thereby reducing manual efforts and providing safety to a user operating the lathe machine.

[0010] Another object of the present invention is to develop a device that provide guidance and alerts to users for indicating presence of chuck key on chuck, thereby preventing machine operation until chuck key is removed.

[0011] Yet another object of the present invention is to develop a device that is capable of monitoring RPM of the chuck key during tightening of the chuck and accordingly regulates tightening process, thus ensuring that chuck maintains an effective grip on workpiece at very high speeds during machining operations.

[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 safety device for lathe machine operations that is capable of providing safety to a user during the lathe machine operations by allowing the user to remotely monitor lathe machine’s operational status and provides real-time alerts regarding presence of chuck key over the chuck to prevent any damage or harm to the user.

[0014] According to an embodiment of the present invention, a safety device for lathe machine operations comprises of a platform positioned on a ground surface in proximity to a lathe machine, the platform is installed with a pair of motorized track wheels for allowing the body to navigate autonomously around an industrial site to perform various tasks related, an artificial intelligence-based imaging unit installed on the platform and paired with a processor to detect profile structure and dimensions of the lathe machine, based on which a vertical rod attached with the platform and integrated with a rack-and-pinion arrangement extend and position a horizontal bar attached with a free-end of the rod at an optimum height, an authorized user access an user-interface installed in a commuting unit to monitor lathe machine operations, the user-interface allows authorized user to monitor lathe machine’s operational status and receive real-time alerts regarding presence of chuck key, the user-interface featuring two operational modes: a three-jaw chuck mode and a four-jaw chuck mode for managing chuck key engagement, a horizontal plate attached with a free-end of the bar that facilitates proper tightening and loosening of chuck key during lathe machine operations by engaging the chuck key with spindle jaws, the plate further includes a pneumatic link and gear mechanism to apply a pushing force to the chuck key during tightening and loosening.

[0015] According to another embodiment of the present invention, the proposed device further comprises of an articulated robotic arm installed on the bar that retrieve a chuck key from the spindle when the chuck key is left in place, the retrieval is based on image analysis of chuck key's dimensions and position, a pair of electromagnetic clamps are mounted on the plate to secure the chuck key during operation and preventing slippage, a holographic projection unit is mounted on the platform to project holographic images that provide guidance and alerts to users, including a flashing alert indicating presence of chuck key on spindle, if a three-jaw chuck is detected, the microcontroller utilizes an RPM (Revolution Per Minute) sensor integrated with the clamps to regulate tightening process, if a four-jaw chuck is detected, the microcontroller rotates a first key slot of chuck using the clamps, and further the clamp is engaged to move and align with next keyhole of chuck, in a sequential manner for facilitating insertion and fastening of chuck key into subsequent keyhole for proper fastening/ loosening, and a battery is configured with the device for providing a continuous power supply to electronically powered components associated with the device.

[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 safety device for lathe machine operations.

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 safety device for lathe machine operations that allows a user to remotely monitor the lathe machine operations and also tighten and loosen the chuck of the machine during operation in an automated manner as per the user command. Additionally, the proposed device is capable of guiding the user regarding the machine operation and also alerts the user regarding the presence of chuck key on the chuck for preventing machine operation until chuck key is removed.

[0022] Referring to Figure 1, an isometric view of a safety device for lathe machine operations is illustrated, comprising a platform 101, a pair of motorized track wheels 102 installed with the platform 101, an artificial intelligence-based imaging unit 103 installed on the platform 101, a vertical rod 104 attached with the platform 101 and integrated with a rack-and-pinion arrangement 105, a horizontal bar 106 attached with a free-end of the rod 104, a horizontal plate 107 attached with a free-end of the bar 106 by means of a pneumatic link 108, an articulated robotic arm 109 installed on the bar 106, a pair of electromagnetic clamps 110 are mounted on the plate 107, and a holographic projection unit 111 is mounted on the platform 101.

[0023] The device disclosed herein comprises of a platform 101 positioned securely on a ground surface near to a lathe machine. The platform 101 serves as a stable base for integrating additional safety components and ensures a fixed position during operation. The platform 101 is made from strong, lightweight, and durable materials which includes but not limited to hardened steel, aluminum alloy, hard fiber, and composite materials. These materials offer strength and rigidity to the platform 101 making the platform 101 resistant to mechanical stress and pressure.

[0024] A user is required to activate the device manually by pressing a button installed on the platform 101 and linked with an inbuilt microcontroller associated with the device. The button is a type of switch that is internally connected with the device via multiple circuits that upon pressing by the user, the circuits get closed and starts conduction of electricity that tends to activate the device and vice versa.

[0025] The lateral bottom section of the platform 101 is installed with a pair of motorized track wheels 102 to navigate the platform 101 autonomously around an industrial site to perform various tasks related. The motorized track wheels 102 consist of a direct current motor and a continuous tracks made up of interlocking metal or rubber pads. These tracks wrap around a series of track wheels. The tracks are connected by a series of pins and bushings, forming a flexible loop that moves around the track wheels. The track wheels 102 are the primary components responsible for driving the tracks and propelling the platform 101 forward or backward.

[0026] On actuation by the microcontroller, the motor generates power which is transmitted to the drive train. The power from the drive train is transferred to the drive sprocket, which is connected to the track wheel. The drive sprocket engages with the links of the track. As the drive sprocket rotates, it causes the track wheel to rotate as well. The rotation of the track wheel moves the track's links, which are engaged with the teeth or cleats on the rim of the track wheel. The movement of the track's links propels the platform 101 on the surface to navigate autonomously around the industrial site to perform various tasks related.

[0027] After activation of the device, the microcontroller generates a command to actuate an artificial intelligence-based imaging unit 103 installed on the platform 101 and paired with a processor for capturing and processing multiple images of surroundings, respectively. The artificial intelligence-based imaging unit 103 comprises of a high-resolution camera lens, digital camera sensor and a processor, wherein the lens captures multiple images from different angles and perspectives in vicinity of the platform 101 with the help of digital camera sensor for providing comprehensive coverage of the surroundings.

[0028] The captured images then go through pre-processing steps by the processor integrated with the camera. The processor carries out a sequence of image processing operation including pre-processing, feature extraction and classification in order to enhance the image quality, which includes adjusting brightness and contrast and removing any distortion or noise. The pre-processed images are transmitted to the microcontroller linked with the processor in the form of electrical signals.

[0029] The microcontroller processes the signals received from the imaging unit 103 in order to detect profile structure and dimensions of the lathe machine. A vertical rod 104 is attached with the platform 101 and integrated with a rack-and-pinion arrangement 105, wherein based on the determined dimensions of the lathe machine, the microcontroller generates a command to actuate the rack-and-pinion arrangement 105 to extend the rod 104 in order to position a horizontal bar 106 attached with a free-end of the rod 104 at an optimum height.

[0030] The rack-and-pinion arrangement 105 mentioned herein is a commonly used mechanism for converting rotational motion into linear motion. The arrangement consists of two main components: the rack and the pinion. The rack is a long, flat gear with teeth along its length and resembles a straight bar with gear teeth cut into one side. The pinion, on the other hand, is a small gear with teeth that engage with the teeth of the rack. The pinion is mounted on a rotating shaft which is powered by a DC (direct current) electric motor. On actuation, the motor rotates pinion in clockwise and anti-clockwise directions. As the pinion rotates in clockwise and anti-clockwise directions, its teeth meshed with the teeth of the rack, causing the rack to move vertically upward and downward, resulting in vertical upward motion of the rod 104 in order to position the horizontal bar 106 at an optimum height relative to the lathe machine.

[0031] An authorized user is required to access a user-interface installed in a computing unit (such as a smartphone, tablet, or other handheld devices) wirelessly linked with the microcontroller, to monitor lathe machine operations. The user-interface serves as a dedicated control panel for enabling the user to monitor the lathe machine's operations seamlessly. The interface allows authorized user to monitor lathe machine’s operational status and provides real-time alerts regarding the presence and engagement of the chuck key, for ensuring safety during machine operations. These modes enable precise management of the chuck key engagement based on the specific type of chuck in use. In case chuck key is detected over the lathe machine, a notification is given to the user to stop the lathe machine.

[0032] The microcontroller actuates a holographic projection unit 111 mounted on the platform 101 to project holographic images that provide guidance and alerts to users. The holographic projection unit 111 operates by using a combination of light sources, mirrors, and lenses to create a three-dimensional visual representation.

[0033] The projection unit 111 consists of a laser light source that projects onto a beam splitter, which divides the light into multiple paths. These paths are then directed onto a diffraction grating to produce the holographic image. Micro-lenses and mirrors further focus and align the light to form a clear 3D projection. The microcontroller linked with the projection unit 111 controls the image content, ensuring the correct hologram or information is depicted over the ground surface to provide guidance and alerts to users, including a flashing alert indicating presence of chuck key on chuck, thereby preventing machine operation until chuck key is removed.

[0034] The computing unit is wirelessly associated 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.

[0035] The communication module allows the microcontroller to send and receive data to and from the computing unit without the need for physical connections. The Wi-Fi module provides connectivity over local networks, enabling real-time communication over longer distances. The Bluetooth module offers short-range, low-power communication, ideal for close proximity. The GSM module allows for communication over mobile networks, facilitating remote monitoring and control from virtually anywhere. This versatile connectivity ensures seamless interaction between the microcontroller and the computing unit for enabling the user to remotely provide input commands regarding tightening and loosening of the chuck during lathe machine operations.

[0036] The microcontroller process the input command received from the computing unit regarding tightening and loosening of the chuck and accordingly actuates a pneumatic link 108 attached with a free-end of the bar 106 in a perpendicularly downward direction to extend and position a horizontal plate 107 integrated with the link 108, in contact with a chuck key present over the lathe machine. The extension of the pneumatic link 108 is powered by a pneumatic unit associated with the device that includes an air compressor, air cylinder, air valves and piston which works in collaboration to aid in extension and retraction of the link 108.

[0037] The air compressor used herein extract the air from surrounding and increases the pressure of the air by reducing the volume of the air. The air compressor is consisting of two main parts including a motor and a pump. The motor powers the compressor pump which uses the energy from the motor drive to draw in atmospheric air and compress to elevated pressure. The compressed air is then sent through a discharge tube into the cylinder across the valve. The compressed air in the cylinder tends to pushes out the piston to extend. The piston is attached to the link 108, wherein the extension/ retraction of the piston corresponds to the extension/ retraction of the link 108 to position the plate 107 in contact with the chuck key.

[0038] Post positioning of the plate 107, the microcontroller actuates a pair of electromagnetic clamps 110 mounted on the plate 107 to acquire a grip over the chuck key. The electromagnetic clamps 110 used herein consists of an electromagnetic coil, iron core, and a clamp body. Upon actuation, the electromagnetic coil gets energized for generating a magnetic field. This magnetic field attracts the iron core, which in turn pulls the clamp body toward the chuck key, for creating a secure grip. The strong magnetic force ensures that the clamp holds the chuck key firmly in place during lathe operations and prevent any slippage or unintended movement.

[0039] Once the chuck key is securely gripped by the clamps 110, the microcontroller by means of the imaging unit 103 detects the type of the chuck. In case, a three-jaw chuck is detected by the microcontroller, the microcontroller directs the plate 107 to engage the gripped chuck key with a key slot of the chuck. Upon engagement of the chuck key with the key slot, the microcontroller actuates a gear mechanism integrated between the pneumatic link 108 and the plate 107 to rotate the plate 107 along with the chuck key in a clockwise/ anti-clockwise direction in order to tighten/ loosen the chuck.

[0040] The gear mechanism used herein consists of interlocking gears that enable the rotation of the plate 107 in both clockwise and anti-clockwise directions. The mechanism includes a driving gear connected to a DC (direct current) power source, which, when turned, transmits motion to the adjacent gear(s) through their interlocking teeth. Depending on the configuration, the rotation direction of the driving gear determines whether the plate 107 rotates clockwise or anti-clockwise in order to tighten/ loosen the chuck.

[0041] In case a four-jaw chuck is detected, the microcontroller rotates a first key slot of chuck by engaging the chuck key and initiating first phase of fastening the chuck, further the clamp moves and align the chuck key with next key slot of chuck, in a sequential manner in order to properly tightening/ loosening the four-jaw chuck.

[0042] During the tightening/loosening of the chuck, the microcontroller in association with an RPM (Revolution Per Minute) sensor integrated with the clamps 110, monitor the speed of the chuck key. The RPM sensor used herein is an optical RPM sensor that measures rotational speed using light and a rotating disc. The sensor consists of a light source (LED or laser) and a light detector (photodiode or phototransistor). The rotating disc, attached to the rotating component, has alternating opaque and transparent sections. As the disc spins, it periodically interrupts the light beam emitted by the light source. The detector converts these interruptions into electrical pulses. The frequency of these pulses correlates to the rotation speed, allowing the sensor to calculate RPM of the chuck key. This data is further transferred to the microcontroller in the form of electrical signals.

[0043] The microcontroller continuously processes the received signals in order to monitor the RPM (Revolution Per Minute) of the chuck key during tightening of the chuck and accordingly regulates the tightening process for ensuring that chuck maintains an effective grip on workpiece at very high speeds during machining operations.

[0044] In case the the chuck key is left in place, the user provides input command by means of the computing unit for retrieval of the chuck key from the chuck. Based on the user-specified commands, the microcontroller generates a command to actuate an articulated robotic arm 109 installed on the bar 106 to retrieve the chuck key from the chuck. The articulated robotic arm 109 mainly comprises of motor controllers, arm, end effector and sensors.

[0045] The arm is the essential part of the robotic arm 109 and it comprises of three parts, the shoulder, elbow and wrist. All these components are connected through joints, with the shoulder resting at the base of the arm, and connected to the microcontroller. The elbow is in the middle and allows the upper section of the arm to move forward or backward independently of the lower section. Finally, the wrist is at the very end of the upper arm and attached to an end effector that act as robotic finger for retrieving the chuck key left in place. The retrieval is based on image analysis of chuck key's dimensions and position as monitored by the imaging unit 103.

[0046] Lastly, a battery is installed within the device which is connected to the microcontroller that supplies current to all the electrically powered components that needs an amount of electric power to perform their functions and operation in an efficient manner. The battery utilized here, is generally a dry battery which is made up of Lithium-ion material that gives the device a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. As the device is battery operated and do not need any electrical voltage for functioning. Hence the presence of battery leads to the portability of the device i.e. user is able to place as well as moves the device from one place to another as per the requirement.

[0047] The proposed invention works best in the following manner, where the platform 101 is positioned on the ground surface near the lathe machine. The pair of motorized track wheels 102 allows the platform 101 to navigate autonomously around the industrial site to perform various tasks related. The artificial intelligence-based imaging unit 103 paired with the processor detect profile structure and dimensions of the lathe machine. Based on which the vertical rod 104 integrated with the rack-and-pinion arrangement 105 extend and position the horizontal bar 106 at the optimum height. After which the authorized user access the user-interface installed in the commuting unit to monitor lathe machine operations. The user-interface allows the user to monitor lathe machine’s operational status and receive real-time alerts regarding presence of chuck key. The user-interface featuring two operational modes: the three-jaw chuck mode and the four-jaw chuck mode for managing chuck key engagement. Based on the user input mode, the pair of electromagnetic clamps 110 mounted on the plate 107 grip the chuck key for proper tightening and loosening of chuck key during lathe machine operations by engaging the chuck key with spindle jaws.

[0048] In continuation, upon engagement of the chuck key with the spindle jaws, the pneumatic link 108 and gear mechanism apply rotational and pushing force to the chuck key for proper tightening and loosening of chuck key. Based on user-specified commands the articulated robotic arm 109 retrieve the chuck key from the spindle when the chuck key is left in place. Further, the holographic projection unit 111 project holographic images that provide guidance and alerts to users, including the flashing alert indicating presence of chuck key on spindle. If the three-jaw chuck is detected, the RPM (Revolution Per Minute) sensor integrated with the clamps 110 regulate tightening process. If the four-jaw chuck is detected, the chuck key rotates the first key slot of chuck using the clamps 110. Further, the clamp is engaged to move and align with next keyhole of chuck in the sequential manner for facilitating insertion and fastening of chuck key into subsequent keyhole for proper fastening/ loosening.

[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. , Claims:1) A safety device for lathe machine operations, comprising:

i) a platform 101 positioned on a ground surface in proximity to a lathe machine, wherein said platform 101 is installed with a pair of motorized track wheels 102 allowing said platform 101 to navigate autonomously around an industrial site to perform various tasks related;

ii) an artificial intelligence-based imaging unit 103 installed on said platform 101 and paired with a processor for capturing and processing multiple images of surroundings, respectively to detect profile structure and dimensions of said lathe machine, based on which said microcontroller actuates a vertical rod 104 attached with said platform 101 and integrated with a rack-and-pinion arrangement 105 to extend and position a horizontal bar 106 attached with a free-end of said rod 104 at an optimum height;

iii) a user-interface installed in a commuting unit accessed by a user providing an interface for authorized user to monitor lathe machine operations, wherein said user-interface allows authorized user to monitor lathe machine’s operational status and receive real-time alerts regarding presence of chuck key to enable the user to stop said lathe machine in case it is in operation state;

iv) a horizontal plate 107 attached with a free-end of said bar 106, wherein said plate 107 facilitates proper tightening and loosening of said chuck during lathe machine operations by engaging said chuck key with a key slot of said chuck, and said plate 107 further includes a pneumatic link 108 and gear mechanism to apply a pushing force to said chuck key during tightening and loosening; and

v) an articulated robotic arm 109 installed on said bar 106, configured to retrieve a chuck key from said chuck when said chuck key is left in place, said arm 109 being controlled by said microcontroller based on user-specified commands, wherein said retrieval is based on image analysis of chuck key's dimensions and position.

2) The device as claimed in claim 1, wherein a pair of electromagnetic clamps 110 are mounted on said plate 107 to secure said chuck key during operation, preventing slippage.

3) The device as claimed in claim 1, wherein a holographic projection unit 111 is mounted on said platform 101, configured to project holographic images that provide guidance and alerts to users, including a flashing alert indicating presence of chuck key on chuck, thereby preventing machine operation until chuck key is removed.

4) The device as claimed in claim 1, wherein if a three-jaw chuck is detected by said microcontroller, said microcontroller utilizes an RPM (Revolution Per Minute) sensor integrated with said clamps 110 to regulate tightening process, ensuring that chuck maintains an effective grip on workpiece at very high speeds during machining operations.

5) The device as claimed in claim 1, wherein if a four-jaw chuck is detected, said microcontroller rotates a first key slot of chuck using said clamps 110, initiating first phase of fastening said chuck, and simultaneously said clamp is engaged to move and align with next key slot of chuck, facilitating insertion and fastening of chuck key into subsequent keyhole for proper tightening/ loosening.

6) The device as claimed in claim 1, wherein a battery is configured with said device for providing a continuous power supply to electronically powered components associated with said device.